yor — Spesificalian for Fabr on & Supply © | OT aerial in 2S Control 1 Materia! in © seal | | AANED Sennett | aveysinsoking | pan, Ennore TPS Project __—- SUB-SECTION: 4B TECHNICAL § SPECIFICATION OR URAL STEEL MATERIAL | RUCT (ORKS FABRICATION & SUPPLY on sr | pocumeNt Ko. 30, TL. oversTpesificalion for Fabrication & Supply of EZRA EG Srctira Soot tora in Centra) Contd : Building and Flue Gas duct supports for 4x60 vo ag MV. Ennore TPS Project | CONTENT CLAUSE NO. DESCRIPTION PAGE NO. 1.0.0 SCOPE 03.93 2.00 GENERAL 93-15 3.00 WORKMANSHIP “622 4.0.0 INSPECTION, TESTING, ACCEPTANCE 23-80 GRITERIA AND DELIVERY 5.0.0 INFORMATION TO BE SUBMITTED 3081 500 RATES azaz 700 METHOD OF MEASUREMENT 32-33 LMECVEOASPEC-PUBOR] Pape 20f 25 DOCUMENT NO. Utjlivation for Fabricalion & Supply of I Steel Material in Central Control Building and Flue Gas duct supports for tx660 MW, Ennore T?S Project ‘ysis TECHNICAL SPECIFICATION FOR FABRICATION OF STRUCTURAL STEELWORK 19.0 SCOPE lee! stiuclures for Cental Control Ths specification covers supply of fubrical Bldg and Flue Gas Quct Support Struciuress ~ ESP Inel, ESP Oulle & In Chimney and delivery of the same for all tems, structures rotguirad fr all Lype of connection Including the bolts, nuts, washers, and other materials required ‘OF Tisid Connections of all structural steelwork In general covered under tha scope ofthe contract. This specfication contains the technical requirements for the supply and fabrication of slecl structures. In no way this specication is intended! to deseribe or replace the expected and required first class workmanship for the complete fabrication of structural items, both for stronglh/technical issues and for visual sspec's Fabrication Contractor shall prepare the required calculationsidesign work for ail the connections Contractor shall prepare ard present drawings and calculations timely for approwal hy LIT and annmvel Authority 2.0.0 GENERAL 24.0 Details of works fo be provided by te Contractar ~ The work to be provided by the Contractor, unless otherwise speci‘ied elsewhere In the contact, shall nelude, but not be limited to the following: ~ a) The etructural stool work required to be fabricated, painted and supply for arass as listed below and for 1X 660 MW Ennore TPS project, Central Control Bldg (CCB) Fius Gae Duct Suppor: Siructures — ESP Inlol, ESP Outlet & Chimrey Inlet vv Major steel structural works involves are listed as below — Fabrication of all Main & Aus, columns includirg colrn base plates Fabrication of all main & sccordary beams Fabrication af brecings and wall beams Fabrication of siaireaso stucturoe including landing platforms 4 grating stops ob. Fabrication of plalforms, handrails (corfiming te 18 1298) gratings (prossure locked), chequered plates ote, veyyve % DOCUMENT NO. LITLO?6.VE-104.5PEC-PUB.O20 | Page 4 ofLANED Structural 2) DOCUMENT NO. LITL-026-CVE104-SPEC-PUBAI20 | Page i ot 3 & Supply ot in Contra) Co: Speciticat Building ann Flue Gas duct supports for 4x660 | pla ic NeW, Ennore TPS Project ©) Surlace Preparation & Painting — “& Surface reparation - surfaces shall bs elannad hy qrisend blasting conforming lo Swedish Standards SA 2.1/9 “Primer Coat — Application of Zine sieato Primer of OFT 75 microns by sprayfailess spraylas per manufacturer -spesifications + Intermediate Coat — undsrcoat of 2 pack epoxy with micaceous iron oxide pigment in bvo coats as ser manufacturer instructions giving a total DFT 0! 109 microns. + Finish Goal- finish ceat of high build polyamiee cured with 2 pacc epoxy pignented with lade resistance, chemi fesistance, colar pigmants giving a total DFT of 100 Microns, + Top finish coat of polyurethane paint of DFT 35 micron for UV protection. Thus structuros/surtaces expored ta slmosphern coating with @ total DFT of 905 ricrons would applied, ) Supply ard Delivery of al fabricatod materials f sections as ep conrestions, supply of all necessary bolts, nuts, washers, ctc. completion of the above stated arzas up th tne project sile. ‘All payment shal be med2 as per final / approved 30Q of aulo cad ‘drawings and the certified wt. shall be considered for payment, Na payment shall be mado towards weld deposit wi, painting wee Suitably mark, bundle and pack for transport ol al fabriceiec materials Preparation of detailed fabrealion dranings for above listed areas {Works ‘which shell be approved by LITL betore siart of fabricarion worss. Prepare and fumish detailed Bl of Materials, packing lists, coanecton ‘calculations for auproval, Bolt List and any other list o bough! out items required in| Gormigclon with the fabrication and eraction of the structural ssloviwark All field connections shall be of Lulted type and the quality of bolts shall ba HT /HSFG Bolts (10.9 Gi) used Contraster jo may alsa read ly inleracl ¢ ulscuss wil client censutant (SWEPDI / Chengdu) for any problem | carily in cunsullation wih Client am. Contractor to provide al the relevant connection caluulations in Excel fexrrat.‘Specilication for Fabrication & Supply of LANCO | Spectra Steel Motrin Coral Conte Building and Fiue Gas duct supports for 12660 TOES MMW, Ennore TPS Project l m) Contractor to taco Immedaile steps in case of any revision in Design drawings. (proviced by client) by revising the fabrication drawings andl changes in fabricatad structuress whenever needed without any oxtrs cost to cient (LIL. n) Contractor to ensure the correct & accurate fabrication and also to canyout prote lest for each assembly of the fabricated maternal in the shop itself belore dispatching of the consignment. 