Study for Enhancement of Existing BRDA

STUDY FOR ENHANCEMENT

OF EXISTING BRDA
At Vedanta Limited, Lanjigarh, Odisha
 Study for Enhancement of Existing BRDA

Contents:

1.0 Project Overview ........................................................................................................................ 2

1.1 General ................................................................................................................................... 2
2.2 Intent of Specification ............................................................................................................. 2
2.0 Site Information .......................................................................................................................... 2
2.1 Site Location............................................................................................................................ 2
2.2 Meteorological Data ............................................................................................................... 3
3.0 Technical Scope ........................................................................................................................... 3
4.0 Instructions ................................................................................................................................. 5
5.0 Standards/ Statutory Rules and Regulations............................................................................... 5
6.0 Quality Assurance ....................................................................................................................... 6
7.0 Time Schedule ............................................................................................................................. 6

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 Study for Enhancement of Existing BRDA

1.0 Project Overview

1.1 General
Vedanta Limited is the world’s 6th largest diversified natural resources conglomerate with
business operations in India, South Africa, Namibia and Australia. It is a leading producer of
oil and Gas, Zinc, Lead, Silver, Copper, Iron Ore, Steel, Aluminium and Power.

Vedanta contributes 1% towards Indian’s GDP, as per IFC. We are investing $9Bn in capital
projects over the next 2-3years to double our revenues from current levels of $15Bn.

Vedanta Limited is a leading producer of metallurgical grade Alumina and Aluminium

products. The Alumina Refinery Complex is situated at Lanjigarh in the State of Odisha, India.

2.2 Intent of Specification

Vedanta Limited (VL) had developed storage area, known as Bauxite Residue Disposal Area
(BRDA), for red mud waste generated from the alumina refinery. This area is divided into two
part i.e. West cell and East cell. West cell and part of the East cell (356123 sqm) was filled with
wet slurry. After installation of red mud filtration unit (RMF), wet slurry is converted to dry
red mud which contains 23 - 25% moisture and started dry stacking of red mud in left out area
of east cell (2,75,186 sqm). For enhancement of holding capacity of the BRDA, VL had engaged
M/s Golder for the detail design of new BRDA in the area adjacent to the existing BRDA, land
acquisition for which is under progress. M/s Golder also designed wick drain system for the
wet pond area to consolidate the slurry, so that wet area can be utilised for the dry stacking.
Hence, VL had implemented the pilot wick drain project in 2400 sqm area to perceive actual
benefits of the wick drain system. Presently, the same is under observation stage. For
enhancement of holding capacity of the existing BRDA system, VL is constructing gabion wall
so that stacking height can be increased.

Lately, VL is facing problem for stacking of dry red mud due to intermittent rain and is unable
to make proper plan for utilisation of available space. So, VL is looking for the consultant who
can do detail stability study of existing dykes and dry stacking area, study effectiveness of
pilot wick drain project area as well as suggest wick drain for additional area, do detail design
for proper stacking in the available space, suggest approach road for movement of the
vehicles for red mud dumping without considering new BRDA area, find out life of the existing
BRDA and prepare detail road map, working methodology and SOP to achieve the same.

2.0 Site Information

2.1 Site Location
Place South-West side of Existing Pond (Towards Rengopalli Village)

District Kalahandi, Odisha

District Head Qtr. Bhawanipatna (70 Km from plant site)

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 Study for Enhancement of Existing BRDA

Nearest State highway Rayagada-Bhawanipatna State Highway 8 Km from plant site

Nearest Railway Station Muniguda on Rayagada–Titlagarh route 25 Km

Nearest Town Bhawanipatna

Nearest City Vizag (270 Km from site)

Nearest Sea Port Vizag

Nearest airport Vizag

2.2 Meteorological Data

Temperature Dry Bulb Wet Bulb Relative Humidity
Maximum 48.8°C 21.6°C 89% (Average)
Minimum 5.3°C 14.0°C 50% (Average)

Rainfall data
Rainy Season June, July, August, September
No. of the rainy days / month Max 21.6; Avg. 7 days

Precipitation
Average Annual Rate 1624 mm
Max. Annual Rate 2158 mm
Max. Intensity to be considered 80 mm in one hour for design.

Wind Velocity
Wind velocity 19 m/sec to 44 m/sec
Basic pressure for the wind effect 150 kg/m2 up to 30 m height

Barometric Pressure
Monthly average Max. 915.1 mbs; Min. 901.8 mbs
Yearly Average Morning (0830 hrs) 909.8 mbs
Evening (1730 hrs) 907.2 mbs
Design 901.0 mbs
Earthquake ZONE II as per IS 1893 (Part 1): 2002

3.0 Technical Scope

1. The Consultant needs to do detail survey and prepare a topographic map for the
existing BRDA.
2. Consultant needs to collect, including but not limited to, data like red mud dumped,
previous history of existing BRDA till date and forecast the same for the future.

