Kakatiya TPP I - Wet Ash Handling System, Rev 3 (09.10.2012)

ANDHRA PRADESH POWER GENERATION
CORPORATION LIMITED
HYDERABAD

KAKATIYA THERMAL POWER PROJECT, STAGE-I
UNIT # 1 (1 X 500 MW)

TECHNICAL SPECIFICATION

FOR

WET FLY ASH HANDLING SYSTEM

Job No D-0349 Name / Sign Date

DESEIN PRIVATE LIMITED
DESEIN HOUSE,
GREATER KAILASH II.
NEW DELHI 110 048
Prepared By K.M 09.10.2012
Checked By BHS 09.10.2012
Approved By BHS 09.10.2012
Document No. 4125 REV. 3
DESEIN Continuation Sheet

KAKATIYA TPP, Stage-I, Unit # 1 (1 X 500 MW)
Technical Spec # 4125
Wet Fly Ash Handling System
Sheet - 1

FOR

INDEX

Clause No Description Page No.
1 Scope 1
2 Project Data 2
3 Plant Description 3
4 Description of Existing Fly Ash Handling System 3
5 Description of Proposed System 4
6 Required Equipment and Services 6
7 Work by Others 11
8 Terminal Points 12
9 Design Codes and Standards 12
10 Design Data 13
11 Equipment Specifications 13
12 Maintenance Tools, Tackles and Accessories 26
13 Mandatory Spares 28
14 Painting 32
15 Materials and Workmanship 32
16 Tests 33
17 Packing and Transportation 36
18 Erection and Commissioning 36
19 Co-Ordination With Other Contractors/Site Staff 37
20 Winds and Seismic Considerations 37
21 Guarantee 37
22 Bid Power Evaluation 38
23 Bid Data 38
24 Bid Drawings 39
25 Instruction Manuals 40
26 Post Contract Data and Drawings 41
27 Progress of Works 41
28 Deviations 42
29 Delivery and Completion Period 42
30 Force Majeure 42
31 Inspection 43

Sheet - 2

32 Operation & Maintenance for a period of three (03) months 43

SCHEDULES

Schedule-A Schedule of General Particulars 2 Sheets
Schedule-B Schedule of Technical Particulars 7 Sheets
Schedule-C1 Schedule of Prices 2 Sheets
Schedule-C2 Schedule of Prices for Mandatory Spares 1 Sheet
Schedule-C3 Schedule of Prices for Recommended Spares 1 Sheet
Schedule-C4 Schedule of Prices for Maintenance Tools and Tackles 1 Sheet
Schedule-D Schedule of Weights 1 Sheet
Schedule-E Schedule of Deviations Guarantee 1 Sheet
Schedule-F Schedule of Guaranteed Performance 1 Sheet
Schedule-G Schedule of Drawings enclosed with the Bid 1 Sheet
Schedule-H Schedule of Tests 1 Sheet
Schedule-I Schedule of Self Manufactured Items 1 Sheet
Schedule-J Schedule of reinforcement steel & cement requirement 1 sheet
Schedule-K Schedule of structural steel requirement 1 sheet
Schedule-L Schedule of Bidders Work Experience 1 Sheet

ANNEXURES

Annexure-I Project Data & Auxiliary Supplies 3 Sheets
Annexure-II Pipe Work, Valves, Specialties and Instrumentation 6 Sheets
Annexure-III Standard Technical Specification for Induction Motors 23 Sheets
Annexure-IV List of Approved Sub Vendors for Bought Out Items 1 Sheet
Annexure-V Specification for Electrical and C&I Works 53 Sheets
Annexure-VI Specification for Instruments 25 Sheets
Annexure-VII Specification for Civil Works 77 Sheets

DRAWINGS

111-13-5203A Flow Diagram Wet Fly Ash Handling System
111-29-0200 Plot Plan


Sheet - 1


FOR


1.0 SCOPE

1.1 This specification covers the design, engineering, manufacture, supply, inspection
as per approved QAP and Inspection Methodology, packing and forwarding, transit
insurance, supply FOR site of Wet Fly Ash Handling System complete with
required equipment and accessories hereunder to be installed at Kakatiya Thermal
Power Project Stage I (1x500 MW), Unit # 1, Chelpur (Village), Ghanapur (Mandal),
Warangal Dist, of Andhra Pradesh, India.

1.2 The scope of work shall also include unloading, storage, intra-site handling,
storage and erection insurance, complete erection, final painting, trial operation,
testing, commissioning, and putting into trouble free satisfactory operation of the
complete system. The scope shall also include operation and maintenance of
the offered system for a period of three (3) months from the date of
completion of the performance testing of the offered system. During the
period of three (3) months operation and maintenance after commissioning, the
Purchaser's operators are to be trained to efficiently operate and maintain the plant
throughout the period to avoid mal operations and mishandling of the equipment
and the Contractor's operating/ service engineers shall remain at the power plant
in all shifts.

1.3 The scope of work shall also include complete design, engineering, construction of
civil works, furnishing of civil construction drawings including steel inserts and bar
bending schedules for the associated civil works for the wet fly ash handling
system including auxiliaries. All materials required for civil construction works such
as sand, aggregate, structural steel, cement and reinforcement steel bars shall be
supplied by the Contractor.

1.4 The locations shown in the tender drawings of some of the existing facilities/
equipment/structures are indicative. It shall be the sole responsibility of the bidder
to provide the complete system including foundations based on correct disposition
of the existing structures, soil conditions etc. For proper engineering, the
contractor shall carry out detailed survey for accurate location of ash disposal pipe
routing, profile of land, existing structures, roads, storm water drains, and railway
crossings etc. before finalizing the layout.
.
1.5 The successful bidder shall carry out necessary detailed soil investigation to
establish actual soil conditions in the area of construction. The layout of
foundations shall be based on the detailed survey. The bidder shall satisfy himself
after visiting the site as to the nature of terrain, the sub-soil and working conditions
to be encountered.

1.6 The bidder shall visit the site and satisfy himself in all respects with site conditions
before quoting. After acceptance of tender, claim for extra payment on the
grounds of any special local working or site conditions, will not be entertained.

Sheet - 2

1.7 The bidder shall study the specification and satisfy himself thoroughly regarding
the workability and suitability of the equipment and system offered by him. He shall
take full responsibility for the guaranteed and satisfactory operation of the system
as regards its performance and smooth and reliable working for supplied
equipment.

1.8 All equipment shall be complete, with adequate safety devices wherever a
potential hazard to personnel exists. Provision for safe access of personnel, to and
around equipment for operation and maintenance, shall be provided. These items
shall include not only those usually furnished with elements of machinery but also
the additional covers, guards, handrails etc. which are necessary.

1.9 Equipment furnished shall be complete with all mountings, fittings, fixtures and
standard accessories normally provided with such equipment and/or needed for
completion and safe operation of the equipment as required by applicable codes
though they may not have been specifically detailed in the respective
specifications.

1.10 All working parts, as far as possible, are to be arranged for convenience of
operation, inspection, lubrication and ease of replacement with minimum
downtime. All parts of similar equipment furnished shall be interchangeable.
Efforts shall be made to minimize the variety of repetitive items and to maximize
the interchangeability. Also efforts shall be made to maximize the shop fabrication/
assembly and minimize the site fabrication/ assembly.

1.11 Any additional services required to complete the system to meet the guaranteed
performance shall be provided by the bidder at no extra cost to the Purchaser. No
additional benefits will be given to the bidders offering materials/equipment better
than those specified.

2.0 PROJECT DATA

2.1 Project Data is enclosed with specification as Annexure-I.

2.2 Services by Purchaser

The Purchaser shall provide the following facilities free of cost to the contractor
during the course of work at site:

2.2.1 Temporary electric power shall be provided at 415V, 3-phase, 50 Hz at one fixed
point at site for construction subject to following conditions:

a. The contractor shall make his own arrangements for the supply and
erection of distribution panel and other equipment as he may require for
his construction work. On completion of the works, the contractor shall
arrange dismantling the temporary distribution system.

b. The contractors temporary distribution system shall be subject to the
approval of the Purchaser in every respect.

c. The Purchaser will not be responsible for any consequence of un-
intentional or unplanned interruptions to power supply.

Sheet - 3

d. The contractor shall state his actual requirements of power at various
stages of work.

2.2.2 Water required for construction purpose will be provided at one fixed point.
Further distribution of water piping shall be in bidders scope.

2.2.3 Space for construction of contractors storage sheds and offices. On completion of
the works, the bidder shall remove or dispose off, in a satisfactory manner, all
temporary structures, office buildings, storage sheds, debris and leave the
premises in a condition satisfactory to the Purchaser.

2.2.4 Quarters are not available in APGENCO town ship. Quarters will not be provided
for contractors staff. Contractor shall make his own arrangements.

3.0 PLANT DESCRIPTION

3.1 Kakatiya Thermal Power Project comprises of two (2) units; Unit # 1 of 500 MW
which is under operation and Unit # 2 of 600 MW generation capacity is under
construction.

4.0 DESCRIPTION OF EXISTING FLY ASH HANDLING SYSTEM

4.1 Unit # 1 Fly ash handling system comprises of 4 APH hoppers, 4 Duct hoppers,
144 ESP hoppers and 1 stack hopper. The unit has dry fly ash handling system to
convey fly ash from various fly ash hoppers to fly ash silos. Fly ash hoppers of the
unit are grouped in to four (4) streams and further converged to 2 streams as
shown in the flow diagram. Fly ash collected from various fly ash hoppers is
extracted automatically and sequentially (along the flue gas path) and
pneumatically conveyed to buffer hoppers through vacuum system. One
mechanical exhauster is provided for each stream to create the vacuum required
for conveying fly ash from ESP hoppers to buffer hoppers. One mechanical
exhauster is provided as common standby for two streams. Each stream is
provided with one buffer hopper for collecting fly ash from various fly ash hoppers
and feeding to pressure conveying system. Four (4) pressure conveying streams
are provided for transporting fly ash collected in buffer hoppers to fly ash silos; two
working and two standby. The pressure conveying streams are provided with
Conveying Air Compressors for supplying air required for transporting fly ash from
buffer hoppers to fly ash silos. Bag filters are mounted on buffer hoppers and fly
ash silos to vent the conveying air.

4.2 Two (2) low speed, oil free, lobe type fluidising air blowers with heaters are provided
for fluidising ESP Hoppers.

4.3 Two (2) reciprocating air compressors with refrigerant type air driers and air
receivers are provided for supplying instrument air to various valves and cleaning
of pulse jet type bag filters for the dry fly ash handling system.

