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c) Heat Treatment facilities
d) Area for Pre-Assembly bed

Welding

a) Welding of Structural steel shall be done by an electric arc process and shall
conform generally to relevant acceptable standards viz. IS:816, IS:9595, IS:814,
IS:2014, IS:4354 and Indian Standard Hand Book for metal arc welding, and other
standards, codes of practice internationally accepted. For welding of any particular
type of joint, Bidder shall give appropriate tests as described in any of the Indian
Standards - IS: 817, IS: 7307 and international standards as relevant.

b) Submerged arc-welding shall be used for welding longitudinal fillet welds (connecting
flange with web) and longitudinal / transverse butt joints for fabrication of columns,
framing beams and crane girders and all other built-up members, unless manual arc
welding is specifically approved by the Engineer. Necessary jigs and fixtures and
rotation of structures shall be so arranged that vertically down-hand position of
welding becomes possible. ‘Open-Arc-Welding’ process employing coated
electrodes shall be employed for fabrication of other welded connections and field
welding.

c) Wherever welding is done for assembling the components of structures, the job shall
so positioned that downhand welding is possible.

d) Any structural joint shall be welded only by those welders who are qualified for all
welding procedures and positions in such type of joint that is welded.

e) All records for entire welding operations such as welders identification marks, the
joints welded by the each welder, the welding procedures adopted, welding machine
employed, pre and post heating done and any non destructive test done and stress
relieving /heat treatment performed on such joints shall be accessible to the
Engineer for scrutiny.

f) In a fabrication of plated columns/beams and built up members all shop splices in

each component part shall be done before such component part is welded to other
parts of the member. Wherever weld reinforcement interferes with proper fitting
between components to be assembled by welding, these welds shall be ground flush
prior to assembly.

g) The members to be jointed by fillet welding shall be brought and held as close
together as possible and in no event shall be separated locally by more than 3mm. If
the local separation is 1.5mm or greater, the fillet weld size shall be increased by the
amount of separation.

Edge preparation for welding as per weld joint detail shall be prepared either by machines or
by automatic gas cutting. All edges cut by flame shall be ground before they are welded.

Electrodes

a) The electrodes used for welding shall be of suitable type and size depending upon
specification of the parent materials, the method of welding, the position of welding
and quality of welds desired e.g. normal penetration welds or deep penetration
welds. However, only low Hydrogen electrodes shall be used for plate thickness
above 20 mm.

b) All low hydrogen electrodes shall be baked and stored before use as per

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manufacturer recommendation. The electrodes shall be rebaked at 2500C - 3000 C

for one hour and later on cooled in the same oven to 1000C. It shall be transferred to
an holding oven maintained at 600C - 700C. The electrodes shall be drawn from this
oven for use.

c) Where coated electrodes are used they shall meet the requirements of IS:814 and
relevant ASME-Sec. Covering shall be heavy to withstand normal conditions of
handling and storage.

d) Only those electrodes which give radiographic quality welds shall be used for welds
which are subjected to radiographic testing

e) Where bare electrodes are used, these shall correspond to specification of the
parent material. The type of flux-wire combination for submerged arc welding shall
conform to the requirements of F-60 Class of AWSA-5-17-69 and IS:3613. The
electrodes shall be stored properly and the flux shall be baked before use in an oven
in accordance with the manufacturer’s requirements as stipulated.

f) 308L and 309L electrodes / fillers shall be used for welding of stainless steel to
stainless steel and stainless steel to mild steel respectively.

g) Specific approval of the Engineer shall be taken by Bidder for the various electrodes
proposed to be used on the work before any welding is started.

Preheating inter-pass temperature and post weld heat treatment.

a) Mild steel plates conforming to IS:2062 and thicker than 20mm, may require
preheating of the parent plate prior to welding as mentioned in Table-I.

