Design, Supplying, Construction, Erection and Commissioning of Water Pumping Scheme from ...

91 Pages·2014·1.82 MB·English

Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

NMDC LIMITED

(A Government of India Enterprise)

10-3-311/A, Khanij Bhawan, Masab Tank, Hyderabad – 028 Andhra Pradesh.

Design, Supplying, Construction, Erection and Commissioning of Water
Pumping Scheme from Screening Plant Dep 5 to Filter House Dep 10 & 11A
at Bailadila Iron Ore Mine Bacheli Complex Distt Dantewada, Chhattisgarh
on EPC basis.

VOLUME –II

TECHNICAL SPECIFICATIONS

Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 1
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

PROJECT OBJECTIVE

The National Mineral Development Corporation Ltd (NMDC Ltd)
(referred to as Employer in these documents) invites Bid
for Design, Supplying, Construction, Erection and Commissioning
of Water Pumping Scheme from Screening Plant Dep. 5 to Filter
House Dep. 10 & 11A at Bacheli, Bailadila Iron Ore Mine, Bacheli
Complex, Dist: Dantewada, Chattisgarh on EPC basis. (as
defined in these documents and referred to as "the works"). The
offers shall be based on the bidder's own design which is to
be within the overall framework and guidelines specified by
NMDC Ltd in the Bid document and its
specifications.

GENERAL INFORMATION OF SITE LOCATION AND ACCESS

1.0 LOCATION

Bailadila range of hills is situated in the District of Dantewada in
Chhattisgarh State, at a distance of about 120 Kms south-west
of Jagadalpur Town, 40 km south west of Dantewada. The
Bacheli Complex in the Bailadila area was developed by NMDC
initially with Deposit No. 5 in the year 1977. Later on, Deposit
10 & 11A was added in 1997. Deposit 5 and 10 & 11A were
developed as independent projects with separate mine, crushing
plant, downhill conveyor system, screening plant and loading
plant.

2.0 ACCESSIBIILITY

Bacheli is easily accessible and well connected to Raipur,
Visakhapatnam and Hyderabad by all weather roads. It can be
reached by rail from Visakhapatnam. Raipur is located at a
distance of 425 km from Bacheli by road, while, Visakhapatnam
is about 450 km. Bailadila can also be reached by road from
Hyderabad, which is about 570 km away via Bhadrachalam (AP)
and Sukma (CG).

3.0 CLIMATE

The climate of the area is mild and pleasant during summer
months and moderately cold during winter. During 1997, the
maximum temperature recorded in summer was 40 degree
Celsius, while, the minimum in winter dropped at 10 degree
Celsius. The area receives heavy rainfall during monsoon.
Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 2
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

Annual rainfall on the Hilltop is about 3000 mm, while, at the
foothill is about 2500 mm. Humidity is very high during
monsoon. Weather is stormy during rainy season and the
maximum wind speed so far recorded is 70 kmph.

4.0 NOTE

The above information is for the bidder’s general guidance only
and does not relieve him in any of his responsibilities to satisfy
himself of the site conditions and sufficiency of his tender.

SECTION – I

CIVIL WORKS

1. GENERAL & SCOPE OF WORK

Scope of work includes all but not be limited to the following:
 Carrying out necessary site surveys and soil investigation.
 Required site development including Clearing the site of
trees/shrubs, debris etc. Carrying out necessary tree cutting,
transplantation of trees, new plantation etc. as per guidelines
and permission from the respective dept., leveling and grading,
taking in to consideration that the Finished Ground Level (FGL)
and the Highest Flood Level (HFL) and to improve the aesthetics
and to facilitate the vehicular movement as required, piling if
found necessary.
 Cost of shifting of poles, cables, pipe lines etc. if required shall
be borne by the Contractor.
 Preparation and submission of process design and hydraulic
calculation, plant layout and hydraulic flow diagram,
Preparation and submission of Civil and structural design,
electrical, mechanical, Preparation and submission of Civil and
structural drawings, architectural drawings, G.A. Drawings for
construction of all civil works and electrical and mechanical
equipment drawings including equipment installation drawings.
 Construction of civil engineering works for all the units plus all
the ancillary structures as detailed in Civil Specifications and as
required in complete for plant operation including Plinth
protection along the periphery of all the units.
 Supply, erection testing & commissioning of all the mechanical
equipment and as required in complete for plant operation.
Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 3
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

 Supply, erection testing & commissioning of all the Electrical and
as required in complete for plant operation.
 Supply, erection, testing & commissioning of all the piping &
valves as required in complete for plant operation.
 Providing and applying internal and external plaster to all units
as per technical specifications, Water proof cement painting to
all units with oil painting with anticorrosive treatment to railing
and all MS, CI and GI works, Drain with valve and pipe
arrangement to all the units.
 Construction of walkway, storm water drain.
 Plinth protection along the periphery of all the units shall be
provided as per technical specifications.
 Landscaping of the plant area.
 Trial Run of the constructed & hydraulically tested plant along
with electrical & mechanical equipment for a period of three (3)
months.
 Guarantee period of 12 months from the date of successful
commissioning and obtaining necessary Certificate of Completion
and Readiness from the NMDC Ltd.
 Supply of all documentation for the plant such as as-built
drawings, Operation & Maintenance manuals (3 sets) along with
soft copy.
 Supply of all spares required during performance run.
 Providing “on the job” training to NMDC Ltd personnel.
 Development of transformer yard of suitable size as per the
requirement.
 Bidders are advised to visit the proposed site before quoting for
the work.

