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Presentation onthe construction of a
Nitroglycerine Plant atNalanda, Bihar
byPriyadarshini DasM.S.Ramaiah Institute of Technology
Bangalore
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Reviewed by :-
Mr. Mukut Paul
Vice President
Project Division
Nicco Corporation
Kolkata
Mr. Shibaji Banerjee
Senior Manager
Project Division
Nicco Corporation
Kolkata
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Nitro-glycerine plant forOrdnance factory,
Nalanda, Bihar
Contract between The President of India
and M/S Biazzi, SA Switzerland dated
12/06/2008
Indian Collaborators Nicco Corporations
Project
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About Nicco
NICCO Group is a proprietorship with Mr. Rajive
Kaul as Chairman established in 1942.
It is a group of four companies, viz:
Nicco Corporation Limited
Nicco Parks & Resorts Ltd.
Nicco Internet Ventures Ltd.Nicco Engineering Services Ltd.
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Nicco Corporation Limited (NCL) headquartered in
Kolkata is the flagship company of the Nicco
Group. For nearly six decades, NCL has been oneof the pioneers in the Indian Cable
manufacturing industry
It has two divisions:Cable Division
Project Division
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About the Nitro-glycerine Plant
The plant consist mainly of the Nitration plant and NG emulsion
transfer to storage buildings which is automatically controlled,
remotely operated and continuous.
This is done by means of a BIAZZI patented Eductor
Its rated capacity is 500kg/hrof nitro-glycerine.
The explosives holding at any stage is minimum and the NG mixture
produced meets the strictest quality requirements.
The plant has inbuilt safety controls that takes care of any abnormal
condition during manufacture.
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C3H5 (OH)3 + HNO3 C3H5 (NO3)3 + 3 H2O
In the plant esterification of glycerine occurs
following this equation :-
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NG Physical Properties
Specific gravity is 1.591 at 25C (77F) and 1.6 at 15C
(59F)
Melting point is 13.5C (56.3F)
Solubility in water is 0.18 % at 20C (68F)
Vapour tension is 0.00025 mm of Hg at 25C (77F) and
0.00038 mm of Hg at 30C (86F)
Specific heat is 0.32 kcal/kg (1.3 kJ/kg)
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Hazardous Properties of Nitro
GlycerineNitro-glycerine represents a dangerous fire and explosion hazard
and is toxic as well.
It is a powerful vasodilatorthat causes reduction in blood
pressure. It also effects the skin and eye.
Severe poisoning is often manifested by confusion,
pugnaciousness, hallucinations and maniacal manifestations.
Physiologically, its introduction into the body will cause severe
headaches, excitement, vertigo, fainting, respiratory ailments and
cyanosis, ultimately death from asphyxiation due to respiratory
paralysis.
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Danger of explosion
The detonation of nitro-glycerine is caused by concentrations of
energy such as sparks, friction, impact, flame orheating.
The setting-off of an explosion is subject to considerations of
probability. With a small amount of energy, the probability of setting
off an explosion is small ; with a large amount of energy, this
probability is greater although not certain.
Nitro-glycerine should be handled with greatest care.
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Scope of Civil Engineering
To provide utmost safety measures in order to avoid explosion inthe first place and to avoid widespread damage in case of an
accidental explosion
To provide separate and viable units for Acid and GlycerineStorage, Nitration, Nitroglycerine emulsion transfer through
specialized eductor, Nitroglycerine Storage and Waste
water treatment
To provide an electrical MCC Room
To provide other buildings such as Security cabin, Changing
room for industrial staff, Canteen etc.
Maximum Utilization with Maximum Safety
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The Plant Concept
All the equipment supplied is ofhigh quality NG type constructions
without any pinch point, pocket potentials or metal-to-metal contacts; it
is also highly polished, free draining and consistent with good
accepted NG practices.
All the parts in contact with acids or acidic fumes are in stainless steel
304 L or 316 L and 329.
All the equipment components located in the process room and the
lubricants used are non-nitratable and compatible with NG.
The equipment construction is carefully supervised by our experts.
Water running trials and X-ray checking of the welding are carried out
in the workshops prior to the shipment of the equipment.
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S. No. Building
No.
