Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 1 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

Document No: G3IR-1050-65-SP-9042

Unit: Discipline: Document Type:

General Electrical Specification

Document Title: SPECIFICATION FOR OUTDOOR SWITHCYARD STRUCTURE (STEEL

SUPPORT STRUCTURE)

DISCLAIMER
THIS DOCUMENT DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS DOCUMENT CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.

ISSUED FOR DESIGN

08 Aug 2012

1 0 Revision

30-Jul-12 18-Jul-12 Date

Issued for Design Issued for RFQ Purpose

HS HS Prepared By

NG NG Checked By

VP VP Fluor BASF Approved By

G3IR-1050-65-SP-9042_R0

Page 1 of 8

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 2 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 Date Description

18-Jul-12

Issued for Design (RFQ)

30-Jul-12

Issued for Design

G3IR-1050-65-SP-9042_R0

Page 2 of 8

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 3 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

TABLE OF CONTENTS

1.0 1.1 2.0 2.1 2.2 2.3 3.0 4.0 5.0 6.0 7.0 8.0 9.0

GENERAL .................................................................................................................................................. 4 Scope......................................................................................................................................................... 4 DESIGN CRITERIA.................................................................................................................................... 4 General ...................................................................................................................................................... 4 Constructional Requirement................................................................................................................... 5 References ................................................................................................................................................ 5 FABRICATION OF STEEL MEMBERS .................................................................................................... 6 PROTO ASSEMBLY.................................................................................................................................. 6 WELDING .................................................................................................................................................. 7 FOUNDATION BOLTS .............................................................................................................................. 7 STABILITY OF STRUCTURE ................................................................................................................... 7 GROUTING ................................................................................................................................................ 7 GALVANISING .......................................................................................................................................... 7

10.0 INSPECTION BEFORE DISPATCH.......................................................................................................... 8 11.0 ERECTION................................................................................................................................................. 8 12.0 SAFETY PRECAUTIONS .......................................................................................................................... 8 13.0 STANDARD EQUIPEMNT SUPPORT STRUCTURES ............................................................................ 8

G3IR-1050-65-SP-9042_R0

Page 3 of 8

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 4 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

1.0 GENERAL 1.1 Scope 1.1.1 The scope of specification prescribes design, fabrication, proto assembly, supply and erection of galvanized steel structures for towers, beams and equipment support structures. Towers, beams, CT, CB and other equipment support structure shall be lattice type structures fabricated from structural steel conforming to IS 2062 (latest) 1.1.2 The scope shall include supply and erection of all types of structures including bolts, nuts, washers, hangers, shackles, clamps anti climbing devices , bird guards ,step bolts , inserts in concrete, gusset plates, equipments mounting bolts , structures earthing bolts , foundation bolts, spring washers , fixing plates , ground mounted marshalling boxes ( AC / DC marshalling box & equipment control cabinets if any) , structure mounted marshalling boxes and any other items as required to complete the job 1.1.3 2.0 The scope shall also include switchyard fencing and loose gravel filling

DESIGN CRITERIA 2.1 General 2.1.1 All structure shall be designed for the worst combination of dead loads, live loads, wind loads as per applicable parts of code IS:875 , seismic forces as per code IS : 1893( latest) , loads due to deviation of conductor , load due to unbalanced tension in conductor , torsion load due to unbalanced vertical and horizontal forces , erection loads , short circuit etc. 2.1.2 Short circuit forces shall be calculated considered a fault level of 31.5 kA, IEC: 865 may be followed for evaluation of short circuit forces. 2.1.3 All pipe support used for supporting equipments shall be designed for the worst combination of dead loads, erection loads, wind loads / seismic forces , short circuit forces and operating forces acting on the equipment and associated bus bars as per IS : 806 . The material specification shall be as per IS: 1161 read in conjunction with IS: 806 2.1.4 If luminaries are proposed to be fixes on gantries / towers, then the proper loading for the same shall be considered while designing. Also holes for fixing the brackets for luminaries should be provided wherever required. 2.1.5 2.1.6 Foundation bolts shall be designed for the loads for the structures design Foundation bolts shall be Grade 4.6 Confirming to IS: 1367
Page 4 of 8