However, higher preheat and interpass temperatures required due to joint restraint
etc. and will be followed as per approved welding procedure. In welding materials of
unequal thickness, the thicker part shall be taken for this purpose.

c) Base metal shall be preheated, not withstanding provisions of IS:9595, to the

temperature given in Table-1 prior to welding or tack welding. Preheating shall bring
the surface of the base metal to the specified preheat temperature and this
temperature shall be maintained as minimum temperature while welding is in
progress.
TABLE – 1
MINIMUM PREHEAT and INTER PASS TEMPERATURE FOR WELDING

Thickness of thicker part Welding using Low hydrogen

at point of Welding electrodes or Submerged
arc welding

Upto and including 20mm None

Over 20mm and upto and 20 0C

including 40m

Over 40mm and upto and 66 0C

including 63mm

Over 63mm 110 0C

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c) Preheating may be applied by external flame which is non-carbonising like LPG, by
electric resistance or electric induction process such that uniform heating of the
surface extending upto a distance of four times the thickness of the plate on either
side of the welding joint is obtained.

d) Thermo-chalk, thermo-couple or other approved methods, shall be used for

measuring the plate temperature.

e) All butt welds with plates thicker than 50mm and all site butts weld of main framing
beam shall require post weld heat treatment as per procedure given in AWS D-1.1.
Post heating shall be done upto 600 deg.C and rate of application shall be 200 deg.C
per hour. The post heat temperature shall be maintained for 60 minutes per 2.5cm.
thickness. For maintaining slow and uniform cooling, asbestos pads shall be used
for covering the heated areas.

Sequence of Welding

a) The sequence of welding shall be carefully chosen to ensure that the components
assembled by welding are free from distortion and large residual stresses are not
developed. The distortion should be effectively controlled either by a counter effect
or by a counter distortion. The direction of welding should be away from the point of
restraint and towards the point of maximum freedom.

b) Each case shall be carefully studied before finally following a particular sequence of
welding.

c) Butt weld in flange plates and/or web plates shall be completed before the flanges
and webs are welded together.

d) The beam and column stiffeners shall preferably be welded to the webs before the
web and flanges are assembled unless the web and flanges to the beam or column
are assembled by automatic welding process.

e) All welds shall be finished full and made with correct number of runs, the weld being
kept free from slag and other inclusions, all adhering slag being removed.

f) Current shall be appropriate for the type of electrode used. To ensure complete
fusion, the weaving procedure should go proper and rate of arc advancement should
not be so rapid as to leave the edges unmelted.

g) Pudding shall be sufficient to enable the gases to escape from the molten metal
before it solidifies.

h) Non-uniform heating and cooling should be avoided to ensure that excessive

stresses are not locked up resulting ultimately in cracks.

i) The ends of butt welds shall have full throat thickness. This shall be obtained on all
main butt welds by the use of run off and run on pieces adequately secured on either
side of main plates. The width of these pieces shall not be less than the thickness of
the thicker part joined. Additional metal remaining after the removal of extension
pieces shall be removed by grinding or by other approval means and the ends and
surface of the welds shall be smoothly finished. Where the abutting parts are thinner
than 20mm the extension pieces may be omitted but the end be welded to provide
the ends with the required reinforcement.

j) The fusion faces shall be carefully aligned. Angle shrinkage shall be controlled by

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presetting. Correct gap and alignment shall be maintained during the welding
operation.

k) All main butt welds shall have complete penetration and back surface of the weld
being gouged out clean before first run of the weld is given from the back. However,
partial penetration butt weld shall be permitted, when specifically shown in the design
drawings.

l) Intermittent welds shall be permitted only when shown in the design drawings.

m) The welding shrinkage shall be minimised by adopting the correct welding procedure
and method. In long and slender member extra length should be provided at the
time of fabrication for shrinkage.

Testing of Welders

All the welders to be employed for the job shall have to qualify the appropriate tests laid
down in IS: 817 and IS: 1181 and ASME IX/AWS D1.1. All the necessary arrangements
required for the testing of welders are to be provided by the Bidder.

Inspection of Welds

a) Visual Inspection

100 percent of the welds shall be inspected visually for external defects.
Dimensions of welds shall be checked. The lengths and size of weld shall be as per
fabrication drawings. It may be slightly oversized but should not be undersized. The
profile of weld is affected by the position of the joint but it should be uniform. The
welds should have regular height and width of beads. The height and spacing of
ripples shall be uniform. The joints in the welds run shall as far as possible be
smooth and should not show any humps or craters in the weld surface. Welds shall
be free from unfilled craters on the surface, under-cuts, stages on the surface and
visible cracks.