Purpose
1 0210 Nitration, Separation and Storage
2 0211 Storage (I)
3 0212 Storage (II)
4 0213 Waste Water Treatment
5 0214 Control House
The Plant consists of the following
buildings :-
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6 0207 Electrical MCC Room
7 0209 Glycerine Storage Area
8 & 9 0215, 0216 Soda Soln. Preparation and Compressed Air
Cooling Unit
10 0208 Acid Storage and Mixing Area
11 0201 Security / Attendant Cabin
12 0202 Unit Office and Store
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13 0203 Industrial Employees Change Room / Canteen
14 0204 Cycle / Scooter Shade for staff
15 0205 Cycle / Scooter Shade for Industrial Employees
16 0206 Non-Explosive Store
17 0217 Water Reservoir
18 401 Electrical MCC Room for Storage (I) 0211
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19 451 Electrical MCC Room for Storage (II) 0212
20 - Static Tank
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The detailed Plot Plan
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A TRAVERSE around the explosivebuildings has been constructed to limit the
effect of an explosion.
Also fire fighting installations such as the
DOUBLE HYDRANT VALVES are used.
Safety measures
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Detailed Drawing of the traverse
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The double dots denote the double hydrant valves
used to prevent fire hazards
(According to STEC Pamphlet 15)
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Fire Safety
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Detailed Design of the
Plant Sections
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Nitration and Washing Unit Top View
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Important
features of the
Nitration Unit :-
There is aPolycarbonate
Sheet Wall all
around.
On th
e processside flooring is of
epoxy conductive
coating and walls
and ceiling have
acid resistantpaint.
On the motor side
floor, walls and
ceiling have
washable paint.
Nitration and Washing Unit side view
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Key Plan of the Acid Storage
Building
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Acid storage is composed of five tanks :-
1 tank (25 m3) in MS for oleum
1 tank (25 m3) in aluminum for concentrated nitric acid
2 tanks (2 x 25 m3)in stainless steel for the mixed acid needed for nitration
1 tank (30 m3) in stainless steel for the spent acid rejected from nitration
Additionally, a mixing unit for the preparation of mixed acid is needed in the
same area.
This unit can be automatic. This mixing operation can be done even during
the production of NG.
One of the mixed acid tanks is selected for production after acceptance from
the laboratory and the other one is used for mixing.
Loading of the oleum and CNA can be done by means of pumps from the
trucks.
All the tanks are equipped with a moisture trap.
The mixed acid levels tanks are monitored in the control room.
Constructional Aspects
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Key Plan of the Glycerine
Storage Building
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Constructional Aspects
Glycerine storage consists mainly of two tanks (2 x 6 m3), in stainless
steel.
Filling of the tanks can be done either from drums or directly from a
truck.
The tanks are sealed with an air breather trap for preventing moisture
contamination.
A small room, in which at least six drums can be kept, is needed to
preheat the drums during the cold season.
The whole piping, pumps, etc. are in stainless steel.
The tanks are designed so as to permit their easy cleaning and
maintenance.
Levels are monitored in the control room.
Temperatures are monitored in the control room.
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Key plan of the Waste WaterTreatment Building
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Plan at EL. 0.000m level WaterTreatment
Building
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Compressed Air Brine Cooling and Soda Soln.
Preparation Unit
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Soda Solution Preparation Unit
The preparation area for soda solution needed in the neutralization
process consists mainly of one batch dissolver(0.8 m3).The soda ash, contained in normal 25 kg bags, is poured into the
dissolver through a screening in stainless steel, which is filled under
stirring with a fix amount of water.
Once dissolution is completed and concentration accepted, the charge is
drained into the storage tank (3 m3).
A pump transfers the soda solution to the nitration plant. All theequipments are in stainless steel.
The level is monitored in the control room. The temperature is monitored
in the control room.
Constructional Aspects
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Brine Cooling Units
Two compressed air units are required, one of them as a stand-by unit.
A buffer tank receiver allows carrying out the shutdown procedures in case
of main power failure.
Compressed Air Units
Two cooling units are required. One unit is enough for the nitration
process.
The second one is needed during the mixed acid preparation.
The capacity of both units is identical, and one of them can be used as a
stand-by unit if necessary.
The cooling medium is brine/sodium nitrate (or equivalent).The return line from the brine closed loop flows through the evaporator
before going into a buffer tank.
Two pumps from the buffer tank can feed the cooler for mixed acid
preparation or the nitrator.
Constructional Aspects
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The Plant Operation
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Nitration SectionMixed acid and glycerine are pumped from intermediate overhead tanks
into the nitrator by means of gear pumps. These pumps are driven by an
electrical motor controlled by a frequency variator.
The feeding rates can be set at will by remote control and can bechecked volumetrically by means of integrated calibration pots.
Glycerine flows through a mass-flow meter and a retractable arm into the
nitrator. This feeding arm moves forward into the feeding position above
the nitrator only when all the correct operating conditions are fulfilled.