The plant shall be designed for the following facilities as detailed
below:
1. Making connection by laying pipe line of suitable dia
minimum 250 mm with a MOV & a flow meter in between from
intake well to the proposed new RCC sump adjacent to the pump
house for water to flow by gravity for water supply scheme.

2. One number (above /underground as per site condition)
RCC sump of net capacity min 600 Cum (preferred size 15 m
x10m x 4m) with provision of ladder, all round drains, inlet,
outlet and Overflow arrangement.
Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 4
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

3. Pumping of raw water by best acceptable design (one working +
one standby(preferred for horizontal multistage centrifugal
pump) of capacity 200 cum/hr at 549 mWc static Head for the
pump house is proposed to work for 20 hrs every day.

4. Pump house and electrical panel room.
A new pump house and electrical panel room of minimum area
144 Sqm (preferred size 18 m x 8 m) is proposed near
Screening Plant Thickeners to accommodate pumps and
motor/electrical panel/control panel to pump 200 cum/hr
capacity including the foundation and superstructure work and
structural steel works.

5. Pump house cum electrical panel room shall be
constructed with permanent walls all-round and covered with
gal-Valume sheet roofing. The pump house shall also be
equipped with 5 tonnes capacity electrically operated under
slung crane for the purpose of easy and early handling of
maintenance work inside the pump house. Concealed wiring for
MCC room building shall be considered.

6. The water will be pumped from this pump house to
existing tank no.1 and tank no. 2 of 1000 cum capacity each at
top of the hill at approximate elevation 1182.65 M. The cross
country pipe line of 200 mm dia is proposed. The total length of
pipe line is approximately 2000 M and pipe will run as per the
sketch enclosed at annexure-I. The necessary supports, anchor
blocks above the ground, underground depending on the terrain
shall be in the scope of the bidder.

7. The proposed cross country pipe line shall cross the roads,
nalla and other similar structures for which necessary supports,
suitable casing pipe shall be provided.

8. ELECTRICS: Scope of work includes Supply, Erection,
Commissioning of 3.3 KV HT panels (approx. 6 no’s), Capacitor
banks, Lighting transformer, LT MCC panel (different feeder
rating) 110V battery charger, DC distribution board, control
desk, power cables (LT & HT) control cables, cable trays,
illumination (internal & external) safety equipment etc as
required.

Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 5
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

9. It is proposed to supply two years mandatory spares
required for normal operation beyond the warranty
period/commissioning and acceptance of the system.

2.0 Deleted

3.0 DESCRIPTION OF BUILDINGS AND FACILITIES

3.1 Ground Level Water Sump and Pump House

One No. of reinforced cement concrete ground level water sump of
minimum capacity 600cu.m. This Sump shall have RCC walls, Top
covered, manholes, inlet and outlet facilities, over flow and drain
vents, GI ladders for access to top and the inside of the tank. The
floor of the RCC tank shall be suitably sloped towards the sump to
collect wash water and the same shall be let out to the surface
drain. Approved admixtures shall be used in the concrete for
waterproofing and reduction of water cement ratio. The inside of
the Sump shall be plastered in cement mortar mixed with water
proofing compound. The external surface of the water tanks shall
be provided with approved shade and colour of cement based
colour wash. The area around the Sumps shall be leveled to
150mm above the approach leading to the area. Suitable drainage
facilities like PCC apron of 1000mm width, brick/ stone masonry
drains, including pipe/RCC box culvert shall be considered to
effectively drain off surface runoff. The surface runoff from the
area shall be let off in to a suitable location.

One No. of Pump House and Electrical Panel Room of size as given
in the Scope of work shall be provided. The pump houses shall be
constructed in RCC columns with structural steel frame for side
wall and roof with Gal Valume sheet. The foundations for pumps
shall be in RCC. All other facilities like pipe trenches, conduits,
inserts etc shall be provided as per the technological requirements
approved by the client. The area around the Pump House shall be
levelled to 150mm above the approach leading to the area.
Suitable drainage facilities like PCC apron of 1000mm width, brick/
stone masonry drains, including pipe culvert shall be considered to
effectively drain off surface runoff. The surface runoff from the
area shall be let off in to a suitable location.

3.2 Pipe supports:

Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 6
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

The new pipeline from Screening plant pumping station to
proposed 600 cu. m sump at Filter House shall be supported with
RCC pedestals as per the proposed scheme. Adequate provision
for walkway shall be provided.

