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Spec No.

TCE. M4-410-01

TCE CONSULTING ENGINEERS LIMITED

Section : D

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Sh i of i

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

VALID UP TO : 2003-05-28
FILE NAME : M4-410-01(R3).DOC

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DATE
TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 1 of 19

1.0

SCOPE

1.1

This specification covers the general requirements for design, supply where
specified, fabrication, delivery at site and erection of self supporting or guyed
mild steel stacks with all connected appurtenances, as specified in DATA SHEETA which covers the specific technical requirements for the project, to form a
complete and workable arrangement. The two are complementary and are to be
read together for a correct interpretation of the provisions of this specification.
Where requirements of the two are in conflict, those of DATA SHEET-A shall
govern. This specification also covers preparation of all design and arrangement
drawings, all shop fabrication drawings, inspection and painting of the stack and
appurtenances by CONTRACTOR.

1.2

The scope of work shall not be deemed to have changed in case BIDDER's
drawings submitted with his bid do not show some part of the work as called for
in this specification unless categorically agreed to in writing before contract
award. The CONTRACTOR shall not be entitled to any extra claim on account of
his having (in OWNER's opinion) mis-interpreted, mis judged or overlooked any
aspect called for in this specification.

1.3

It is not the intent to specify completely herein all the details of design and
construction of the works involved under this specification. However, the works
shall conform in all respects, to high standards of Engineering, design and
workmanship.

1.4

The design and construction of Chimney foundation, pedestal, guy wire anchors,
grade slab (both inside and outside chimney) are excluded from the scope of this
specification. However the CONTRACTOR shall supply all embedments like
anchor bolts,inserts,anchorages etc.

2.0

APPLICABLE CODES & STANDARDS

2.1

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


Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

Section : D

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Sh 2 of 19

(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
( All Parts )

Technical supply conditions to Threaded Steel Fastners

(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)

Aluminium paint - Heat resistant.

IS:13183

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.


Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

Section : D

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Sh 3 of 19

(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.

2.2

SI units shall be adopted for all design and drawing work.

2.3

The following is the list of publications referred to in this specification.


Report of Task Committee on steel chimney liners, Fossil Power Committee,
Power Division, American Society of Civil Engineers, 1975.
BS 4076 : 1989

British standard specification for steel chimneys

3.0

STEEL MATERIALS

3.1

Rolled steel sections and Mild steel plates of thickness 20mm and below shall
conform to IS:2062 Grade A. Mild steel plates of thickness above 20mm shall
conform to IS:2062 Grade B.

3.2

Steel Supplied By OWNER

3.2.1

When steel is supplied by OWNER, it will be supplied ex- OWNER's Store in


such condition and in such length/sizes as are available in stock or as received
from the steel units.

3.2.2

On receiving each consignment of steel from OWNER, CONTRACTOR shall


acknowledge in writing the receipt thereof giving full particulars of sections,
sizes, quantities, grade and quality. Should there be any damage or distortion of
the materials in transit, CONTRACTOR shall immediately report the matter to
ENGINEER in writing.

3.2.3

CONTRACTOR shall take proper care of the steel supplied by OWNER and
protect the same from weather and damage. Any such materials rendered
unserviceable or damaged while in CONTRACTOR's custody shall be replaced or
repaired by CONTRACTOR at his own cost as directed by ENGINEER.

3.2.4

In cases, where after receipt of visibly good tested quality steel from OWNER,
defects such as laminations, seams tears, fins etc. are discovered during
fabrication,
the work on such sections shall be stopped immediately and the matter shall be
brought to the notice of ENGINEER/OWNER who shall arrange for replacing the
affected sections, if necessary.
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 4 of 19

3.2.5

The other conditions governing issue of steel by OWNER, if any, shall be as


mentioned elsewhere in Tender documents.

3.3

Steel Supplied By CONTRACTOR

3.3.1

CONTRACTOR shall furnish OWNER/ENGINEER duplicate copies of all mill


orders covering the material ordered by him for this project and also the test
reports received from the Mills for OWNER's/ENGINEER's review and
information.

3.3.2

It is not the intention of OWNER that all the steel materials to be supplied by
CONTRACTOR for the work shall be specially purchased from the rolling mills.
Material from CONTRACTOR's stock may be used, provided the mill test reports
identified with the materials, satisfactorily demonstrate the specified grade and
quality. OWNER shall have the right to test random samples to prove authenticity
of the test certificates produced by CONTRACTOR at CONTRACTOR's cost. All
steel materials supplied by CONTRACTOR shall be in a sound condition, of
recent manufacture, free from defects, loose mill scale, slag intrusions,
laminations, pitting, flaky rust etc. and be of full weight or thickness specified.
The lengths/sizes of steel sections and plates shall be as supplied by the steel
mills.