Mixed acid flows through a mass-flow meter provided with an alarm
which signals when flow-rate is not correct.
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The heat of reaction developed in nitrator is removed by the circulation of
refrigerant in the cooling coils. The temperature of nitration is
automatically controlled.
The reaction mixture overflows from the nitrator and enters into thecentrifugal separator. The latter is provided with a speed detector with
alarm and with a vibration detector with alarm which signals to the operator
any irregularities in the operation.
The spent acid coming from the centrifugal separator flows into the post-
separator. The dilution with water is done in the dilutor ; this in order toensure the complete dissolution of possible remaining NG droplets. From
there, spent acid is pumped to the spent acid disposal tank.
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Wash
ing SectionThe washing section is formed of two washing groups in series
equipped with washers provided with a powerful stirrer and a dynamic
separator.
For NG production, neutralization is made in the first washing group.
For other NE, the first washing group is used for pre-washing of the
acidic NG by dilution with water. This water is recycled till nitric acid
concentration reaches 28 30 %. In the first washing group, the acidic
NG separated by the dynamic separator is sucked by a water ejector fedby recycled water delivered by a special pump immersed in an
intermediate water collecting and settling tank.
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The possible NG which separates in the collecting and settling tank is
occasionally recycled by a water ejector into the first washer. This
operation is automatically controlled by a level probe in the tank.
Pre-washed NG is separated and overflows into the second washinggroup formed of two washers where it is neutralized, the pH being
automatically controlled by addition of weak soda solution.
A pH-meter shows the pH of the final emulsion and any irregularity is
signalled by an alarm.
The water-NG emulsion overflows from the last washer into the last
centrifugal separator from which NG is sent by means of water eductor
to the storage building.
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NGTransport
NG is transferred in emulsion form from the nitration house to storage
building I or II by means of a BIAZZI patented eductor, in which the levelof energy is moderate.
The motive water for the eductor is continuously recycled by means of
a specially designed pump immersed in the catch tanks located in both
storage buildings.
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NG StorageThe NG water emulsion form is transferred in either the two storage tanks
of 1'000 kg NG capacity each(max. capacity in each storage building, 2'000
kg NG).
Both tanks are provided with a soda solution feed and an air stirring in the
event a postwashing is required.
The storage tanks are equipped with a mechanical stirring systempermitting to keep the content in emulsion form during storage conditions
only.
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After its separation from NG, the transfer water flows into a catch tank
provided with a NG recycling system. The transfer water is then recycled by
means of the pump. This permits to keep low water consumption and
prevent NG losses, and therefore to decrease drastically the amount of
effluent water.
Each storage tank is provided with a sampling device. During sampling
operation, NG is sucked out from the storage tank by means of an air lift
system and flows into the adequate sample container located under a funnelconnected to the vessel.
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Portions from the SurveyDrawing (Site Plan and Contours)
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Longitudinal & Cross
Sections (L Sections and X
Sections
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Soil Testing ReportThe geotechnical Investigations comprise of3 boreholes of 150 mm
nominal diameter
Borehole A & B terminate at 15m and c terminate at 7.5m
GWT was not encountered in any of the above three mentioned boreholesduring the time of investigation
Based on lab tests the sub soil stratification is classified as Clayey silt
of intermediate plasticity and having medium compressibility
characteristics
Preliminary analysis indicate that a net SBC of7 9 may be possible for
open foundation & supported in clayey silty stratum at 3 m depth.
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Detailed Technical Specification for Civil Work
As obtained from the original contract between BIAZZI SA Switzerland and NICCO
corp. Ltd.
Earthwork
Concrete
Reinforcement
Shuttering
Brickwork
Plastering
Finishing Works / Colouring scheme
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Flooring
Bitumen Painting
DPC
Foundations, bolts and inserts
Drain
Acid ProofTiling Work
Rolling Shutter
Plant Roads
Static Tanks
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Earthwork
Excavation shall be carried out in all kinds of soil, (soft and hard),
boulder studded etc. Excavated soil shall be always kept dry bypumping out of sub-soil/rain water during construction.
During excavation shoring work shall be provided and proper slopeto be kept during cutting. If good soil at designed depth is not found
then further excavation shall be done to reach a strong foundation
level.
After completion of foundation, back filling shall be done with good
excavated earth in layer of 150 mm and well compacted, rammed,watered before next layer is laid.
Surplus excavated earth shall be dumped at an allotted place within a
lead of1km inside the plant.