6) Ia case af major discrepancy in the latvivated material recd trom thi contractor, all such moctficator shall be cared out the cantracior at sits at their own cost. I lailod to da, ellent (LITL) shall be carrying out such modification at site by themselves and the incured cost shall be recovered | debited from the Contractor. ph Contractor to deploy their engineer at project sily during nloading and throughout the erection period for receiving ad icertitying the each sonsignment J material so ‘hat to ayole any missing of the fabricated material q) ‘Contactor to provide the erection sequence / procedure for their scope of Jabricated materia $0 that smooth erection of tie matesial done at site. 1) Contractor shall provide the deiail marked up drawings by merking 1 coouring the fabricated tems / dissalched items of eactt consignment packing list ¢9 that completeness of the fabrication scope cf works ean be roviewed / checked by slient (LITL) and to avoid any dupiily of the work 5s) Contractar to cary out the Fabrication works crid wise covering top to boltom elevation and as per direction of LITL enginecr. {) Insuro, load and ‘rarsport all fabricated steelwork field connection materials to site 220 Codes and Standards Ailwork under this specification shall, unless athenvise specified in the contrat onfiem to the requirements of the latest revison andior replacements of lhe ‘ollowing or any other relevant Indian Standard specications and codes of raetice. equivalent international codes. List of applicable Indian codes are ligted below = Is:890 ~~~ Cade of practice far general construction in steel. [oocumentno, cruarecvenioasreerupaze |Ppage = of * \ification for Fabrication & Supply of i Structural Stecl Material in Gentral Gontrol Building and Fiue Gas duct supports for 1x660 LAM Anes nspirg | MW. Ennore TPS Project I$:801 = Cade of practine for use of eold formed light gauge tee! structu-al members in general uilding conswruction. 1s: 806 £ Code of practice for uso of steel Lihes in general building constructisn 1$:808 =~ Dimansions for rolled steel beams, channels: and angle sections. Is: 812 Clossary of lorms relating to welding & cutting of metals, 18.813 ‘Schama af symbols for valding is:814 Covered electrodes for metal are welding of carson snd sarcon manganase steal $2815 - _ Classifiection coding of covered slectrodes for metal are welding of mild stecl and law allay high tensile steel, 51816 s ‘Cade of practice for use of metal are welding for genera construction in rid stocl IS: 017 es Code of practice for training & testing motal arc welder. 13:8) = Cote of practice fer safety end health requirements in dectrie ard gas welding and euting operations. 18: 822 = Goce of practise for inspection of walds. Is:919 - Recommendations for limits and fits for angineering. (Part- 182) 15.1182 = Recommended prastice for Radiag-aphic Examination of futon wekled bust joints in stecl plates. 1521200 = Muthad of measurement of steel work and iron work (Part- 8) IS: 1239 = Mild sleed lubes, tubular & other wrought steo! fitings (Pan 182) 1521363 =) Hexagon head bolls, screws & nuts of product grade G (Pan- 110 3) ITL-926-CVE-1o4-SPEC-PUBO20 | Page ¢ ot 2 Sf ;‘Specification for Fabrication & Supply of ZAM E ED | strvctiral Steet Material in Control Contes Building and Fiue Gas duct supports for 1x660 eee MW, Ennore TPS Project 1S: 1364 Hexagon heat bolls, screws and nuts of aroduct grade: {Part - 1105) Aas |S;1808 ~~ ~——_sMlethod for tense testing of steel products. 1$:1730 - Dimensions fer steel plate, sheet anc sli for structural and general engine2ring purpuses. 15: 1852 -—_ Roig and cutting toleranoas for hot-ollad steel praduck 1S:1977 —--—_‘Structurel steel (Ordinary quality} 1S: 2016 + Plain-washer 1$:2062 = —_-Steol for general stuctural purposes. 18:2683 - Method for testing uniformity of coating en zinc coated Is:3787 - ich Shength Strustural Erott 1g:4000 = High strength bolts in staal structure 1g:5369 =~ General requitsmerts for plain washers and lock washer. 1$:8843 —- —-Spenification for hardened and tempered washers for high strength structural bolts ard nuts, 18:6623 - —_‘Secfficatian for high stongth structural nuts 1S:7215 = —_Telerances for fabrication of steel structures, 1S:7280 - -—_-Bare wire electrode for submerged are welding 18-8500 - Structural steel micro alloyed (medium & high stengtn qualiy} PAINTING DOGUMENT NO, LITL.029-C¥" suasreo-ruet2o | Page? of 35‘Specification for Fabrication & Supply of Structural Steel Material in Central Control Bulltng tnd Flue Gas duet supparie for 650 | iv, Erte TPS Projet | LANEO ‘Always nspiving 19:11? + Specificalion for ready mixed paint, brus exterior, semi-gloes, for general purposes. hing, finishing, 183128 = Specification fer ready ritecd paint, brushing, finisring, semi-gloss for general purposes, blac IS. 1477 ‘Gade of practice for painting of fomous metal in building (Pat-18M) Is: 2074 Ready mixed paint, airdrying redoxide zinc chrome pining. 240 Conformity with Designs Except where the standerd connection delails are fumished, the contracior shall design all connections, fabsicate all slawhwork andl fumish all eonneetion materials in agcordance wiih ine approved Uravengs andior as instructed by the Engineer keeping 1 viow the maximum utlizaion of the available sizes and sections of steel materals. The methads of painting, marking, packing and dolvery of all fabricated materials shail 9¢ in accordance with the provisions of the cantact andior as approved by the Engineer, Provision of al relevant Indian ‘Standard Specifications and Codes of Practice or equivalent as specified shall be followed uniess otnenwise: specited in the contract Materials to be used 264 General AM stee! materials shall be free from all imperfections, mill scales, slag intusions, laminations, pitting, rusts ote. thot may impair thelr strengtn, durability and appearance. Il materials shall be of tested quality only unless othenvise permitted by the Engineer and/or Consultant. Hf cesired by the LITL Engineer, Test Gerlficates of raw materials used by the contractor in respest af each consignment shall be submitted. A raneom sample shall be tested at an appravad laboretary