3.3.3

Material from unidentified stock may be used, with the prior permission from
ENGINEER in writing, for short sections of minor importance or for small
unimportant works and connections where, in the opinion of ENGINEER, the
quality of such materials would not adversely affect the strength and/or durability
of the structure. ENGINEER may also permit use of such material for other
works, if adequate random samples taken out and tested demonstrate conformity
with Specification and requirement for the work in view.

4.0

STEEL CASTINGS
All steel castings shall conform to Grade 23-45 of IS:1030, with a minimum
tensile strength of 450 MPa and a minimum yield of 230 MPa. Stresses in steel
castings shall not exceed the permissible stresses specified in Cl.7.7.1 of IS:6533.
Steel castings shall be free from injurious cold shuts and blow holes, true to
pattern and of a workmanlike finish.

5.0

GUY ROPES & FITTINGS

Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 5 of 19

All guy ropes and fittings shall conform to appropriate specifications as listed in
clause 2.0.
6.0

INSULATION

6.1

Upto a height of 2.5m from the base, the chimney shall be insulated externally
with mineral wool slabs made from rock slag or fibrous glass bonded by a
suitable binder conforming to IS:8183 or equivalent with a maximum coefficient
of thermal conductivity of 0.06 kcal/m/hour/C at a mean temperature of 150
deg.C.

6.2

Two layers of insulation material each of a minimum thickness of 25mm shall be


provided and all joints shall be staggered. The material shall have a minimum
density of 80 kg/cu.m.

6.3

The CONTRACTOR shall ensure that the insulation can safely withstand
maximum flue gas temperature without deterioration or break down and the
material shall be free from shots and other impurities which may cause corrosion.
The insulation should be able to withstand vibrations and should not settle down
in any case, such as during transport, storage, erection and operation and also due
to its own weight. It shall not be affected by existing flue gas acids in case of
exposure.

6.4

The insulation shall be tightly secured to the exterior surface by impaling them on
studs welded to the surface at 450 mm c/c both horizontally and vertically. The
studs shall be plated and be of a minimum thickness of 10 gauge. The studs shall
extend a minimum of 25 mm beyond the thickness of insulation and 63 mm
circular or square metal plate speed washers of standard thickness shall be placed
on the extended portion of the studs to hold the impaled insulation material well
in place. Further, a 20 gauge galvanised wire mesh with a 25 mm hexagonal
pattern conforming to IS:3150 shall be wrapped around. Where the wire mesh is
jointed, a minimum 150 mm overlap shall be provided. The mesh shall be bound
and tied in place with a 16 gauge GI wire at 300 mm centres. Any form of lacing
the mesh fibres together will not be permitted. Further, this portion of insulation
shall be provided with 1mm thick aluminium cladding to protect the insulation
from weather.

7.0

DESIGN REQUIREMENTS

7.1

The design data for this chimney are indicated in Data Sheet-A and should be
used as a basis for design by CONTRACTOR.

7.2

ENGINEER reserves the right to make changes in these to reflect additional


data/details received and more updated requirements. Revisions to drawings and
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

Section : D

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Sh 6 of 19

any new drawings made by CONTRACTOR on account of such changes shall be


considered a part of this contract and OWNER shall entertain no extra claims on
this account.
7.3

The Data Sheet-A and specification covers the general requirements for the design
and installation of the steel chimney; but they are not intended to provide for all
minute design and constructional requirements. The CONTRACTOR is deemed
to have provided for all such minor details which are necessary for the
satisfactory design and installation of the steel chimney as well as meeting all
statutory requirements.

7.4

Design and construction of the stack shall conform in every respect to boiler and
factory inspector's regulations, civil aviation authorities regulations and all other
local and state regulations governing such work including stipulations of Indian
Standards and Codes. Where the requirements are at variance, the most stringent
of them shall govern.

7.5

The stack shall be designed to resist stresses due to the following loadings and
load combinations as specified in Clause 6.5 of IS:6533 :

7.6

i)

Self weight of the steel stack. The weight of permanent fixtures such as
platforms, ladder, baffles, guys, etc. shall also be included.

ii)

Weight of the lining. The weight of lining shall be treated as a separate


loading for the purpose of load combinations.

iii)

The wind loading on the stack both static and dynamic as per IS:6533.

iv)

Earth Quake load as per IS:1893.

v)

Effect of temperature.

vi)

A live load of 300 kg/m2 shall be considered on each platform.

vii)

Additional customer loads acting vertically and horizontally at the flue


openings, if so specified under DATA SHEET-A.

viii)

Any other loads specified in DATA SHEET-A.

The stack shall be so designed that stresses do not exceed those maximum
permissible stresses specified in IS:6533 as modified to take account of the most
adverse temperature to which the member or part may reasonably be expected to
be exposed.
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 7 of 19

7.7

The minimum thickness of the stack shall be the calculated thickness obtained
from stress and deflection considerations plus an allowance for corrosion, but
shall not be less than 6 mm, nor less than 1/500 of the outside diameter of the
chimney at the considered wazzu height. The corrosion allowance shall be
obtained from Table-1 of IS:6533.

