Annexure-III Chimney Spec (1) .

SPECIFICATION FOR CIVIL, STRUCTURAL &
ARCHITECTURAL WORKS
GMR ENERGY LIMITED
FOR MAIN POWER BLOCK AREA

Doc. No. K8V07-GEL-SPC-008
Project
1200-1320 MW THERMAL POWER PLANT
CHHATTISGARH, INDIA
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CHIMNEY

1.00.00 SCOPE OF WORK

1.01.00 The scope of work covered in this specification in general, comprises the
design construction & commissioning of 275 m high twin flue RCC Chimney
required for 1200 1320 MW power plant of GMR Energy Limited at Raipur
District, Chhattisgarh, India.

1.02.00 The scope of work shall consist of but not be limited to the following:

a) Preparation of design basis report, design and construction
drawings and obtaining approval.

b) All excavation works in all types of soils/rocks including dewatering
as necessary.

c) Providing and laying of grounding mat

d) Construction of pile/raft foundation

e) Backfilling around the foundation

f) RCC shell

g) Internal platforms with flue restraint bearing and top internal platform
with support bearing & External platforms

h) Hopper

i) Steel Flues, stainless steel flues of suitable height above chimney
roof slab.

j) RCC corbels at intervals

k) Chimney cap

l) Companion flange and brackets including inserts on the shell for the
flue duct connection.

m) Access, maintenance and clean out doors

n) Staircase, ladders and hand railings

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o) Insulation material.

p) Platforms, inserts & miscellaneous bolts and anchors required for
instrumentation of chimney.

q) Lightning protection and grounding systems.

r) Arrangement for maintenance on outer face of chimney at top.

s) All painting work including for aviation, day warning painting as per
aviation requirements.

t) Aviation night warning lights, lighting system inclusive of all
accessories and cabling work from power supply point.

u) Installation of lights at all external platforms.

v) Providing and installation of rack and pinion elevator of 400 kg
capacity with (G+27) landing platform.

w) Providing expansion compensators to steel flues.

1.03.00 Some other tall structures i.e. Cooling Towers and chimneys are located in
close vicinity of the Chimney. The aerodynamic interference effect due to
these shall be studied and incorporated in the design of the Chimney. Wind
tunnel model study for determining the aerodynamic interference is
included in the bidders scope. The study shall be done by a specialist
agency in this field acceptable to owner.

1.04.00 The works covered in this specification shall include furnishing of all
materials, labour, tools, plant and equipments, transportation, fabrication,
supervision, construction as per drawings including embedment of bolts,
inserts, leaving holes, pockets, grooves, chamfers as shown therein and all
incidental items not shown or specified but reasonably implied of necessary
for satisfactorily completion of the project as a whole.

1.05.00 It is not the intent to specify completely herein all details of design and
construction of the works covered under this specification. All works shall
be done as per specification and approved for construction drawings and in
a manner acceptable to Engineer; who shall have the power to reject any
work or material which in his judgement is not in full accordance therewith.
In case of any conflict regarding the interpretation of the intent or meaning
of the specifications or drawings, Engineer shall interpret such intent or
meaning, which will be final and binding on the contractor.

1.06.00 Contractor shall rectify and make good all defective work during the defects
liability period of 12 months from the date of commissioning.

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1.07.00 Attending meetings at Owner/Consultants office at Mumbai or any other
place as fixed by Engineer as and when required for review, discussions,
co-ordination etc.

1.08.00 Making all necessary arrangements for access to the storage yard from the
nearest approach road and further to the actual site of work including
dewatering as necessary, and maintenance of same in order to facilitate
transportation of machinery and equipment such as cranes etc assessing
the suitability of already existing access roads.

1.09.00 All other works not specifically mentioned above but indicated in the
drawings, which are necessary for the satisfactory completion of the work
as a whole.

1.10.00 Necessary grooves, holes etc. shall be provided in the structure for erection
of the elevator.

2.00.00 GENERAL

2.01.00 General parameters of the Chimney

1 Total height or the chimney above : 275 m
grade level
2 Multi flue R C C Wind shield (shell)
enclosing two flues, one for each
500MW Boiler
3. No. of Boilers : Two
4. Volume of Gas per Boiler : 790 m
3
/sec
5. Mass flow of Gas : 2332 T/h
6. Density of gases : 0.82 kg/m
3
7. Temperature of flue gases : 134 C
8. Inlet-duct Centre line elevation : During Detail Engg.
9. Duct opening Dimensions : During Detail Engg.
10. Internal diameter of flue : 6300 mm
11. Maximum ambient temperature :
12. Minimum ambient temperature :
13. Each flue of the chimney shall be
Connected to one of 500 MW steam
Generator boiler.
14. Top of Foundation level : 2 m below
grade level (min)
15. Allowable Soil Bearing capacity : Ref: Soil Report
(NETT)
16. Minimum top internal shell diameter : 16 m
17. Minimum bottom internal shell : Bidder to decide.
diameter

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18. Flue gas pressure at Chimney entry : During Detail Engg.
level

2.02.00 The Chimney shall be 275 m high RCC Chimney comprising of two nos
acid and heat resistant steel flue encased by windshield of reinforced
concrete shell. The flue ducts shall be entering from diagonally opposite
ends.

2.03.00 Five numbers of external platforms excluding Hood Platform, with minimum
clear width of the platforms as 1.0 M shall be provided at an interval of
approx. 40.0 M. These platforms shall be spaced approximately equally
between the Hood platforms and ground level.

2.04.00 All internal platforms, supporting liners, shall be supported on R.C.C. shell
of the chimney. Access doors at grade level and external platform levels
shall be provided for access into the shell at finished grade level and for
access to external platforms. The clean out doors shall also be provided in
the steel liners.

3.00.00 CODES AND STANDARDS

a) IS:456-2000 : Code of practice for plain and
Reinforced Concrete

b) IS:4998 (Part 1-1992) : Design Criteria for Reinforced
Concrete Chimney

(Read in-conjunction with IS 4998-1975.)

c) IS:875 (Part 3-1987) : Code of Practice for Wind Load

d) IS:1893 (Part-1 & Part-4) : Criteria for Earthquake Resistant
Design of Structures.

e) IS:432 (Part-I) : Mild steel and Medium steel Bars.

f) IS:1786 : Cold twisted steel bars for Concrete
Reinforcement

g) IS:800 : Use of Structural steel in general
Building Construction

h) ACI Standards

i) Reference may also be made to ACI: 307 Specification for design
and construction of R.C. Chimney if some items are not covered in
India Codes.

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4.00.00 MATERIALS TO BE USED

Chimney foundation shall be in concrete grade M-25 with minimum cement
content of 365 kg/m
3
. Chimney shell shall be of min. concrete grade M-25
with minimum cement content of 400 Kg/m
3
. The cement shall be 43 grade
OPC. Reinforcement shall be Fe-415 steel. Only one grade of concrete
shall be used throughout the height of the shell.

5.00.00 LOADING ON THE STRUCTURE AND THEIR COMBINATION

5.01.00 Dead Load

All permanent loads due to the weight of chimney shell, internal platforms
and linings supported on them, flue ducts, staircases, other accessories,
etc.