Sheet - 4

5.0 DESCRIPTION OF PROPOSED SYSTEM

5.1 Wet Fly Ash Handling System:

5.1.1 It is proposed to augment the existing dry fly ash handling system of Unit # 1 for
disposing the fly ash in slurry form to the ash disposal area. The existing fly ash
handling system shall remain unaltered. The proposed wet fly ash handling system
shall be operated independently by-passing the existing dry fly ash handling
system by providing necessary pneumatically operated change over isolation
valves. Only one system; either existing dry fly ash handling system or proposed
wet fly ash handling system will operate at a time.

5.1.2 Fly ash collected in various hoppers below fly ash hoppers along the flue gas path
shall be automatically and sequentially extracted and pneumatically conveyed in dry
form to the proposed collector tanks through vacuum created by existing
Mechanical Exhausters. Dry fly ash conveyed to the collector tank shall pass
through wetting head where water will be mixed with the dry fly ash and resultant
ash slurry shall be discharged in to collector tank. One air washer shall be provided
on each collector tank to clean the air passing to mechanical exhauster. Flow of air
to the Mechanical Exhausters shall contain negligible dust. Air washer drain shall
be connected to collector tank discharge pipe. Adequately sized jetting nozzles, if
required shall be provided below each collector tank to convey fly ash slurry to the
proposed surge tanks (below collector tanks). Ash slurry from the surge tanks shall
be conveyed to the proposed ash slurry sump by jet pumps. Fly ash slurry from
proposed ash slurry sump shall be disposed to ash disposal area.

5.1.3 Four (4) adequately sized fly ash slurry pipe lines shall be provided to convey fly
ash slurry from collector tank discharge to the proposed surge tanks. There shall be
two surge tanks, one surge tank shall be provided between Pass A &B collector
tanks & another for Pass C & D collector tanks.

5.2 Ash Slurry Disposal System

5.2.1 The fly ash slurry from various collector tanks of Unit # 1 shall be routed to
respective surge tanks. The ash slurry shall be pumped to the proposed ash slurry
sump for further conveying to the ash disposal area. It is proposed to install one jet
pump for each surge tank to pump ash slurry to the proposed ash slurry sump.

The proposed slurry sump and the pump house shall be above ground. Retractable
type agitation nozzles along with pipe work shall be provided to ensure pumping of
ash water slurry and not water alone. The sump design shall facilitate self-cleaning.
Slurry sump levels shall be automatically controlled in close limits. To ensure
minimum and maximum water levels in the slurry sumps, motor operated valves
shall be provided. The actuation of the valve shall be affected by level switches
provided in each compartment of the ash slurry sump.

5.2.2 Two (2) ash disposal pumping series shall be provided with three pumps in each
series. The capacity of each pump shall be 660 m
3
/hr. Out of two pump series, one
set series will be working and one will be standby. Provision for adding one more
series in the ash disposal pump house shall be provided by the bidder. Further
space shall be provided in the ash disposal pump house to accommodate 4
th
pump
in series in each series.

Sheet - 5

Two series of ash disposal pumps shall be connected to two (2) ash disposal pipe
lines. Bidder shall install two (2) 9.52 mm thick ash disposal pipes of 200NB from
proposed surge tanks to the proposed ash slurry sump and two (2) 9.52 mm thick
ash disposal pipes of 300 NB MS ERW from proposed ash disposal pumps
discharge to the ash disposal area.

5.2.3 The proposed ash disposal pipelines from the proposed ash slurry sump to the ash
disposal area shall be routed on pedestals parallel to the existing ash pipe rack. At
road crossings, the pipes shall be routed in RCC culverts. At the power plant
boundary wall, ash slurry pipes shall cross the road over a new pipe rack. Clear
height of the pipe rack shall be 8M. After the pipes cross the road adjacent to the
boundary wall, the pipes shall be routed on pedestals up to ash disposal area.

5.2.4 Disposal pipes shall be joined by sleeve type couplings. Couplings for easy rotation
shall be provided at every 30-36 M.

5.3 Water System

5.3.1 Two (2) HP Water Pumps; one working and one standby along with ash water sump
shall be provided for the water needs of wetting head, air washer, jetting nozzles,
slurry pump agitating nozzles of the proposed system. Necessary pipe line from
water pump house to proposed wet fly ash system shall be provided by bidder.
Makeup for the proposed ash water sump shall be from the cooling tower blow down
and one independent raw water source shall be provided as shown in the
enclosed flow diagram. Bidder shall consider 300 NB MS ERW pipe of 750 M
length for this purpose in his scope of work. The makeup water pipe shall be
buried from the tap-off point to the ash water sump. The earth cover over the buried
pipe shall be minimum 1500 mm. At road crossings, hume pipe of NP3 rating shall
be provided. Necessary valves as shown in the flow diagram shall be provided. All
modifications required in the proposed independent raw water source pipeline/
cooling tower blow down shall be in the bidders scope.

5.3.2 Two (2) Seal Water Pumps; one working and one standby shall be installed at Ash
Slurry Pump House. Seal Water Pumps shall draw suction from nearby service
water header. Provision for one seal water pump shall be made for future
expansion as shown in the flow diagram.

5.3.3 Two (2) Drain Water Pumps; one working and one standby shall be installed in the
proposed Ash Slurry Pump House. Necessary drain sumps shall also be
constructed by the bidder. The capacity of drain sump shall be minimum 5 M
3
. The
drain pump discharge shall be routed to the proposed ash slurry sump.

Each ash slurry compartment shall have 5 minutes holding capacity of the ash
disposal pump. One compartment shall be constructed for future expansion.

5.4 Electrical System:

It is envisaged to provide two 11 KV feeders from the existing station switchgear
for the proposed wet fly ash handling system. DC source will be provided shall be
provided in the existing DCDB. Required HT cables including termination at both
ends shall be included in bidders scope. Bidder shall consider two feeders each of
3000 KW capacity for sizing HT switchgear, HT cables and bus bar in addition to

Sheet - 6

the number of feeders including 1 spare feeder for each type and rating
required on each section of the system offered. 415V power supply shall also be
derived from this source by providing 2 nos. 11 kV/415V transformers of required
capacity.

5.5 Controls and Instrumentation

5.5.1 Necessary controls and instrumentation required for trouble free operation of the
proposed system in coordination with existing system shall be furnished. One PLC
Control Panel for the offered system shall be furnished. Signals required from the
existing equipment/drives/instruments for the proposed system shall be derived
from the existing PLC Control Panel either by installing necessary I/O cards or by
providing multi core signal cable between two PLCs.

5.5.2 For each fly ash stream, one selector switch shall be provided in the proposed
PLC Control Panel to select the mode of fly ash disposal - dry or wet. When
selector switch is in Dry mode, the proposed PLC shall send signals to the
existing PLC to initiate fly ash extraction in dry mode and all the controls shall be
transferred to the existing PLC and vice versa.

6.0 REQUIRED EQUIPMENT AND SERVICES

The ash handling system to be supplied complete under this specification shall
include, but not be limited to the following items, facilities and services to provide a
complete, satisfactory and trouble free system:

6.1 Fly Ash System

6.1.1 Lot - 200 NB branch change over isolating valves for ash transport lines as per
enclosed flow diagram.

6.1.2 Lot - 200 NB pneumatic operated butter fly valves for vacuum air lines as per
enclosed flow diagram.

6.1.3 Four (4) - 200 NB Pneumatic operated vacuum breakers for breaking line vacuum.

6.1.4 Four (4) - Collector Tanks for collection of slurry to be discharged to the slurry sump
through gravity.

6.1.5 Four (4) - Wetting heads to wet dry fly ash.

6.1.6 Four (4) Air washer units for washing air before conveying air to mechanical
exhausters.

6.1.7 Four (4) Jetting nozzles for collector tank discharge pipe work.

6.1.8 a) Lot 200 NB Cast Iron transport pipe work from branch off point to wetting
heads with alloy CI fittings and sleeve type couplings and high temperature
resistant asbestos gaskets. Necessary structural steel structure for wetting
head, collector tanks, and pipe racks up to proposed ash disposal pump
house shall be provided.


Sheet - 7

b) Lot 200 NB MS ERW pipes from change over valves to air washers with
fittings.

c) Lot MS ERW pipe work from proposed HP water pumps discharge to
wetting heads, air washers and jetting nozzles with associated valves (motor
operated/ manual operated etc.), specialties, instrumentation and fittings
complete with hangers, supports etc

d) 750 M - MS ERW pipe work from raw water pump discharge to the
proposed Ash water sump with associated valves (motor operated & manual
operated), specialties, instrumentation and fittings complete with hangers,
supports etc.

e) Lot - MS ERW pipe work from collector tanks discharge to the proposed
surge tanks and from jet pump to the proposed ash slurry sump with needed
alloy cast iron fittings and sleeve type couplings and high temperature
resistant asbestos gaskets.

f) Lot GI pipe work for instrument air line with valves, specialties etc for
various pneumatic operated valves.

6.1.9 Air Conditioning for the proposed control room and ventilation system for MCC
room and ash disposal pump house shall be provided.

6.2 Ash Slurry Disposal System

6.2.1 Six (6) - 660 M
3
/hr capacity and adequate head horizontal ash disposal pumps of
sturdy design with AC electric motor drives, V-belt drives with motor and fixed pump
pulley, belt guards etc, as needed to dispose ash slurry from ash slurry sump to ash
disposal area.

6.2.2 Lot - Stainless steel agitating nozzles for agitating slurry in slurry compartments.

6.2.3 Lot - pneumatically operated knife gate valves at outlet of the surge tanks and
proposed ash disposal pumps series and ash disposal pump series discharge end
and for interchangeability.

6.2.4 Lot - 20 mm thick Mild Steel to IS:2062 impingement liners for slurry sump where
actual impingement takes place.

6.2.5 13000 M - 300 NB MS ERW pipes to IS: 3589, 9.52 mm thick with alloy cast iron
fittings and sleeve type couplings for disposal of ash slurry from ash ash slurry
compartments to disposal area. Each pipe length shall be considered as 6500 M.

6.2.6 Three (3) 600 motor/pneumatic operated plug gates for isolation of individual
slurry sump compartments.

6.3 Water System

Water pumps as listed below or as needed for the system, requirements complete
with connected pipe work, valves, specialties, instrumentation and supports etc.
shall be furnished.


Sheet - 8

6.3.1 Two (2) horizontal centrifugal HP Water Pumps (adequate capacity & head);
(one working and one standby) for supplying HP water to wetting head, air washer,
jetting nozzles, jet pumps and slurry pump agitating nozzles.

6.3.2 Two (2) horizontal centrifugal type Seal Water Pumps (adequate capacity &
head); (one working and one standby) for supplying seal water for Ash Disposal
Pumps and drain pumps.