7.8

The maximum deflection of the steel stack due to static wind loading on the
design thickness without including the corrosion allowance, shall not exceed
1/200th of the unsupported height while the stack is in operation.

7.9

The stresses due to the lateral deflections of the stack (P- effect) shall also be
computed and added to those arising out of other loads.

7.10

Where openings are made in the shell plates a structural analysis for the stresses
shall be made and compensating material provided, as required so that no part of
the stack is overstressed. In no case the clear width of openings when under axial
compression shall be greater than 2/3 the diameter of the shell at the level of
opening if structural continuity of shell is to be maintained. Extra reinforcement
in the form of rolled sections or built-up boxes shall be provided at opening edges
both horizontally and vertically to fully restore the required structural capacity of
the uncut section.
(a) Vertical Stiffeners
(i) 100% of shell area removed by opening shall be replaced by additional
steel in the form of rolled sections, plates or built-up sections distributed
equally on each side of opening and located close to the edge.
(ii) The section may be checked as a column to guard against local
instability. Sectional properties shall be taken about the centroidal axis
parallel to the circumference of the shell.
(iii) The additional stiffeners shall extend above and below the limits of the
opening sufficient to properly develop the strength of the stiffeners
without over-stressing the shell plate. Generally, this length is no less
than one-half the width of opening, except where rational analysis shows
a lesser length is sufficient.

(b) Horizontal Stiffeners

Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 8 of 19

The horizontal stiffeners shall be designed and proportioned to carry the total
circumferential loads that occur over the height of the openings and placed at
the top and bottom face of the opening.
7.11

The base plates and holding down bolts shall be adequate to take the loads,
bending moments and reactions between the shell and the foundations without
exceeding the stresses specified in IS:800. Bearing pressure on concrete shall be
as per IS:456. Minimum grade of concrete shall be M20. Anchor bolts shall be
made 3 mm larger in diameter than computed for above mentioned stresses.

7.12

The stack shall be provided with helical strakes for top 1/3rd of the unsupported
height as explained in Clause A-2.2 of IS:6533 to prevent cross wind oscillation.

7.13

Adequate stiffening rings shall be provided to maintain circular shape of stack and
to minimise localised stress. The requiremens of ASCE task committee report
shall also be complied with.

7.14

The design and construction of ancillary steel work shall conform to IS:800.

7.15

For self-supporting stacks with tapered bottom section, a stiffening ring shall be
provided at the junction of the straight and tapered section of the stack. The ring
shall be designed to resist an axial force of Rt1f2tan and a moment in the plane
of the ring of 0.00336R2t1f1tan where R is the radius of the straight shell in
cm, is the acute angle between straight and tapered shells, f1 and f2 are the
maximum stresses in kg/cm at the bottom of the straight shell due to wind or
earthquake loads and due to dead loads respectively, and t1 is the thickness of the
shell in cm. The height in cms of the stack shell acting as one flange of the
annular ring shall equal 1.56 Rt1 + t2 where t2 is the thickness of the annular
ring.

7.16

For guyed stacks the maximum horizontal force P in KN due to wind or


earthquake shall be computed for a single guy from the equation :
M - Mb
P = -------H1
Where M is the moment of wind or earthquake force about base of stack in KNm,
Mb is the moment at base due to restrain foundation in KNm and H1 is the height
above base of stack in m.
The vertical components of guy tension must be taken into account when
computing stresses in the shell.
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 9 of 19

A minimum factor of safety of 3 shall be used over the breaking load for guy
ropes and fittings. Guy ropes shall have an initial tension of not less than 15% of
the calculated maximum wind tension.
7.17

The stability of the structure and foundations as a whole or any part of it shall be
checked as per IS:6533.

8.0

DESIGNS & DRAWINGS PREPARED BY CONTRACTOR

8.1

BIDDER shall submit along with the bid, copies of general arrangement drawings
in triplicate showing the thickness of the shell at different levels, strakes, location
of field joints, base detail and anchor bolts, and all accessories/appurtenances of
the stack as specified in the specification.

8.2

The CONTRACTOR shall submit his method of analysis, design parameters,


allowable stresses, method and sequence of construction including staging, details
of proposed site testing facilities, etc., strictly as per specifications for the
CONSULTANT's review and approval within 15 days from the date of Letter of
Intent or Purchase Order, whichever is earlier.

8.3

The CONTRACTOR shall submit his design/drawing submission schedule and a


construction schedule giving the monthwise requirement of materials to be
supplied by the OWNER; within 15 days from the date of award of work.