5.02.00 Imposed Loads

i) Imposed load on service platform around Chimney shell, shall be
taken as 500 kg/m
2
. Design live load during construction/ erection
shall be considered as 1000 kg/m
2
.

ii) Imposed loads from duct joining the Chimney shall be considered.

5.03.00 Wind Load

5.03.01 The wind loading shall conform to IS:875 (Part-3) : 1987. Dynamic
analysis shall be carried out and stability ensured under such condition.
The details shall be as per Cl. 6.0 of this design basis.

Wind parameters shall be considered for calculating design wind speed and
pressure shall be as follows :

Basic wind speed = 39 m/s (Up to 10m above normal ground level)

K1 = 1.06 as per IS: 875 Table-1

K3 = 1.0

K2 = (Table 2. Category-2. Class-C)

The final design will be checked and verified, as per wind tunnel test, by a
reputed institute and if needed, modifications to be carried out at no extra
cost.

5.04.00 Seismic/ Earthquake Load

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Earthquake forces acting on the Chimney and analysis for the same shall
be carried out as per IS:1893 (Part 1 & 4) using the Response Spectrum
Method and 5% damping shall be considered for the analysis. The
importance factor of 1.75 shall be used. The analysis shall be furnished for
a combination of five modes (minimum).

5.05.00 Thermal Effect

Due to the effect of temperature gradient, vertical and circumferential
stresses are developed. These stresses induced in the concrete shall not
exceed values given in IS:4998.

Flue Gas Data (To be confirmed by BTG SUPPLIER)

Flue gas temperature at inlet =134C
Acid dew point of the gas =137C
Exit gas velocity at top of the Chimney = 25 m/s

The temperature gradient T across the shell thickness will be calculated
as per IS: 4998 (Part-I) 1975 but subject to a minimum of 30C.
Temperature stresses will be calculated according to the procedures given
in ACI-307 and IS:4998 (Part-1) 1975.

Vertical and circumferential reinforcement shall be provided for temperature
stresses.

5.06.00 Local Loads

The effect of following local loads is considered :

a) Local moment produced by corbels (if any).

b) Local moment due to platforms.

c) Local moment due to occurrence of ovalling.

d) Local moment produced by thermal gradient.

5.07.00 Load Combination

Various load combinations for calculation of stresses shall be as under:

a) Dead load + Wind load

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b) Dead load + Earthquake forces.

c) Dead load + Temperature effect.

d) Dead load + Wind load + Temperature effect.

e) Dead load + Earthquake force + Temperature effect.
f) Circumferential stresses due to temperature effect.

g) Circumferential tensile stresses due to wind inducing ring moment.

h) Circumferential compressive stress due to wind induced ring moment
combined with temperature

In Load combinations (a) to (f) above, dead load considered shall be with or
without the weight of lining, whichever condition is more critical, shall be
adopted for design. Across wind loads shall be combined with co-existing
along wind loads. The combined design moment at any section shall be
taken as SRSS of the moments due to across wind loads and co-existing
along wind loads.

6.00.00 PERMISSIBLE STRESSES FOR CHIMNEY SHELL

The stresses in steel reinforcement and concrete shall not exceed the limits
as prescribed in clause 7.0 of IS 4998 (Part I)-1975 for various
combinations of loads. Except for case of dead load + wind load the
maximum permissible stress in concrete in this case shall not exceed 0.32
F
C
where F
C
= Characteristic compressive strength of concrete in kg/cm
2

7.00.00 ANALYSIS

7.01.00 Free Vibration Characteristics of Shaft

Calculation of Natural Frequencies and mode shapes shall be carried out.
For this purpose the chimney shaft shall be idealized as a vertical cantilever
with lumped masses at different nodes. The nodes shall be provided at
each platform level.

Minimum 5 mode shapes shall be considered.

7.02.00 Wind Analysis

7.02.01 Along Wind or Static Analysis

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The basic wind speed V
b
at Raipur, Chattisgarh according to IS 875 (Part-3)
1987 is 39 m/sec. The terrain category is 2 with K1 = 1.06, K2 as per
table 2 of IS-875 (Part-3) 1987 for class C structure and K3=1.0

The gust factor will be calculated according to the method given in IS-
4998 (Part 1) 1992. Dynamic modulus of Elasticity of concrete as
recommended in IS: 4998 (Part-1) 1992 will be used for calculating the
natural frequencies of the chimney.

C
d
will be taken as 0.8 for the concrete shell in general. It will be increased
as per table-1of IS: 4998 over the portion covered with strakes, if required.

Along wind response of chimney shall be calculated both by gust factor
method in A-5.1 and simplified method in A-4.1 of IS: 4998 part-1, 1992.
For design, higher of the along wind loads shall be used.

7.02.02 Across Wind

The across wind response of the Chimney will be evaluated as per the
method given in Section A-4 as well as A-5 of IS: 4998 (Part-I)-1992. C
L

will be taken as 0.16 and S=0.2. Higher of the two moments shall be
considered for design of the Chimney.

7.02.03 Ring Moments Due to Wind.

The circumferential ring moment due to wind will be calculated in
accordance with clause 5.4 of IS:4998 (Part-1) 1992. The wind induced
stresses in concrete and steel shall be calculated in accordance with cl no
D-2.2.7, D-2.2.8 and D-2.2.9 of IS 4998 (part 1) 1975.

7.03.00 Seismic Analysis

The Seismic Analysis will be carried out using the response Spectrum
Method according to IS:1893 taking the first 5 modes of vibration into
account. Raipur, Chhattisgarh is in Zone II of IS 1893. The importance
factor of 1.75 and 5% damping shall be considered for the analysis.

8.00.00 COMPONENT DESIGN CRITERIA

8.01.00 Shell and Foundation

The design conditions for the concrete shell shall be as follows:

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1. The concrete shell shall be designed for natural phenomena and
loads and loads combinations as specified in clause 4.07. Working
stress method shall be used for design of shell. The modular ratio
shall be calculated as per Annexure B of IS 456-2000.

2. The concrete shell shall support all platforms, which in turn provide
support for two independent liners. The beams supporting the
platform shall be made to rest on the shell by making a pocket in the
shell. Below steel beam and above concrete surface electrometric
bearing pads are to be provided. Individual pads for separate floors
are to be design against temperature load and horizontal shear due
to seismic loads.

3. The permissible stress in concrete and reinforcement shall be
limited to as specified in clause 6.0. The stress in concrete at the
junction of shell and foundation will be limited to 0.32 F
c
. Where F
c
is
the characteristic compressive strength of weaker concrete between
shell and foundation.

4. The thickness of RCC shell shall be provided as required by stress
calculations, however, the thickness of shell has also to be
determined in the basis of wind tunnel model studies and any
increase in the thickness of shell or quantities required to be made
as per report shall be followed without any extra cost.

5. The maximum deflection at the top of the chimney for both static
and dynamic cases shall not be more than H/500 where H is the
total height of the windshield above top of the pile cap.

6. The dynamic modulus of elasticity of concrete for various concrete
grades shall be taken as lower values in the range of values
specified in IS:4998 (part I) 1992.