6.3.3 Two (2) - 25 M
3
/hr capacity 25 MWC head external water lubricated vertical Drain
Pumps (ash slurry duty) with AC motor drives to pump drains collected in
proposed Ash disposal pump house to ash slurry sump.

6.3.4 Lot - Water pipe work from various water pumps mentioned above to fly ash system
and ash disposal system with associated valves (motor operated/ pneumatic
operated, solenoid operated etc.), specialties, instrumentation and fittings complete
with hangers, supports, pipe rack etc. as required for automatic operation of the
offered system.

6.4 Electrical and C&I Equipment

6.4.1 Lot 11 KV switchgears for the offered system with two in comers, bus couplers
and required motor modules with 1 spare module of each type and size for each
bus section. The quantity is minimum requirement, at the time of handing over of
the system, any additional quantity required for any increase/changes during
detailed engineering stage also shall be considered.

6.4.2 One (1) lot - 415V MCCs for all equipment, drives & devices. with 1 spare module
for each type & size for each bus section [The quantity is minimum requirement, at
the time of handing over of the system, any additional Qty required for any
increase/changes during detailed engineering stage also shall be considered]..

6.4.3 Lot - 415 V lighting distribution board with lighting transformers etc.

6.4.4 Lot - electrical motor drives for various equipment in accordance with enclosed
Standard Technical specification for Induction Motors.

6.4.5 Lot - local control stations, push button stations for all equipment drives and
devices.

6.4.6 Lot - position limit switches for various valves etc.

6.4.7 One (1) - PLC based control panel for proposed wet fly ash handling system.

6.4.8 Electrical control equipment for selection, interlocking, sequence operation,
auto/manual starting-stopping, indication, metering etc. required for electrical
drives and devices for complete ash handling system shall be provided in the
respective control panels.

6.4.9 Lot - HT & LT power cables, control cables and instrumentation cables from 11kV
switchgear in Station Building and 415 V MCCs to all equipment, drives and
devices for ash handling system including laying and termination at both ends. All
rigid and flexible conduits, conduit fittings, junction boxes, cabling and wiring
accessories.

Sheet - 9

6.4.10 Earthing for all electrical equipment including connection to the Purchasers
earthing grid in the power plant area. Earthing shall include all switchgears, MCCs,
transformers, HT & LT motors, control panels, etc. The necessary materials for
establishing at least two earthing connections for each electrical equipment shall
be in bidders scope of work.

6.4.11 The lighting system for the proposed ash slurry pump house, water pump house,
MCC room and control room etc shall be included. This shall include lighting
fixtures, LDBs dry type transformers, conduits and fittings, cables and wires,
junction boxes and pull boxes, lighting control switches etc. to provide a complete
lighting system for the offered system.

6.4.12 Lot - vacuum gauges, vacuum switches, vacuum transmitters, pressure gauges,
pressure switches, pressure transmitters, limit switches, level switches etc for the
offered system.

6.4.13 Any other electrical equipment or accessories required to completely coordinate
the offered plant.

6.5 Civil and Structural Works

Following civil works as required for the system shall be provided by the bidder. All
needed plate inserts, foundation bolts, embedded pipe sleeves, aux. steel for pipe
supports, hangers etc. shall be in bidders scope of supply.

6.5.1 Ash slurry pump house with Slurry Sump with compartments, water pump house,
MCC Room and Control room.

6.5.2 Structural Steel Works for Collector Tank Tower and Pipe Rack;

6.5.3 Foundations for various equipment, pipe rack trestles, collector tank tower, surge
tank etc.

6.5.4 Concrete pedestals, pipe rack structures and culverts as required for supporting
ash disposal pipe up to final discharge point at the ash disposal area.

6.5.5 The work shall also include the following:

a) Ash slurry pipes from surge tanks to proposed Ash Slurry Pump House
includes pipe trenches, pedestals pipe rack etc., as per site condition to
accommodate two pipe lines with necessary box culverts/ crossover/
structural steel bridges for crossing roads, drains etc., along the alignment
of ash slurry pipe line.

b) All culverts shall be designed for class AA loading.

c) For running ash slurry pipe line across any road, all necessary traffic
diversion works, such as providing temporary by pass roads, caution
boards and barricading etc, shall be in bidders scope.

d) As the proposed Ash Slurry Pump House, sumps and slurry pipe line is to
be executed inside the plant premises, necessary precautions shall be

Sheet - 10

taken to safe guard neighboring structures. Any damages shall be made
good by the bidder at his cost. Any permanent structure coming in the
proposed alignment shall suitably re-located and reconstructed as per
purchasers requirement.

e) Entire ESP and proposed ash slurry pump house area is paved in
RCC. Bidder shall dismantle the same for taking up the civil works.
Also after the work is completed, the RCC paving shall be restored.

f) The scope of work also includes dismantling of existing temporary/
permanent structures as per site condition and disposal of materials as
guided by the purchaser.

g) All the excavated and dismantled materials shall be disposed off properly
and leveled at dumping area earmarked and as guided by the purchaser.

h) Necessary approaches with culverts shall be provided for the proposed Ash
Disposal Pump House, sump and other equipment as functional and
operational requirement.

i) RCC stair case shall be provided for access of building roofs and sumps.

j) Plinth protection and drains connecting to plant drain shall be provided for
pump house and sump.

k) Proper drainage systems shall be provided for cable trenches in MCC and
control room.

6.5.6 Pipe route survey and soil investigation of the proposed buildings and structures
shall be in bidders scope.

6.5.7 Preparation of Architectural drawings.

6.5.8 Design, preparation of drawings and construction of all structures.

6.5.9 Preparation of as built drawings of all structures and facilities to reflect as built
status of construction.

6.5.10 Submission of as built drawings in DVDs.

6.5.11 Provision of a toilet with necessary plumbing & sanitary works in every building.

6.5.12 Painting including anti-termite treatment in all areas/ buildings as per IS: 6313.

6.5.13 All temporary roads and approach roads necessary for construction purpose.

6.6 Miscellaneous

6.6.1 One (1) 5.0 ton capacity EOT crane with all required accessories for Ash Disposal
Pump House and one (1) 5 T capacity EOT crane for the water pump house. (under
slung cranes are not acceptable).


Sheet - 11

6.6.2 Lot pipe work from equipment drains to plant storm water drainage system. This
shall also include pipe work to storm water drainage system as required to keep all
ash handling equipment foundations, buildings and trenches free from water at all
times.

6.6.3 Total ventilation system for the proposed ash slurry pump house, water pump
house and MCC room.

6.6.4 Air Conditioning system for Control Room. 2x100% capacity split type Air
conditioners of approved make shall be provided for the control room.

6.6.5 Maintenance tools, tackles, testing software tools and materials as specified and/or
as required for maintenance and commissioning of the offered system.

6.6.6 Mandatory spare parts and consumables as specified and as recommended by the
bidder for three (3) years trouble free and continuous operation of the specified ash
handling system.

6.6.7 One (1) soft copy and ten (10) hard copies of detailed Instruction Manuals and
drawings as specified for:

a) Satisfactory operation, trial testing and putting into trouble free operation of
the complete plant and

b) Subsequent operation and maintenance of the plant. The number of copies
shall be as per enclosed distribution schedule.

6.6.8 Complete erection, trial run, testing and commissioning of the offered ash handling
system.

6.6.9 Supply of lubricants, greases, oil etc for testing, flushing till the complete plant is
taken over by the Purchaser after putting into satisfactory and continuously
commercial use and during three (3) Months operation & maintenance period after
taken over by the purchaser.

6.6.10 Primary and final painting of all equipment and structures.

6.6.11 Complete design calculations and construction drawings for the offered plant.

6.6.12 Operating Engineers along with adequate skilled/unskilled labour shall be
provided by the bidder in each shift for trouble free operation and maintenance of
the offered system during the O&M period..

7.0 WORK BY OTHERS

The following works and services will be furnished by others unless otherwise
specified herein:

7.1 Service water, potable water, service air and instrument air which the contractor
shall tap from the existing system.

7.2 Fire Hydrant and portable fire extinguishers for Ash disposal and water pump
house.

Sheet - 12

7.3 General plant drainage system to which the contractor shall connect all associated
drains and waste connections.

8.0 TERMINAL POINTS

The major terminal points are indicated below. All equipment and services as
required for the ash handling plant within these terminal points shall be furnished
by the Contractor.

8.1 Dry Fly Ash pipes near the buffer hopper for tapping for the wet fly ash system.

8.2 Vacuum Line near buffer hopper for connecting to the wet FA system.

8.3 Instrument air pipe line shall be tapped from existing ash slurry pump house/ESP
area.

8.4 HT power supply: Two (2) - Outgoing 11 kV feeders in the Station Switchgear in
TG Building. Further distribution to all HT and LT motors shall be in bidders
scope. Required cables, cable laying, termination are included under bidder
scope. The cable length from the existing switchgear to the proposed MCC room
shall be considered as 400M. All necessary supports for routing the cables to the
proposed MCC room shall be in bidders scope.

8.5 Service water for seal water pumps will be tapped from the existing Ash disposal
pump house.

8.6 Construction power and water at one mutually agreed point for construction,
erection, testing and commissioning as described in clause 2.2 above.

9.0 DESIGN CODES AND STANDARDS

All the ash handling system equipment and work covered under this specification
shall conform to the latest edition of codes and standards published by the following
bodies, as applicable:

9.1 Indian Standards as relevant for all the specified equipment

9.2 The Indian Electricity Rules

9.3 The Indian Factories Act

9.4 Other Codes & Standards

9.5 BS: 2831: Method of test of air filters used in AC & general ventilation

9.6 American National Standard Institute (ANSI) including the following codes:

a. Flanges and flange fittings : B16.5
b. Valves : B16.34

9.7 Hydraulic Institute Standards (HIS) for centrifugal pumps.


Sheet - 13

9.8 American Welding Society (AWS)

9.9 Steel Structures Painting Council (SSPC)

9.10 Instrument Society of America (ISA)

9.11 Institute of Electrical & Electronics Engineers (IEEE)

9.12 National Electrical Code (NEC)

9.13 National Electrical Manufacturer's Association (NEMA)

9.14 Other International Standards, such as IEC, VDI, DIN, BS, IS, etc will be accepted
for which the bidder shall furnish along with the offer proper justification for
complying to such codes for Purchaser's approval. For such standards, the bidder
shall also furnish a complete English translation of the same.

9.15 All items of plant and equipment shall comply with the regulations and stipulations
of the Inspectorate of Factories and other applicable statutory bodies of
Government of India and Government of AP wherever applicable. When required
by regulations, the successful contractor will have to render all assistance to the
Purchaser for obtaining the necessary approval from the statutory authorities and
concerned agencies. All costs for such assistance shall be borne by the contractor.