from each lot of 100 tonnes or less of any particular section, The ere walding electrodes shall confirm to the relevant Indian Standard Codes of Practice and Specfications or equivalent and shal bs ol heavily coated ype and the thickness ef the coating shall be uniform and concentric. With each container of electrodes, the manufacturer shall jumisn instructions. giving recommended vollage and temperature (Polarity in case of D.C. sugply) for which the electrodes are suitable. DOCUMENT NO. LITL.O26-CVE-ADLSPEC-PUB-I20 | Pageeee ip AME aise tn Gas bn upper _Mwi, Ennore TPS Project 2.5.2 Steo! All steel malarals lo be used in fabrication within the purview of this spacification chall comply with the following Indian Standard Specifications as may be applicable: indian Cede 18 2062 Gr - E350 BR of Viel strength 850 Mpa — for all stocl matotial such Plates. Beams, Channels, angles ateto be ‘The structure steel and sheped steel used in this project should be straight, sound, fee from taiats, cracks, flaw, laminates ane other dofects, and shall conform to Indian current national standards Table 2.5.1 Mechanical Property of Steel Grade Designation | Thicaness (mm) Vie stress (Himm2) 350 =20 350 20-40) — [330 = ___ [eas 320) a # Steel vall contonm to Grade-Avof 1S:2082 (latest) for rolled steel! mambors er plates up to 2 mm thickness. For alates anove 20 m7 thickness andl welced uction steel conforming te Grade-B (ciled and normalized) of IS: 2062 i Iba used except for srane girders where Grade-C (IS; 2062) ste shall be used. Sleel shall ba prosufec from any other appraved vendors by’ um, The column and beam of main building and other structuresbuileings will be oF net-rolled or welded H-shape sleel. The seller shal provide qualified production and quality certificate. The guaranteed ilerns af steel shall nelude ‘onsile test send test, impact test, Y groove crackabilty tes!, ele. and composition oF Carbon, Sulphur, Phosphorus not exceeding Imitation Tha crane girder shall be quaranteed for match the requirements of notch toughness requirement mentioned in IS:2082 standard, The material of stillerer, gusset and connecting argle steel shall be same with the member to be connected. Chequered plate shall conform to 1S; 3802 jlales!) and minimum thickness of chequored plate for flacrings, covers elt shall be B nim OYP. The grating shall be het dip galvanized. DOCUMENT NO. LITL-O26-CVE-104-SPEC-PUB-020 Fage 9 wt 35LANCGO Structural Steel Material In Central Control Abensinspring 254 Specilicalion for Fabricaion & Supply oF Bullding and Flue Gas duct supports for 1x660 NW, Ennore TPS Project The selection of material of building structures refers to the dasign guide drawings Stecl material property — physical & chemical proportios of the steel material shall be a per attached annexure - | to be used for the fabrication. STEEL SUPPLIED BY THE VENDORICONTRACTOR The contractar should purchase the steel materials from market in strict adherence ta the specications laid down and as per the abave Indian and Intemational code: The VENDOR/GONTRAGTOR shall fumish to the PURGIASCR! CNGINCER duplicate copies of all mill orders covering the material ordered by him for tis prejuct umd alsu lhe lest reports recalved tram the Mills for the PURCHASERIENGINEER'S eheck ant infomation. It is not the intention of tho PURCHASCR that all the stes! materials to be suppled by the VENDOR/GONTRACTOR for the work shall be specially purchased from the rolling mills. Ths VENDOR! CONTRACTOR'S. stock Material ray be usec, arovided the mill test reports identified with the materials, salis‘actorily demonstrate he specified grado and quality. The PURCHASER shall have the rght to test certificates produced by the VENDORIGONTRAGTOR al the VENDORIGONTRACTOR'S cost. All stec maleials supplied by Uz VENDORYZONTRACTOR shall be in a soune vondilion of recent manufacture, free from defecis, loose vill scale, slag intrusions, laminations piling, flaky must, etc, and be of full weight or thickness: specified. The langltsfsizes of steel sections and plates shall be as supplies by the steel mills, SUBSTITUTIONS Wiherever duo to non-availability of design sections work i likely te be fell Up, the substitute seeilone may have to be used, These subsiitutions stall Le nade only afer authorization it writing by the ENGINEER, Electrodes ul elactrodes to be used under the Contract shall comply with relevant Inciian cade or any ol the tallowirg indian Standard Specifications, as ale: Za DOCUMENT NO, LITL-026-CVE-WD4SPEC-PUB-20 | Page Lt of 35‘Specification for Fabrication & Supply of LEMEO ‘Structural Steel Material in Central Control Buikting and Flue Gas duct supports for 1x60 o Lacie MV¥, Ennore TPS Project es 1: 814 =” Covared electrodes for metal are-welding stmchurat steel 1s: 815 - _ Qlatsifleation and coding of covered electrodes for metal are weeding of mild steel and Iew alley High te 1$:7280 --——_Basawiry electrode for submerged are w All electroces, flux bere wire etc. shall be procured by the contractor only from approved manutactursrs, 254 Bolts and Nuts All bolts and nuts shall ccnform to the reculrements of Indian Standard Spaciication or equivalent intammational code, Class 10.9 of LS: 1367 for HSFG Bots and nuts Materials for Bovts-and nuts under the purview of tis centract shall comply with relevant Indian codes or avy of the following Indian Sisndard Specifications as may be applicable. a) Mi Stes! - All mild sleel for bolls and nuls when tested in ecoordance ‘with relevant indian coda or the foloning Indian Standard Specificarior shall have a tensile: sbength of not less than 44 Kamm? and a minimum ‘elongation of 23 per cent on a gauge lengt of 5.6 GA, where ‘A’ is the ‘2058 sectional area of the test specimen : 13.1967 =~ Technical supply conditions for threaded fasteners, 1S : 1608. Wethod for tensile testing 9° steel other than