7. The static modulus of elasticity of concrete shall be taken as under:

5000
ck
F F
ck
for instantaneous loadings. Where F
ck
is the
characteristic compressive strength of concrete as per clause 6.2.3
of IS:456-2000.

8. Minimum thickness of the shell shall not be less than 250 mm.

9. Reinforcement in the shell shall be provided as per IS : 4998 (Part
I) 1975. However, the maximum spacing of reinforcement shall
not be more than 250 mm both ways in the shell and 300 mm for
foundation raft.
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Minimum 0.12% reinforcement shall be provided on either face and
on either side of foundation.

While providing vertical reinforcement steel in the shell, the total
number of vertical bars shall be continued till such height when
alternative bars can be discontinued. However, reduction of bar
diameter along the height is permissible. At any section of the shell
vertical bars shall be uniformly spaced. Non-uniform spacing of
vertical bars is not acceptable.

One third of the vertical bars can only be lapped at one section.

10. Opening in the shell shall be provided for duct work, access doors,
ash channel and ventilation system etc. The maximum width of
opening shall be limited to an angle of not more than 30
o
subtended
at the center of the concrete shell.

The total plan area of the opening at a particular section shall not be
more than 15% of plan area of concrete shell at that location. The
opening size for the purpose of stress calculations shall be taken as
1.1times the actual width of opening. The extra reinforcement
around opening shall satisfy the requirements given in the following
documents and the highest shall be provided.

a) IS 4998 (Part I)

b) ACI 307

c) Reinforced concrete chimney and tower by M.G Pinfold.
The value of K1 as given in the book by M.G. Pinfold on
page no. 186 shall be taken as 0.11.

Minimum half the number of extra horizontal bars in shell around the
opening to continue for complete circle all round for both faces and
both sides.

11. Embedments to support the staircase shall be provided in the shell.

12. Expansion anchors shall be used to attach conduit, lighting and
protection equipment, lighting fixtures and other lightweight
appurtenances.

13. Staircase and elevator enclosures shall be provided keeping
provision of an elevator electrically operated and of rack and pinion
type.

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8.02.00 Liners

8.02.01 The bidders scope includes the design, supply, fabrication, installation and
testing of the steel flues with insulation and expansion compensators
including spares as required. The bidders scope includes the design,
preparation of detailed fabrication drawings for the steel flues fabrication
and installation. It shall be the bidders responsibility to test the supports,
restraint points, stiffeners, expansion joints and insulated steel flues against
vibrations and specified temperature variations. On no account will a leaky
flue be permitted.

8.02.02 The lining material/stiffeners shall be fabricated from mild steel having an
ultimate tensile strength of not less than 410 N/Sq.mm. and conforming to
the requirement of IS:2062 (Grade-A). The minimum thickness of the liner
shall be 8 mm. A minimum corrosion allowance of 2 mm. shall be allowed
for arriving at the desired thickness. All steel shall be of tested quality only.

8.02.03 The portion of liner with stainless steel shall be provided with a grade of
steel conforming with the requirements of AISI type 316 L or equivalent and
the minimum thickness of the stainless steel liner shall be 6 mm.

8.02.04 The individual cans of the liners shall be jointed together by butt welding
internally all round for full strength, after connecting the flanged portion of
the cans with high tensile treaded fasteners conforming to IS:1367.

8.02.05 The bidder shall test all welds in the presence of the OWNER to meet the
following requirements:

i) The bidder shall test at random at least 10% of the butt welds by
radiographic/ultrasonic testing methods.
ii) At least 10% of the fillet welds shall be tested at random by dye
penetration tests.
iii) 10% of the root welds for butt-welding shall be tested at random by
dye penetration tests.

8.02.06 All tests shall be conducted in the presence of the ENGINEER IN
CHARGE. If any test fails, the weld shall be cut out, remade and retested
to the ENGINEERs satisfaction.

8.02.07 Bidder shall ensure that deviations shall not exceed the specified tolerance
spelt out herein below for fabrication and erection of steel flues. The
permissible deviations from the true form are as under :

8.02.08 Internal diameter shall not differ from the true or design diameter by more
than 20 mm. in the horizontal plane.

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8.02.09 Horizontal centre of any section shall not deviate more than 12 mm. from
the shell vertical centre line in any 15 m. height and never more than 1500
of height plus 12 mm. at any level considered.

8.02.10 Locally, the variation of the bent plates from true circular form (flat spots)
should not exceed the plate thickness. All measurement/checking shall be
done by a segmental circular template having the design radius and a
chord length of 0.15 times the design radius.

8.02.11 At welded horizontal seams any form of packing or welding shall not
exceed 4 mm. when measured with a straight edge template, long enough
to make contact with the straight portion of shell on either side of the
peaked area. Where deviations at such areas as flat spots and peaked
seams exceed tolerances, stiffeners may be provided only on prior approval
of the ENGINEER.

8.02.12 Flue liners will not be painted.

8.03.00 Insulation for steel flue liner

8.03.01 The flue shall be semi-rigid insulated externally with mineral wool made
from rock slag or fibrous glass bonded by a suitable resin binder
conforming to IS: 8183 or equivalent with a maximum coefficient of thermal
conductivity of 0.062 W/m deg. C at a mean temperature of 150 deg. C.

8.03.02 Two layers of insulation material each of a minimum thickness of 25mm
shall be provided and all joints shall be staggered. The material shall have
a minimum density of 80 kg/cum. for resin bonded glass wool insulation and
100 Kg./cum. for resin bonded rock wool insulation.

8.03.03 Insulation for the exposed portion of flue at the top shall consist of 6 layers
of insulation material each of a minimum thickness of 25 mm. and all joints
shall be staggered. The material shall have a minimum density of 200
Kg/m
3
. This shall be protected by means of a stainless steel cladding,
flashing and hood of grade 316 L stainless steel.

8.03.04 The bidder shall ensure that the insulation can safely withstand maximum
flue gas temperature without deterioration or break down, slag wool shall be
avoided, and the material shall be free from shots and other impurities
which may cause corrosion. The insulation should be able to withstand
vibrations and should not settle down in any case, such as during transport,
storage, erection and operation and also due to its own weight. It shall not
be affected by existing flue gas acids in case of exposure.

8.03.05 The insulation shall be tightly secured to the exterior surface of the liner by
impaling them on studs welded to the surface at 450 mm c/c both
horizontally and vertically. The studs shall be plated and be of a minimum

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thickness of 10 gauge. The studs shall extend a minimum of 25 mm.
beyond the thickness of insulation and 63 mm. circular or square metal
plate speed washers of standard thickness shall be placed on the extended
portion of the studs to hold the impaled insulation material well in place.
Further, a 20 gauge galvanized wire mesh with a 25 mm hexagonal pattern
conforming to IS:3150 shall be wrapped around. Where the wire mesh is
jointed a minimum 150 mm overlap shall be provided. The mesh shall be
bound and tied in place with a 16 gauge GI wire at 300 mm centres. Any
form of lacing the mesh fibres together will not be permitted.