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Concrete
Plain cement concrete (PCC) grade M-5shall be used at base of foundation forcolumn. The beam at ground level, equipment foundation, underground pipe,
aggregates of 40 mm and below should be used.
PCC of grade M10 shall be laid below floor and wherever applicable 100 mm
thickness (min) with 40 mm downgraded aggregate withblack trap stone
and coarse sand.
Reinforced cement concrete of grade M-20 with 20mm and below gradedaggregate shall be used for all other places like all foundation, column, beam,
slab retaining wall etc.
Cement shall be eitherPortland cement 43 grade orPortland
blast furnace slag cement conforming to IS : 269 of 1989 or IS : 455
of 1987. Cement shall be kept dry.
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All coarse and fine aggregate shall conform to IS : 383 of 1970.
Fine aggregate shall be approved riverbed and coarse aggregate shall be
approved black trap stone.
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Reinforcement
Reinforcement bars shall be eithercold twisted deformed (CTD) or
thermo mechanically treated (TMT) as per IS : 1786 of 1985
These shall be procured from dealer of SAIL, TISCO and VIZAG
Reinforcements shall be free form mill scales, rust, grease or oil
Cover to reinforcement shall be provided by use ofcement sand mortar
block (1:4)
Binding wire shall be gauge 16 SWG approved annealed wire.
Dowels shall be of12 mm dia / 75 mm long at 750 mm c/c
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Sh
uttering and BrickworkShuttering work shall conform to IS : 456 of 1978. This shall preferably be
made ofsteel
The brickwork shall be mostly 230/340 mm thick conforming to IS : 2212
of 1991. The brick shall be class 50B conforming to IS : 1077 of 1992. The
bricks shall be whole, sound, well burnt, free from cracks, well
shaped, uniform in size
The compressive strength shall be 5 N / m2(min). The cement sand mortar
for brick work shall be 1:6
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PlasteringAll plastering work shall be carried out as perIS : 1961 1972
Walls (outside) : 10 mm thick in cement sand mortar 1:6 1st operation and
0.5 mm th
ick with
water proofing compound varying from 3% to 5% as permanufacturer's specification.
Walls (inside) : 15 mm thick in mortar 1:6
Ceiling : 15 mm thick in mortar 1:4
After plastering wall, it shall be covered by watering for7 days
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Finish
ing WorksLead free fire resistant magazine paint in the interior of magazines,
production / technological buildings in line with STEC pamphlet, shall be
provided.
ForEXPLOSIVE BUILDINGS all RCC / brick surfaces shall be painted
withlead free acid resistant paint two coats as primer( 200 micronDFT) and finish coat (100 micron DFT). Total DFT will be 300 microns.
ForNO
N EXPLO
SIVE BUILDINGSi.e. Electrical generator, pump
house, control room, boiler, chiller etc., two coats ofsynthetic enamel
paint for joinery and two coats of white wash on brick wall shall be applied.
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Colouring Scheme
Services Colouring Scheme
Walls & Pillars from
skirting / dado to ceiling
Pastel Green
Ceiling White
Wood work and interior
face
Marine grey / Admiral Grey
Water Pipes Synthetic Enamel Green
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Electric Pipes, Panels,
Switch gears, switch
boards
Synthetic Enamel Light Brown
Coolant Pipes Synthetic Enamel Leaf Brown
Steel Rolling Shutters Aluminium paints
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FlooringIn general, PCC floor( M10) with 150 mm thickness will be
constructed over boulder filled with earth and moorum. Boulder fill (250
mm) will be laid over compacted earth.
For all EXPLOSIVE BUILDINGS, top of the floors shall be lined withsika floor 381 as coating for disseminating static electricity.
ForNON EXPLOSIVE BUILDINGS top of the floor will be IPSS with
40 mm thick with M-15 concrete (25mm thick) cast in panels having 2 mmwidth metal strip divider.
The floor shall be well finished, free from cracks and crevice. It
shall be treated with sodium silicate and must be strong enough.When the floor is cast in panels, the joints must be carefully prepared to
achieve a smooth finish and to avoid chipping
Bitumen painting D P C
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Bitumen painting, D.P.C.,
Foundation bolts & inserts
All underground structures like column foundation, equipment
foundation etc in contact with earth shall be treated with2 coats of
bitumen painting ofgrade 20/30 as per standard.
D.P.C. shall be 40 mm thick with M20 concrete with6mm down graded
stone coarse aggregate with approved water proofing compound mixedin appropriate proportion on all external walls.
