TECHNICAL SPECIFICATON FOR FABRICATION AND ERECTION OF

SELF SUPPORTED STEEL CHIMNEY IN SGTF.

1.0 DESCRIPTION
At SGTF,IGCAR,Kalpakkam, there is a Boiler House which has a fire tube Boiler with one
number of Chimney. This Chimney is the last integral part of the boiler system for maintaining its
efficiency, draft and also for minimizing the atmospheric pollution.The above self-supporting
chimney has a dimension of 1.5m inner diameter at base level tapering through three stages to 0.5
meter straight cylindrical portion with conical hood at top most elevation of 30.5m. The wall
thickness is 12mm at the base and 6mm at the top. The chimney stack is divided into different section
with different sizes. Flanges provided at end of chimney sections enable sections to connect together.
(Details are as per the drawing attached with this tender document). Total weight of the chimney is
approx. 11 Tonnes.
Two structural steel platforms are provided on the stack, which can be accessed from the
ground by means of a ladder with safety cage and safety tie on. In addition, aircraft lights were
located on top of platforms, and a lightning arrester system with one lightning rods and a ground wire
attached to the stack.

2.0 SCOPE OF WORK

The work involves Fabrication of a new Boiler Chimney using IS 2062 Plates along with
accessories like Ladder, platform, Earthing strip as per the drawing attached with this tender, Painting
of newly fabricated Chimney as per painting schedule, Transportation of newly fabricated chimney
after getting inspection clearance from IGCAR inspection authorities at the expense of Contractor
along with the required insurance documents, Dismantling of existing corroded Boiler chimney in
SGTF/IGCAR using required lifting machines, scaffolding etc... after obtaining necessary safety
clearance. Purchase of required material/paint/fasteners for fabrication is within the scope of this
contract. No additional material / lifting equipment/scaffolding would be provided by IGCAR.
This specification together with the drawing is for supply of One (1) number of M S chimney
along with the following accessories.
a) Ladder
b) Earthing strip with 3Mtr extra length
c) Lightning arrestor
d) Clean out and inspection doors Self-supported chimney:
e) Platforms at various elevations
f) Cone hood
g) Aviation lamps
h) Base plate and supports
i) All other accessories exactly as shown in drawing.

2.1 Material Procurement: Purchasing of Material required for fabrication of new Chimney
after site measurement and as per the material specified in the drawing and subject to the inspection
and approval of test certificates by IGCAR. Test certificates of materials/ Paints/ fasteners purchased
should be submitted to IGCAR / testing agency of IGCAR.

2.2 Chimney fabrication: Fabrication of a new chimney as per the drawing attached and to
match the site conditions and foundation bolts of existing Chimney. The newly fabricated Chimney
has to match the site condition and orientation requirements. Wherever there’s a conflict between Site
measured data vs Drawing the fabrication should be as per site measurement or the size of the
component should be modified to suit the site conditions at the expense of the contractor. Bidder has
to assure this by visiting the site and checking the site condition and constraints. The Chimney is
located inside plant area surrounded by Air conditioning plant, DM water plant, Boiler house and
SGTF building. The proposed repair work is to be carried out without creating any
damage/trouble/hindrance to the operation/surrounding equipments. After fabrication, newly
fabricated Chimney need to be safly transported to SGTF site, and necessary transit insurance
coverage is within the scope of the Contractor. No special amount would be awarded for the same.

2.3 Dismantling of the old chimney: Safe dismantling of the existing corroded chimney having
weight of Approximately 11 Tonnes, debris removal and transporting of dismantled steel Chimney
portions from the site of chimney to the scrap yard at IGCAR stores (around 1km distance). All
necessary Double tubular scaffolding, lifting arrangements, tools and tackles, Crane, winches etc...are
to be arranged by the contractor at his own expense. No special amount would be awarded for the
same.

2.4 Erection of new chimney at site: Erection of newly fabricated chimney in place of existing
Chimney following necessary Safety precautions. The scaffolding, lifting arrangements, lifting
equipments like crane, tools, tackles etc… is to be arranged by Contractor at his own expense. No
special amount would be awarded for the same.

2.5 Hookup with the existing flue gas exhuast duct: The newly erected chimney need to be
Hooked up with the existing exhaust duct. After this, with Boiler in operation, trial run of the Stack
without any Flue gas leak need to be ensured. If any leak occurs, repair of the same to be carried out
on free of cost which is also in the scope of this contract. No special amount would be awarded for the
same.

2.6 Painting:Painting work of entire outer surfaces of newly fabricated chimney for protection
from environment corrosion by application of one coat of Epoxy zinc Silicate primer and 2 coats of
Heat resistant synthetic medium based two packs Aluminium paint with surface preparation by air blast
method cleaning with abrasives. Paint has to be purchased by the manufacturer as per specification of
IGCAR.

2.7 Trial run of the newly erected chimney along with all the required accessories like manhole,
platforms, ladders, aviation lamps, conical hood, safety cages etc… to ensure a minimum stack exit
flue gas temperature of 175˚C.

2.8 Lighting Conductor: The supplier shall provide 50 Sq mm standard Cu conductor to be laid
down along the chimney and air terminal to provide 300mm above chimney top. At least 3 meter long
conductor shall be left after foundation and will be further connected by the user.

The scope of work is to be read in conjunction with the Annexures-1 to 6 attached with this
specification.

a) Annexure-1: Materials and Consumables.

b) Annexure-2: Fabrication of Boiler MS Chimney shell and its components.

c) Annexure-3: Dismantling of existing corroded Boiler Chimney

d) Annexure-4: Erection of Boiler MS Chimney shell and its components.

e) Annexure-5: Painting Work of Boiler MS Chimney.

f) Annexure-6: Hookup with existing exhaust duct from Package Boiler

g) Annexure-7: Indemnity Clause

3.0 APPLICABLE CODES & STANDARDS

The following specifications, standards and codes are made a part of this
specification. All standards, specifications, codes of practice referred to herein shall be the
latest edition including all applicable official amendments and revisions. In case of
discrepancy between this specification and those referred to herein, this specification shall
govern.

a) Material

(i) IS:814 Covered Electrodes for manual arc welding of Carbon and Carbon Manganese
Steel.