she | Slip, wire and tube, b) High Tensile Stoul; The imalerial used (or the manufacture of high tensile steel bolls fuls shall have ine mechanical properties appropriate to the particular class of sleel as sel oul in relevant Indien code or |S; 1367 or as approved by the Engineer. Alibolts, nuts ard washers shall be procured from the manufsclurers ass approved by Purchasar. ©) High Strongth Frictior Grip Bolts: HSFG bolts shal be high tensile of 20 mm dia. or of hgher clameter and cf Eropory class & 6 (mnimum) as per relevant [S-1367 (latest) tor all major connections. All nalts, nuts and washers shall be procured from the manufacturers as approved by Engineer. The bolted joints shall be designed fo friction type connection DOCUMENTNG, LITL-026-CVE-104SPEC-PUB-I20 | Page 1i of 33ion for Fabrication & Supply of LANES Structural Steel Material in Gentral Gontval Building and Flue Gas duct supports for 1x600 |_ee DW. Crnore TPS Project and the HT bolts chal be tightened to elewelop the required pretension during their installation 255 Washors Weehers shall ba made of stecl conforming to retewant Indian Codes or any af the fellowing Indian Standard Specifications as may 2 applicable under the provisions of the Contract 18: 1977 Structural stael (Ordinary Qualty) S420 18; 2062 Stool for general structural purposes IS :8500 Structural steel micro alloyed (medium & high strangth quality} 15/6623 = High Strength Struc-ural Nuts (IS: 6549 , Hardened and tampercd washers for high strangth structural bolts & mut 25.6 Surface Preparation & Paints All faoricated steel material, excopt those galvanised or to be ambedded in concrete, shall reosive paint coatings as specifiec. 1. Primer coat shall be applied on surfaces cleaned by grivsond blasting conforming to Swedish Standards SA 2-112 or equivalent IS. One coat oF Zing le primer of mirimum DFT 75 microns coal by spraylairless spray shall be applied after fabrieat on, 2. Intermediate Coal ~ undercoat of 2 peck epoxy with mick ‘oxida pigment in wo coats! as per manufacturer instructions DFT of 100 microns. 3, Finish Coat. finish coat of high build polyamide cured wih 2 pack epoxy Pigmented with fade resistance, chemical resistance, color pigments giving a total DFT of 190 Microns, 4, Top finish coat of polyurethane paint of DFT 25 micron fer UY protection, Thus structurasisurfaces axpased lo atmosphere, coating with a tolal DFT of 305 microns wauld applied. soous iron ving a total Duriny gaining, the air temperature: shall be wall above the dew peint and not less than 4.4 degiee © and the relative humidity not greater than BO%. The lime of painting shall ba such that moisture Coes not condense on the structure bevone cr during paining uF Unbl Wie paints dry. All nsinuctions as par the paint manclacluners specications! requirement shal be:stictly adhered to. DOCUMENT NO. LITL-028-CVE-104-SPEC-PUBI20 | Page 12 of 29Specification for Fabrication & Supply of CT oe oa ive Ges tu! uppee fr 08 re TRS Project Tho surface of steal work ta be painted shall ko thoroughly cleaned of all loose mill scale, "ust. 9 dirt and sitrer foreign matter by sendishot Blasting only. Adequate care should be taken such that fhe Surface does not possess a slick finish to whicn paint may not adhere properly Joints te be site welded shall have no paint apalied within 100 mm of weling zone. Similarly where fietion grip fasteners are :o be used no printing shall be provided. On completion af the joints the surfaces shall raneive the paint a8 specified. Surfaces inaccessible aller assembly shall receive two coats of primey prior to accembly. Surfaces inaccessible siler oroction including top surfaces floor beams supporting gratings or chequered plato shall receive one additional coat of finish paint avar and above number of coats specified be‘ore erection. Portion of steel mamber emoadded / to be encased In concrete shall nal be painted. Painting would net be dong in trey or foggy weather or whon hu such as to cause: cordensation or the surfaces to be painted ty fs All painting works oro carried out oo applicable IS standards, BS 5193 end manufacturer's structions The contact surfaces shell be cleaned by hand wire brushing or by other ‘methods of flux depesit, dit and ether foreign metter. Oil and grease deposits shall be removed by use of solvents, Machine finished surfaces shall be protested against corrosion by a mst inbibiting coating that can be easily removed prior to erection or which hos characteristics that make tersovel unnecessary prior ta e-action. Removing loase mill scalo. rusl, weld slay or After erection touch up painting, making good any damaged shcp painting end completing any unfinished portion of the shop coat shell be carried out by the contractor frae of cos! to the Purchaser. The materials and specifications shall be in asoordance vith the requirements of good practice. All balts, welds, and ebrasiors to the shop cual shall be pointed with the same: gaint used for sop coat 2.6.0 Storage of Material 2.61 General During the transportation /storege the fabricated material shal be subjected to highly corrosive Sea atmosphere and thus all the adequete precautions needs to be taken to avcid ard All materials shall be 50 stored as Wo p «————— | POCUMENT NO, LinLew0-cvs-osserceunny | Page 23 of 95Specification for Fabrication & Supply of LAWEO Structural Steel Mater Central Gontral Building and Flue Gas duct supports for 1x60 ‘Alsnys lasing NW. Ennore TPS Proj deterieretion and to ensure the preservation of their quality and Ftness for the Work Any material that has daterinrated or has baen damaged shall be remaved from the contractor's yard immediately, failing which, the Engineer shall be at liberty ta got tho material remowed and the enst incurroc thereof shall be realized from the Contrectar. Tho Contractor shall maintain up to date accounts in respect cf dispatches