Such inspection shall be done after cleaning the weld surface with steel wire
brushes and chisel to remove the spatter metal, scales, slag, etc., If external defects
mentioned above are noticed, there is every possibility of internal defects and further
radiographic/ultrasonic examination shall be undertaken.

b) Production Test Plate

Test plates shall be incorporated on either side of at least one main butt welds of
each flange plate and web plate of every main frame columns and crane girder. The
weld shall be continuous over the test plate. The test plate extensions of the main
plates and shall be fixed so that metal lies in the same direction as that of the main
plate. Test plates shall be prepared and tested in accordance with the accepted
Standards, in the presence of the Engineer or his authorised representative. Should
any of these tests fail, further radiographic examination of the welds shall be done.
These tests for test plates and radiographic examination are additional to those
contemplated under inspection and testing.

c) Non-destructive and special testing

Radiographic / ultrasonic or other non-destructive examination shall be carried out.

All tests of welds shall be carried out by the Bidder at his own cost. The cordoning of
radiation zone, while Radiography testing is going on, shall be done.

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In case of failure of any of the tests, re-testing of the joints shall also be carried out
after rectification is done.

d) Rectification of defective welding work

Wherever defects like improper penetration, extensive presence of blow holes,

undercuts, cracking, slag inclusion, etc., are noticed by visual inspection/other tests,
the welds, in such location shall be removed by gouging process. The joints shall be
prepared again by cleaning the burrs and residual matters with wire brushes and
grinding, if necessary, and rewelded. The gouging shall as far as possible be done
using gouging electrodes.

Inspection and Testing

a) Fillet Welds

i) All fillet welds shall be checked for size and visual defects.

ii) Macroetch examination on production test coupons for main fillet weld with
minimum one joint per built up beam, column and crane girder, etc.

iii) 25% weld length of tension members of crane girder shall be subjected to
dye-penetration test.

iv) On all other welds, dye-penetration test on 5% of weld length with minimum
300mm at each location shall be carried out.

b) Butt Welds

i) 100% visual examination.

ii) Dye penetration test on all butt welds after back gouging shall be carried out.

iii) Mechanical testing of production test coupons - minimum one joint/built up

beam, column and crane girder. The engineer may reduce the frequency of
the test, after getting consistently satisfactory results of initial 10 tests.

iv) 100% radiography test on butt welds of tension flange (bottom flange) of
crane girder and bunker supporting girders. All other butt welds shall be
subjected to radiography test on 10% of weld length of each welder.

c) Dimensional Tolerance and Acceptance Criteria of Welds

i) Every first and further every 10th set of identical structure shall be checked
for control assembly at shop before erection.

ii) All structures, components/members shall be checked for dimensional

tolerance during fabrication and erection as per IS:7215 and IS:12843
respectively.

iii) Dry film thickness after painting shall be checked by using elchometer.

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iv) Acceptance criteria of NDTs on welds shall be as per AWS D-1.1
(Dynamically loaded structures - Tension welds).

Correction of Defective Welds

Correction of defective welds shall be carried out without damaging the parent metal. When
a crack in the weld is removed magnetic particles inspection or any other equally positive
means shall be used to ensure that the whole of the crack and material up to 25mm beyond
each end of the crack has been removed.

Erection of Structures

All erection work shall be done with the help of cranes, use of derrick is not envisaged.

Erection Marks

a) Erection marks in accordance with fabrication drawing shall be clearly painted on the
fabricated steelwork. Each piece shall be marked in at least on two places. Each
piece shall also have its weight marked thereon.

d) The centre lines of all columns, elevations and girder bearings shall be marked on
the sections to ensure proper alignment and assembly of the pieces at site.