G3IR-1050-65-SP-9042_R0

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 5 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

2.1.7 The contractor shall submit the design as per related standards and best industrial practices to the client for the approval 2.2 Constructional Requirement 2.2.1 The connection of all Structures to their foundations shall be by base plates and embedded anchor / foundation bolts shall be fully galvanised. The weight of the zinc coating shall be at least 0.650 kg / m2 for anchor bolts / foundation bolts and for structural members. One additional nut shall be provided below the base plate which may be used for the purpose of levelling. 2.2.2 For designing of steel structures loads such as dead loads , live loads , wind loads etc shall be based on IS: 875 , Parts 1 to 5 . 2.2.3 For material and permissible stresses IS: 802, Part -1, Section -2 shall be followed in general: However, additional requirements given in following paragraphs shall be also considered. 2.2.4 Minimum Thickness of galvanised tower member shall be as follow: Leg Members, Peak Members/Main members Other members Redundant members 2.2.5 5 mm 4 mm 4 mm

Maximum slenderness ration for leg members, other stressed members and redundant members for compression force shall be as per IS: 802

2.2.6

Minimum distance from hole centre to edge shall be 1.5 x bolt diameter. Minimum distance between centre to centre of holes shall be 2.5 x bolt diameter.

2.2.7 2.2.8

The minimum bolt diameter shall be 16 mm, Step Bolts In order to facilitate inspection and maintenance, the structures shall be provided with climbing devices. Each tower shall be provided with bolts not less than 16 mm diameter & 175 mm long spaced not more than 450 mm apart , staggered on faced on one leg extending from about 0.5 meter above ground level to the top of the tower . The step bolt shall confirm to IS: 10238. Ladders on Towers with lighting appliances shall be provided with safety guards.

2.3

References 2.3.1 The steel structural assembly shall conform to the latest editions of following standards issued by BIS (Bureau of Indian Standards) unless otherwise specified. Each publication shall be the latest revision and addendum in effect on the date this

G3IR-1050-65-SP-9042_R0

Page 5 of 8

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 6 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

specification is issued for Purchase, unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, as a minimum, Work included in this specification shall conform to the applicable provisions of these publications. 3.0 IS: 209 IS: 800 IS: 802 Specification for Zinc ingot General Construction In Steel - Code of Practice Code of Practice for Use of Structural Steel In Overhead Transmission Line Towers, IS: 819 Code of Practice for Resistance Spot Welding for Light Assemblies in Mild Steel IS: 875 Code of Practice for Design Loads (Other Than Earthquake) For Buildings and Structures IS: 1161 IS: 1893(Part 1-4) IS: 2062 IS: 5624 IS: 7205 IS: 10238 Specification for Steel Tubes for Structural Purposes Criteria for Earthquake Resistant Design of Structures Hot Rolled Medium and High Tensile Structural Steel Specification for Foundation bolts Safety code for erection of Structural Steelwork Specification for Fasteners - Threaded Steel Fastener - Step Bolts for Steel Structures IEC: 865 Effects of Short-circuit Currents

FABRICATION OF STEEL MEMBERS The Fabrication and erection works shall be carried out generally in accordance with IS: 802. A reference, however, may be made to IS 800 in case of non-stipulation of some particular provision in IS: 802. All materials shall be completely shop fabricated and finished with proper connection material and erection marks for ready assembly in the field.