8.4

The CONTRACTOR shall submit based on the approved concept, the detailed
design including forces at base plate level for the design of foundation and general
arrangement drawings for the ENGINEER's review within 30 days from the date
of issue of Letter of Intent or Award of Contract whichever is earlier. All shop
fabrication drawings for the stack, lining and all other accessories such as coping
angles, cast iron cap, stainless steel exit piece, obstruction lighting conduit and
cable, balcony aviation warning beacons, painter's trolley, ladder with safety cage,
platforms, handrails, flue opening, soot/ash hopper, clean-out door, access door,
lightning protection and various other inserts all as required and shown in the
enclosed sketch shall be submitted in a progressive manner within 75 days from
the date of Award of Contract or Letter of Intent whichever is earlier. These
design/drawings will be returned after the CONSULTANT's review within about
15 days from the date of receipt by CONSULTANT. No claims shall be entertained
due to delay in review of the CONTRACTOR's drawings. Lining and accessories,
appurtanances shall conform to the relevant specifications attached.

8.5

In case the CONTRACTOR adopts computerised designs, only validated


computer programs shall be used for analysis and design. The computer output
listing should include all input data covering the loads and load combinations.

Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 10 of 19

8.6

CONTRACTOR shall submit typical hand calculations for a few important


members / structures to be chosen by the CONSULTANT in order to validate the
computer program used for analysis/design.

8.7

Timely submission of design/drawings to the CONSULTANT for review is the


sole responsibility of the CONTRACTOR and postal or other delays will not be
entertained as reasons for late/non-submission of design/drawings.

8.8

All modifications suggested by the CONSULTANT to meet specification


requirements and sound engineering practice, shall be incorporated by the
CONTRACTOR at no extra cost to the OWNER. In this respect, the decision of
the OWNER shall be binding on the CONTRACTOR. The CONSULTANT will
accord his approval only after the CONTRACTOR has incorporated in his
design/drawings all modifications required by the CONSULTANT.

8.9

Any modifications/change in subsequent revisions of design/drawings shall be


clearly marked and identified with a revision for the ENGINEER's
review/approval.

8.10

Fabrication shall not be started until CONTRACTOR has received copies of such
fabrication drawings upon which ENGINEER has endorsed his approval.
Approval by ENGINEER shall not relieve CONTRACTOR of his responsibility
for correctness of engineering design, dimensions workman- ship, fit of parts,
details, material etc. and soundness, safety and stability of the stack and the
efficient, smooth and trouble-free operation of the same.

8.11

CONTRACTOR shall furnish to the OWNER/ENGINEER all approved final


drawings and reproducibles of each drawings. These reproducibles shall
incorporate all modifications, field changes, substitutions etc. effected and reflect
the status "as built". All these drawings will remain the property of OWNER.
OWNER reserves the right to use them in any manner whatsoever.

8.12

Drawings prepared by CONTRACTOR and all subsequent revisions etc. inclusive


of incorporation of all modifications, field changes, substitutions etc. effected
shall be at the cost of CONTRACTOR, for which no separate payment will be
made. The price quoted for supply where specified, design, fabrication and
erection work shall be deemed to include the cost of such drawing work.

8.13

The CONTRACTOR shall distribute copies of drawings/ schedules, etc., prepared


by him in accordance with the schedule given below :

Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

Section : D

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

PRELIMINARY

COMMENTED

Sh 11 of 19

FINAL

SCHEDULE
S

DESIG
N

DWG

DESIGN

DWG

SCHEDU
LES

DESIGN

DWG

OWNER
(HEAD
OFFICE)

2P

1P

1P

2P

1P

2P+1R

OWNER
(SITE
OFFICE

2P

---

1P

---

2P

---

6P

TCE

2P

6P

6P

1P

3P

3P

VENDOR

LEGEND
P Prints
S Source
R Reproducible
The CONTRACTOR shall send one copy of all correspondence to OWNER's
head office and site office. The cost of these and that due to design/drawings
submission as per distribution schedule specified above is deemed to have been
included in his quoted rates.
9.0

ACCESSORIES
CONTRACTOR shall provide all necessary and accessories specified in Data
Sheet-A.

9.1

Coping and Cap


CONTRACTOR shall supply and fix suitable coping angles and grey cast iron
cap for the top of stack where required as specified in DATA SHEET-A.

9.2

Soot Hopper
Soot hopper with 50 mm thick lining of specified material shall be provided as
per the DATA SHEET-A. CONTRACTOR shall get ENGINEER's approval for
the design of the hopper and its supporting arrangement.

9.3

Stainless Steel Exit Nozzle


Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 12 of 19

Where specified, top of stack shall be provided with a stainless steel exit nozzle as
specified in DATA SHEET-A fabricated from 6mm thick stainless steel sheet
conforming with the requirements of AISI type 316L grade or equivalent. This
nozzle will have a flanged connection with the steel stack below. This nozzle will
not be insulated. Electrical continuity between stainless steel nozzle and the rest
of the mild steel chimney shall be achieved by means of proper bonding with
M.S. strip at two diametrically opposite points.
9.4

Ladder

9.4.1

The chimney shall be provided with a hot dip galvanised steel ladder having
access to intermediate resting platforms extending from bottom to top and
fabricated in 2.4, 3.6 or 4.8m sections and constructed as per the following
details.