8.03.06 The bidder at his own cost shall test the insulation material to satisfy the
specific requirements and properties as outlined in this specification IS :
8183. The test shall be carried out in accordance with IS :3144.

8.03.07 The design of the steel flue shall be as per the requirement of Task
committee report on steel chimney liners, ASCE, New York 1975 and the
insulation shall be adequate to ensure the temperature rise in the annular
space is less than 20 deg. C above outside air temperature.

8.04.00 Expansion joints

8.04.01 The suspended portion of the steel liner shall be connected to the bottom
supported portion of the liner by an Expansion Joint shall be able to
compensate for the large thermal movements of the steel flue, be gas tight,
acid resistant, heat resistant and provide an adequate insulating medium to
avoid excessive overheating in the access void. The material used for the
fabrication of the expansion joints shall be suitable for the flue gas
conditions.

8.04.02 The expansion joints shall be made of flexible fibre. They should be tight
and impermeable and should withstand the maximum serviceable
temperatures of the flue gas.

8.04.03 The bidder shall also supply spare expansion joints to suit the requirements
of this specifications, complete with instructions for storage, fitting,
instructions, spare accessories, tools for installation etc. to replace
faulty/used expansion joints at a later date. The spares should withstand a
storage period of not less than 10 years.

8.04.04 The bidder shall procure the units from any specialist manufacturer
fabricating the type of expansion compensator. The recommended
specialist manufacturer of such expansion compensators is SCANDURA
LTS., P.O.BOX-18, CLECHEATION, WEST YORKSHIRE,BD 193 UJ,
ENGLAND. Installation of the expansion compensators shall be strictly as
per the manufacturers instructions. The manual shall indicate the
sequence of installation procedure and shall be strictly adhered to once
approved.

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8.05.00 General requirements for steel liner

8.05.01 Liner Hood/Cap for Steel Flue Chimney
The liner hood shall be designed and fabricated from 6 mm. thick stainless
steel sheets of grade 316L. The hood shall completely cover the annular
area packed with insulation material between the stainless steel flue and
cladding. This will prevent exposure of insulation to the surrounding flue
gas environment. Special care should be taken to provide sufficient overlap
of the stainless steel flashing cladding over the shield plate attached to the
chimney roof cap. All sections of the cladding/flashing and shield plate
shall be anchored in place with stainless steel bolts/nuts. Slotted holes
shall be provided to make allowances for differential
expansions/movements.

8.06.00 Interior Platforms

8.06.01 The interior platforms shall be provided at intermediate levels. Distance
between two platforms shall not be more than 40 M. The platforms for the
steel flue chimney include a grillage of M.S. beams provided for supporting
the roof slab, supporting the flue cans, restraint platforms for flues and for
access within the shell. Except for the roof slab, all the platforms shall be
provided with M.S. grating. The platforms shall be designed for self weight
vertical/horizontal liner loads and a live load of 50 kN/m2.

8.06.02 The members of the beams grillage shall be assembled by high precision
bolted connections only. The member dimensions shall be made to suit
with the as built conditions within the wind shield. The beam grillage shall
be painted as per the requirements of IS:1477 with 2 coats of zinc rich red
oxide primer and 3 coats of synthetic enamel paint of approved shade.

8.06.03 The grating shall be fabricated from M.S. flats comprising of 25 x 5 thick
bearing bars spaced at 25 mm c/c and 12 x 5 thick space bar. The grating
shall be hot dip galvanized and shall be procured by the contractor.

8.06.04 The Hand railing shall be of medium quality 32 mm NB GI pipe conforming
to IS 1161 in 3 rows with railing post of 40 mm NB GI pipe spaced at
approximately 1300 centre to centre. Hand railings shall be provided for all
platforms.

8.06.05 Handrails shall be provided with kick plates along the platform edges.
Hand rails shall be provided at all staircase ladder access points.

8.07.00 Deleted

8.08.00 Soot Hopper

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8.08.01 Soot hopper shall be of MS and lined with acid-resistant brick work of min
75 mm thick in acid-resistant mortar. Only shaped acid-resistant bricks
shall be used. Laying and joining shall conform to the requirements laid
down for acid-resistant brick lining. In addition to the above an insulation
layer of minimum thickness 50 mm shall be provided on the external face of
the hopper and suitably covered with aluminum foil of minimum thickness of
1 mm.

8.08.02 The acid resistant bricks shall conform to Class I of IS:4806 and the mortar
for this brick work shall conform to IS:4832 Part-I : Silica type with
potassium silicate liquid binder. Curing of mortar joints with 25% dilute HCL
shall be done for a minimum of three days and as per MANUFACTURERs
recommendation after which exposed face shall be thoroughly cleaned.
8.08.03 At the bottom of the hopper, a flanged pipe of specified diameter and length
shall be welded. Inside of this pipe sleeve shall be coated with sodium
silicate.

8.09.00 Flue Support Arrangement

8.09.01 The support brackets and bearing assembly shall be welded to the locally
thickened portion of the flue and in turn support the flue on the support
platform. The arrangement shall cater for thermal movements of liner
elements in a smooth and easy manner.

8.09.02 The support arrangement shall typically consist of the flue support shoe
(which is part of the flue), flue support bracket which is connected to the
shoe by a precision bolted connection. The bracket in turn is welded to a
bearing assembly. The bearing assembly is later bolted to the support
beams available.

8.09.03 The bearing assembly shall be fabricated from mild steel units with a
stainless steel sheet bearing plate and load bearing insulation blocks. This
plate shall be provided with a recess to seat a PTFE film conforming to
BS:5400 dimpled on the upper surface and lubricated with silicon grease.

8.09.04 Suitable restraint brackets and stop plates of MS shall be provided to avoid
excessive movement, and keep the different units of the bearing assembly
in position.

8.09.05 The insulation blocks shall be of natural grade fibre reinforced asbestos or
an equivalent material which shall primarily consist of the following physical
properties :

i) Minimum compressive stress prior to onset of compression yield of
not less than 12 N/Sq.mm. An allowable compressive stress of 4
N/Sq.mm. shall be considered for sizing of bearing assembly.

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ii) Minimum shear strength of 30 N/Sq.mm. when tested in accordance
with BS:3497-1979.
iii) Thermal conductivity shall not exceed 0.67 W/m deg. C at a mean
temperature of 200
o
C and its coeff. of linear expansion not to
exceed 1.2 x 10E-5 per deg. C.
iv) Adhesive used for bonding purposes shall be of material with
equivalent high temperature properties as approved by the
ENGINEER.

8.09.06 At flue restraint platforms, necessary restraint arrangement with load
bearing, insulation blocks and stainless steel bearing plates fixed to the
insulation blocks shall be provided.

8.09.07 Restraint and support brackets shall also be provided for the bottom
supported portion of the flue which rests on the support platform provided at
the base to cater for bearing and restraint requirements.