4.0

PROTO ASSEMBLY a) The component parts shall be assembled in such a manner that they are neither twisted nor otherwise damaged and shall be so prepared that the specified camber, if any , is provided. In order to minimize distortion in member the components parts shall be positioned by using the clamps, clips, jigs and other suitable means and fasteners (bolts and welds) shall be places in a balanced pattern. If the individual components are to be bolted, paralleled and tapered drifts shall be used to align the part so that the bolts can be accurately positioned. b) Sample towers, beams and equipment support structures shall be trail assembled in the fabrication shop and shall be inspected and cleared by Owner/engineering consultant based

G3IR-1050-65-SP-9042_R0

Page 6 of 8

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 7 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

on the approved fabrication drawing before mass fabrication. Pursuant to above the BOMs along with proto-corrected fabrication drawings and shop manufacturing drawings for every member shall be prepared and submitted by the contractor to Owner / engineering consultant as document for information. Such BOM, which shall be duly certified by the contractor for its conformity to approved design, shall be the basis for Owner / engineering consultant to carry put inspection 5.0 WELDING The work shall be done as per approved fabrication drawings which clearly indicated various details of joints to be welded, type of weld, length and size of weld whether shop or site weld etc. symbols for welding on erection and shop drawing shall be according to IS : 819 . Efforts shall be made to reduce site welding so as to avoid improper joist due to constructional difficulties 6.0 FOUNDATION BOLTS a) Foundation bolts for the towers and equipment supporting structures and elsewhere shall be embedded in first stage concrete while the foundation is cast. The contractor shall ensure the proper alignment of these bolts to match the holes in the base plate. b) The Contractor shall be responsible for the correct alignment and levelling of all steel work on site work on site to ensure that the tower/ structures are plumb. c) d) All foundation bolts for lattice structures are to be supplied by the contractor. All foundation bolts shall be fully galvanized so as to achieve 0.650 kg / m2 of zinc coating as per specifications. e) 7.0 All foundation bolts shall conform to Grade 4.6 as per IS 1367

STABILITY OF STRUCTURE The contractor shall be responsible for the stability of the structure at all stages of its erection at site and shall take all necessary measures by the additions temporary bracing and guying to ensure adequate resistance to wind and also to loads due to erection equipment and their operations.

8.0

GROUTING The method of grouting the column bases shall be subject to approval of employer / engineering consultant and shall be such as to ensure a complete uniformity of contact over the whole area of the steel base. The contractor will be fully responsible for the grouting operations

9.0

GALVANISING a) All structural steel works shall be galvanised after fabrication.

G3IR-1050-65-SP-9042_R0

Page 7 of 8

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9042 Date 18-Jul-12 Page 8 of 8

OUTDOOR SWITHCYARD STRUCTURE (STEEL SUPPORT STRUCTURE)

b) c) d) Zinc required for galvanising shall have to be arranged by the contractor Purity of zinc to be used shall be 99.95 % as per IS: 209. The Contractor shall be required to make arrangement for frequent inspection by the employer / engineering consultant as well as continuous inspection by a resident representative of the employer, if so desired for fabrication work 10.0 INSPECTION BEFORE DISPATCH Each part of the fabricated steel work shall be inspected as per approved quality plans and certified by the owner or his authorised representative as satisfactory before it is dispatched to the erection site. Such certification shall not relieve the contractor of his responsibility regarding adequacy and completeness of fabrication. 11.0 ERECTION The contractor shall arrange on his own all equipment arc equipment, welding set, tools and tackles, scaffolding, trestles equipments and all other accessories and ancillaries required for carrying out erection without causing any stresses in the members which may cause deformation and permanent damage 12.0 SAFETY PRECAUTIONS The contractor shall strictly follow at all stages of fabrication, transportation and erection of steel structures, raw materials and other tools and tackles , the stipulation contained in Indian standard code for safety during erection of structural steel work IS : 7205 . 13.0 STANDARD EQUIPEMNT SUPPORT STRUCTURES It is intended that only standard structures shall be used in the switchyard to the maximum extent. However, if necessary, as per site equipments, different designs may be adopted. Structures other than those standardised, if required, are to be designed, supplied and erected, as described in preceding paragraphs, without any extra financial implication to Employer .

G3IR-1050-65-SP-9042_R0

Page 8 of 8