(ii) IS:1030 Carbon Steel Castings for General Engineering Purposes

(iii) IS:1239 Mild steel tubes, tubulars and other wrought steel fittings. Part 1 - Mild Steel
Tubes Part 2- Mild Steel Tubulars and Other Wrought Steel Fittings

(iv) IS:1363 Hexagon head bolts,screws and nuts of product grade C (Size range M5 to M64 )
Parts 1,2 and 3

(v) IS:1367 Technical supply conditions to Threaded Steel Fastners ( All Parts )

(vi) IS:2062 Steel for General Structural Purposes

(vii) IS:2266 Steel Wire ropes for general Engineering purposes

(viii) IS:2315 Thimbles for wire ropes.

(ix) IS:2361 Bull dog grips.

(x) IS:2485 Drop forged sockets for wire ropes for General Engineering Purposes.

(xi) IS:3121 Rigging Screws and stretching screws.

(xii) IS:3150 Hexagonal wire netting for General Purposes.

(xiii) IS:5624 Foundation bolts.

(xiv) IS:8183 Bonded mineral wool.

(xv) IS:13183 Aluminium paint - Heat resistant.

b) Code of Practice

(i) IS:800 Code of practice for general construction in steel

(ii) IS:816 Code of practice for use of metal arc welding for general construction in mild steel

(iii) IS:822 Code of practice for inspection of welds

(iv) IS:875 Code of practice for design loads (other than earthquake) for buildings structures
(Part 1 to Part 5).

(v) IS:1893 Criteria for earthquake resistant design of structures.

(vi) IS:6533 Code of practice for design and construction of steel chimney Part 2 Structural
Aspects

(vii) IS:9595 Recommendations for metal arc welding of carbon and carbon manganese steel.

4.0 SAFETY REQUIREMENTS

Staff on site should undergo competence and health cum safety training on the following
areas:

a) Height pass training and Safe work at heights;

b) Hot work permit

3.1 Hoardings & Notices: the contractor will be required to install “DANGER” warning signs at
all accesses to the site and suitable safety hoarding are to be erected to all site perimeters.

3.2 Scrap Metal: Generated from dismantling of chimneys and other. Scrap metal shall be cut into
manageable components on-site, transported by a contractor to the SGTF’s Scrap yard which is hardly
a km distance apart.

3.3 As the Machineries are working underneath Roof, work is to be carried out at utmost care
without damaging site property. In case of any damage, cost will be recovered from the contractor.

3.4 At the end of each working day, the contractor needs to ensure that all elements of the boiler
chimney that remain in place are adequately secured to prevent the collapse of free standing elements
during silent hours.

3.5 Electrical Isolation: Before commencement of works, the contractor shall identify the
equipment and cables to be isolated.

3.6 All work must be carried out in accordance with the requirement of safety guidelines of
ATOMIC ENERGY REGULATORY BOARD or equivalent Indian standard and all most HSE
regulations applicable. Prior to commencement of any works the contractor will need to supply a site
specific method statement for the works and will be required to meet the Engineer In-charge on site.

5.0 SITE FACILITIES PROVIDED BY IGCAR

a) Electric power will be made available free of charge at a single point near work site. The
contractor shall arrange for further connections if required by him. The contractor shall indicate
approximate power requirement (capacity in KW) while quoting. All statutory regulations are to be
observed.

b) Single point water free supply will be made available near the work area. Accommodation /
transport of workmen and supervisors of the contractor shall be the responsibility of the contractor.

c) Only open area at work site at SGTF , where fabrication work is to be executed will be
allocated to the contractor. The contractor shall make his own arrangement for shed for carrying out
his fabrication activities. Contractor also has to ensure safe storage of his tools and engineering
materials issued from stores for fabrication.

6.0 SAFETY RULES

a. The Contractor shall follow the Safety regulations as prescribed in the Indian
Standards. He shall provide necessary safety appliances to his employees depending upon the
nature of work as instructed by the Engineer-in-Charge/Safety Officer deputed by the Project
Engineer.

b. In case of an accident resulting in any rest or disability to the workmen the same should be
immediately reported to the Engineer-in-Charge/Safety Officer.

c. During the execution of the Contract and until Completion Certificate is issued, the
Contractor will be fully liable to compensate all concerned for any loss, damage or
destruction of works, structures, plant and machinery, persons, property etc. including third
party risk arising due to causes attributable to the Contractor as may be decided by the
Engineer whose decision in this regard will be final. No claim shall be made against
Government on this account.

d. The Contractor shall take necessary precautions to ensure safety of his crew, materials,
equipment and the works during the period of the Contract. No claim from the Contractor for
loss of or damage to equipment, materials, crew or the works during the course of the work
due to natural causes like cyclones, gales, floods, rains or other cause or combination of
causes will be entertained by Government. The Contractor shall be fully liable to compensate
Government for any loss or damage to works till the time of taking over of the work by
Government.

e. Any person found under the influence of alcohol or any intoxicating drugs on duty is unfit
for duty and should not be allowed to work. His work permit should be confiscated and he
should be sent out of the premises of the work.

f. Drums or other make shifts must not be used in place of ladders or work benches or
supports on any job.

g. First aid kits or boxes and stretchers should be readily available at all times with the
Contractor.