8.10.00 Louvers for air outlet/inlet openings

8.10.01 Air inlet and outlet louvers shall be provided as per the requirement.

8.11.00 Liner Test Ports for steel liner

8.11.01 Four gas sampling ports fabricated from SST or MS pipes as the case may
be with flanged ends shall be provided for liner at platform levels. The
sampling equipment is not in the scope of this contract. The Contractor
shall, however, provide all the necessary fittings required for the port holes.
The cost of these provisions shall be included providing a power connection
with 15.5 Amps/220 V plug sockets near every port hole. The load shall be
1000 Watts.

8.11.02 Bidder shall provide for the purpose of instrumentation other than the
sampling ports mentioned in clause 8.8.1 above required number of 38 NB
conduits including pull wires, junction boxes and pull boxes, all securely
tacked/anchored to internal surface of shell and S 316 L plates below each
pipe insert for fixing of measuring instruments.

8.12.00 Stair Case for Chimney

8.12.01 A steel staircase of 900 mm clear width shall be provided internally within
the shell from the bottom to the top to provide access to all platforms. It
shall be fabricated from MS rolled I or channel section stringers. Treads
shall be of steel grating designed for self-weight and a live load of 500
Kg/m
2
. Treads shall be provided with an approved anti-slip nosing set flush
with the stair tread. Hand railing shall be provided for the stairs for the
whole height. The staircase shall be supported on a steel frame work
independent of shell with all members connected with suitable, bolted

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connections only. The supporting structure shall be painted as per the
requirements of IS:1477 with 2 coats of zinc rich red oxide paint and 3
coats synthetic enamel paint of approved shade. The steel treads shall be
hot dip galvanized.

8.13.00 Access door @ roof

8.13.01 One access door of size 750 mm x 1000 mm shall be provided to cover
access opening at + 270 m floor.

8.14.00 Cleanout Doors/manholes for steel liner

8.14.01 One pair of doors 650 x 825 mm in the lining shall be provided for cleaning
soot hoppers and for access to inside of the flue. Clean out
doors/manholes shall also be pro vided at intermediate levels.

8.14.02 The doors shall be hinged and provided with a locking device in addition to
swivel studs with wing nuts on the remaining three edges at spacing not
more than 500 mm

8.15.00 Foundation

A circular raft/ pile cap foundation, preferably annular, shall be provided.
The raft/ pile cap (min M25) shall be designed as rigid member with uniform
thickness and no tapering of thickness shall be allowed. Minimum
thickness of raft shall neither be less than 0.09 times the diameter of raft
or0.3 times the overhang the foundation beyond shell, whichever is greater.
Minimum reinforcement shall not be less than 0.12% in each direction.
Wind and earthquake shall be treated as normal load and no enhancement
of stress is permitted on this account in soil, concrete and steel. No
tension will be allowed under the raft/pilecap during earthquake and wind.
Working stress method shall be adopted for design of foundation.
Foundation will be designed for SRSS of moments of along wind response
and across wind response.

9.00.00 SOIL DATA AND BEARING CAPACITY

All recommendations for final detail geo-technical soil investigation (to be
carried out by successful bidder and approved by Owner/Consultants) are
to be considered as per soil report and specifications.

10.00.00 GALVANISED STEEL STRAKES

Based on actual parameters, arrived at after detailed analysis and design,
aerodynamic studies shall be carried out. The arrangement of the
galvanized steel strakes, if needed, shall be decided, based on these
studies.

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11.00.00 OUTER PLATFORMS

11.01.00 Nos. of outer platforms to be provided are governed as per the
requirements of aviation obstruction lights which are required to be
provided at various levels so as to meet the requirements of IS: 4998 (latest
edition). I.C.A.O regulations and instructions issued by the Director General
of Civil Aviation.

11.02.00 The minimum clear width of the platforms shall be 1000 mm and a live load
of 500 kg/m2 shall be considered for their design.

11.03.00 At 270 m level platform, on upper surface 20 mm thick acid resistant tiles
conforming to IS: 4457 over water proofing shall be provided, using acid
resistant mortar. The average thickness of mortar bed shall be 10 mm and
it shall be sloping outwards.

11.04.00 Hand railing shall be provided all around external platforms, including hood
platform using 32 mm G.I. pipes. The spacing of railing posts shall not be
more than 2000 mm centre to centre. The height of hand railing shall not be
less than 1250 mm. There shall be three handrails at about 450 mm and
850 mm & 1250 mm respectively above platform level.

11.05.00 32 mm dia G.I. drainage spouts shall be provided in platforms for drainage
of rain water.

11.06.00 150 mm dia MS (galvanized) RWDC pipe shall be provided to carry
rainwater from Hood platform to discharge point at ground level. The
number of down take pipe shall be decided as per design.

12.00.00 ENCLOSURE WALLS

12.01.00 Reinforced concrete walls shall be provided at grade level around staircase
and elevator to make the enclosed space airtight and free from ash and
dust for the comfort and safety of personnel who are required to go inside
the chimney for maintenance and inspection purposes.

12.02.00 All materials to be used and design of wall shall be as per relevant I.S.
Codes.

13.00.00 ROLL-UP DOOR

13.01.00 A rolling steel chain operated door of size 4.0m x 5.0m shall be installed at
the base of the chimney shell as indicated on the drawings so that a truck
could go inside the chimney in case of emergency. The door shall be
installed complete with guides hood hardware, weather baffles combination

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end locks and wind locks mechanisms and accessories, as required for
proper operation and weather protection. The complete details of rolling
shutter shall conform to IS: 6248 (latest edition) Metal Rolling Shutters &
Rolling Girds and to these specifications.

13.02.00 The door shall be installed in accordance with the details and the
manufacturers directions. When installed, the door shall be free from warp
twist, or distortion and shall be lubricated and adjusted to operate freely and
smoothly.

14.00.00 PERSONNEL/ ACCESS DOORS

14.01.00 A steel personnel door of size 1200 x 2100 shall provide access to the
chimney at grade level.

14.02.00 Personnel doors of size 1200 x 2100 shall be provided for access to each
airtight enclosures at grade level inside the chimney (i.e. enclosures for
staircase and elevator) and also in chimney shell at external platforms
levels so that civil aviation lights mounted on these platforms could be
approached for maintenance and replacement purposes.

14.03.00 The doors shall be hinged and provided with positive locking device. The
hinges required for connecting the door with door frame shall be either
heavy weight. Butt Hinges conforming to IS: 1341 (latest) Steel Butt
Hinges & Strap Hinges. The size and number of hinges required for each
door shall be decided as per the overall weight of the door and it shall be
ensured that door shall remain in its perfect position after installation under
service conditions. The minimum size of the hinges shall not be less than
150 mm.

15.00.00 INSPECTION/ MAINTENANCE DOORS

15.01.00 Two steel leak proof doors of size 750 x 1000 mm and 750 x 600 mm shall
be provided diametrically opposite in each steel liner at all those levels
where external platforms are provided.

15.02.00 Proper sealing arrangement using asbestos ropes shall be provided in the
doors so that there is no leakage of flue gases from steel flues into the
annular space between liners and shell through these doors.

15.03.00 The doors shall be constructed of two outer sheets not less than 6 mm thick
mild steel reinforced inside with steel stiffeners not more than 600 mm
centers. Hollow space between two plates shall be filled up with insulating
material such as bonded glass wool/ mineral wool. The doors shall be
hinged and shall be provided with locking device such as swivel studs with
wing nuts.