Erection Scheme

a) The Erection Scheme for the erection of all major structures shall be furnished. The
erectability of the structure shall be checked by the Bidder before commencement of
fabrication work to avoid future modification. The erection scheme shall indicate the
approximate weight of the structural members, position of lifting hook, crane boom
length, crane capacity at different boom length and at different boom inclination, etc.,
Bidder shall take up the erection work only after he has obtained the approval of the
erection scheme from the Engineer.

b) The erection scheme shall also give details of the method of handling, transport,
hoisting, including false work/staging, temporary, bracing, guying, temporary
strengthening, etc., It will also give the complete details of the number and capacity
of the various erection equipment that will be used such as cranes, winches, etc.,
along with disposition at the time of erection of columns, trusses, etc.

c) The erection of columns, trusses, trestles, portals, etc., shall be carried out in one
single piece as far as practicable. No column shall be fabricated and erected in
more than 3 pieces. Galleries shall generally be erected as box i.e. the bottom chord
and bracings, top chord and bracings, side vertical posts and bracings, end portals
and roof-trusses shall be completely welded prior to erection and if required
temporary strengthening during erection shall be made. The inside sheeting runners
and roof sheeting purlins may be erected individually. When erection joints are
provided in columns, their location shall generally be just above a floor level.

8.07.00 Steel Helical Springs And Viscous Damplers

8.07.01 General Requirement

This part of the specification covers the requirement for the manufacturing, testing, supply,
transport to site, pre-stressing erection, supervision of erection by the vendor, release of pre-
stress, alignment, commissioning, etc. of Steel helical springs and viscous dampers.

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10.00.00 MATERIAL SPECIFICATION

10.01.00 Cement

Fly ash based portland pozzolana cement conforming to IS:1489 (Part-1) shall be used for all
areas other than for the critical structures identified below. Other properties shall be as per IS
code.

Ordinary Portland Cement (OPC) shall necessarily be used for the following structures.

a) TG foundation top deck, Columns & Beams

b) All machine foundations such as PA/FD/ID Fans and TDBFP/MDBFP

c) RCC for Chimney shell.

The grade of cement shall be Grade 43 for OPC conforming to IS:8112.

In place of fly ash based portland pozzolana cement, OPC mixed with Fly Ash can be used.
Batching plant shall have facility for mixing fly ash. Fly ash shall conform to IS:3812(Part I &
Part II). Percentage of fly ash to be mixed in concrete shall be based on trial mix. Mix design
shall be done with varying percentage of fly ash mix with cement

10.02.00 Aggregates

a) Coarse aggregate

Coarse aggregate for concrete shall be crushed stones chemically inert, hard,
strong, durable against weathering of limited porosity and free from deleterious
materials. It shall be properly graded. It shall meet the requirements of IS: 383.

b) Fine aggregate

Sand shall be hard, durable, clean and free from adherent coatings of organic matter
and clay balls or pellets. Sand, when used as fine aggregate in concrete shall
conform to IS : 383. For plaster, it shall conform to IS : 1542 and for masonry work
to IS : 2116.

10.03.00 Reinforcement Steel

Reinforcement steel shall be of high strength deformed TMT steel bars of grade Fe-500 and
shall conform to IS:1786. However, minimum elongation shall be 14.5%.

Mild steel & medium tensile steel bars and hard drawn steel wire shall conform to grade-1 of
IS:432 (Part-1) or grade A of IS:2062. Welded wire fabric shall conform to IS:1566.

10.04.00 Structural Steel

Structural Steel (including embedded Steel) shall be straight, sound, free from twists, cracks,
flaw, laminations and all other defects. Structural steel shall comprise of mild steel, medium
strength steel and high tensile steel as specified below.

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10.04.01 Mild Steel

a) Rolled sections shall be of grade designation E250, Quality A/BR, Semi-killed/ killed
conforming to IS 2062. All steel plates shall be of Grade designation E250, Quality
BR (fully killed), conforming to IS 2062 and shall pass the impact test value at room
temperature. Plates beyond 12mm thickness and up to 40mm thickness shall be
normalized rolled. Plates beyond 40mm thickness shall be vacuum degassed &
furnace normalised and shall also be 100% ultrasonically tested as per ASTM –A578
level B-S2.

b) Pipes shall conform to IS: 1161.

c) Hollow (square and rectangular) steel sections shall be hot formed conforming to IS:
4923 and shall be of minimum Grade Yst 240.

d) Chequered plate shall conform to IS 3502 and shall be minimum 6 mm thick

excluding projection. Steel for chequered plate shall conform to grade E250A semi
killed of IS: 2062 or equivalent grade conforming to ASTM & BS standards only.