h. For all work that cannot be done from the ground level or from part of any permanent
structure or from other available means of support, soundly constructed scaffoldings of
adequate strength shall be used as a safe means of access to places of work.
i. All scaffolding shall be securely supported or suspended and wherever necessary be
properly braced to ensure stability.

j. Defective scaffolding or ‘make shift’ must never be provided. All scaffolds must be
inspected by a competent person in-charge before commencement of work.

k. Chains, ropes or other lifting materials used for the suspension of scaffolding must be of
adequate strength and suitable quality and shall be of tested quality.

l. The platforms of suspended scaffoldings shall be sufficiently wide. Suspended scaffolding

shall have hand rail of about 1 metre height from the floor of the platform. Such scaffolding
or staging shall be fastened to prevent it from swaying away from the structure.

m. All sides of the platform from which a person is liable to fall shall be provided with guard
rails to a height of at least 1 metre with the toe boards of at least 15 cms high so placed as to
prevent the fall of materials and tools from the platform.

n. Every ladder shall be securely fixed at top and bottom. A ladder more than 5 metres long
shall have a prop.

o. Spacing between the side rails of the ladder shall not be less than 45 cms. Uniform step
spacing shall not exceed 30 cms.

p. Whenever it is necessary to work at elevated places not adequately protected by railing,

safety belts with life lines securely tied to some firm structure or other support which is
independent of the equipment on which the person is working, must be worn.

q. Nobody should be allowed to work at elevated places without wearing safety belts. As an
additional precaution, safety nets made of coir rope or nylon or any other suitable material
should be hung at suitable elevation to prevent people and equipment falling below.

r. Dropping or throwing materials from roof structures or other elevated position is

prohibited.

s. Where work is going overhead, the area below should be cordoned. If it is not possible to
cordon the area, place caution sign ‘CAUTION-MEN WORKING ABOVE’ or depute
responsible person to warn passer-by.

t. Helmets (made of fiber glass or any other suitable material) must be used by all
employees working in shuttering or staging jobs, material handling jobs or where the chances
of falling objects are present or where there is a possibility of person striking against
projecting objects etc.

u. All necessary personnel safety equipment such as face masks, safety helmets, safety boots,
safety belts, gloves, safety goggles etc. as considered adequate by the Engineer-in-charge
have to be kept available for the use of persons employed at the site of work and maintained
in condition suitable for immediate use and Contractor shall take steps to ensure proper use of
equipment by the workers.

v. The Contractor shall furnish along with the Tender the type of staging, formwork, and
type of access for men, materials and the construction technique he proposes to use for the
work.

w. The Contractor shall use only tubular steel for scaffolding for all heights more than 5
meter height as approved by the Engineer.

x. The areas where painting work is being done shall be kept adequately ventilated by the
agency executing the work and shall meet the approval of the Engineer.

7. OTHER TERMS AND CONDITIONS

1. The contractor should deploy sufficient number of personnel at site to meet the above
mentioned service requirements failing which recovery will be made from your bills.
2. No accommodation, medical facilities or transport will be provided to the contractor’s
personnel. It is the sole responsibility of the contractor.
3. The contractor shall arrange for the entry passes for the site following the procedures
existing at site.
4. The contractor shall ensure the safety of his personnel by providing the required safety
devices.
5. The Contractors have to follow strictly the Government labour acts which are in force at
present including any amendments or additions that may be made by the Government
during the entire period covering the date of publication of this Tender Notice till the
completion of the work covered by the Contract and all necessary arrangements for
labour will have to be made by the Contractor.
6. During the execution of the Contract and until Completion Certificate is issued, the
Contractor will be fully liable to compensate all concerned for any loss, damage or
destruction of works, structures, plant and machinery, persons, property etc. including
third party risk arising due to causes attributable to the Contractor as may be decided by
the Engineer whose decision in this regard will be final. No claim shall be made against
Government on this account
7. The Drawing attached is to be read in conjunction with other terms and conditions,
General Conditions, Tech. Specifications.
8. It may be noted that the Government as a part of the emergency preparedness for any
eventual site emergency civil defence which would require the entire or part of the
Contractors personnel and labour to be evacuated from the site without any advance
notice as and when deemed necessary. This may result in temporary stoppages of work
 with possible loss of time and productivity not likely to exceed 1 day. This aspect shall be
taken into account while quoting their rates and the department will not entertain any
claim/compensation on this account. However, the department may grant suitable
extension of time only.
9. All prices quoted shall remain firm throughout the period of the contract and shall not be
subjected to any escalation for changes in the cost of labour and material and any other
cost.
10. The Tenderer should note that if any clarifications regarding Specifications, Conditions of
Contract, Schedule of Quantities or Scope of Work are required he should consult
Director, RD&TG,Kalpakkam-603102. No claim on account of any ambiguity in any
respect will be entertained. The decision of Director, RD&TG is final in case of any
ambiguities between different portions of Tender and drawings.
11. During execution of the Contract and until the completion certificates issued the
Contractor shall be fully liable to compensate all concerned for, any loss, damage or
destruction of any of departments plant and machinery, persons, building, property
including third party risks attributable to the Contractor as may be decided by the
Engineer whose decision in this regard shall be final.
12. Transportation of materials, required platform and material handling are in the scope of
the contractor. Safety items like shoes, goggles and safety belts etc. required for the
work are in the scope of the contractor. Daily cleaning of the work area is very much
essential and is in the scope of the contractor. After erection of the structural material,
roofing sheets and the tank, work area should be cleaned. All temporary arrangement
should be removed by the contractor.
13. The Engineer In-charge reserves the exclusive right to decide, giving no reason
whatsoever, the suitability of the field personnel deputed by the Contractor. The
Engineer also reserves the right to ask the Contractor to withdraw any personnel from the
site who, according to the Engineer, is not suitable for the proper supervision of erection
of the work, non following safety rules and ask for replacement and/or additional
supervisory staff for proper execution of the Contract according to the requirement of the
drawings, specifications and field instructions within the scheduled construction period

(Radhakrishnan Unni.K.G,TO/D)

SGTF OS
 Annexure-1

Materials and Consumables.