9.4.2

The ladder shall be made of 75 mm x 8 mm flats spaced 400 mm apart with 20 mm


dia rungs spaced 300 mm centre to centre. Each sect ion shall be bolted together
with the adjoining sections. The ladder shall be provided with suitable supports
spaced 1.2m centres and welded to the chimney shell. A minimum distance of 250
mm shall be maintained between the chimney and the ladder.
The ladder shall have straight sides and its construction shall conform to all state
and local laws and regulations governing such installations. The ladder shall be
provided with a safety cage made up of hot dip galvanised steel flats starting from
a height of 2.10 m from ground as per enclosed sketch.

9.4.3

If individual section of a ladder exceeds 20m in height an intermediate landing


platform shall be provided.

9.4.4

The ladder and its connections shall be designed to support a concentrated load
of 175 kg at any location.

9.4.5

Ladder safety device shall be provided for the entire height of the chimney. Safety
device fixed to ladder rungs shall consist of a galvanised steel rack carrier with
two sets of safety sleeves and safety belts. The device shall be of proven quality
manufactured by a firm specialising in this equipment.

9.5

Lighting Conduits

9.5.1

CONTRACTOR shall supply and install three G.I. pipe conduit risers of specified
diameter fixed on the outside of the shell. One conduit riser will carry a cable to
the aviation warning lights on the platforms as specified in clause 13.7. The
second conduit riser will be required for power supply to outlets and flood lights
to be

Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 13 of 19

provided on the platforms. The third conduit riser will be required for
instrumentation cables to anemometer, accelerometer and probes for measurement
of wind velocity, wind pressure and smoke density respectively as specified in
DATA SHEET-A.
9.5.2

G.I. Pull boxes, fixed to the steel shell, shall be installed at 10.0 metres interval
vertically. The lowest pull box shall be located 450 mm above grade level. Each
conduit riser shall run from the lowest pull box to the highest junction box. The
conduit risers shall be run adjacent to the ladder, one on each side such that the pull
boxes are easily accessible from the ladder. Suitably fixed G.I. pipe conduits of
specified diameter shall also be provided from the lowest pull box to a suitable
outlet point at the base of the chimney to receive OWNER's cables. Two Numbers
Switchfuse units of 63A shall be supplied for Flood lighting and Aviation warning
lighting feeders respectively. All hardwares like bolts, nuts, glands, lugs etc. shall
be included in the scope of the CONTRACTOR. GI conduits shall be supported at
an interval of 1000mm for horizontal run and 750mm for the vertical run.

9.5.3

Each conduit riser shall be connected to a circumferential- conduit at each


platform level. The circumferential conduit at each level shall be provided with
three more G.I. junction boxes, for each of the lighting equally spaced, at the
location of the aviation warning lights or flood lights as the case may be. Suitable
fixed conduits shall also be provided from the junction box to the respective light
point. The G.I. pull boxes and junction boxes shall be of size 150 x 150 x 100 mm
and fixed to the steel shell.

9.5.4

Cables and wires for feeding aviation warning lights as well as the flood lights,
power outlets and instrumentation shall be supplied and installed by
CONTRACTOR. CONTRACTOR shall also supply three flood lights of 250W,
HPMV/HPSV type and one power plug of 30 amp, 240V for each platform.
Suitable mounting arrangement for these shall also be provided by
CONTRACTOR.

9.5.5

All conduits and wiring upto the lowest junction box, shall be furnished and
installed by CONTRACTOR as directed by ENGINEER. The conduits shall be
electrically connected to the steel shell.

9.5.6

Cabling and Wiring of flood lights and aviation warning lights shall be carried out
using a minimum size of 6 sq.mm aluminium conductor, 1100V grade and 250V
grade, PVC insulated cables respectively.

9.6

Lightning Protection
The chimney shell shall be provided with two grounding terminals on diagonally
opposite sides at the bottom at 500 mm above grade level. The details of the

Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 14 of 19

grounding terminals shall be as per the enclosed sketch. Grounding terminals


shall be connected to two numbers earth electrodes of suitable type specified and
to the main earth grid by two number leads as specified in DATA SHEET-A.
9.7

Platform And Aviation Warning Lights

9.7.1

Unless otherwise stated, a minimum of two platforms shall be provided, one near
the top and the other at an intermediate level. Platforms shall be of steel brackets
with gratings and be 1.0m wide (clear) with 32 NB MEDIUM CLASS, pipe
handrailing consisting of three rails, the two intermediate rails being 450 mm and
900 mm above platform level and posts spaced not more than 2m centres. Top
handrail shall be 1300 mm above platform level. Toe plate 65 mm x 8 mm
projecting 75 mm above the Gratings shall also be provided all round.