10.04.02 Medium and High Tensile Steel

Rolled Sections and plates shall be of grade designation E350 or higher, Quality B0 (Fully
killed), conforming to IS 2062. Plates beyond 12mm thickness and up to 40mm thickness
shall be normalized rolled. Plates beyond 40mm thickness shall be vacuum degassed &
furnace normalised and shall also be 100% ultrasonically tested as per ASTM –A578 level B-
S2.

10.05.00 Bricks

Bricks shall be table mounted/ machine made of uniform size, shape and sharp edges and
shall have minimum compressive strength of 50kg/cm2. Burnt clay fly ash bricks and fly ash
lime bricks shall conform to IS:13757 and IS:12894 respectively. Minimum fly ash content in
fly ash based bricks shall be minimum 25%. Common burnt clay bricks shall conform to
IS:1077.

10.06.00 Foundation Bolts

Material and details of foundation bolts shall conform to IS:5624. Mild steel bars used for the
fabrication of bolt assembly shall conform to grade 1of IS432 and/ or grade A of IS:2062.
Hexagonal nuts and lock nuts shall conform to IS 1363 & IS1364 upto M36 diameter and IS
5624 for M42 to M150 diameter.

10.07.00 Stainless steel

The material specification for stainless steel plates are mentioned in the design concept area
of Bunker building.

10.08.00 Water

Water used for cement concrete, mortar, plaster, grout, curing, washing of coarse aggregate,
soaking of bricks, etc. shall be clean and free from oil, acids, alkalis, organic matters or other
harmful substances in such amounts that may impair the strength or durability of the
structure. Potable water shall generally be considered satisfactory for all masonry and
concrete works, including curing. When water from the proposed source is used for making

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 abH4'1. <B ,a-yo,d 6'N
sFc!- '' {o 'tvt

REF: EQD/ Durgapur mai^ f (Z>-

Dated: June, 16,2015
Fax-(0120-2410211)

Sub: Preliminary report for site specific earthquake parameter studies for Durgapur Power
Plant Project Site, West Bengal.

Dear Mr. Agarwal,

This has reference to the Site-specific design earthquake parameters studies of Durgapur
power plant Project, West Bengal. Based on the preliminary studies and the seismotectonic
modelling (as given in Fig. 1) of the region falling in seismic zone III, the value of Maximum
Considered Earthquake (MCE) for the Durgapur site is recommended to be 0.169.
Accordingly, the Design Basis Earthquake (DBE) is recommended as 0.089 for the site. The
PGA values from various seismogenic sources are given in Table I. The time history of the
ground motion and the acceleration response spectra are enclosed for the Durgapur site as
Fig. 2 and Fig. 3. Table II contains the equation for response spectra (normalized to 1 g) for
various values of percentage of damping. The time history and the normalized smoothened
acceleration spectra as given in Fig. 2 and Fig. 3 has to be multiplied by 0.169 and 0.089 for
the MCE and DBE conditions respectively. The final report for the site will be submitted
soon.

With best wishes.

Your's sincerely,

Encl. As above
(M.L Sharma)

Mr. Abhishek Agarwal

Deputy Manager (Engg)
NTPC-SAIL Power Company P\t. Ltd.
"/.!V[,-'-
4ftFloor, NBCC Tower,
Bikali Cama Place,
,15
NewDelhi- 110 066
 85"8 88'E
Legend MAG o ooo
Fault
$9 !9 5$ 69 {}
-r'r'rr fggft_gubcurface
ir

t9'bt' ;|'6t'5|

X'ig.l Seismotectonic setup around the Durgapur Power Plant Project Site, West Bengal.