Responsibilities of the contractor includes, but not limited to the following.

1.0 Purchasing of all materials and consumable like Structural Steel, Pipes, welding electrode,
Bolts, and Gasket of Standard make & paints required for complete work as per drawing and as per
scope of work shall be in bidder’s scope. The quantity is indicative only. In case any item of material
is insufficient to carry out the job as per the drawing and site conditions, the Contractor will have to
bring additional quantity for completion of work. No separate payment for such expenditure will be
made under any conditions.

a) Structural steel: confirming to IS226 /IS 2062 (Make: From reputed Indian manufacturing
firms like TATASTEEL /SAIL/MSL/JINDAL/JSW etc.,).

b) Bolts & Nut: IS: 1363-1992.

c) Welding Electrode: IS: 814-1991.

2.0 The material shall strictly confirm to the specifications / make given by IGCAR/SGTF.

2.1 Unloading of the material/ fabricated Chimney shall be done with your own arrangement.

2.2 All consumables like welding electrodes, gas, grinding wheel, for surface preparation shall be
of approved make.

2.3 Arranging all tested tools and tackles, safety items, ladders, scaffolding etc. required for the
completion of the job.

Only tested material shall be used. The contractor shall submit Manufacturer’s valid approved
test certificate to IGCAR. If test certificate for the material is not available from main producer, the
following tests shall be carried out at the discretion of IGCAR and should be certified by a NABL
accredited lab.: a. chemical composition, b. mechanical properties c. weldability test. Cost towards
this testing need to be borne by the contractor only.

2.4 The contractor has to arrange all tools, tackles, safety equipment, Crane and other lfting
equipments required for dismantling, erection of Chimney, welding equipments, Gas cutting tools,
grinding tool, gas cylinders and material handling equipment on their own. IGCAR will not extend
any of the above facilities / services under any circumstances. No balance material / scrap shall be
allowed to be taken outside the plant on completion of work

2.5 All material procured by the supplier including weld materials if any shall be tested as
required by material designation standard. Proof in the form of mill certificates will be acceptable, but
if these are not available the supplier shall perform these tests. The purchaser reserves the right to
cross check the material. Samples will be drawn by the purchaser for chemical analysis and
Mechanical properties.Plate material shall be free from any defects like cracks, inclusion laminations,
surface distonion while handling etc. UST for plates sizes above 6 mm to be as per the ASTM A435.
Reg. defect standard for angle beam shall be 5 % deep notch & for straight beam 1.5 mm dia. flat
bottom hole as per latest ASTM specification and mill test certificates shall be approved.
2.6 Marking / Material Identification: Each plate / pipe shall bear clear identifiable marking /
stamping with respect to material heat number, plate No., grade, size marking. The material
Identification markings for fabrication of these equipment shall remain distinguishable until
fabrication is completed. The identification scheme shall be evolved in consultation with the purchase.
 Annexure-2

Fabrication of Boiler MS Chimney shell and its components.

1. Responsibilities of the contractor includes, but not limited to the following.

1.0 Fabrication of M.S. Chimney top shells and components as per existing design and dimension
and as per tender drawing,

2.0 Cold straightening of section and plates, whenever they are bent and kinked.

3.0 Control, assembly of steel structural components at site/shop, whenever required.

4.0 Loading, transporting from fabrication workshop to site of erection and unloading of all steel
structural components/unit/assemblies.

5.0 All the items are to be cut as per requirement of drawing. If joints are to be provided in any
item in order to meet the requirement of size and shape, cutting plan showing location of joints shall
be prepared for consideration of SGTF.

6.0 Rolling and cutting tolerances shall be as per IS: 1852-1985.

7.0 Cut edges shall be finished smooth by grinding or machining whenever necessary. Sufficient
allowance (3mm to 5mm) should be kept in the items in case machining is necessary.

8.0 Cutting may be effected by gas cutting, shearing, cropping or sawing. Straightening and
bending shall be done in cold condition as far as practicable. If required, straightening and bending
may be done by application of heat between 900°C and 1100°C. Cooling down of the heated item
shall be done slowly.

9.0 Drilling and punching of holes for bolts shall be done as per clause no.11.2.4 of IS: 800-1984.

10.0 Fabrication of all steelwork shall be accordance with IS: 800-1984 and in conforming to
various clauses of the specification, unless otherwise specified in the drawing. Requirements of IS
code of practice is IS 6533 part 1, 1989, (reaffirmed 1998) and IS 6533 part 2 1989.

11.0 Permissible deviation from designed (true) geometrical form of the despatch elements shall be
accordance with IS: 7215-1974.

12.0 The contractor shall work out welding procedure for SGTF’s approval, considering the
following factors: a. specification and thickness of steel, b. specification of electrode or and base wire,
welding procedure, c. sequence of welding, d. weather condition, e. inspector procedure to be
followed, f. design requirement of the joints.

13.0 All metal arc welding shall be carried out as per IS: 9595-1980. Welding Electrode conforms:
IS: 814-1991. Specification of Welding Electrode: AWS: A5.1: E7018, Make:
Esab/D&H/Ador/Modi/Sudo only. All inspection of welds shall conform to IS 822

14.0 The extent of quality control in respect of welds for structural elements shall be as follows
and shall be conducted by the contractor at his own cost:

a) Visual examination- all welds shall be 100% visually inspected to check the following: a.
presence of undercuts, b. visually identifiable surface cracks in both, welds and base metals.
b) Dye penetration test (DPT) - this shall be carried out for all important fillet welds and groove
welds to check the following: a. surface cracks, b. surface porosity.

c) Cleaner, penetrant, developer, DP testing etc..are in the scope of the Contractor. No additional
amount would be sanctioned for carrying out the same.

d) Record of all the welding inspection report and other associated documents related to
fabrication need to be mainatined by the contractor and a copy of complete set of these
documents or part of these documents need to be handed over to the purchaser as and when
demanded by the purchaser.