SPECIFICATION OF MECHANICAL EQUIPMENT AND ACCESSORIES

3.3 WATER PUMP HOUSE NEAR FILTER HOUSE

Sl No. QUANTITY DESCRIPTION
1. PUMPS
Two sets. Water Supply Pumps
(1W + 1S)
Horizontal, Multistage
Centrifugal pump
Capacity : 650 HP for (1W+1S)
Head : 542 – mWc (static Head)
Standard : IS: 5120-2001; IS: 9137-1978

Complete with
o Base plate, Foundation bolts
o Coupling, Coupling guard

Material of construction:
Body & Impeller : Cast Steel
Shaft : AISI 410

2. VALVES
Motorized Gate/Sluice Valve: As per requirement.
Type : Flanged
Standard : BS 1414-1975/
API 600-1997
Pressure Rating : PN 1.0 (Class 150)
Size : 200 mm
Material of Construction
Body, Bonnet : Cast Iron
Wedge : Cast Iron
Stem : Stainless Steel

3. Gate/Sluice Valve As per requirement.
Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 7
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

Type : Flanged
Standard : BS 1414-1975/
API 600-1997
Pressure Rating : PN 1.0 (Class 150)
End Connection : Flanged
Size : 200 mm

Material of Construction
Body, Bonnet : Cast Iron
Wedge : Cast Iron
Stem : Stainless Steel

4. Dual Plate Check Valve As per requirement.
Type : Spring loaded
Standard : API 594 -1991
Working Pressure : 21kg/sq.cm (g)
Pressure Rating : PN 4.0(Class300)
End Connection : Flanged
Size : 200 mm
Material of Construction
Body : Cast Steel
Disc : Stainless Steel

5. 5 ton Capacity Electrically operated, As per IS
Underslung crane Class II duty.
Capacity : 5ton
Height of lift : 4m (approx.)
Span : To Suit P/H
Min. size of track beam : ISMB 200mm (as per make)

6. One (1) Lot Surge protection system for cross
country piping.

7. One (1) Lot Pipes and specials inside the
water pump house.
Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 8
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

SECTION – II

4 DESIGN PARAMETERS

General

4.1 This part of the specification covers the design parameters for
analysis and design of the civil buildings/facilities.

TERRACE LEVELS:
4.2 The terrace levels shall be fixed based on the topography of the
area and the filling/ cutting requirements as well as road
gradients. In general the road top level shall be 150mm above
the terrace level of the area.
4.3 In areas of rock outcrops/ cutting the surface shall be so
chiseled so as to be aesthetically pleasing.
4.4 Finished floor levels:
4.5 In general finished floor levels of the building/Sumps shall be
determined with respect to top of approach road or pavement.
Generally FFL shall be 600mm above terrace levels near the
building as indicated in the drawings.
Steps/ Ramps:

4.6 Steps/ ramps shall be provided for access to the building for
pedestrian/ vehicular, equipment entry. Minimum 1000 mm
wide platform shall be provided in between entrance door and
steps/ ramps. Following dimensions of steps/ ramps shall be
adhered to:

Tread A 250 mm minimum

Rise B 175 mm maximum
(preferably 150mm)

Slope oCf ramp Not steeper than 1:6

Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 9
Design, Supplying, Construction, Erection and Commissioning of Water

Pumping Scheme from Screening Plant Dep. 5 to Filter House Dep. 10

& 11A at Bailadila Iron Ore Mine, Bacheli Complex, Dist: Dantewada,
Chattisgarh on EPC basis.

5. ARCHITECTURAL FINISHES

5.1 All architectural finishes shall be as per specifications, standards
and approved list of vendors.

5.2 Colour scheme for all architectural items shall be as approved by
Owner.

6 ANALYSIS & DESIGN

6.1 Analysis and design of buildings, structures, facilities like roads,
drains, fencing etc, shall be done, as per good engineering
practices by experienced personnel. All data required for
checking of analysis and design shall be properly documented
and shall be readily available. Cross-references to relevant
data and clauses of codes shall be explicitly mentioned at every
stage.

6.2 Design and construction of buildings, structures shall take into
account requirements of operation and maintenance of all
equipment and there users. All the design work shall be carried
out as per latest IS codal requirements. The buildings shall have
good architectural features.

6.3 The Tenderer is free to use Staad Pro software for the purpose of
analysis. However detailed working of design shall be submitted
based on the results of analysis. The Tenderer shall be solely
responsible for the results of analysis and the design not
withstanding the approval accorded by the Owner. If, in the
opinion of the Owner the results are not satisfactory, alternate
method of analysis and design shall be used with the approval of
Owner.

6.4 Preliminary soil investigation of site indicates that ordinary
spread footing/raft will suffice for various structures. However,
the Tenderer shall carryout his own soil investigation and satisfy
himself on the characteristics of soil and type of foundation
system to be provided. No claim shall be entertained on account
of ignorance of soil characteristics.

7. LOADS AND LOAD COMBINATIONS

Tender Enquiry no. HO(contracts)/BIOMSP/2012/150 dated 11/03/2014 Page 10