EHZ - Eocene Hinge Zone, DBF - Debagram Bogra Fault, GKGF - Garhmayna Khanda Ghosh
Fault, PF - Pingla Fault, NPSZ - North Purulia Shear Zone, SPSZ - South Purulia Shear Zone, SSZ
- Singbhum Shear Zone, WPF - West Patna Fault, EPF - East Patna Fault, MSRF - Munger Saharsa
Ridge Fault, MSRMF - Munger Saharsa Ridge Marginal Fault, MKF - Malda Kishanganj Fault,
SBF - Sainthia Bahmani Fault, RF - Rajmahal Fault, JF/GF/JGF- Jangipur Fault/Gaibandha
Fault/Jangipur-Gaibanda Foult, KNF- Katihor-Nailpharnari Fault, TF-Tista Fault, DF-Dhubri Fault,
DFZ-Dauki Fault Zone.
 TABLE- I Peak Ground Acceleration from Various Seismogenic Sources for
Durgapur Power Project Site, West Bengal.

Sl. Sources Magnitude Rrs*G-m) Max. Accl(g)

No.
I Pingla Fault 6.5 53 0.10
2 Garhmayna Khanda Ghosh 6.5 63 0.08
Fault
a
J Sainthia Bahmani Fault 6.5 63 0.08
4 North Purulia Shear Zone 6.0 75 0.04
5 Rajmahal Fault 6.5 93 0.0s
6 Jangipur-Gaibanda Faults 6.0 116 0.02
7 Debagram Bogra Fault 6.0 t36 0.019
8 Singhbhum Shear Zone 6.0 t4l 0.018
9 Eocene Hinge Zone 6.5 t63 0.02
l0 Munger Saharsa Ridge 6.5 244 0.009
Marginal Fault
l1 Dhubri Fault 7.5 315 0.009
*-Rra: Horizontal distance to surface projection of the fault. (Boore and Atkinson, 2008).

TABLE II - Equations for Response Spectra (One sigma) (Normalised to 1 'g') for
Various Values of Percentage of Damping for Durgapur Power Plant
Project Site, West Bengal.

1; 0.00s?<0.030

s"lvGA) I A;(r10.030)"; T0.03097<?i

<T 5Tz
vlr; rr{rsr$
I IT'; T t*Ts
D

Damping o T1 A T2 V T3 D
,h (s) (s) (s) (s) s2

0.80 t.894 0.075 5.670 0.300 t.701 2.000 3.402

1.00 r.826 0.075 5.330 0.300 1.599 2.000 3.198
1.60 1.401 0.080 3.950 0.320 t.264 2.t00 2.78r
2.00 1.361 0.080 3.800 0320 1.2t6 2.r00 2.675
3.00 t.tr7 0.084 3.160 0.330 1.074 2.300 2.579
5.00 0.834 0.090 2.500 0.3s0 0.900 2.450 2.340
7.00 0.680 0.090 2.tt0 0.350 0.760 2.450 r.975
10.00 0.570 0.090 1.870 0.350 0.673 2.450 1.7s0
 Design Acmlerogram: Durgapur TFP
1.S0
E
.c 1.00
6
o 0.50
o
C) 0,00
&
-n.50
d
g -1"00
z.
-1.50
0.0t) en 00 40.00 60.00 80.00 100.00 120.00
Tims {e)

Fig.2 Time history of ground motion for Durgapur Power Plant project site, West
Bengal.

Ogrlm Srctrr: Xhrgrytr TFF

8"00
ll 0.8t6lhmplu
7.5{t --'- -'-T'-'---'--'f ---- -- 1.0% Dlmplrp -------'
!!
7.00 --,-.-.-L,-.--.-.-.-.r.-.--,-.-,-. -
!.q!t 9llnplry '--..'.--
6.8{'
!!
8.ott -.-.--.-.-.-F'-.--.-'-'-.+.-.
!! ll
8.5{t -'-'--'- -'-F'-'--'-'-'- f '-'
!!
5.ffi :'-'--'- -'-F'-'---'--
ll
t'-'--'-'--'
l|'5|l tl
-'-'--'- -'-r'-'--'- -'-'1
H 1.W
ii
-.-'--'-.-.-F.-.--.-.-.-.+
B s.5tt
9.00
9.50
9.00
t.50
1.00
0"st
0.{to
o.tl0 1.O0 t.f,o e00 u.50
prnsd{4

Fig.3 Normalised horizontal spectral acceleration for various conditions for Durgapur
Power Plant project site, West Bengal.