2. FABRICATION

CONTRACTOR shall post an experienced and qualified ENGINEER to supervise the

fabrication work. All workmanship and finish shall be of the best quality and shall conform to
approved method of fabrication. All holes and edges shall be free of burrs. All shell plates
shall have a smooth curvature without faults or kinks.

The edges of shell plates to be welded may be prepared by shearing, machining or

machine-operated flame cutting. Shearing shall be limited to 10mm thickness of plates. When
edges are flame cut, the resulting surface shall be uniform and smooth and free of scale and
slag accumulations.

All shell plates shall be rolled accurately to the proper curvature so as to obtain a true
cylindrical or conical shell as required

Welding shall conform in all respects to IS:816 and IS:9595. All joints shall be butt-
welded joints with suitable edge preparation to obtain penetration to the full thickness of the
plates.

3. INSPECTION

All materials and fabrication covered by this specification shall be subject to

inspection by ENGINEER/OWNER or his authorised representative. They shall have access
to all parts of the shop while material is being prepared, and shall be provided by
CONTRACTOR with all inspection services and facilities.

CONTRACTOR shall give due notice to ENGINEER/OWNER in advance of

materials or workmanship getting ready for inspection. All rejected material shall be
promptly removed from the shop and replaced with new material for ENGINEER/OWNER's
approval/Inspection. Approval of material/workmanship shall not relieve CONTRACTOR
from his responsibility for furnishing material conforming to requirements of these
specification or invalidate any claim which OWNER may make for defective or
unsatisfactory- material or workmanship. No materials shall be painted or despatched to site
without the inspection and approved by OWNER/ENGINEER, unless such inspection is
waived in writing by ENGINEER. Adjacent shell strakes be shop assembled and match
marked to ensure satisfactory matching at site.
 OWNER's/ENGINEER's inspector shall also have free access to all parts of the job
during erection. The erection and installation methods employed such as welding, bolting etc.

All inspection of welds shall conform to IS 822. Material test certificates of Plates and
fasteners used should be handed over to OWNER/ENGINEER at the time of inspection.

4. TOLERANCE ON OVALITY, VERTICALITY ETC...

1. The difference between the maximum and minimum internal diameter of shells
measured at any one cross section shall not exceed 1% of the nominal diameter or 25
mm whichever is lower. There should be no flats at seams and any local deviations
from circularity shall be gradual.

2. After erection, the departure of the stack from the vertical at any level, shall not
exceed 1/1000 of the height, at that particular section

3. When fitted together before bolting any gap between the flanges should not exceed
1.5mm

5. DIMENSIONAL CHECKS / INSPECTION:

1. Maximum misalignment permitted 10 % of nominal plate thickness up to 100

mm.1mm misalignment for longitudinal joints.

2. Maximum misalignment permitted 10 % of nominal thickness +1 mm with maximum

overall limit of 4 mm for circumferential joint.

3. Maximum misalignment permitted for circumferential tolerance + 0.25 %.

4. Maximum misalignment permitted for roundness difference of maximum diameter at

any cross section of a shell welded longitudinal shall not be done mote than 1 % of
ID. with a maximum of (D1 -1250)/200.Maximum misalignment permitted out of
straightness of shell not more than 0.3 % both of total cylindrical length in any 5
meter length.

6. Liquid Penetrate tests: All welds shall be fully DP for all passes (layer by layer) as per
ASTM E 15. All defects shall be repaired and retested.
 Annexure-3

Dismantling of Existing Boiler Chimney.

Carefully dismantling the free standing boiler chimney using suitable Platforms, safety
equipments,, heavy lift crane, guide lines and cutting equipment down to ground level. Lower the
sections safely to ground and dismantle by mechanical means and cart away to SGTF’s scrap yard
following safety procedures. Contractor should ensure that dismantling of damaged portion of
chimney is undertaken in such a way so that the safety of boiler house, DM plant, AC Plant building
and pipe lines situated adjacent to the boiler chimney is not compromised. Necessary double tubular
scaffolding with suitable jally, pipe sections, fixtures etc.. should be provided by the contractor for
safe dismantling of the stack without affecting the nearby structures/plant/office buildings.

1.0 DISMANTLING TECHNIQUE: Top- down segmenting of the boiler chimney in horizontal
slices or pieces:

a) Top-down segmenting comprises cutting the boiler chimney into large but manageably sized
sections and lifting and lowering these sections to ground level. This approach includes three main
activities:

- Establishing safe working platforms.

- Cutting operations.

- Lifting operations.

b) Working platforms are required for workers to safely cut through the stack and to sling the
section being released. Safe working platforms can be provided by several means, including
scaffolding, mobile platforms (independent or attached to or suspended from the boiler chimney) and
crane suspended cages.

c) Cutting operations are required to separate a section of the boiler chimney from the main
structure. Appropriate techniques depend upon the type of stack construction. Cutting techniques
generally use established construction industry methods, including: Mechanical saws, shears, nibblers,
etc., Flame or plasma cutting. All the tools required for cutting, shearing, dismantling, lifting etc…
are in the scope of the contractor. IGCAR would provide only free electricity and water.

d) The segmenting will be carried out by specialized workers suspended by cables.