9.16 The equipment shall also conform to the latest Indian Electricity Rules as regards
safety, earthing and other essential provisions specified therein for installation and
operation of electrical equipment and plant. Electrical contractor shall have valid
license from Government of AP.

10.0 DESIGN DATA

10.1 The coal is expected to have variation resulting in variations in quantity of ash
collected at various times.

For design calculation following figures shall be used:

i. For volume calculation (fly ash) : 750 kg/M
3
.
ii. For load calculation (wet ash) : 1600 kg/ M
3
iii. For load calculations (Dry fly ash) : 1200 kg/M
3

10.2 The existing Mechanical Exhausters are designed for 45 TPH removal rate and the
proposed system shall be designed to extract 45 TPH per stream.

11.0 EQUIPMENT

11.1 Changeover Isolating Valves

11.1.1 200 NB air-electric operated change over isolating valves shall be provided in fly
ash transport pipes.

11.1.2 Valve body shall be of alloy cast iron, 230 BHN, gate and replaceable seat ring shall
be of wear resistant stainless steel type 316. The clearance between slide and seat

Sheet - 14

ring shall be closely controlled to minimize wire drawing and quick cutting of slides
& seat rings.

11.1.3 Solenoids mounted on valve shall be of outdoor duty type, Class-H insulation, rated
at 240V, 50 cycles, AC supply.

11.1.4 Each valve shall be provided with limit switches and indicator to indicate open and
closed position of valve locally and remotely. Construction of the valve shall be
such that worn out components (slide plate and seat etc.) can be replaced easily.

11.2 Vacuum Breaker

11.2.1 200 NB air-electric operated vacuum breaker shall be provided for each vacuum
transport line connecting to collector tank for breaking the vacuum in the event of
sudden Mechanical Exhauster power failure and at the end of de-ashing cycle of
the fly ash system. The vacuum breaker shall be mounted on fly ash handling pipe
line above each collector tank. This shall be of stainless steel slide gate type
similar to the isolating valves described above. Suitable steel fabricated rain hood
shall be provided for each vacuum breaker.

11.3 Collector Tank

11.3.1 One adequately sized 10 mm thick MS fabricated collector tank shall be provided
for each fly ash stream. Collector Tank shall be located adjacent to respective buffer
hoppers at a height adequate to seal system vacuum and ensure slurry flow by
gravity to the surge tank. The tank shall be designed to withstand high pressure. It
shall be provided with 20 mm thick replaceable MS to IS: 2062 liners.

11.3.2 All accessories like access holes, manhole doors etc, shall be furnished. All pipe
connections to collector tanks shall be flanged. All required staircases, grated
platforms etc. shall be furnished.

11.4 Wetting Head

11.4.1 One adequately sized wetting head shall be provided for each fly ash stream for
wetting dry fly ash and separating dust from transporting air. Wetting Head shall be
mounted on collector tank.

11.4.2 Parts of the wetting head coming in contact with fly ash or ash water mixture shall
be of close grained alloy cast iron with minimum 230 BHN hardness). Nozzles shall
be of stainless steel with replaceable ceramic liners. Three (3) flanged connections
for air fly ash mixture inlet, water inlet and ash water mixture outlet shall be
provided. One flanged connection with blind flange shall be provided for cleaning
nozzles without removing wetting from position.

11.5 Air Washer

11.5.1 Air washer shall be provided one (1) for each fly ash transport line for scrubbing
away any carry over dust in air. It shall be fabricated out of 10 mm thick mild steel
plates to IS 2062. The nozzles shall be fog jet type to have mist like flow and shall
be easily renewable. Materials for the nozzle tips shall be hardened stainless steel
to 500 BHN.


Sheet - 15

11.5.2 Three (3) flanged connections shall be provided one for fly ash air mixture inlet, one
for air outlet to Mechanical Exhausters and other for ash water mixture drain. One
screwed water/flanged inlet connection to fog jet nozzles shall be provided.
Provision shall be made to remove the nozzles for cleaning purpose.

11.6 Fly Ash Pipe work

11.6.1 Fly ash transport piping from tap off point to collector tanks shall be 200/250NB cast
iron conforming to IS: 1536 Class D/BS:1211 Class D. Fittings shall be long radius
(minimum 3D) alloy cast iron (minimum 500 BHN) with integral wear back. All pipes
and fittings shall have plain ends joined with sleeve couplings provided with single
piece high temperature resistant asbestos gaskets, bolts and nuts for tightening
coupling flanges. Couplings shall be designed so that it permits easy rotation of
pipes when needed.

11.6.2 Fly ash slurry pipe work from collector tank discharge to proposed surge tank shall
be MS ERW pipes to IS 1239 (heavy) or IS: 3589 with long radius alloy cast iron
fittings (minimum 500 BHN) with integral wear back.

11.6.3 Vacuum pipe work from air washer located on collector tank to mechanical
exhausters shall be as per IS 1239 (heavy) or as per IS: 3589 with needed fittings.

11.7 Surge Tank

11.7.1 Two - 5 M
3
capacity surge tanks shall be provided in MS construction (10 mm thick);
one per 2 fly ash streams. Each Surge Tank shall be located adjacent to two buffer
hoppers at a height adequate to seal the system vacuum and ensure slurry flow by
gravity to the surge tanks. The tank shall be designed to withstand high pressure.
Impingement liners as required shall be provided The liners shall be 20 mm thick
replaceable MS liners to IS: 2062. The tank shall be provided with adequate
stiffeners as required for the stability of the tank as per relevant IS.

11.7.2 Required staircases, grated platforms etc. shall be furnished.

11.8 Jet Pumps

11.8.1 One (1) adequately sized jet pump shall be mounted below each surge tank The jet
pumps shall pump surge tank contents to the proposed ash slurry sump.

11.8.2 All parts of jet pump coming in contact with fly ash slurry shall be suitably built in
Ni-hard alloy cast iron material with 525/575 BHN hardness. The jetting nozzle
body shall be stainless steel with replaceable ceramic liners.

11.8.3 The jet pump shall be designed for 25 mm throat wear margin.

11.9 Ash Slurry Sump

11.9.1 Each ash slurry compartment of ash slurry sump shall be of 5 minutes capacity of
ash disposal pump and shall be constructed in RCC. All sump accessories
complete with pipe sleeves, inserts, conduits etc. shall be furnished by bidder.

11.9.2 Sump levels shall be displayed by mechanical means also (float type level indicator)
inside ash disposal pump house for operator's guidance locally.

Sheet - 16

11.9.3 Sump liners shall be installed in the common trough and ash slurry sump
compartments to prevent damage to RCC at the locations where the ash slurry
impinges the concrete. The locations for fixing sump liners shall be finalized during
detailed engineering. Liners shall be of 20 mm thick MS plates to IS: 2062.

11.9.4 Retractable agitator nozzles (provision for easy removal of agitating nozzles along
with pipe work, wherever nozzles are not in operation) shall be provided in each ash
slurry sump compartment and common trough shall be provided for agitating ash
slurry. Nozzle body shall be stainless steel with replaceable ceramic tips complete
with water piping. Two nozzles shall be provided at each ash disposal pump suction
pipe.

11.10 Knife Gate Valves

11.10.1 Adequately sized pneumatic operated knife gate valves shall be provided as shown
in the flow diagram. The valve shall be provided with Ni-hard deflection cone in 500
BHN and stellited SS seat ring (replaceable). The knife gate valve shall be designed
suitably to take care of disposal line back pressure also. Knife gate Valve shall be
provided with a mechanical indicator and limit switches to indicate open or close
position of the valve locally and remotely.

11.10.2 The effort on the hand wheel while operating knife gate valve manually shall not
exceed 18 kg force. Necessary gear box shall be provided to this effect.

11.10.3 Valve material of construction shall be as follows :

a) Body : Stainless Steel nitrided to 600 BHN

b) Gate : SS-316 nitrided to 600 BHN (Minimum 10 mm thick)

c) Stem : SS-410

d) Gland packing : Chevron packing of Natural rubber

e) Deflection cone : Ni-hard 500 BHN

f) Hand wheel : Malleable Iron

11.10.4 Solenoids mounted on valves shall be encapsulated, outdoor duty type operating at
240 V AC 50 cycles with Class H insulation.

11.11 Plug Gate

11.11.1 600 mm electric actuator/pneumatic operated plug gate shall be provided for
isolation of ash slurry compartments.

11.11.2 The valve operators shall be designed to produce the required torque with a
maximum effort of 18 kg on hand wheel.

11.11.3 Material of construction shall be as follows:

i. Gate : Alloy cast iron 300 BHN

Sheet - 17

ii. Seal : Hard Rubber

iii. Plug/stand : Cast Iron IS 210 Gr. 260

iv. Hand wheel : Malleable Iron

v. Gland : Cast Iron IS-210 Gr.260

vi. Stem (Submerged portion): Stainless Steel 410

vii. Lead Screw : EN-8

11.12 Ash Slurry Disposal Pumps

11.12.1 Six (6) - 660 M
3
/hr capacity and adequate head ash disposal pumps complete with
ac electric motor drives slide rails and V- belt drives shall be furnished to pump ash
slurry from the proposed ash slurry sump to the ash disposal area.

The pump head shall be calculated considering ash disposal length of 6500 M and
static rise of 20M meters form the FFL of the proposed pump house (182.5 M above
MSL).

11.12.2 Ash slurry disposal pumps shall be of double casing and low speed. Ash disposal
pumps shall operate at a speed such that the impeller tip speed does not exceed 28
meters/second.

11.12.3 Provision shall be made for adjusting internal clearances, without dismantling pump.
Casing shall be subjected to a hydrostatic test pressure of at least two (2) times
working pressure of the pump series or 1.5 times shut off head of the pump series
whichever is higher.

11.12.4 Noise level produced by any pump individually and collectively shall not exceed 85
dBA at a distance of 1.0 meters from it in any direction under any load condition.
Vibration isolators of proven performance shall be furnished by bidder for
preventing transmission of vibration from one equipment to the other neighboring
equipment & structure. Vibration (peak to peak) measured at bearing level of
pumps shall not exceed 50 microns.

11.12.5 Ash disposal pumps complete with AC electric motor drives, slide rails, V-belts and
fixed speed pulleys shall be furnished.

11.12.6 Materials of construction shall be as follows:

1. Type of pump Horizontal Centrifugal Single Stage Non Clog type

2. Drive transmission V-belt thru flexible coupling/V-belt

3. Type of gland sealing External forced water gland sealing

4. Material of Construction

Outer Casing CI IS:210 Gr. FG 260

Sheet - 18

Inner Casing : ACI as per IS: 4771 Type 1(a) with 4.5%
Nickel content 500 BHN (min).