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15.04.00 All surfaces of doors & frames internal as well as external shall be painted
with one coat of primer and finish painted with two coats of acid and heat
resistant paint.

16.00.00 HATCHES

16.01.00 A mild steel hatch shall be provided as an access to the hood of the
chimney.

16.02.00 The hatches shall be constructed of two outer sheets not less than 3 mm
thick mild steel reinforced inside with steel stiffeners not more than 600 mm
centers. In addition, they shall also be designed to withstand a live load of
300 kg/m
2
.

16.03.00 Hatches shall be painted with one coat of primer and finish painted with two
coats of acid and heat resistant paint on both sides.

16.04.00 Other requirements with regard to design and construction shall be same
as for Personal / access doors.

16.05.00 The hatches shall be flat type and shall be operational upwards. They shall
be provided with locking arrangements from under side for the hatch for
hood.

17.00.00 BEARINGS

A fully moulded elastomeric bearing shall be provided to accommodate
thermal movements and to provide a suitable distribution of load between
liner support platform beams and the platforms.

18.00.00 ELEVATOR

It is required to accommodate the elevator and staircase within the
R.C.C shell having two flues for two 500 MW units.

The travel of the lift shall be up to the last but one platform which shall be
about +270 m from 0.0 m level.

19.00.00 FLUE OPENINGS AND DUCT WORK

The concrete shell at flue duct entry shall be adequately protected against
high temperature by cast able refractory lining and the gap between the
shell and duct shall be properly sealed off by asbestos/or any other suitable
seal.

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The openings in the windshield shall be sufficiently reinforced to withstand
design loads. Similarly the openings in steel flues shall be properly
reinforced for receiving the flue ducts.

The R.C.C. shell shall provide support for duct work from the expansion
joint to the chimney liner.

Exposed ductwork shall be insulated and lagged to protect equipment &
prevent injury to personnel. The insulation and wire mesh shall be secured
to the lagging by means of pins or prongs welded to the exterior sheet and
spaced on intervals not exceeding 450 mm in both the directions. The
insulation shall be impaled over the pins or prongs, wire mesh applied over
the insulation and the insulation and mesh shall be held in place with speed
clips.

20.00.00 CHIMNEY PAINTING

Painting the entire inner surface for full height as well as exposed surface of
internal platforms and beams, internal / external surface of mini shell, all air
tight enclosures with acid and heat resisting black impregnated bitumastic
paint (not less than four coats) to give a paint DFT not less than 150
micron.

The entire outside surface of concrete shell shall be painted with alternate
bands of signal red and white colour, out of which top 50 m shall be painted
with acid heat resistant paint and rest of the outside surface shall be
painted with synthetic enamel paint conforming to IS: 5410 in alternate
bands of red and white colour.

21.00.00 SPECIFIC CONSTRUCTION REQUIREMENTS

21.01.00 Concrete

21.01.01 Batching of concrete

For controlled concrete, only weigh batching shall be allowed. All concrete
ingredients, except water, shall be batched by weight, using an approved
make of weigh batcher. Batching shall be accurate to 1/2 Kg. The batcher
shall be tested for accuracy of calibration, first before commencement of
work and at least once a fortnight or as directed by the Engineer thereafter.
Water shall be batched by weight or by volume measures, as approved by
the Engineer.

21.01.02 Construction Joints

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In concreting the chimney shell one full ring lift shall be completed in a
day's pour. Before the formwork for the following pour starts the horizontal
surface of the Chimney shell shall be chipped, cleaned and washed with
water, and when the formwork is complete, the surface shall be cleaned
and washed again and covered with 1:2 sand cement slurry before fresh
concrete is placed. The horizontal construction joints shall be so arranged
and made that they are regular and neat. No vertical joint shall be allowed.
No separate payment shall be allowed to the Contractor for forming joints or
chipping and cleaning them or cover with slurry prior to concreting. The
number of construction joint shall be kept minimum and the spacing should
not exceed three (3) meters. The Contractor shall submit to the Engineer,
any proposal of providing construction joints to facilitate his work, for the
study and approval of the Engineer well in advance.

21.02.00 Construction by Slip-Form Method

21.02.01 Slip Form

The RCC shell of the chimney shall be constructed by using slip form
technique. The slip form shall consist of a central ring and tower system.
Normally the slip form shall be of radial beam system having two levels of
beams, upper and lower level beams, radiating out from the central ring
beams to the slip form yokes equally spaced around the circumference of
the structural wall.

The lower beams shall be made up of hand able standard unit trusses
bolted together to make up the required start diameter. To accommodate
the wall taper the beams are shortened by removing units as the slide
proceeds.

The bottom beams shall be further supported by under trussing. A Radial
Control gear by which the radius of the concrete shell is controlled shall be
attached to the outer ends of the upper and lower beams. This shall be
activated automatically or manually linked to the upward movement. The
slip form shall preferably have at least two working platforms at lower radial
beam level as a main working deck and for access to the hoist cage and at
the upper radial beam level as a control point for the radial and batter
adjustments at the yoke positions.

Access to the shutters and to the concrete surface shall be provided by a
circular platform under the lower radial beam for the inner surface and by a
three level circular platform supported from the outer yoke post for the outer
surface.

A special safety net consisting of man carrying mesh with a smaller mesh
for materials shall be provided to envelope both the outer platforms and the
inner hung platform.

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Shuttering shall be of standard lap sheets hung from high tensile steel rod
walers, threaded through holes drilled in the yoke posts.

Steel embedment, chases and openings as per approved drawings shall be
fixed or formed in the shell where steel frames are used for openings, they
shall be rigid, reassembled and fixed in position. For small openings
wooden frames may be used.

The spacing of jack rods, shall not be more than 1 m or as approved by
Engineer. The jack rods shall be left (no retrieval of jack rods is allowed) in
concrete and they shall not be figures as reinforcement.

Jacks used in Hydraulic Jacking system for slip form shall conform to
relevant Indian Standards.

An accurate height measure shall be installed.

The Contractor shall furnish with his bid complete details and literature of
the slip form he proposes to use for the concreting of the shell.

The Contractor shall be responsible for the safe operation of the slip form
and the safety of the labour, supervisory staff, others during the concreting
of the shell by providing hand railing around the platforms, lighting (500 to
1000 lamps with reflectors shall be provided, fixed on scaffold tubes
attached to the yokes, 3m to 4.5 m above the working deck and 4.5m to 6
m apart), Intercom arrangement, etc. In case of power failure, battery
operated emergency lights on working deck shall be provided.

The Contractor shall also provide all arrangements like hoists, winches,
chutes etc. required for the transport of the materials to the working
platforms.

Ambient temperature and the resultant impact on the concrete temperature
at the time of placement shall be taken into account while deciding the
speed of the slip form. If slip forming is to be carried out in summer, (May to
September) slip-forming speeds up to 250 mm per hour may be used. In
case lesser values are contemplated, retarders conforming to relevant
Indian Standard Codes and approved by the Engineer shall be used.