2.0 Chimney dismantling methodology: a heavy lifting mobile crane will be utilised for
dismantling of damaged portion of boiler chimney. Contractor needs to atatch equipment technical
data and performance sheet with tender as per Annexure-C. If any other method to dismantling is
envisaged the same is to be discussed with Engineer In charge and a mutual consensus has to be
reached.

a) Position the mobile heavy lifting equipment (Crane) at predetermined site, ensuring stability
safety and secure foundation (positioning site, to be inspected for any possible instability by way of
inferior, damaged, and worn or poor quality road/surface covering).

b) Once the suitable crane has been securely positioned in place, together with the help of
another mobile heavy duty crane, metal basket and operated by skilled and fully qualified personnel in
the art of dismantling; utilising a type of choker system, chain, grips and cables will used to establish
a safe working platform and securing first suitable length of the chimney to be lowered to the ground.

c) Once inspected and confirmed the first suitable length of the stack is firmly secured, ready for
cutting and lowering to the ground, two (2) operator will be climbed up in safe working platform
attached to the boiler stack; equipped with oxy settling cutting equipment will proceed to cut right
round the stack just above the joint of the second suitable length of chimney and the attached access
ladder.

d) Before cutting the final section, the crane operator will be communicated with, via walkie-
talkie, to ascertain the correct aplomb of the crane.

e) Dismantling of damaged/tilted top portion of chimney with wire rope sling net for avoiding
free fall of damaged metal of top portion.

f) This process will be repeated exactly until the final level of damaged portion of chimney is
finally dismantled.

g) However, if any other material discovered not attached to damaged portion of chimney, it will
be allowed to drop down the inside of chimney to be collected at the disposed of the end.

3. Scaffolding
Double tubular scaffolding should be provided for safe and secure dismantling of the various
sections of Boiler Chimney. The safety of double tubular scaffolding would be assessed by the staff
concerned and the staff concerned should be taken in confidence regarding the utility and safety of the
scaffolding. No additional payment would be given for erection and dismantling of scaffolding.
Required safety nets, drop area markings, required hollow pipe sections , fixtures, platform jally etc..
are in the scope of the contractor. The contractor has to ensure the workers are following safe working
practices like wearing of safety belts, helmets etc..and if any erroneous practice is found the staff
concerned would take action against the errant contract employee. Necessary safety training /
obtaining height permit/ height pass/hot work permit etc… to be obtained , staff have to undergo
safety training and the staff at erection site may have to undergo medical examination at the expense
of the contractor. It is the responsibility of the contractor to meet the safety standards of IGCAR
Safety sections and if any violations of safety rules are observed the safety officers concerned may
issue stop memo and it’s completely upon the contractor to get necessary clearance for starting the
work. Any request for noncompliance of safety rule, temporary unsafe arrangements , additional
payment etc… would not be entertained.

4. Caution during Dismantling.

The Foundation bolts of the existing chimney should not be damaged while dismantling
the bottom portion of the Boiler Chimney. The same is to be used for the new chimney also.
Sizing of the foundation of bolt and it’s orientation is to be matched with the new Steel Chimney
which is being fabricated by this contract. Contractor / his representative have to visit site and
match the base plate template to the site condition. All expenses for this should be anticipated
during quoting. This Chimney is to be erected inside a running plant surrounded by different
equipments, machinery, plant structures. The work should be planned carefully so as not to damage
any surrounding equipment. All necessary departmental safety permits like height work permit, hot
work permit to be obtained by the contractor.
 Annexure-4:

Erection of Chimney shells and its components.

Erection of Chimney

Erection of chimney involves, but not limited to

1) Installation of newly fabricated pieces of the chimney on the existing foundation matching
with the existing foundation bolts.

2) Installation of the Lightening Arrestor (LA) & Aviation lights (02 nos) on the top portion of
new installation.

3) Connection of earthing strip with new LA & laying and fixing of same on the newly
fabricated chimney pieces.

4) Connection of earthing strip to existing old earthing strips of the existing installation and
checking & proving of the continuity of the complete strip

5) Installation of the new platforms with railing on newly fabricated chimney as per existing
installation.

6) Installation of the monkey ladder with cage for complete newly fabricated chimney pieces.

7) Painting of complete new installation as detailed in the Annexure 5.

8) Electrical connection of the aviation lights with the cable and power supply at the bottom of
chimney.

9) Submission of actual (as built) GA drawing of complete chimney after erection &
commissioning

10) Trial run of the chimney .

11. In addition to provision of erection and transport equipment, the scope of work includes
supply of tools and tackles, consumables, material, labour and supervision and shall cover the
following:

12. Storing &unloading of all fabricated steel components/units/assemblies at site storage yards.

13. Transportation of steel components from storage yard to site of erection, including multiple
handling, if required. Handling and storage of materials shall be as per IS: 7969-1975.

14. All minor rectification/modification of steel components as per instruction of Engineer-In-

charge.

15. Erection of steel components including making connection by bolts/welding as required.

16. Alignment of all steel chimney components true in line, level plump and dimensions within
specified limits of tolerance.
17. Erection shall be carried out accordance with IS: 800-1984 and conforming to the
requirements of is code of practice is 6533 part 1, 1989, (reaffirmed 1998) and is 6533 part 2
1989, other relevant standards referred to therein.

18. For safe and accurate erection of steel work, staging, temporary support, false work etc. shall
be erected as required. The fabricated material received at erection site shall be verified with
respect of marking on key plan/marking plan.

19. The approved erection drawings and any approved arrangement drg., specification or
instruction accompanying them shall be followed in erecting chimney components.

20. Erection work shall be taken up after receipt of clearance from SGTF.

21. For safety requirement during erection, provision in IS: 7205-974, IS: 7969- 1975 and other
relevant Indian standards shall be followed.