9.7.2

Holes of 75 mm dia. shall be made in the platform as per directions of the


ENGINEER for passing ropes during maintenance of the chimney

9.7.3

CONTRACTOR shall provide and fix aviation warning Lights and their supports
(equally spaced) at every 45m height or part thereof. The aviation warning lights
shall conform to the requirements of the Civil Aviation Department, Government
of India. These aviation warning lights shall be adequately secured to the chimney
against wind and seismic forces. The lights shall be red in colour having an
intensity sufficient to be conspicuous considering the intensity of the adjacent
lights and the general level of illumination against which they would normally be
viewed. In no case shall the intensity be less than 100 Lux.

9.7.4

Temporary warning lights shall be installed during construction above the top
most point of the obstruction and shall be shifted up as construction progresses.
These lights need be installed only after the level of obstruction is greater than 45
metres above grade.

9.7.5

All bolts, nuts, washers, pipe railing, posts etc., shall be galvanised. The railing
posts, aviation warning lights supports etc. will be fitted to the chimney platforms
by G.I. fasteners. The CONTRACTOR shall submit detailed drawings indicating
layout of lighting, conduits for lighting, instrumentation and grounding etc. for
approval before taking the fabrication work in hand.

9.8

Painter's Trolley

9.8.1

Where specified in DATA SHEET-A a trolley track for painter's trolley shall be
provided on the outside of the chimney near the top. CONTRACTOR shall
submit drawings for both the painter's trolley and the track to ENGINEER for
approval.

Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 15 of 19

9.9

Access Door

9.9.1

Unless otherwise stated an access door of 1000mm x 2100mm size shall be


provided. The door and the frame shall be fabricated from mild steel sections. The
doors shall be hinged and shall be provided with a locking device such as swivel
studs with wing nuts.

9.9.2

The door shall be painted with 3 coats of approved acid and heat resistant paint
after thorough cleaning.

9.10

Clean Out Door


A clean out door of size 750 mm x 750 mm shall be provided for access to inside
of the flue and for cleaning soot hoppers. Doors shall properly seal the escape of
flue gases by suitable construction and same shall be acceptable to the
ENGINEER. The door shall be hinged and shall be provided with locking device
in addition to swivel studs with wing nuts. The door shall be painted with 3 coats
of approved acid and heat resistant paint.

9.11

Flue Openings

9.11.1

The number, size and location of flue openings shall be as specified in DATA
SHEET-A.

9.11.2

All the inserts and bolts required for fixing of the flue duct shall be in accordance
with the requirements of the equipment suppliers and shall be provided and
installed by CONTRACTOR. The breaching will extend through the lining.

9.12

Baffle Plates
When there are two or more breach openings or flues entering the chimney, baffle
plates shall be provided to properly direct the gases from flue duct up the chimney
and prevent them from interfering with the operation by the other flue.
CONTRACTOR shall get the approval of ENGINEER for the design of the baffle
plate and its supporting arrangement. The baffle plate shall be properly insulated
as specified in Data Sheet-A.

9.13

Strakes
Helical strakes of three rails having a projection of 0.1 to 0.12 times the diameter
of the chimney, wound, equally spaced, round the perimeter of the shell at a pitch
of about five times the diameter of the chimney shall be provided for the top one
third height of the chimney.

10.0

CONSTRUCTION PROGRAMME
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 16 of 19

Bidder shall submit along with his bid the following data :
a)

Construction plant layout in the area where the stack is fabricated.

b)

A descriptive list of major items of equipment he proposes to use on the


job.

c)

The method he proposes to use for building up and erection of the stack.

d)

A construction schedule showing the order in which he proposes to carry


out the work, the data on which he proposes to start (including
procurement of plant and materials) and complete the work.

11.0

FABRICATION

11.1

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.

11.2

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.

11.3

All shell plates shall be rolled accurately to the proper curvature so as to obtain a
true cylindrical or conical shell as required. Shell angle rings for supporting
refractory brick lining or studs for keying mesh reinforcement for gunited linings
or metal/fibre- glass wool insulation shall be welded to the shell plates as
required.

11.4

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.

11.5

All fabrication work shall also conform to the specification TCE.M4-405-01


except as otherwise specified in clauses 11.1 to 11.4.

12.0

INSPECTION

12.1

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


inspection by ENGINEER/OWNER or his authorised representative. They shall
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 17 of 19

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.
12.2

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.

12.3

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. shall be subject to his approval.

12.4

All inspection of welds shall conform to IS 822.

13.0

PAINTING
The fabricated materials shall be given the protective treatment as specified in
DATA SHEET-A. Before applying any protective treatment, the exterior or
interior surfaces shall be cleaned to remove all dirt, loose scale, grease, rust or
other deleterious materials. This shall be carried out either at works or on site
after erection of the stack shell as specified in the specification TCE.M4-405-04
and DATA SHEET-A.