of the malarial on the hasis of area of usa | respective drawng na. ane rrark no, of tie s2eion, All materials maant for use in bis contract shal ke with easily identifiable marks 262 Steel The steel to be used in fabrication and the resultirg cut pieces shall ba stored in coparate stacks off the ground section wise and lengthwise sc that they eat bbe cacily inepocted, measured and accounted for at any time if needed. The fabricated matoviols may have to be stored under caver and sulably painted for protecticn againsl weather, f required as par instructions of LITL-Engineer, 26.5 Electrodes ‘The electrodes for electric sre welding shall be stored in property ¢ racks, sepavalng diferent types of clostredos in distinatly marked compartments, The elecirades shall be kept in a dry and warm condition nacassary by reserling to heating. All low hydrogen clectuces svall be beked and stored before uso as per manufacturer's recommendation. The electrodes shall be re baked at 26 Deg. = 300 Dag C for 1 hour and later an cooked in the same aven to 106 Deg.G, It shall be transfered to holding oven maintained at 60 Dec.C ~ 70 Dey.C. The electrodes shall be dravin from this oven for use, 254 Bolts, Nuts and Washers 3olks, rls and washers ad other festening materials shall be stored on racks off the ground willy a Gualing of suitable protective ol, These shall te stored in separals gunny bags ar comailinents eccording to diametes, length and ually 27.0 Quallty Gontro! ‘Tha Contactor svall establish and maintsin qual'y cunlrol procedures for different items of work and materials as per the Quelity Assurenice Plan ari im sccordance with this specification. in addition to the Gontractor's qualily cunt DOCUMENT NO, LITLO76-CVEdoa.sPEC-PUB-Ze | Page <4 or‘Specification for Fabrication & Supply of | ean | oe ai eat ara nore TPS Project. Contractor's fabrication shop. Thy Contractor shall an-orerala wth tha Engineer or Engineer's representative in permitting) acnass for insertion to all placa where werk is being done and in providing [roe of cost all neressary help in respect of tocls and plants, instrument, livour and matoriala roquined tr carry aut the inspection, The inspection shell be 30 scheduled as ta provirie the minimum in tomupton to tha work of the Contractor Materials or workmanship nol in reasenable conformance ‘ith the provisiens of thie Spacificatan may be rejected at any time during the progress of the work The cuality cone procecure shall cover but not be lirrited 10 the following itome of wrark a) Quality, manufacturers last cortifeates, teat reports. of rapresenistive samples of matorials from unidentified stocks f permitted to ba used, b) Bolts, Nuts: = Mangfosiurers certificate, dimension & Washers chocks, material tating, ©) Electrodes; «== Manufacturers cortificals, thicknose ane quality of Fux eonting dy Welders. t Qualifying Tests: 2) Weldingsots ; Performance Tests | Welds 2 Inspaction, X-ray, Ultrasonic tests, Dye panetration Test 0) Paints i Manufacturer's corificate, physical Inspection reports az Quality Assurance Plan (QAP) The contractor shal submit and ablain Purctasur's approval of the detalec QAP for workmanship, materials, testing and approval fer each tem of structural work prior to executing the works, Cuality Plan as slated in Section) 5-0 Is for reference only. GAP should includ the following minimum tests: a) Steel material - coCUMENT Na UTLaMFCESrEERURAAE [Rage te 2Supply of in Cantral Control duct supports for 4x660 LANEO Builuing and Flue G, Alas Inspiing i | my", Ennere ls above 26 mm thickness. shall bo ultrasonic tested as per ASTM the presence of lamination. (435 or equivalent le ct it Weld - ») Dye-ponetration Tests: 6% of the total length, dye-penotration test shall be carried out to the ) Butt-weld ii Dye-penetration Test - 105 of the total length. dye-penetration test shall be carried out to the root run afer back gouging, Radiography - Spot radiography shal be carried out on 100% joints in tenson zone of Crane Girder # Bunker Girder / Bunker & Deverator supporting structures aid 19% joints in compression zone. nae 300 rim length shal be spot radia craphod. Wherwver radiogtadtiy is not possible, ullrasonic test shall be carried oul aller grinding the surface with priar approval of Engineer. 19% of ull oller bull welds shall be subject to soct radiography tas fi) Ultrasonic Test - Balance out welds shall be subject jo ultrasonic lust 280 Standard Dimensions, Forms and Weights The dimensions, forms, weignts and tolerances of al rolled shapes bolls, nuts studs, washers atc. and other members used in the fabricatan of any structure shall, wherever applicable, conform to the roquirements of the latest relevai ingian Standards, wherever they exist, or, in tha abser-ce of Indlan Standards, to other equivalent standards. 290 ‘Shop Fab, Drawings Preparation & providing of detalad fabrication drawings is in the scape of DOCUMENT NO, LITL-O26-CVE-ID4SPEC-PUBI20 | Page Ii uf 3bcate ‘Specification for Fabrication & Supply of LANED Structural Steol Matorial in Centra! Control Guilding and Flue Gas duct supports for 1x660 ici BAW. Ennare TPS Project The contraster shall submit the dataled sequanticl schedule fer submission of tabrication drawings in Ine with the soqueatial fabrication works, 10 LITI within fourteen (14) days after the award of the sontract J previding of the design rererings. “Tho shop drawings provided by contracte’, will be mainly towards the general conform'y mith the design requirements as well as epocification, LITL shall also review the fabrication drawings. (correctness of general amangement for centerline dimensions and levels, Section sizes, and adequacy of conneetions including splice joints as to the no. of bolts, weld length, size of gussovend plates) at their end and if any discrepancy noticed, will inform to LITL immediotoly. The correctness