Inner Casing Liner : ACI to IS: 4771 Type 1 with 4.5% Ni 500
BHN (min)

Impeller : Alloy CI to IS: 4771 Type 1 with 4.5% Ni
500 BHN (min)

Shaft : EN 24 (Heat Treated; tensile strength 50-60
T/in
2
)

Shaft Sleeves : SS 410

Gland Packing : Teflon impregnated graphite asbestos

Gaskets : Wire reinforced rubber

Bearings : Antifriction

Bolts & Nuts : Cadmium plated high tensile steel

Motor slide rails : Close grain CI/MS Fabricated

Pulley : CI IS-210 Gr. FG.260

11.13 Disposal Line

11.13.1 Two disposal pipes each of 6500 M length shall be supplied by the bidder

11.13.2 The pipe shall be plain ended 9.52mm MS ERW pipe to IS:3589. Pipe fittings shall
be alloy cast iron (minimum 500 BHN) with integral wear back, plain ends. The pipe
and pipe fittings shall be joined with sleeve type couplings and formed rubber
gaskets, bolts, and nuts for tightening the coupling flanges. Facility for easy rotation
of line shall be furnished. The pipe line shall be connected with sleeve couplings at
a length of 30M-36 M and at all bends.

11.13.3 Ash slurry pipes shall be routed on RCC pedestals/culverts to suit site
requirements.

11.14 Pump Houses and buildings

11.14.1 Ash Disposal Pump House in RCC columns and brick walls of dimensions indicated
on the enclosed layout drawing shall be provided. The Ash Disposal Pump House
shall accommodate three (3) series of Ash disposal pumps, one (1) maintenance
bay, and seal water pumps piping, drain sump and ash slurry sump.

Provision for one (1) additional pump in series shall be provided in the ash slurry
pump house.

One tool room of 30 M
2
shall be provided adjacent to the MCC room.


Sheet - 19

11.14.2 MCC room shall accommodate 11 kV switchgears, 415 Volts MCC, lighting
Distribution Boards and control panels to control the ash handling system in
addition to two dry type transformers and bus ducts. Bidder should clearly indicate
if any modification inside the layout is required.

11.14.3 Water Pump House shall be provided with RCC columns and brick walls shall be
provided. The water pump house shall accommodate 2 HP water pumps with
provision for installing one additional HP water pump, one (1) maintenance bay and
500 M
3
water sump in RCC construction.

11.14.4 One (1) 5.0 ton capacity EOT crane of required span shall be furnished by bidder
complete with needed gantry rail section and fixtures to handle all equipment
housed inside the ash disposal pump house and water pump house.

11.15 Drain Sumps

One (1) drain sump of 5 M
3
in ash disposal pump house shall be constructed in
RCC.

11.16 MCC Room

11.16.1 MCC Room in RCC/brick/masonry construction shall be furnished. MCC room shall
accommodate 11 kV switchgears, 11kV/415V transformers, 415 Volts MCC,
Lighting Distribution Boards and control panels to control the ash handling system.

11.17 Pumps General

11.17.1 The pumps shall comply with the requirements of the latest revisions of the
following approved codes and standards:

a) Standards of Hydraulic Institute, USA

b) IS-1520: Horizontal centrifugal pumps for clear cold fresh water

c) IS-1710: Vertical turbine pumps for clear cold fresh water

11.17.2 Pump shall have a continuously rising and stable head capacity characteristic rising
towards shut-off. The head capacity characteristics combined with its drives shall
ensure equal load division in parallel operation at all times.

11.17.3 Pumps shall operate at speed not exceeding 1500 rpm and the normal speed shall
have a minimum margin of twenty (20) percent from first and second critical speeds.
The rotor shall be dynamically balanced at the operating speed. The combined
pump & motor vibrations shall be limited to be under 50 microns.

11.17.4 Pumps and/or drives shall not be overstressed or suffer any damage owing to
sudden power failures to any of the pumps, while the other pump is in service and
the discharge valve of the idle pump is open. Normally, the pump shall be started
with the delivery valve open.

11.17.5 The suction and discharge connections shall be flanged and drilled to ISS/BSS as
applicable.


Sheet - 20

11.17.6 Horizontal Pumps - General

a) Horizontal pumps shall be single/multi-stage, single suction and the casing
shall be horizontally split type or back pull out type construction.

b) Replaceable type 316 stainless steel shaft sleeves shall be provided to
protect the shaft where it passes through stuffing boxes unless the pump is
equipped with mechanical seals. Shaft sleeve shall be securely fixed to the
shaft to prevent loosening or rotating.

c) Deep stuffing boxes shall be provided in two (2) halves to facilitate
repacking without removing any part other than gland.

d) All water passages in casing and impeller shall be smooth finished surfaces.
Casing drains shall be plugged where required and vent/priming
connections shall be provided with approved isolating valves and/or funnels
where needed.

e) Approved type of flexible couplings shall be provided for connecting the
pumps with the driving motor. The flexible coupling shall be provided with
guards made of expanded material and bolted to the base plate. Where
motor and driven equipment are mounted on a common fabricated steel
frame base provided by bidder, the bidder shall be responsible for the
design of the base and its adequacy for proper operation of both pump and
motor. Pumps shall be supplied with suitable drain pans of drain rim type
base plate with tapped drain connection.

f) The pump bearings shall be double ball bearings and shall be grease/self
water lubricated. Pumps offered with bearings suitable for external water
lubrication arrangement shall be rejected.

g) Impeller shall be made in single piece and securely keyed to the shaft.
Means shall be provided to prevent loosening during operation including
rotation in reverse direction. Impeller fastening nuts shall be of cap type and
shall tighten in the direction of normal rotation. The rotor assembly shall be
dynamically balanced so as not to cause any vibration during operation.

h) At times, centrifugal pumps are required to operate with their discharge
valves closed. If the pumps are not suitable for zero flow operation for a
reasonable period, the contractor shall furnish bypass recirculation
connection complete with piping, valves and orifices as required.

11.17.7 Water Pumps

11.17.7.1 Two (2) adequately sized horizontal centrifugal multi stage Seal Water Pumps
shall be furnished for sealing and/or lubricating of ash disposal pumps and drain
pumps in the proposed ash disposal pump house. Out of 2 pumps, one shall be
working and one shall be standby. These pumps shall be with common suction
header, valves and fittings to one (1) service water supply connection. The pumps
shall be connected to a common discharge header and distribution piping and
valves up to equipment as needed shall be furnished.

Sheet - 21

11.17.7.2 Two (2) adequately sized (capacity and head) horizontal centrifugal HP water
pumps; one (1) working and one (1) standby shall be furnished for water
requirements of the wetting head, air washer and jetting nozzles. The pumps shall
be connected to a common discharge header and the distribution piping and valves
up to equipment as needed shall be furnished.

11.17.7.3 The water pumps with ac electric motor drives shall be of horizontal, centrifugal, ,
multistage type provided with thrust balancing devices, thrust bearings (carrying not
less than 30 percent of total thrust, irrespective of balance device). Selected pump
shall have a margin of at least fifteen (15) percent in capacity over the system
actual requirement.

11.17.7.4 Material of construction for water pumps shall be as follows :

a) Base plate/frame : Fabricated steel/ machined frame common
for pump and motor

b) Shell, diffusers and cover :

Seal water pump : Cast carbon steel ASTM A216 Grade WCB

HP water pump : Cast Iron to IS 210, Grade FG 260

c) Impeller : Stainless steel ASTM A351CF8M

d) Shaft : SS 410

e) Shaft sleeves : SS 316

f) Shaft packing : Braided impregnated Teflon

g) Thrust bearings : Antifriction type

h) Stuffing box : Deep bronze, not less than 6
packing ring deep water cooled.

i) Couplings : Cast/forged steel

j) Coupling guards : Fabricated mild steel

k) Gaskets : Rubber

l) Bolts and Nuts : High tensile steel cadmium plated

11.17.8 Drain Pumps

11.17.8.1 Two (2) - 25 M
3
/hr capacity 25 MWC drain pumps (Ash slurry duty) shall be
furnished complete with AC drive motors, couplings and accessories. All required
pipe work shall be furnished. Discharge shall be to proposed ash slurry sump when
disposal pumps are in operation.


Sheet - 22

11.17.8.2 These pumps shall be vertical type, mounted over the sump. Material of
construction shall be similar to that specified for ash disposal pumps.

11.17.8.3 Pumps shall be so arranged and interlocked that they start automatically when
water level in the sump reaches at pre- determined level. Should the water level
continue to rise and reach another pre-determined higher level than the second
(standby) pump shall start automatically. Should the sump water level continue to
rise, with both pumps in service, and alarm shall be raised. When water level falls
below and reaches a pre-determined low level, operating pump/s shall stop
automatically.

11.17.8.4 Each drain pump shall be provided with seal water arrangement to prevent ingress
of ash into seals. Necessary interlocks to ensure that pumps start only with
adequate seal water flow shall be provided.

11.17.8.5 Required stainless steel agitating nozzles for agitating slurry in drain sumps along
with pipe lines shall be provided. Water shall be drawn from seal water pump
discharge pipe.

11.17.8.6 The selected drain pump shall have a margin of at least ten (10) percent in head
over the system actual requirement.

11.18 Pipework

11.18.1 All needed instrument air, water, slurry and drain pipe work for the offered wet fly
ash handling system shall be furnished as specified.

11.18.2 Complete water system including drains to plant storm drainage system, and air
piping complete with all globe, gate, needle, check, pressure relief, motor
operated, valves; flow indicators; stainless steel type 316 orifice plates and
stainless steel office nipples; pressure gauges (local and panel mounted; pressure
gauges local and panel mounted) pressure switches; pneumatic pressure
regulators; air filter regulators; strainers; high and low level switches; level gauges
etc whether specified or not shall comply with the requirements as indicated in the
enclosed flow diagrams and shall be complete in all respects for the complete
system proposed.

11.18.3 All water and air pipe work, valves and specialties shall be in accordance with
enclosed Annexure-II: Schedule of Pipe work, valves, specialties and
instrumentation.

11.19 Pipe & Equipment Supports

11.19.1 All fabricated steel supports complete with auxiliary steel, hangers, clamps
required to adequately support ash, water and air pipe work for the complete ash
handling system shall be furnished. Required concrete bases or trenches shall be
furnished by the bidder.

11.19.2 All valves shall be located for easy access for maintenance and/or operation.
Where such locations are not possible, bidder shall furnish access platforms with
staircase, handrails and supporting structures etc.


Sheet - 23

11.19.3 Bidder shall also furnish all required pipe sleeves, inserts or foundation bolts to be
embedded in concrete work.