The Contractor shall ensure, that no dragging of concrete with the upward
movement of the slip form shall occur. Twisting in the horizontal plane of
the slip form assembly and tilting. In the vertical plane of the slip form
assembly shall not be allowed. The Contractor shall be responsible for any
such occurrences and he shall have to make good for these as per the
directions of the Engineer at no extra cost.

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The minimum compressive strength of concrete immediately below the
bottom of the form panel as the slip form proceeds shall under no
circumstances be less than 1.5 kg/ cm
2
.

The Contractor shall submit to the Consultant / Owner with two months
after the award of the work a construction methods statement indicating the
following in his statement:

a) Description of equipment for slip forming and for concreting
operation.

b) Structural analysis regarding the adequacy of slip form equipment.

c) Standby arrangements for equipment.

d) Requirement of quantity of materials for each stage of construction.

e) Planned manpower for operation and supervision.

f) Planned rate of slip forming and details of concrete mix.

g) Planned interruptions.

h) Description and frequency of dimensional and verticality checks.

i) Description and frequency of tests for concrete and raw materials.

j) Methods of preparing, transporting, pouring and vibrating and
finishing concrete.

k) Contingency solutions for rectification of probable defects during slip
forming.

l) Plan of operation during planned interruptions including retrieval of
jack rods, resetting of from panels etc.

21.02.02 Tolerances:

The permissible tolerances should be as per IS specification

21.02.03 Precision instruments using laser beams (minimum 2 nos.) shall be used
for maintaining the formwork in required axis and for carrying out various
checks.

21.02.04 Precision instruments like optical plummet to monitor the tilt and twist in the
vertical plane and horizontal plane respectively shall also be provided.

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21.02.05 Sufficient anchorage shall be provided for the slip form structures in the
initial stages of work against wind pressure till the jack rods are embedded
enough to take grip.

21.03.00 Chimney Steel and Metal Work

All workmanship shall be of best practice in modern structural shops, and
shall conform to the provisions of the IS:800 and other relevant IS
Specifications, unless otherwise specified.

21.04.00 Painting

The metal surfaces, which are to be painted, shall be prepared properly as
stated elsewhere in the specification.

All paints shall be of make and shade as instructed and approved by the
Engineer. Necessary test certificates, manufacturer's literature and samples
shall be submitted to the Engineer, for his approval, before bulk purchase is
made.

21.05.00 Galvanizing

All steel including threaded bolts, nuts and washers, unless specified
otherwise in contract, shall be hot dip galvanized in accordance with IS
Specification or American Society for Testing and Material Specification
ASTM 123.

All members to be galvanized shall be cleaned thoroughly, to the
satisfaction of the Engineer, by the process of pickling. Pickling shall be
carried out in an acid bath containing sulphuric or hydrochloric acid of
suitable and adjusted concentration and temperature. Pickling process shall
be completed by rinsing the members thoroughly in warm water.

Galvanizing shall be carried out by hot dip process in a proper and
uniformly heated bath and it shall meet all the requirements when tested in
accordance with IS: 2633. The zinc coating shall be of uniform thickness
with an acceptable minimum value of 610 gms/m
2
for structural steel. If the
galvanizing of any member is damaged, the Engineer shall be shown of the
extent of damage and if so directed, the galvanizing may have to be redone
in the similar manner stated above.

21.06.00 Erection

Erection of structural members and C.I. Chimney caps shall be done as per
requirement of IS: 800. The Contractor shall submit to the Engineer a
programme of erection for his approval. All plant, equipment, tools, tackle
and any other accessories required for the erection shall be provided by the

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Contractor. Storing and handling of fabricated materials for erection, setting
out of members, providing temporary supports, bracing, fasteners, bolts,
nuts etc. shall be the responsibility of the Contractor and shall be taken into
account in quoting the rate.

21.07.00 Cast Iron Cap

The Cast Iron cap, fitted at the top of the chimney, shall be of thickness not
less than 12 mm. This shall preferably be a single cap covering both the
concrete shell and the lining, with the segments bolted together securely
and properly anchored inside the concrete in such a manner as to form a
complete annular unit, allowing for unequal circumferential and vertical
expansion and contraction of concrete shell and lining and for deflection of
shaft due to wind.

All bolts, nuts, washers, rag bolts and other fasteners as required for fixing
cast iron cap shall be of bronze material. Gaps between segments are to be
filled with asbestos mill-board or fibre-glass packing. Casting is to be
assembled to match with the dimensions specified in drawings, before
despatch to site. C.I caps to be painted with two coats of Acid Resisting
Paints over primer coats as recommended by paint manufacturer.

21.08.00 Insulation and Packing

All packing and insulation material shall be of thickness, diameter and type,
shown in the drawing. The packing and insulating material shall be made of
asbestos rope, vermiculite concrete, slag or mineral wool and asbestos mill-
boards.

a) Asbestos Rope

The diameter of the rope shall be as per drawing. The material shall be
of best quality available in the market and shall be purchased after a
sample is approved by the Engineer. The rope shall be plain, Grade-I,
conforming to IS: 4687-1968. The strand shall be long, well twisted and
no torn thread shall stick out. The rope shall be firmly packed so as to
prevent gas leakage.

b) Slag or mineral wool

The thickness of packed slag wool shall be as shown in the drawing.
The packed density of the wool shall be within the range of 175 to 200
Kg./m
3
and the co-efficient of thermal conductivity shall be within the
range of 0.025 to 0.035 Kilo Calories/hour metre
o
C at a mean

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temperature of 150oC. The material shall be well packed in position
where possible. IS: 3677 for Rock and Slag wool mats for thermal
insulation may be referred for guidance. The co-efficient of thermal
conductivity and packed density shall be tested according to IS: 3677
and IS: 3346.

c) Vermiculite Concrete

Vermiculite concrete shall be made by mixing exfoliated vermiculite,
portland cement and water. It shall be of Grade-B, having a density of
210 Kg./m
3
. The vermiculite aggregate size shall be maximum 6 mm.
The mix shall be 1 cement and 8 vermiculite by volume.

d) Asbestos Mill Board

Asbestos mill board shall be of thickness as indicated in drawing. It shall
be of best quality of standard make available in the market and samples
shall be submitted to the Engineer for approval. It shall be plain, dense
and homogeneous texture, without cracks, flaw and any other
manufacturing defect. It shall be laid directly onto the concrete bed after
removing any loose material or any aggregate. The concrete shall be
prepared without mortar so that the board can have a good seating.

21.09.00 Lightning Protection System

21.09.01 General

The lightning protection system to be installed on the chimney shall satisfy
the following requirements.

21.09.02 Air Terminals

The Chimney shall be provided with pointed air terminals uniformly
distributed along the top rim of the chimney. The projected length of the air
terminals above the top of the chimney shall not be less than 1000 mm.
The air terminals shall be made of lead coated solid copper rods having a
minimum diameter of 20 mm. The air terminals shall be secured to the top
of chimney by at least two fasteners of substantial construction to withstand
high wind pressure acting in the area commensurate with the height
involved. All the air terminals shall be electrically connected together by
means of a band of 75 x 6 mm galvanized steel flat, which shall form a
close loop 600 mm. below the top of the chimney. Each segment for the
cast iron cap of the chimney shall be connected to this galvanized steel flat
band by means of tightly bolted connections.