22. Erection shall be carried out with the help of suitable crane and maximum mechanization
possible.

23. Prior to commencement of erection, all the erection equipment, tools, tackles, ropes etc. shall
be tested for their load carrying capacity. Such tests may be repeated at intermediate stages
also if considered necessary and frequent visual inspection shall be done of all vulnerable
areas and components to detect damages or distress in the erection equipment, if any.

24. Erected members shall be held securely in place by bolts to take care of dead load, wind load
and erection load.

25. No final bolting or welding of joints shall be done until the structure has been properly
aligned.

26. Checking of correctness of initial setting out of steel components of chimney and adjustment
of alignment shall be carried out in sequence and at different stages as required. The final
levelling and alignment shall be carried out immediately after completion of each section.

27. The contractor shall design, manufacture, erect and provide false work; staging temporary
support etc. required for safe and accurate erection of chimney components steelwork and
shall be fully responsible for the adequacy of the same.

28 The contractor shall also provide facilities such as adequate temporary access ladders,
gangways, tools & tackles, instruments, etc. to SGTF for his inspection at any stage during
erection.

29. Caution before Lifting: At each new job site prior to hoisting personnel, the personnel lift
platform, rigging, and hook block shall be proof-tested by a qualified inspector to 125 percent
of the personnel platform's rated capacity by holding it suspended for 5 minutes with the test
load suitably distributed on the personnel platform.

30. After proof-testing, any deficiencies revealed by inspection, or by the proof test, are corrected
and another proof-test conducted. Any modification to the personnel lift platform or rigging
requires retesting. Test reports are kept on file and be readily available to appointed
personnel.
31. A meeting, with the qualified operator, signaler, persons to be lifted, and the person
responsible for overall worksite safety to plan is held prior to the trial lift to review the
procedure.

32. The crane before lifting shall be uniformly level within 1 percent of level grade and firm
footing exist under both crawler tracks or under each outrigger float. Cribbing mats under
tracks or blocks under outrigger floats are used as necessary to provide a firm and substantial
footing. Cranes equipped with outriggers have outriggers extended in accordance with the
manufacturer’s instructions

33. Crane systems, controls, operator aids, and safety devices are activated and functioning
properly.

34. The total weight of the loaded personnel lift platform (including personnel) and related
rigging does not exceed 50 percent of the crane rating under the planned conditions of use.

35. The personnel lift platform is not loaded in excess of its rated load capacity.

36. The number of employees occupying the platform does not exceed the number required for
the work being performed.

37. Trial Lift:

Before each lift, personnel initially enter the personnel lift platform, the operator and signaler
shall conduct a trial lift. The trial lifts shall include:

(i) Loading the unoccupied personnel platform to at least the maximum anticipated load.
Materials and tools to be used during the actual lift, if secured to prevent displacement, can be
in the platform for the trial lift.

(ii) Making the trial lift from the location where personnel will enter the platform to each location
where the platform will be hoisted and positioned. It is acceptable to perform a single trial lift
on each shift for all locations to be reached from a single setup position.

b) The trial lift shall be repeated whenever:

(i) The crane (mobile) is moved and setup in a new location or returned to a previously used
location.

38. CONTRACTOR shall post an experienced and qualified ENGINEER who shall be in
full time charge of the erection job.

39. CONTRACTOR shall complete all preliminary works at site well before the arrival of
fabricated materials such as establishment of office, labour quarters if any, electrical
connections, electrical winches, gin poles, compressors, cranes, all tools and tackles,
rivet guns, welding sets, staging etc. as a part of his contract and any other work that
may be necessary so as to start erection immediately after arrival of fabricated
material at site.

40. CONTRACTOR shall furnish at his own expense, the necessary non inflammable
staging and hoisting materials or equipment required for the erection work and shall
 remove and take them away after the completion of the job. CONTRACTOR shall
also provide necessary protection for all equipment and works, necessary passage
ways, fences, safety bolts, helmets, lights and other fittings to the satisfaction of
OWNER/ENGINEER and to meet the rules of local authorities and for protection to
his men and materials. A licenced electrician shall be kept on the job for the entire
duration of the work to maintain CONTRACTOR's electrical equipment and
connections.

41. CONTRACTOR shall protect all existing plant structures, piping, conduits,
equipment and facilities against damage during erection. CONTRACTOR shall
perform his work in a manner which in no way will endanger any of the existing
facilities.

42. CONTRACTOR shall carefully check the location and layout of anchor bolts
embedded or foundations constructed to ensure that the stack can be properly erected.
Any discrepancy in the anchor bolts/foundations shall be reported to ENGINEER.
CONTRACTOR shall carry out erection as required by ENGINEER/OWNER. The
method of erection shall be modified whenever required by ENGINEER/OWNER.
The vertical seams in adjacent stack strakes shall be staggered by atleast 15°.

43. In case of faulty erection all consequent dismantling re-erection required will be at
CONTRACTOR's cost.

44. All shim stock required to maintain the specified thickness of grout as well as for
levelling of the structure during erection shall be of good M.S. plates and shall be
supplied by CONTRACTOR at his cost.

45. A certain amount of cleaning of foundation and preparing the area is considered
normal and shall be carried out by CONTRACTOR at no extra cost.

46. The holding down bolts shall be adequately tightened and shall be provided with a
nut and a lock nut. Grouting of the base plate will be carried out by CONTRACTOR
to match site conditions. Quick setting grout for this to be supplied by
CONTRACTOR .

47. Anchor bolt straightening or bending by heating is prohibited.

 Annexure-5

Painting Work of Boiler MS Chimney.

Surface preparation for painting

1. Procedure for Surface Preparation :

Near white metal Blast cleaning to near white metal cleanliness, until at least 95% of each
element of surface area is free of all visible residues with desired surface profile.