of all other details ike auting lengths, matching of holes, notch dimensions, match markings, bill of materials, bolt ist ots. will bo entity the contractor's responsibilly Steel stuctures shall be delailsd and connection end joints provided as par orovisions of 18:20, 18:9695, I8:1967, ISG178 and ete. and as per the fobawing requirement © Connection of vertizal bracines wilh cannestion members and diagonals of truss members shal le designed for full tensile capacity of the bracings unless the actual oads are indicaiwe un the drawings. © Size of filet weld for flange to web comnoctior for bull: up scion shall boas follows: + For box saction weld size shall be casignec for 607% of full smear capacity o° actual shear whichever is more. YWhere Mat weld is. not passiblo, full penetration but weld shell ke provided ® For builtup | section, weld size shall be dosigned for 80% of lull shear capacity or acival shear, ff indicated in drawings) whichewer is mara. However, weld size shall not be less 0.78 times the web th ‘Weld shall be double fillet. All welds shall he continuous unless otherwise specially aapraved. The minimarr size of the filet weld stall be 6 rin. ‘= Shear connections shall be designed for 70% of section strength for volled sections and 80% of section sirenath of buill-up section or rolled section with cover plales. However, if actual shear load is more than above, the conneciion shall be designed for actual load. © Moment connecticn between beam ard column shall be designed for 100% of moment capacity of the bam sacticn, This can.achewed gither ] 5 DOGUMENTNO, LITL-026-GVEO4SPEC-PUBO2 | Paq2 17 of 35 gjs for Fabrication & Supply of ral Steol Material in Contral Control Building and Flue Gas duct suppons for 1x660 MW. Ennore TPS Project J Specitical [caneco Ahwngs baiting by direct but! welding of the top flange of beam with ealumn Range ar by providing top moment piste with suitable notch for additonal weld Fength +All bull welds shall be full penetration butt welds. The connection between top flange and web of crane girder shell be full perelralion bull weld, Bottom flange, canrection with wab can be filet Weld or bull wald, = Connection of basa plais and associated slifienuis wilh the columns shail be designed cansidering the total losd jransferred Uucugh welds. Homever, minimum weld size (GOUDIe fllet) shall not bu less than 0.é Umes the thickness of stifenars. + Splicing shall be full strength. Finie splicing svall be done with wed and flange cover plates ‘or full strength. In oxzeptional cases, the fielc splicirg shall be designed for 50% of load camned by the cavar plates and remaining $0% load through full peratraton butt weld. Shop splicirg for all sections other than rolled shall te caried out by ful penetration butt welds with no cover plates. Splicing for all rated sections shall be carried out using web and flange cover plates. + The provisions of 1S: 800 shall bo followed as general quidance along with all other relevant Indian Standards, Cares and Acs. unless athenwise specifcally mentioned. ‘The review of the drawing by LITL however shall not relieve the contractor of his sole responsibility in carrying out the work correctly and fulfilling the complete requirements of contract documents. 2.0.0 WORKMANSHIP 34.0 Fabric: 344 General All werkmnanship shall be equal to the best practice in modem structural shops, and shall conform 10 the provisinns of the relevant Indian code or Indian Standard 1S:200 - Code of Practice for use of Structural Steel in Generel Building Construction and other relevant incian and international Standards or‘Specification for Fabrication & Supply of | EAUMELZ | Sirvctwrt Steot watorat in Central Control nh Building and Flue Gas duet supports for 1x660 a FerOReG MWY. Ennore TPS Project Rolled materials before being laid off or worked, must be clean, free from sharp Kinks, bunds or twists and straight within the: tolerances allowed by the relevant jar’ code of Indian Standard Specification |S: 1862 - Specification tor rolling and c.tling tolerance for holeallad steel products. Hf straightening is necessary, it may be dons by mecharical means or by the applicaiion ef limited amount of localizee heal. The temperature of heatsd areas, as measured by aaprowed methods, sha I nat exceed 609 Dag, C. 343 ‘Cutting ‘Curling shall be affected by shearing, cropping or sawing. Us mechanically controlled gas-cutting torch may be permitted for mid st ‘Gas cutting of high tensile steel may also be panmitted provided special caro is taken to leave sufficient metal to be removed by machining, so that all metal that ras been hardened by flame is removed, Gas outing without @ mechanically controlled torch may be permitted if special care is taken end done under expert hand, subject to the approval of the Cngineer. To determine the effective size of mombers cut by gas, 3 mm shall be deducted from each cut edge. Gas cut edges, which will be subjected to substantial stress or which are 10 have weld metal deposited an them, shall be reasonably free from gouges. Cecasional notches or gauges nat more than 4 mm doop vail be permitied. Gouges greater than 4 mm that remain from cutting shall be iemoved by grinding. All re-ntrant Gomers shall be shaped notches te a tadius of el least 12 rin, shearing, cropping and ges cutting shal be clean, Teasormauly syuare and fnew from acy distortion. Planning of Edges Planning or finishing of sheared or cropped edyes of plates or stapas or of edges gas-cut with a mecharically controlled torch shall not be required, unless specifically required oy design and called for on the drawings, included in stipulation for edge preparation for welcing or a5 may he required after the Inspection of tha cut surface. Surface cut with hand-fame shall generally be rcund, unless speciteally instructed othorwise ay the Engineer, 15 Clearances. The