14.0

ERECTION

14.1

CONTRACTOR shall post an experienced and qualified ENGINEER who shall


be in full time charge of the erection job.

14.2

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.
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 18 of 19

14.3

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.

14.4

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.

14.5

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.

14.6

In case of faulty erection all consequent dismantling re-erection required will be


at CONTRACTOR's cost.

14.7

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.

14.8

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.

14.9

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
OWNER/CONTRACTOR as indicated in DATA SHEET-A.

14.10

All erection work shall also conform to the specification- TCE.M4-405-02 except
as otherwise specified in the clauses 14.1 to 14.9.

15.0

CONSTRUCTION TOLERANCES

15.1

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
Issue No.
R3

TCE FORM 329 R3

Spec No.

TCE CONSULTING ENGINEERS LIMITED

TCE. M4-410-01

DESIGN, SUPPLY, FABRICATION & ERECTION


OF STEEL STACKS

Section : D
Sh 19 of 19

25 mm whichever is lower. There should be no flats at seams and any local


deviations from circularity shall be gradual.
15.2

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.

Issue No.
R3

TCE FORM 329 R3

Spec No.

TATA CONSULTING ENGINEERS

TCE. M4-410-01

DATA SHEET - A
DESIGN,SUPPLY, FABRICATION & ERECTION
OF STEEL STACKS

1.0

NO. OF CHIMNEYS

2.0

EXPECTED LIFE OF CHIMNEY

: 20 YRSwazzu

3.0

DIMENSIONS OF CHIMNEY
3.1

CLEAR INSIDE DIA OF CHIMNEY AT EXIT


ELEVATION

CLEAR INSIDE DIA OF FLUE AT EXIT


ELEVATION

3.3

TOP ELEVATION OF CHIMNEY

3.4

CILL ELEVATION OF ACCESS DOOR

3.5

CILL ELEVATION OF CLEAN OUT DOOR

3.6

GRADE SLAB ELEVATION INSIDE CHIMNEY

3.7

GRADE SLAB ELEVATION OUTSIDE CHIMNEY

3.8

ELEVATION OF BOTTOM OF BASE PLATE

3.9

GROUT THICKNESS

: 50 mm

3.10

NUMBER OF FLUE OPENING AND THEIR


ORIENTATION

CENTRE LINE ELEVATION OF FLUE


OPENING

INSIDE DIMENSION OF FLUE GAS DUCT


(LxB)

3.13

THICKNESS OF FLUE GAS DUCT

3.14

THICKNESS OF MATING FLANGE

3.15

DISTANCE FROM CL OF CHIMNEY TO TERMINAL


FLANGE OF FLUE DUCT SUPPLIED BY OTHERS
:

3.2

3.11
3.12

4.0

Section : D
Sh 1 of 5

FLUE GAS DATA


4.1
4.2

MAXIMUM QUANTITY OF FLUE GAS THROUGH


EACH FLUE GAS DUCT

MAXIMUM FLUE GAS TEMPERATURE AT


ENTRY TO CHIMNEY

Issue No.
R3

TCE FORM 329 R3

Spec No.

TATA CONSULTING ENGINEERS

TCE. M4-410-01

DATA SHEET - A
DESIGN,SUPPLY, FABRICATION & ERECTION
OF STEEL STACKS

5.0

4.3

MINIMUM FLUE GAS TEMPERATURE AT ENTRY TO


CHIMNEY DURING OPERATION
:

4.4

SULPHUR CONTENT IN FUEL

4.5

AVAILABILITY OF FLUE GAS DESULPHURISATION


PLANT
:

4.6

AVAILABILITY OF PREHEATING AFTER


DESULPHURISATION

Sh 2 of 5

DESIGN PARAMETERS
5.1

TYPE OF CHIMNEY

5.2

DEGREE OF CORROSION EXPECTED (IS 6533)


EXTERNAL
INTERNAL

5.3

5.4

5.5

: SELFSUPPORTING/
GUYED
: NONE/ABOVEAVERAGE
: NONE/AVERAGE/
ABOVE AVERAGE

TEMPERATURE
5.3.1 OUTSIDE AMBIENT TEMPERATURE
MAXIMUM
MINIMUM

6.0

Section : D

:
:

WIND FORCE (IS 875)


5.4.1 BASIC WIND SPEED

5.4.2 TERRAIN CATEGORY

5.4.3 CLASS OF STRUCTURE

5.4.4 TOPOGRAPHY FACTOR (K3)

: 1.0

5.4.5 SHAPE FACTOR

SEISMIC FORCES
5.5.1 SEISMIC ZONE

5.5.2 SOIL FOUNDATION COEFFICIENT

5.5.3 IMPORTANCE FACTOR

LINING / INSULATION
6.1

INTERNAL LINING

: 50MM THK MINERAL


WOOL WITH 12 MM
FINISH

Issue No.
R3

TCE FORM 329 R3

Spec No.