11.19.4 Bidder shall furnish all supporting structures with access platforms and staircases
for collector tower.

11.19.5 All steel used shall conform to IS: 2062 tested quality.

11.20 Pipe rack

11.20.1 To accommodate the fly ash slurry and HP water pipes from collector tank towers
to proposed surge tanks and from proposed surge tanks to the proposed ash
disposal pump house, a continuous overhead pipe rack shall be provided by the
bidder. The width of the piperack shall be as required to accommodate the
proposed pipes and generally at a height of 8.00 M above FFL. A minimum 750
mm wide walkway shall be provided. Necessary access ladders and staircases
shall be provided as per layout and maintenance requirement.

11.20.2 The pipe rack shall consist of two (2) horizontal and longitudinal runners,
adequately sized made out of mild steel rolled beams or channel sections. Needed
cross members either for lateral support of these runners or for supporting the
smallest diameter pipe, shall be provided. Plain bracings as needed for structural
adequacy shall also be provided. No portion of bracing member thus provided shall
project higher than the top of the cross members or longitudinal runners.

11.20.3 The pipe rack columns shall be adequately spaced to clear roads as shown on the
above mentioned drawing. Each column consist of two (2) independent steel
fabricated sections, spaced as needed but not exceeding the corresponding width
of the pipe rack. Horizontal and diagonal bracings as needed shall be provided for
each column.

11.20.4 The proposed ash disposal pipelines from the proposed ash slurry sump to the ash
disposal area shall be routed on pedestals parallel to the existing ash pipe rack. At
road crossings, the pipes shall be routed in RCC culverts. At the power plant
boundary wall, ash slurry pipes shall cross the road over a new pipe rack. Clear
height of the pipe rack shall be 8M. After the pipes cross the road adjacent to the
boundary wall, the pipes shall be routed on pedestals up to ash disposal area.

11.21 Ventilation System

11.21.1 Ventilation system shall be provided for ash slurry disposal house, MCC room and
control room.

11.21.2 Exhaust fans shall be provided on the basis of 15 air changes per hour.

11.21.3 Positive pressurised ventilation system shall be provided in MCC room. Accordingly
bidder shall provide supply air fans and exhaust fans.

11.21.4 Fans shall have axial/propeller type impeller directly driven by AC electric motor
mounted integral with the fan casing. The fans shall be furnished with a pressed
sheet mounting rings and rubber cushions to act as resilient suspenders.


Sheet - 24

11.21.5 The speed of the fans shall not exceed 960 rpm. The motor shall be of totally
enclosed type with class 'B' or 'E' insulation and suitable for electrical supply
connection of 415V, 3 phase, 50 Hz AC supply.

11.21.6 Accessories such as louver shutter or wall cowl with bird screen as required shall be
provided for exhaust fans. All exhaust fans shall be provided with wire guard on
motor side.

11.22 Air Conditioning System.

Control room housing PLC Control Panel shall be provided with split type air
conditioning units. Number of split air conditioners shall be selected in such a way
that it is capable of maintaining 22 1
0
C temperature in all weather conditions.
100% standby capacity air conditioners shall be provided. Air conditioners
shall be industrial type and designed for continuous operation of 24 hours a day.

11.23 Cranes and Hoists
11.23.1 Two EOT Cranes shall be supplied; one (1) for ash disposal pump house and one
(1) for water pump house shall be provided. The capacity of each crane shall be
minimum 5.0 Tonnes.

11.23.2 The cranes shall conform to the following codes:

IS: 807 : Code of Practice for design, manufacture, erection and testing of
cranes and hoists

IS: 3177 : Code of Practice for design of overhead traveling cranes and
gantry cranes other than steel work cranes

Operation of hoisting shall be electrically controlled and cross travel and longitudinal
travel shall be manual. Needed accessories for this shall be included in bidder's
scope.

11.23.3 The crane girder shall be adequately designed for mono hoist load plus all
applicable factors as per IS codes. The maximum vertical deflection of the girder at
any location and under worst operating conditions shall not exceed 1/900th of the
girder span.

11.23.4 Runway rails & DSL's complete with fixtures for entire length of the building shall
be furnished. Needed attachment/fixtures suitable for mounting on concrete/steel
construction complete with inserts/ embedment shall be included in bidder's scope.
Bidders arrangement on rail fixing shall be such as to align the rail irrespective of
non-alignment of the crane supporting girder. Seller's proposed arrangement shall
be furnished in his bid.

11.23.5 All steel materials used for manufacture shall be new, flawless, free from defects
and shall confirm to IS: 2062 or IS: 1977, ST-42 or ST-44 (commercial quality).
ST-32 material to IS: 1977 or off grade material shall not be used.

11.23.6 Hoist trolley wheels shall be accurately machined to match the profile of the bottom
flange of the mono hoist girder, furnished by the bidder. All the wheels shall have

Sheet - 25

perfect bearing on the flange and in no case the trolley shall fall out of the hoist
girder.

11.23.7 The hoist shall be provided with positive and definite breaking mechanism for
hoisting movement. In no case arrangement lowering of the load shall be possible
where not required. All needed safety devices; guards etc to ensure human safety
and protect accidental hazards shall be provided. All connected equipment/drives
shall have antifriction ball/roller type bearing with dust tight enclosures. All spur or
double helical gears shall be machine-cut, heat treated and completely enclosed in
the oil bath lubricating box.

11.23.8 Hoists and connected accessories shall be manufactured out of new, flawless,
defect free material as specified below. Materials for accessories or parts not listed
herein or elsewhere shall be of approved quality conforming to applicable IS or
approved equal:

a) Gears : Alloy steel heat treated machine cut

b) Axles & shafts : Bright steel

c) Hooks : Freely rotating and swiveling type standard hook in
heavy duty forged steel materials and supported on
antifriction thrust bearings.

d) Trolley wheels : Single flanged, taper thread to suit supporting
girder flange in cast iron or cast steel material.

e) Chains : Alloy steel to BS: 3114 Gr.80 or approved equal,
heat treated to ensure ductility and toughness.

f) Chain wheels : Fabricated out of pressed sheet steel or approved
equal

11.23.9 The mono hoist girder shall be adequately reinforced horizontally. It shall not have
excessive horizontal deflection (preferably not exceeding 6 mm) under worst
operating conditions. Adequate reinforcement/supports in either side of the girder
shall be provided and connected to the end of the carriage.

11.23.10 The electric hoist shall have the provision of creep speed to ensure inching
operation. All drives shall be sturdy to ensure frequent 'ON' and 'OFF' needed for
inching operation.

11.23.11 The electrical operated cranes, the speeds for various movements shall be as
follows:

a) Hoisting : 3 M/Min.
b) Micro hoist speed : 0.3 M/min.
c) Cross Travel : 10 M/min
d) Long Travel : 10 M/min


Sheet - 26

11.24 Drive Motors

11.24.1 Indoor Motors shall be Totally Enclosed Fan Cooled IP-55 enclosure, 11kV/415 V,
3 phase, 50 Hz, AC squirrel cage, single speed induction motor. The bidder shall
quote for motors with Class-F insulation with temperature limiting to Class B
insulation. Technical particulars as required to be furnished in Motor specification
should be indicated. Motors should have built in space heaters of adequate
capacity.

Outdoor Motors shall be Totally Enclosed Fan Cooled IPW-55 totally enclosed
weather protected) enclosure.

11.24.2 Unless otherwise specified, the motors shall comply with the requirements of the
enclosed Standard Technical Specification for Induction Motors.

11.24.3 The motor shall not get overloaded at any point of operation of the equipment on
its characteristic curve from shut-off to run out and including stating up with
delivery valve closed or crack open and/or priming and filling the system. Voltage
and frequency of the system shall be at their minimum.

11.24.4 The motor characteristics shall be such that when put on the line with eighty (80)
percent of normal voltage and discharge valve closed, its torque developed shall
be sufficient to bring the equipment to full speed and full load without overheating
or tripping of the motor on overload.

11.24.5 The HT motors shall be provided with both winding as well as bearing RTDs for
monitoring the motor temperature, temperature scanners shall be mounted on the
control panel for each HT motor. The temperature scanner shall be provided with
both alarm and tripping contacts for high and very high temperature conditions.

11.24.6 At least 6 nos. winding RTDs and 1 no. each bearing RTDs of dual type for drive
end and non-drive end shall be provided.

11.24.7 In addition to this, for monitoring temperature of motor bearings, similar
arrangement shall be provided.

11.24.8 The rated KW of the drive motor shall be at least fifteen (15) percent higher than
the KW requirement of the equipment at duty point or the maximum power
consumed on the characteristic curve, whichever is higher. The motor rating
should be selected for the equipment input, considering pump efficiency without
any negative tolerance. The equipment maximum, efficiency should be selected at
the duty point.

12.0 MAINTENANCE TOOLS, TACKLES AND ACCESSORIES

A complete set of all maintenance tools, tackles and accessories required for
testing, dismantling, overhauling and servicing of the offered equipment shall be
supplied. All tools and tackles shall be furnished neatly arranged in special portable
tool cabinets, which shall also be used as work benches and racks.

The items shall be of approved quality and specially protected against rusting in
tropical climate. The supply shall include the following:


Sheet - 27

12.1 Two (2) - spur geared chain pulley blocks of 2 ton capacity.

12.2 Two (2) bearing pulleys (One hydraulic , one manual).

12.3 Two (2) - 2 lbs ball pein hammers.

12.4 Two (2) Cinclip plier.

12.5 Two (2) - Cold chisels.

12.6 Two (2) - 6 inch outside and inside calipers.

12.7 One (1) set Box spanner set up to 36mm.

12.8 Two (2) sets of double end spanners and ring spanners up to 36mm size.

12.9 Two (2) 30m long metalic measuring tape and two (2)- 5m long metalic measuring
tape.

12.10 Two (2) - Hacksaw frames with a dozen hacksaw blades.

12.11 Two (2) sets - Allen keys. Up to 24mm

12.12 Two (2) - 18 inch pipe wrenches.

12.13 One (1) - 10 inch right angle.

12.14 Two (2) - 12 inch aluminum Spirit levels.

12.15 Two (2) - 12 inch bastarted flat, round and half round files.

12.16 Two (2) set of hole punch - 6mm to 24mm.

12.17 One (1) potable drilling machine up to 16mm.

12.18 Two (2) - 10 inch slide wrenches.

12.19 One (1) - 6 inch, 8 inch, 10 inch & 12 inch screw drivers.

12.20 Two (2) - Insulated pliers.

12.21 Two (2) - Tommy bars.

12.22 Two (2) pairs - Hand gloves.

12.23 Two (2) - Lifting wire rope slings 8 feet with eye at each end 1/2 inch size and 5/8
inch size.

12.24 Two (2) - 12 inch smooth, flat, round and half round files.

12.25 Testing software tools.

12.26 Any other recommended tools & tackles shall be furnished.

Sheet - 28

13.0 MANDATORY SPARES

Mandatory spares shall be quoted as below in the bid vide Schedule-C2 for
three (3) years continuous trouble free operation of the offered plant.