2. Method: Air Blast cleaning with abrasives

The surfaces shall be blast cleaned using one of the abrasives like angular chilled cast iron or
steel grit, copper slag or Nickel slag, Al 2O3 particles at pressure of 7kg/cm 2 at an appropriate distance
and angle depending of nozzle size maintaining constant velocity and pressure.
Chilled cast iron or steel shall be in the form of shot or grit of size in the range of G16 – G42
conforming to SSPC AB1 and S250 grade size of steel shots (maximum) to obtain a desired surface
profile of 35-50 microns trough to peak. For all other abrasives, size shall be in the range of G16 –
G24. The combination of steel grits and shots shall be normally in the ratio of 3:1. The quality of
abrasives shall be free from contaminants and impurities and shall meet the requirements of SSPC
AB1. Compressed air shall be free from moisture and oil. The blasting nozzles should be venturi style
with tungsten carbide or boron carbide as the materials for liners. Nozzles orifice may vary from
3/16” to ¾”. On completion of blasting operation, the blasted surface shall be clean and free from any
scale or rust and must show a grey white metallic luster.
3. Primer/first coat of paint shall be applied within 4 hours of surface preparation. Blast cleaning
shall not be done outdoors in bad weather without adequate protection or when there is dew on the
metal, which is to be cleaned. Surface profile shall be uniform to provide good key to the paint
adhesion (i.e. 35 to 50 microns). If possible vacuum collector shall be installed for collecting the
abrasives and recycling.
4. PAINT MATERIALS: All the paint materials shall be of first quality, should not be of
beyond expiry date and conform to the following general characteristics as per the table-1.

Table-1
Sl.No Description Heat resistant Two pack self Two
Silicone curing solvent component
aluminium based Acrylic
paint suitable Inorganic Zinc Polyurethane
up to 500C dry silicate Primer Finish paint
temperature
1 Type & composition Single pack Ethyl A two
silicone resin silicate/Metallic component
based medium Zinc acrylic
with Aluminium polyurethane
flakes finish giving
excellent
durability and
long term
recoatability
2 Volume of solids 20% 40±3 57±3
(approx.)
3 DFT per coat (Approx.) 20-25 65-75 50-75
4 Theoretical covering 8-10 8-9.2 11.40
capacity, M2/coat/Ltr
 5 Weight per liter (Kg/litre) 1.1 - 1.2
6 Touch dry at 300C 30 mts. 30 mts 90 mts
7 Hard dry at 300C 24 hrs Overnight 6 hrs
8 Overcoating interval Min 16 hrs, Min. Overnight 6 hrs
Max Unlimited Max. Indefinite
9 Pot life at 300C for two Not applicable 4-6 Hrs 2 hrs
component paints
10 Temperature resistance 500C
5. Painting
a. Painting system for the boiler chimney covering surface preparation, application of primer coats
and final coats to develop the required minimum dry film thickness on steel surface is as per
Table-2. The same will be assessed by Engineer in Charge of Inspection. Elcometer for
ascertaining DFT shall be arranged by the contractor.

b. Application of paint be by spraying or brushing as per IS: 487-1985 and in uniform layers of
50% overlapping strokes. Painting shall not be done when the temperature is less than 5°C or
relative humidity more than 85% unless manufacturer’s recommendations permit. Also painting
shall not be done in frosty or foggy weather. During application, paint agitation must be provided
whenever such agitation is recommended by the manufacturer.Areas which become inaccessible
after assembly of steel components shall be painted before assembly, after cleaning the surface as
specified. Edges, corners, crevices, depression, joints and welds shall receive special attention to
ensure that they receive painting coats of the required thickness.

TABLE-2

Sl.No Item Primer Finish Total DFT 

1 Stack External 1x65  DFT 2x20  DFT Heat 105
Inorganic Zinc resistant Silicone
Silicate Primer Aluminium Paint
2 Stack Top Aviation colour band 3x25 DFT 130 (Including DFT
Aviation colour of Primer)
bands of 3 Red
bands & 2 white
bands of 400mm
height each from
Top
3 Platform brackets, Platform 1x65  DFT 2x100  DFT High 305
members & Cleats etc. Inorganic Zinc build epoxy paint,
Silicate Primer 1x40  DFT
Acrylic
Polyurethane finish
paint
4 Ladders, Handrails, Misc. 1x65  DFT 2x100  DFT High 305
Structurals etc.. Inorganic Zinc build epoxy paint,
Silicate Primer 1x40  DFT
Acrylic
Polyurethane finish
paint
5 Stack Internal Painting 2x30  DFT Red
Oxide Zinc
chromate primer
Annexure – 6

Technical Specification of Heavy mobile Crane:

(Contractor shall submit the certified current load chart of crane with following information).

(i) Model:

(ii) Make:

(iii) Machine description:

(iv) Maximum tested lifting capacity: ……………………ton at 20m radius.

(v) Boom extension:

(vi) Lattice jib:

(vii) Carrier engine output: kW.

(viii) Crane Engine output: kW.

(ix) Operational weight: ton.

(x) Total Counterweight: ton.

(xi) Renter Name & Address:

Annexure-7

Indemnity Clause
 The Steel Chimney is located inside plant area surrounded by Air conditioning plant, DM
water plant, Boiler house and SGTF building. The proposed repair work is to be carried out without
creating any damage/trouble/hindrance to the operation/surrounding equipments.

In the event of any damage to the surrounding equipments/ building/ structures, the contractor
has to pay the compensation for repairing of equipment / purchasing new equipment/ building new
structure as the case may be as per the discretion of Engineer In charge.

No relaxation for this would be allowed even on grounds like genuine oversight. The
contractor has to sign this clause and plan the work accordingly with utmost discretion and care not to
damage any structure/ machinery/component/cable tray etc...