erection clearance for cleated ends of members connecting steel to steel shall oreterably be net greater than 2 mm at each end, The erection clearance at ends of beaiys without Web cleats Shall be not more than 3 mm at each end, but where, for practical reasons, greater clearance is necessary, suitably designad cleats shall be proved5 {ion for Fabrication & Supply of ] Structural Steol Material in Central Control eT eer tepe te tare io iam 3.2.0 B24 Bolted Construction All connections in the field shall be with baaring type HT / HSFG bolts of grade 40.8 (minimum) Holes Holes through more than one thickness of material for members, such as compound stanchions andl girder flanges, shall ba riled after tho members a esscmblod and lighlly carmped ar bolted together. Punching may be parmitied before assembly, ifthe thickness of the mate-tal is nat greater than the nominal diameter of bolt plus % mm subject fa a maxinurm thickness of 16 mm provided thst the holes are punched 8 mm less in diameter than the required size and reamed star assembly tothe full diameter. lioles for rivets o° black bolts shall be not more than 4.5 me or 2.0. mi depending on whether the diameter of the baltis less or mere: than orequa te 25 mm) larger in diameter than the nominal diemeter cf the black balt passing through them Holes for sumed and filled bolls shall be drilled to a diameter cqual to the nominal diameter of the shank ar barrel subect to a tclerance grade of HB as specified in relevant Indian code or IS:819. Parts lo be connected shall be firmly heh! 1ogether by tacking welds or clamps and the holes drilled through all the Uickrwsses in one operatian and subsequently reamed to size, Holes no: iifed through all thickness in one operation shall be driled to 4 smaller and reamed oul afler assembly. Hules for bolls shall nol be formed by gas cutting process. 3.2.2 Assembly Dniting 10 eniarge un rralching holes shall rat geriorally o8 permitted. In case arining Is permitted to a slight extent during essumbly, it stall nat distert the metal or enlarge the holes, Holes that must be entarged to adrnit the bolts shall ne reamed. Poor matching of holes shall be cause far rejeclion. The component parts shall be 86 assembled that they ae neither twisted nor othensise Jarnaged, and shall be 50 prepared that te specified cambers, if any, are maintained. Washers shall be taprad or otherwise sultably shaped, where necessary, to give the herds and ruts of bolls a satisfactory Dearing. The threaded portion of ch bolt shall project out though the nut at least one thread. In all casus te bot shell be prayded with a washer of suiiciert thickness under the mu. lo avoid any threaded portion of the bolt being within the thickness of. the parks DOCUMENT NO. LITL-028-CVE-104SPEC-PUB-I20 | Page 20 of 2Specification for Fabrication & Supply of Structural Steel Matorial in Central Control Building and Flue Gas duct supports for 1x660 MMW, Ennore TPS Project LANCO ‘Anz Inspting . bolted together, In addition to the rormal washer, onw spring washer or leck ni shall be provided for each bill for conreciions. suisjected t0 vibraing forces ar otherwise as may be specified on the: Drawings, 3.3.0 Welded Construction 334 General Welding shall bo in acoardance with relevant Standards and as supplemented in tho Specification Welding shall be cone ay experienced and good welders who have been qualited by tests. aa2 Preparation of Material Surface te ba wolded shall be free from lonse szale, slag, rust, giease, pail and any ether foreicn Tictorial except that rill seals shel withstands vigorous cwira brushing may remain, Joint surfaces shall ba free from fins and tears, A mechanically quided torch shall wherever practicable, da preparaton of Com by gas-cutting 333 Assembling Paris to be fillet welded shal be brought in as close contact a5 practicable and inno event shall bo seaaratad by more than 4 mm. If the separation is 1-9 mm or grestor, the size of the filet welds shall be increased by the amount at the Separaion. The ft of joints at contact suriaces which are not completely sealed by welds, shall be clase enough to exclude water alter painting. Abutting parts tg be bull-»olden shall be carefully aligned, Misalignments greater than & mm shall be corrected andin making the correction the parts shall no! be drawn into a sharper slope than two depress (2 Deg ). The wark shall be pasttionad for flat welding whenover practicable. 334 Welding Sequence In assembling and jeining parts of a structure cr of builtup members. the procedurs and sequence of welding shall D0 such as wil avoid needioss Sistortion and mitimiza shrinkage stresses. Where itis impossible io avoid high residual straccos in the closing welds of a rigid assembly, such closing welds shall be mad in compression elements. For important and crifcal welding, can‘rastor should submit the welding ‘sequenco ta the Purchaser and get the same approved In the fabrication of cover-plaled berms and built-up memDers, all stop splices in each component part shall 3e made before Such component patt js welcled to ‘ther parts of the memacr. Long ginters or girder sections may be made by DOCUMENT NO. LITL-U26-GVE-104-srEC-PuB170 | Page 21 of 45‘Specification for Fabri ‘& Supply of | LANECO Structural Steel Material in Contral Control net belts Building and Flue Gas duet supports for 12660 | wshvaling MW, Ennore TPS Project = shop splicing net more than tht this paragraph, sub-sections, cach mada in accordanés with When required by the Engnesr, welced assemblies shall be atross relinvad by heat-trealing in accordance with the provisions of the relevant Indian Standard fr any olher Standard approved by the Engineer 3.3.5 Welding Technique All complete penetration groove welcs made by manual welding, exeeat when produced with lhe aid of Lacking meterisl not more than O mm thick with root ‘opening nul