An itemized price list shall be furnished with the bid separately of all
recommended spare parts vide Schedule-C3.

13.1 Branch Isolating Valves
a Complete assembly 2 Nos.
b Disc and Seat 4 Nos.
13.2 Vacuum breakers
a Complete assembly 2 No.
b Disc and Seat 2 Nos.
13.3 Knife gate valves
a. Slide plate : 4 No. per size
b. Body : 4 No. per size
c. Complete Assembly : 2 nos. per size
13.4 Wetting Head
a. Complete Assembly 1 No
b. Nozzles 1 Set (required for one
Wetting Head)
13.5 Air Washer
a. Fog Jet Nozzle Assembly 1 Set (required for one Air
Washer)
b. Nozzles 1 Set (required for one Air
Washer)
13.6 Collector Tank
a. Tail Pipe 4 Nos
b. Wear Plates 1 Set (required for one
Collector Tank)
13.7 Ash Slurry Disposal Pumps
a. Impeller 2 Nos.
b. Wear liners (each set of one suction
and one discharge liner)
4 Sets
c. Casing (inner & outer) 2 Nos.
Pump bearings 4 Sets (each set consist of
all bearings)

Motor bearings 4 Sets (each set consist of
all bearings)
Shaft sleeves 4 Sets
Water seal rings 4 Sets
Suction sleeves 4 Sets
V belts 6 Sets
13.8 Water Pumps (for each type of pump)
a. Impeller along with wearing rings : 2 sets
b. Shaft : 2 Sets
c. Shaft sleeves : 2 Sets
d Gland along with packing : 4 Sets

Sheet - 29

e. Flexible coupling bushings and lock
nuts
: 2 Sets
13.9 Slurry Pipe Line
a. Sleeve Couplings with rubber
gaskets, flanges, fasteners etc
(From sump to ash dyke)
100 Nos.
b. Pipe clamps 10% of erected Qty for each
type
13.10 Cranes (for each Crane)

a. Motor 1 No for each type & rating

b. Motor bearings 1 set

c. Reduction gear unit bearings 1 set

d. Bearings for cross travel 1 set

e. Bearings for long travel 1 set

f. Lining for each of the brake shoe
complete with rivets
1 set

g. Brake springs for EM brake (if
applicable)
1 set

h. Rubber bushes for flexible coupling 1 set

i. Controls/Limit switches 1 set each type
13.11 11 kV Switchgear
1 Trip coil : 2 Nos.
2 Closing coil : 2 Nos.
3 Spring charging motor : 2 Nos.
4 L.V. fuse (assorted rating) : 5 Nos.
5 Relays
a. U/V R/L 1 pole (27) : 1 No.
b. ISMT O/C Relay, 3 pole (51) and
EF Relay single pole (51N)
: 1 No.
c. Motor Protection R/L (99) : 1 No.
d. Time delay relay (2) : 1 No.
e. Aux. relay electrical reset (52X) : 1 No.
f. Aux. R/L self reset (3) : 1 No.
g. Trip supervision R/L (74) : 1 No.
h. Lockout R/L (86) : 1 No.

13.12 415 V Switchgear

1. Trip coil : 2 Nos.
2. Closing coil : 2 Nos.
3. Spring charging motor : 2 Nos.

Sheet - 30

4. L.V. fuse (assorted rating) : 5 Nos.
5. Relays
a. U/V R/L 1 pole (27) : 1 No.
b. ISMT O/C Relay, 3 pole (51) and
EF Relay single pole (51N)
: 1 No.
c. Motor Protection R/L (99) : 1 No.
d. Time delay relay (2) : 1 No.
e. Aux. relay electrical reset (52X) : 1 No.
f. Aux. R/L self reset (3) : 1 No.
g. Trip supervision R/L (74) : 1 No.
h. Lockout R/L (86) : 1 No.

13.13 HT & LT Motors

1. Complete Motor 1No. for each type & rating
2. Bearing 4Sets of (each set consist of
all bearings) for each type
and rating.

13.14 Ventilation System
1. Complete set of supply & exhaust
fans/ comprising Motor & fan
10% (min 2 no.) of each type
and rating.
13.15 Instruments
a. Pressure Gauges : 10% (minimum 2 nos. of
each type)

b. Pressure switches : 10% (minimum 2 nos. of
each type)

c. Temperature indicators : 10% (minimum 2 nos. of
each type)

d. Temperature transmitters : 1 no
e. Temperature switches : 10% (minimum 2 nos. of
each type)

f. Level switches : 10% (minimum 2 nos. of
each type)

g Level Transmitters : 10% (minimum 2 nos. of
each type)

h Pressure transmitters 10% (minimum 2 nos. of
each type)

Sheet - 31

13.16 Electrical/Control Panels
a. Electrical Modules (Complete) : 1No for each type & rating.
b. Indication lamps : 20%
c. Lamp holders and globes : 10%
d. Control fuses : 15% or 2 sets which ever is
greater
e. Control Switches : 10% or 2 sets which ever is
greater
f. Selector switches : 10% or 2 sets which ever is
greater
g. Push buttons : 15% or 2 sets which ever is
greater
h. Auxiliary relays : 20% or 2 sets which ever is
greater
i. Timers : 10%
j. Annunciation window lamps : 20%
k. Annunciation printed circuit card for
solid annunciation
: 1 set
l. Resistor for indicating lamps : 20%

13.17 Lighting
a. Fixtures : 10% (min 2 No.) of each type
& rating.
b. Switches, fuses, MCBs etc : 10% (min 2 No.) of each type
& rating
13.18 Jet Pumps
13.19 Complete assembly : 2 nos
Nozzle tips with ceramic liners : 4 nos.
Tail piece

: 2 nos
Gaskets/0-seals (one set consist of all
sizes) used in jet pump
: 2 sets

Note: Quantity in percent means percentage of total number of items as finalized with the
contract.

13.20 PLC spares Minimum 2 electronic modules for each model and type (e.g. analog
I/O, digital I/O, temperature input, CPU, Power supply, communication interface
etc.)

13.21 Bidder shall quote vide Schedule C3 the recommended spare parts for three (3)
years operation of the plant not listed above.


Sheet - 32

14.0 PAINTING

14.1 Before packing and transportation, all equipment and fabricated structural work
shall be sand blasted or mechanically brush cleaned to remove all rust, oil dirt, mill
scale and foreign matters and shall be painted inside and outside as per approved
painting scheme in an approved colour on completed equipment such as panels,
pumps, motors, valves etc. to give a neat and clean finish.

All site welding joints of equipment, structure and piping shall be applied with two
(2) coats of zinc silicate primer after necessary cleaning of parent metal.

14.2 Final painting of equipment, structures and piping shall be done at site as per
approved painting scheme of approved quality paint in an approved colour
scheme.

14.3 All metal parts not accessible for painting shall be made of chemical corrosion
resisting materials. All finished surfaces subject to rust preventive compound.
Surfaces shall be putty filled and rubbed down to ensure first quality glossy finish.

14.4 Paints shall be carefully selected to withstand tropical heat and extremes of
weather specified herein. It shall not scale off or crinkle or be removed by abrasion
in handling.

14.5 All external surfaces of reinforced cement concrete work after removing and
rubbing all marks & uneven surfaces, cleaning & finishing shall be applied with two
(2) coats of cement wash to give a neat and tidy appearance.

14.6 Final painting of equipment, structures and piping shall be done at site with one (1)
coat of approved quality paint in an approved colour scheme.

The DFT of each primer coat (zinc silicate primer) shall be 35 microns totaling to 70
microns. The DFT of each finish coat shall be 35 microns totaling to 70 microns.
The total DFT of the painting shall be 140 microns.

15.0 MATERIALS AND WORKMANSHIP

15.1 All materials used in the manufacture of the equipment shall be high grade, free
from defects and imperfections, of recent manufacture and unused. Materials not
specifically described elsewhere, shall as far as applicable and practicable
conform to the latest specification of ISS where applicable and American Society
for testing materials (ASTM). Liberal factors of safety shall be used throughout the
design for all parts of the equipment when subject to the most severe operating
conditions. The working stress in all parts of the pumps shall be low, with ample
margins for possible overstressing due to shock and water hammer.

15.2 All work shall be performed and completed in accordance with the best modern
shop practice in the manufacture of high grade equipment.

15.3 Castings shall be free from blow holes, flaws, cracks or other defects and shall be
smooth, close-grained and of true form and dimensions. No plugged or filled up
holes or other defects will be accepted.


Sheet - 33

15.4 All materials, supplies, parts and assemblies supplied under his specification shall
be tested as far as reasonably practical.

15.5 Shop Assembly

15.5.1 The bidder shall make such assemblies of the various component parts as may be
required to ensure that all parts are properly fitted and the sub-assemblies
conveniently transported.

15.5.2 All assemblies shall be properly match marked to facilitate erection at site.

16.0 TESTS

16.1 General

16.1.1 During manufacture, the Purchasers representative shall have the right to
expedite and/or inspect the design, materials workmanship on the progress of
manufacture of the bidder and his sub-Contractors and may reject any defective
materials considered and unsuitable for the intended purpose or which does not
comply with the intent of this specification. The bidder, upon any such rejection by
the Purchaser or his representative, shall rectify or replace the defective unsuitable
material. Bidder shall provide every reasonable inspection facility to the
Purchasers Inspector/representative at his own and his Sub-Contractors works.

16.1.2 Bidder shall give fifteen (15) days notice of readiness for inspection component
parts and/or before final assembly and tests, so that the Purchasers
representative may inspect the materials and witness such tests before shipment.
The Purchasers representative may, at any time, inspect and request copies of
any or all test data, which shall be immediately furnished.

16.1.3 Material being furnished against this order shall only be shipped when factory
inspection satisfactory to the Purchaser and/or his representative has been
conducted. Such inspection and acceptance for shipment shall not, however
relieve the bidder from entire responsibility for furnishing equipment conforming to
the requirement of this specification nor shall it prejudice any claim, right or
privilege which the Purchaser may have, because of the use of supply of defective
or unsatisfactory materials or equipment. Should the inspection be waived by the
Purchaser, such waiver shall not also reliever the bidder, in any way, from his
entire obligations under this order.

16.1.4 The equipment and motors shall, at the factory or after installation, be
demonstrated capable of performing satisfactorily up to the bidders guaranteed
performance. All tests required by this specification including retests and
inspection, that may be necessary owing to the failure to met any tests specified,
shall be made at the bidders expense. Should the equipment ultimately fail to pass
the specified tests, the Purchaser will have the option to reject the equipment
provided ash handling system overall performance with regard to the time of
removal is not met.