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3. Consultant needs to conduct soil investigation as per requirement for detail analysis,
including but not limited to, exiting dyke and stacking incorporating latest technology.
4. The consultant needs to suggest methods to improve the capacity of the existing BRDA
without additional land procurement
5. The consultant needs to study the existing stacking in the east cell and suggest
methods to maximize the storage capacity of the same and also design the stack with
proper stability analysis.
6. The Consultant needs to identify the locations where existing mud stacking is safe and
does not require any modification. The same shall be physically reviewed with
engineer - in - charge at site. Variations needed, if any, shall be submitted with proper
design and drawing for consideration.
7. The Consultant needs to identify the locations where mud stacking profiling needs to
be improved to make stacking structurally safe. After verification of design the same
shall be physically reviewed at site by engineer- in - charge.
8. The Consultant needs to provide detail design and drawings of mud stacking and their
combination into the single zone for further stacking, at various zones specific to site
location.
9. The Consultant needs to prepare the cross sectional drawing for mud stacking along
gabion wall with suggestions for optimization of mud disposal area.
10. The Consultant needs to do detail design and drawing for approach road preparation
all around the mud stacking, so that dumping vehicle can reach at required elevation
area for mud stacking with due consideration to the monsoon as well as dry season.
11. The consultant needs to consider and propose proper drainage system for storm
water ensuring hinder less movement of manpower and vehicles.
12. The consultant needs to visit the site to check the work that has to be carried out as
per the proposed design and drawing ensuring proper quality check.
13. The consultant needs to verify the existing wick drain pilot project carried by VL and
also provide proper recommendations for further action on wick drain in the balance
area.
14. The consultant needs to evaluate, in detail, the red mud quantity in proposed wick
drain and any other methodology.
15. The consultant needs to review the past geotechnical test report, which was carried
out at site.
16. The consultant needs to do stability and strength analysis of the north dyke of east
cell and suggest the risk considering all proposed stacking plan. Also do detail design
and drawing for strengthening of the same.
17. The consultant needs to visit the site during the construction of north dyke to check
proper construction methodology, ensure quality compliance and provide the
completion certificate post construction.
18. The consultant needs to check and study the drainage system upstream and
downstream of the BRDA

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 Study for Enhancement of Existing BRDA

19. The consultant needs to recommend detail design and drawing for garland drain
preparation upstream of the BRDA.
20. The consultant needs to recommend the modification of existing toe drains in and
around BRDA.
21. The consultant needs to make detail comparison of best practices and utilization of
land in national and international level.
22. The consultant needs to provide detail report after detail design and drawing for
above areas and prepare detail road map in addition to the SOP to be followed for the
enhancement of storage capacities of existing BRDA.
23. The consultant needs to vet all the design and drawing through NIT/IIT and also help
for necessary technical clarification with SPCB, if any.

4.0 Instructions
Consultant shall study the General Conditions of Bid document, other relevant documents of
VL and the collect the necessary documents before starting of any analysis. The plan shall be
furnished with all the relevant technical information, data, etc. as asked for. Plan with
inadequate documents / data / drawings / information / calculations may not be considered.
It is suggested that Consultant shall fully get acquainted with the site conditions and the
nature of work to be carried out before submitting the final offer. Execution plan / Timelines
to be mentioned in the offer.

The Consultant shall submit PERT chart / Time Bar chart indicating the duration and
completion schedule of all activities. The PERT chart / Time Bar Chart furnished shall form an
integral part of the contract and cannot be altered arbitrarily except Force Majeure conditions
as may be agreed with the Owner. However detailed schedule will be done based on the
master schedule submitted along with contract document.

Consultant shall use all IS code and approved international code for the detail design and
drawing and references of all the code used for the design needs to be shared to VL.

5.0 Standards/ Statutory Rules and Regulations

All detail design and drawing shall be in conformity with codes and standards/ VSAP guideline
as applicable and nationally / internationally acceptable for the type of design. The different
safety procedures to be followed shall be submitted along with the safety Master plan by the
Consultant. All codes and standards used / referred to shall be to their latest edition / version
as on date of the acceptance of the order. Consultant needs to take care of all safety and
SPCB/CPCB/EC norms related parameters during detail design and drawing and same shall be
incorporated in the drawings.

All relevant statutory norms of State and Central shall be followed during consultancy work.

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6.0 Quality Assurance

1. Consultant shall prepare QAP as per drawing, applicable codes, standards and its approval
system.
2. Consultant shall ensure testing and survey as per QAP for man, machine, methods (work)
and material as per applicable codes.
3. Consultant shall conduct all the test at government authorised quality lab and report shall
be submitted along with registration certificate of lab.
4. Consultant shall have a dedicated team for Quality assurance for survey and soil testing
required for the detail design and drawing and final clearance as per the agreed QAP
during the entire project phase.

7.0 Time Schedule

Consultant shall complete construction and handing over within 3 months from the date of
LOI/work order whichever is earlier.

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