less thar urie-trsif the thickness of the thinner part joi all have: tie rool of Ue iil layer gauiged out vn the back side before welding is started from thal sid, and sail Le so welded as to secure sound metal and ‘complete fusion roughoul the enlire Goss suctiun. Groave welds made with the use of the baccing of the sari materal, as thw use metal shell have the ‘wed metal thoroughly fused with the backing material, Backing stips need nol be removed. If required, they may be removed by gouging or gas cutting alter ‘woiding Is completed, providsd no injury iS done to the busw metal and wld metal and the weld metal surface Is left flush or slightly corwex with full throat thickness. Groove welds shall be tenminated at the ends of a Jolnt in a manner Lal il ensure their soundness. Where possible, his snoukl be done by use uf extension bars or run-off plales. Extension bars of rur-o'f plates need nol be removed upon completion of tne weld uniass othenaise Saecified elsewhere: ir the Contract. To got the best and consisten: quality of welding, automatic submerged arc process shall be preferred. The technique of welding employed, the Appearanca and quality of welds mace, and the methads of correcting defective \work, shall all conterm to tne relevant Indian Stancres, 3.3.6 Temperature No welding shall normally be done on parent male‘al at a tempercture below C1 5 Deg.C. However, if welding is to be undertaken at low temperature, adequate sracautions a8 recommended in relevant indian Standard shall be taken, When the parant materia’ is less: than 40 mm thick and the temperature is between (-) 5 Deg. Cand 0 Dag, C, the surface around the joint fo a distance of 100 mn or 4 times the thickness of thé matelial, whichaver is greater, shall ye preheated til itis hand warm. When the parent material is more thar 49 mrs thick, the terrperaiure of the area mentioned above shall 9¢ in n¢ casa ba loss than 68 Deg, C. All requirements regarding preheating of the parent material \‘Specification for Fabrication & Supply of LANE! Structural Steel Material in Contra) Gontral Building and Flue Gas duct supports for 1x000 Aweysascig | hw. nnore TPS Project shall 2e in accordance whh the relevant Indian Standard ras mentioned in ‘Specification BAT Peening ‘Whom requirud, inler mediate layers of multiple-layer welds may be pened with ght blows fron a power hamier, usiny @ raund-nase tool, Peesing shall be done after the weld has cooled lo a lemperalure warn to the hang, Care shall be exercised to preven; soalng of faking ef weld and buse metal from over pening. 338 Equipment These shall be capable of producing proper current 0 that the operstor may Produce satisfactory welds. The welding machine shal be of a type and capacity as recommended by the manufacturers of electrodes or a8 may be ‘approved by the engineer. 34.0 Fi h Column splices and butt joints of compression members depending on contact ‘or sttose transmission shell be accurately machined and cicse-bulted over the ‘whole section with a clearance not exceerting 0.2 mn lozally at any place. in calurnn caps and bases, the ends of shafts together with the allached gussets angles, channels etc, ater welcing together, should be accu-alaly machined sa thel the parts connected butt over the entire surksces af contact, Care shoukd pe laken that those connecting angles cr channels are fixed with such accuracy thet they are nol reduced in thickness by machining Ly more than 2.0 mm, 3.5.0 Slab bases and caps Bases anc caps fabricated out of steel slabs, except when cut from material with true surface, shall be azcurately machined over the bearing surfaca and shall be in effoctive comact with the end of the stancion, A bearing face that is to be grouled drect to a foundation need not be machined if such faoe is true and parallel to the upper face. To faciltate grouting, holes shall be provided, where necessary. in stanchion bases for the escape of air, 3.6.0 Lacing bars ‘The encs of lacing bars shall be neatand free from burrs. 370 Separators DOCUMENT NO. LITL-026-C¥R especeurAod | Page ss otTpectiicaiion for Fabrication & Supply af [ LANE Struetursl Stel Material in Central Control ‘2 ways Inspiting 3.8.0 39.0 3400 2410 3120 343.0 3434 Building and Flue Gas duct supports. for 1x000 MW, Ennoro TPS Project Roled section oF builltu steel separators of diapiragms shall be required for all double beams excepl where encased in concrete, in which case, pipe separators shall be used Bearing Plates rovision shall be matie for all necessary slee! bearing pietes to lake up eaction of beans and columns and the required stiffeners and gussets whrelher or not sporiffed in Drawings. Architectural Clearances Bearing plates and stiffener connections shail not be permitted to encraach on the designed architectural clearances. ‘Shop Connections A) Al Shap connections shall be welded ype & as specified on the Drawings bh) Cetain connections, specilied to ba chon carnections, may be changed ‘a fiald connocions if desired by the Engineer lor convanience of ction | Vangperiation and tha Contractor will have to make the iced changes al no extra cst to the Purchaser. Locations of shop joins for flange and webs of built up Giders sh specified along with ‘ype of connection in rasa plete size aval inadequate splicing. Castings Stool castings chal bo annealed Shop Erection ‘The stcelwerk shall be tomporcrily chop-crocted complate or as directed by the Enghneor so that accuracy af fit may bo checked before dispatch The parts shall be shop-crected with @ sufficient number of parallel drifts ta bring and keep the parts in plage, In ence af parts drliod or punched usirg steel jigs * aks all sivilar parts interchangeable, the stvelwors shall be shop erected in such a wey as will facilitate the check of interchangeability. Shop Painting General ai DOEUMENT NO, LITLIZ6-CVE-1D¢SPEE-PuBG20 Page 24 of 29