21.09.03 Down Conductors

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Two numbers of vertical down conductors of 50 x 6 mm. galvanized steel
flats shall be provided, spaced as shown in drawings. The down conductors
shall start from the top encircling band, leading to the ground. Galvanized
steel 50 x 6 mm. flat bands shall be provided below each balcony.
Encircling band, below each balcony, shall be electrically connected to
each down conductor. The connections of the galvanized steel down
conductors to the copper air terminals shall be brazed and connection to
the nearest grounding grid at the bottom shall be arc welded. Connection
between any two galvanized steel flats/bands shall be made by arc welding.

The galvanized steel flat encircling bands shall be supported at an interval
of maximum 600 mm. and the vertical down conductors shall be supported
at an interval of approx. 2500 mm. The fasteners shall be of same grade of
material as the conductors and have to be galvanized. The conductor shall
be laid straight and sharp bends shall be avoided as far as practicable. A
suitable bolted test piece shall be provided at each down conductor at a
convenient height near the bottom of the chimney.

At All supports, the portion embedded inside the chimney shell concrete
shall not touch the reinforcement bars and shall be duly insulated from
them.

21.09.04 Bonding

All exposed metallic parts of the chimney shall be bonded to the down
conductors. Such parts shall include ladders, balconies, conduits, etc. If the
metal has considerable length, it shall be bonded at each end. If the
metallic components are composed of electrically discontinuous parts, each
part shall be bonded to the down conductors. The bond shall have a
minimum cross sectional area equal to that of the down conductor.

21.09.05 Joints

The joints in the lightning conductors shall be kept to a minimum and there
shall be no joint in the underground portions of conductors. All joints, except
those for the air terminals, shall be done by arc welding process.
Overlapping of the conductors at straight joints shall not be less than 150
mm. The bolted joint of the test piece shall be covered with thick coating of
bituminous paint after successful testing. The connections between the
M.S. down conductors/short piece (of 50 x 6 mm. galvanized steel flat) and
the copper air terminals shall be brass brazed as shown in the drawing
(with the help of brass rods, manufactured by Indian Oxygen Limited (Silos
or Ruptum 14) or equivalent.

21.10.00 Aviation Obstruction Lighting System

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Anx-III

Date: 25-11-2008 Page 29 of 31

21.10.01 Lighting System

The Contractor shall supply and install the aviation obstruction Lighting
system on the chimney: -

a) 4 sets of single obstruction lights with fixtures at balcony levels.

b) Complete C.I. conduits, PVC insulated wires, G.I. grounding conductor,
weatherproof outdoor junction box and all accessories viz. supports,
clamps, junction boxes, etc. to make the installation complete in all
respects. Conduit wiring shall be from the lighting fixtures to the junction
box located at the bottom of the chimney.

21.10.02 Lighting Fixtures

The lighting fixtures shall be suitable for 240 V + 10%, 50 Hz + 5%, single
phase, A.C. supply. All fixtures and accessories shall be weatherproof,
outdoor type, capable of withstanding highly humid and flue-laden
atmosphere. The obstruction lighting fixtures shall be LED based of
medium intensity and complete with all necessary accessories. A set of four
nos. single lights shall be installed on each balcony at 90
o
apart with
suitable supporting arrangement to withstand high wind pressure. The
number of fixtures and the levels on which the fixtures shall be placed shall
be decided based on ICAO regulation.

21.10.03 Conduit Wiring

All the obstruction lights shall be uniformly distributed over three single-
phase circuits. Conduit wiring for lighting installation shall be done with PVC
cables drawn through the G.I. conduit of proper size. The GI conduits shall
be terminated to a fuse box mounted on the chimney shell, at an accessible
height from the ground. The cables shall be 1100/650 V Grade, 1/c, 10mm
2
,
PVC insulated and sheathed Stranded Aluminium conductor. The conduits
shall be clamped at interval not greater than 600 mm. by means of
approved type of saddles, clamps, etc. securely fixed on the shell/ladder.
PVC bush shall be used at either end of the conduit. The minimum size of
conduit to be used for the installations shall be 65 mm. Pull boxes, at
intervals of not more than 10 meters, inspection bends, etc. are to be
provided at suitable locations to facilitate laying of wires. 8 SWG G.I. wire
shall be run along the conduit for grounding purpose. All conduit
accessories and junction boxes shall be hot-dip galvanized and of approved
type. Wiring shall be done as per the relevant IS. Specification.

21.10.04 Junction Box

The junction box at the chimney bottom shall be weatherproof and suitable
for flue laden atmosphere and provided with suitable terminal blocks and

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GMR ENERGY LIMITED

Project
CHHATTISGARH, INDIA
Vol.II,
C0
Anx-III

Date: 25-11-2008 Page 30 of 31

conduit knockouts for incoming and outgoing conduits. 4-core PVC
insulated cable with Aluminium Conductor will be used to feed power
supply to the bottom most junction box which shall have suitable double
compression type cable gland for erection and installation of cables.

21.10.05 Painting and Lead Coating

All welded joints with galvanized steel shall be provided with cold
galvanizing paint. Other accessories necessary for lightning protection as
well as brackets, supports and other items of obstruction lighting
installations, shall be painted with two coats of Red Oxide priming paint and
one coat of Aluminium finishing paint. The Red Oxide paint shall be applied
on the down conductors and bands before installation and the Aluminium
paint coating shall be applied after the installation is over. The copper air
terminals, conductors, fasteners and other accessories upto the top
encircling band shall have a continuous lead covering of about 2 mm.
thickness, for protection against corrosion due to gases and weather.

21.10.06 Temporary Obstruction Lights

The Contractor shall provide at least two (2) lights located at diametrically
opposite points at the top of the chimney during the period of construction
till the permanent obstruction lights are installed and energised, to serve as
temporary obstruction lighting.

21.11.00 Information to be Submitted

21.11.01 After Award

The following information and data including samples where necessary,
shall be submitted by the Contractor, progressively during the execution of
the Contract.

21.11.02 Design Mix

Design mix as per details of this specification giving proportions of
ingredients, sources of aggregates and cement along with accompanying
test results of trial mixes as per relevant IS Specifications shall be
submitted to the Engineer, for his approval, before it can be used on the
work.

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GMR ENERGY LIMITED

Project
CHHATTISGARH, INDIA
Vol.II,
C0
Anx-III

Date: 25-11-2008 Page 31 of 31

21.11.03 Detail Drawings

Following items shall be provided by the Contractor, which are to be
approved by the Owner.

a) Detail drawings and designs of formwork including scaffolding to be
used. If slip form method of construction is adopted, then detail
drawings showing all the arrangements for slip form technique including
methods for reducing internal diameter and providing required slopes on
outer diameter.

b) Detail drawings and bar bending schedules for concrete components.

c) Shop drawings for steel and metal work, including inserts etc.

d) Detail drawings for templates and temporary supports for embedments.

Annexure-III Chimney Spec (1) .

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