All the materials for foundation bolts, nuts inserts shall conform
to IS : 2062 - 1992
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Drains
All drains along road will be considered as main drain and around the
building as secondary drain connected to main drain. The cross
section of the drain will be trapezoidal made of 230 mm thick brickwall / floor. Inside surface will be cement plastered 15 mm thick (1:6)
All effluent and storm watershall be collected to these drains. Slope
will be as per standard. Where road crossing is ere, box drain will beprovided. Near entry to the building, suitable pre-cast concrete cover
slab shall be provided.
Acid Proof Tiling Work & Rolling
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Acid ProofTiling Work & Rolling
Shutter
Acid resistant tiles ofsize 230mm X 114mm X 40mm thick shall beused in the acid prone area and as per specification is IS : 4860 class II
Acid proof bricks having 64mm thickness shall be required to be fixed inacid prone area in the building periphery.
Rolling shuttershall be provided in boilerhouse, chillerhouse,
pump house, generator room etc.
This shall be made ofMS sheets as per IS 6248
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Plant RoadsThe CBR value is considered as 7.0. Width of the plant roads except CC' will
be 3.00 meter RCC
Width of the approach roads to the plant buildings will be 2.5 m
Minimum berms on both sides of the plant roads will be 1m
All roads should be designed and constructed as per the standards /
stipulations of IRC ( Indian Road Congress ) and MOST( Ministry of surface
transport )
The roads should be designed taking into consideration maximum of50
heavy vehicles / day
Raised road kerbs shall be provided on both sides of concrete road.
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Static Tanks
RCC circular tank having capacity 110 KL shall be constructed forwater storage purpose having following features-
Mix of RCC tank shall not be less than M-20
RCC wall with bottom will be 150mm thickness (min) all around
Base Slab will be 300 mm thick ( min) and size
Depth of the tank will (-) 3.0 m (app) below EGL
Necessary water proofing, plastering will be done inside andoutside the wall, base slab
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There will be a sump at one corner 1200 mm X 300 mm X 150 mm
Minimum 4 to 5 fire hydrant to be provided at side as per requirement.
The tank should be linked with approach road not less than 3.6 m in width andhard standing for quick manoeuvrability of the appliances
One RCC post and 25 mm dia GI pipe will be connected to tank for water inlet.
Necessary insert in wall made of 16mm thick plate will be @ 300 c/c for entry
into the tank.
Sluice valve will be there inside a pit 600 mm X 600 mm size.
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Worked involved
Fabrication
Erection
Painting
Grouting
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FabricationAll the fabrication of trestles, bridges, structural rolled columns,
built up columns, beams, bracings, runners, purlin, chequered
plates etc shall be in accordance with IS-800.
Tolerance of fabrication shall be in accordance with IS : 7215
1974
Fabrication shall be done once in yard and shall be inspected byOFB authority, prior to clearance for despatch
Construction shall involve :
-Welding and erection bolts
-Bolting with black or HT bolts
-Bolting with HSFG bolts
Minimum welding shall be 5mm fillet U.O.W. If there is butt weld,this must be tested radio graphically at 2% of welded joints. For
normal welds, ultrasonic testing at one drill hole for50 m shall be
carried out. Bolt shall be minimum 12mm dia. Holes shall be more
than the bolt dia
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Erection, Painting & Grouting
All fabricated structure on receipt of inspection certificate from Ordnance
Factory Board shall be erected in the site as per erection marking. Erection
procedure shall be as per IS : 800 - 1964
All the fabricated structure shall have at least one coat of primer of approved
quality in the yard inspection. Before erection the structure shall receive at leastone coat of intermediate paints as per specifications. After erection the structure
shall receive final 2 coats of finished paints.
All works related to fabrication, erection, painting, testing, commissioning shall
conform to IS : 800 - 1964
After final alignment all the structural column, trestles shall be grouted with M-25
concrete along with anti-shrinkage compound at least 25 mm thick laid to slope
adjusting levels.
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Acknowledgements
I would like to thank, firstly, Nicco Corporation Limited,
Project Division for giving me the opportunity to pursue
this SummerTraining at this esteemed organization.
I forward my sincere thanks in this regard to Mr. Mukut
Paul, Vice President, Project Division.I would also like to specially thank my guide and mentor,
Mr. Shibaji Banerjee under whose able guidance I learnta lot during this period.
I am also grateful to Ms. Annie Moothedam, Manager,
HRM forher support.Finally, I would take this opportunity to thank Mr. Pradip
Ganguly without whose help this training would not havebeen possible.
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Thank You !