TATA CONSULTING ENGINEERS

TCE. M4-410-01

Section : D

DATA SHEET - A
DESIGN,SUPPLY, FABRICATION & ERECTION
OF STEEL STACKS

Sh 3 of 5

50 MM GUNITING
WITH REFRACTORY
AGGREGATE
STAINLESS STEEL
LINER 6 MM THK
OF TYPE SS 316L

7.0

6.2

EXTERNAL LINING

: 50MM THK MINERAL


WOOL FOR THE BOTTOM
2500MM WITH 1 MM THK
ALUMINIUM.PROTECTIVE
CLADDING

6.3

LINING FOR BAFFLE

: STAINLESS STEEL LINER


6 MM THK OF TYPE
SS 316L

6.4

DENSITY OF MINERAL WOOL

6.5

SOOT HOPPER

: ACID RESISTANT TILE


LINING CONFORMING TO
IS 4457 SET IN ACID
RESISTANT MORTAR

6.6

GRADE SLAB, SKIRTING (200 MM HIGH)


AND DRAINS

: ACID RESISTANT TILING


AND DRAINS SET IN ACID
RESISTANT MORTAR

PAINTING
7.1

7.2

INTERNAL PAINTING
UNLINED CHIMNEY

: TWO COATS OF RED


OXIDE ZINC CHROMATE
PRIMER

LINED CHIMNEY

: ONE COAT OF RED OXIDE


ZINC CHROMATE PRIMER
AND TWO COATS OF HEAT
RESISTANT ALUMINIUM
PAINT CONFORMING TO
IS 183

EXTERNAL PAINTING

: ONE COAT OF RED OXIDE


ZINC CHROMATE PRIMER
AND ONE FINISH COAT OF
HEAT RESISTANT
ALUMINIUM PAINT
CONFORMING TO IS 13185
BEFORE ERECTION

Issue No.
R3

TCE FORM 329 R3

Spec No.

TATA CONSULTING ENGINEERS

TCE. M4-410-01

Section : D

DATA SHEET - A
DESIGN,SUPPLY, FABRICATION & ERECTION
OF STEEL STACKS

Sh 4 of 5

TOP PORTION TO A HEIGHT


OF 2 TIMES DIAMETER FROM
THE TOP SHALL BE GIVEN 2
COATS OF ACID RESISTANT
PAINT CONFORMING TO IS
158
BALANCE
PORTION
SHALL BE PROVIDED WITH
TWO COATS OF SYNTHETIC
ENAMEL
PAINT
CONFORMING TO IS 2932
WITH ALTERNATE BANDS OF
ORANGE AND WHITE SHADE
WITH A BAND WIDTH OF H/7
WHERE H IS THE HEIGHT OF
THE
CHIMNEY
WITH
EXTREMITIES
BEING
OF
ORANGE
8.0

ACCESSORIES
8.1

GI STRAKES

: HELICAL STRAKES
3 NOS.

8.2

CAGE LADDER

8.3

STEPS INSIDE

8.4

SOOT HOPPER

8.5

CLEAN OUT DOOR

8.6

ACCESS DOOR

8.7

PLATFORM - EXTERNAL - ELEVATIONS

8.8

PAINTER'S TROLLEY

8.9

GASKET AND BOLTS FOR FLUE GAS DUCT

8.10 SUPPLY OF MATING FLANGE

8.11 ERECTION OF MATING FLANGE

8.12 CAP

8.13 COPING

8.14 GROUTING OF BASE

8.15 AR TILED DRAINS IN GRADE SLAB

8.16 SS EXIT NOZZLE

Issue No.
R3

TCE FORM 329 R3

Spec No.

TATA CONSULTING ENGINEERS

TCE. M4-410-01

DATA SHEET - A
DESIGN,SUPPLY, FABRICATION & ERECTION
OF STEEL STACKS

8.17 HEIGHT OF EXIT NOZZLE


9.0

10.0

Section : D
Sh 5 of 5

ELECTRICAL
9.1

GROUNDING TERMINALS

9.2

LIGHTING CONDUITS

9.3

EARTHING ELECTRODES/LEADS

9.4

LlGHTING

a) AVIATION WARNING

b) OBSTRUCTION LIGHTS/FLOOD LIGHTS

c) SWITCH FUSE UNITS

d) RECEPTACLES

9.5

CABLING

9.6

LIGHTNING PROTECTION

INSTRUMENTATION
10.1 CABLE CONDUITS

10.2 STUBS FOR ANEMOMETER

10.3 STUBS FOR ACCELEROMETER

10.4 PROBES

10.5 CABLING

Issue No.
R3

TCE FORM 329 R3

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