16.1.5 Tests of systems guaranteed capacities shall be conducted on MCR condition of
boiler. Should tests indicate that the equipment fail to meet guarantees, bidder
shall make necessary changes and corrections and assume full responsibility and

Sheet - 34

take necessary steps to ensure compliance by the equipment of the prescribed
guarantees within reasonable time as may be decided by the Purchaser.

16.2 Shop Tests

During the manufacture of all equipment, manufacturers standard tests shall be
performed and requisite number of copies of test certificates shall be furnished.

16.2.1 Tests at shop include but not be limited to the following:

a. Material tests of principal items.

b. Performance testing of the water pumps.

c. Hydrostatic testing of pump casings, pipes, valves, fittings etc.

d. Calibration tests of all instruments and control equipment.

e. Routine tests on all electric motors and other electrical equipment.

f. Dynamic balance tests on rotating elements of pumps and determination of
vibration levels.

g. Any other tests mutually agreed upon between the bidder and the
Purchaser.

h. Pumps shall be given full speed cold water running test over full operating
range at Sellers works, if facilities permit to establish the following:

i. Noise and vibration free operation
ii. Head, capacity characteristics
iii. Efficiency of pump and HP characteristics
iv. Temperature rise of various parts

Alternatively, reduced speed tests may be agreed upon for interpretation of full
speed results by mutual agreement. Performance curves showing head, efficiency
and power requirement at various capacities shall be supplied by the Contractor for
Purchasers approval. Such tests may be repeated at site at Purchasers option.

16.2.2 The test performance curves showing head, efficiency and power requirements at
various capacities shall be supplied by the Contractor for approval of Purchaser.

16.2.3 Each pump shall be completely assembled in the shop with its motor and base
plate and general alignment and dimensions checked

16.2.4 Shop tests for equipment such as valves, specialties, instruments etc. shall be
conducted and shop test results/certificates shall be furnished to the Purchaser for
approval prior to their dispatch. The Purchaser (if he so desires), shall have the
right for inspection of these equipment during test or otherwise.


Sheet - 35

16.3 Tests at Site

16.3.1 After the wet fly ash handling system is installed at site, all the equipment including
pipe work, wherever possible shall be hydrostatically tested at a pressure equal to
1.5 times the design pressure or twice the working pressure which ever is higher.

16.3.2 The following tests and checks shall be done at site to verify the guarantees given
by the bidder:

a. Proper operations of each item of equipment.

b. Guaranteed fly ash removal rate and ash slurry transportation capacity.

c. Guaranteed power consumption.

d. Any other tests as mutually agreed upon

16.3.3 The purchaser shall be notified four (4) weeks in advance of the tests to enable
him to send his specialist to conduct the test jointly with the Purchaser. No extra
cost will be paid by the Purchaser.

16.3.4 The duration of each test, under specified operating conditions shall be such as to
make it possible to obtain not less than three (3) periods of simultaneous check
readings for which the results shall be computed separately. Test results shall not
differ from the individual test results for any one of the three (3) periods by more
than five (5) percent.

16.3.5 Should field test indicate that the equipment fails to meet guarantees, bidder shall
make necessary changes and corrections and assume full responsibility and take
necessary steps to ensure complimentary the equipment of the prescribed
guarantees within one (1) month from the date of notification or within such
reasonable time as maybe decided by the Purchaser.

16.3.6 All needed standard test instruments and devices shall be loaned by the bidder for
conduction such tests at site.

16.3.7 Acceptance tests shall be made within a period of three (3) months from the date
the complete plant is commissioned put into satisfactory commercial operation, at
a time convenient to the Purchaser and the bidder.

16.3.8 If even after rectification, the performance achieved is deficient compared to the
guaranteed figures, penalties shall apply.

16.4 Test Reports

16.4.1 Two (2) copies of preliminary test results shall be supplied for approval prior to
dispatch of equipment. Bound copies of complete test results shall be furnished
later as per attached distribution schedule.

16.4.2 Test reports of standard factory test carried out on each equipment shall furnish
the following information:

a. Complete identification data including serial number

Sheet - 36

b. Method of application and duration of test
c. Results of test conducted

17.0 PACKING AND TRANSPORTATION

17.1 All accessories which are likely to get damaged during transit, if transported
mounted on the equipment shall be removed, adequately packed and shipped
separately. All inlet and outlet flanges shall be blanked with thick bolted wooden
planks.

17.2 Packing shall be sturdy and adequate to protect all assemblies, components and
accessories from injury by corrosion dampness, heavy rains, brakeage and
vibration encountered during transportation, handling and storage at the plant site.

17.3 Spare parts shall be packed separately and clearly marked. They shall be specially
packed for long storage without injury.

17.4 The bidder shall ascertain at an early date and definitely before commencement of
manufacture and transport limitations such as weights, dimensions etc. from his
manufacturing plant to the project site.

18.0 ERECTION AND COMMISSIONING

18.1 Bidder shall quote lump sum price for complete erection, testing and
commissioning of the offered system. This shall include all works from taking
delivery by trucks at plant, until commissioning and testing at site and any work
needed during the offered equipment warranty.

18.2 For all the above work, bidder shall furnish the required services of Erection
Superintendent, Erection Supervisors, fitters, Riggers and other skilled and semi-
skilled labour, erection tools, tackles and other required equipment. These
materials shall be taken back after the erection is complete. The quoted lump sum
price for erection shall cover all the above services.

18.3 Bidder shall be responsible for satisfying himself as to the correctness of the
electrical and mechanical connections between all equipment in his supply. The
Engineer will check whether all work has been installed in accordance with the
approved drawings. Any faults reveled by the Engineers inspection shall be made
good by the bidder to the complete satisfaction of the Engineer before the plant is
taken over.

18.4 Any workmanship or materials inspected in the field and found not to comply with
the specification shall be replaced or repaired at the bidders expense. All
expenses incurred by replacement or repairs shall be borne by the bidder.

18.5 The erection work shall be governed by the Purchasers General Conditions of
Contract attached with the specification. Lubricants, greases and other
consumable materials shall be furnished till the plant is taken over by the
purchaser.


Sheet - 37

19.0 CO-ORDINATION WITH OTHER CONTRACTORS/SITE STAFF

19.1 The bidder at the times shall be work in co-ordination with the Purchasers staff
and offer them all reasonable facilities to become familiar with the erection,
operation and maintenance of the equipment.

19.2 The Purchaser reserves the right to perform the works during the time when the
bidder is performing his work hereunder, such other work as the Purchaser
desires, and the bidder shall make all reasonable effort to perform his work
hereunder in such manner as will enable such other work to be performed with
hindrance from the bidder and shall make no claim for damage against the
Purchaser arising out of such other work or interference there from. The bidder
shall work in harmony with such other contractors who are required to perform
other works.

19.3 If any part of the bidders work depends for proper execution, upon the work of any
of the Contractor, the bidder shall inspect and promptly report in writing to the
Engineer any defect in such a work of other Contractor that render its unsuitably
for proper execution of the work under this contract. His failure to inspect and
reports shall constitute acceptance of the other Contractors work as fit and proper
for the reception of his work, except as to defects which may develop in the work
of other contractor after the proper execution of the work.

20.0 WINDS AND SEISMIC CONSIDERATIONS

20.1 All structures shall be designed for a maximum wind velocity as per IS: 875 latest
revisions plus a wind enhancement factor as indicated in data sheets.

20.2 The station site is located in the seismic Zone-II of India as per IS: 1893: 2002.
The bidder shall take all necessary precautions and care while designing ash
handling system structures to take care of this condition as specified herein.

20.3 Design against seismic shock, requires that works be designed to withstand the
seismic conditions safely with no loss of function or damage to the system.

21.0 GUARANTEE

21.1 The Bidder shall undertake to remedy any defect resulting from faulty design,
materials or workmanship.

21.2 In fixing this period due account shall be taken of the time normally required for
transport as agreed in the Contract.

21.3 In respect of component parts (whether of the bidders own manufacture or not) of
the offered equipment as are, expressly mentioned in the Contract, the guarantee
period shall be same as is specified in respect of each of the equipment.

21.4 The guarantee period not shorter than twelve (12) months for complete system
shall start from the date of commissioning of the offered system.

21.5 A fresh guarantee period equal to that stated shall apply under the same terms &
conditions as those applicable to the original part, to parts supplied in replacement
of defective parts or to parts renewed in pursuance of this clause. This provision

Sheet - 38

shall not apply to the remaining parts of the valves, the guarantee period of which
shall be extended by a period equal to the period during which the valves are out
of action as a result of a defect covered by this clause.

21.6 In order to be able to avail himself of his rights under this clause, the Purchaser
shall notify the bidder in writing without delay of an defects that have appeared and
shall give him every opportunity of inspecting and remedying them.

21.7 On receipt of such notification, the bidder shall remedy the defect forthwith at his
own expense.

21.8 Defective parts replaced in accordance with this clause shall be placed at the
disposal of the bidder.

21.9 If the bidder refuses to fulfill his obligations under this clause or fails to proceed
with due diligence after being required to do so, the Purchaser may proceed to do
the necessary work at the bidders risk and expense, provided he does so in a
reasonable manner.

22.0 BID POWER EVALUATION

22.1 The bidder shall comply with the ash handling system specified in the specification.

22.2 For every 1 KW differential in power consumption as measured at motor terminals
compared to the offer with the lowest guaranteed power consumption figures, Rs.
150,000/- shall be considered for evaluation. However it shall be specifically noted
that if guaranteed input to motors during performance testing at site are observed
higher than guaranteed, penalty shall be levied @ Rs.275,000/- KW pro rata
differential. The power evaluation will be made for the water pumps and the ash
disposal pumps.

23.0 BID DATA

The Bidder must furnish all information and fill in the schedules completely as
desired in the specification. Failing to do so, may result in rejection of the offer.
Ambiguities kept in the bids shall be considered as irresponsive bids and are likely to
disqualify the bidder.

Drawings and technical schedules incorporating the following particulars shall be
submitted along with their proposals:

23.1 General particulars shall be furnished in the bid in the form set forth in Schedule-A.

23.2 Technical particulars shall be furnished in the bid in the form set forth in Schedule-B.

23.3 The material of construction for various components of equipment proposed to be
offered by the bidder and particularly its hardness shall be clearly stated.

23.4 The price schedule duly filled vide Schedule-C1, complete with all break-up of prices
for supply and installation separately as well as unit prices as specified.

Bidder shall furnish estimated time required for the complete civil works after
drawings are approved and area is given at site for construction

Sheet - 39

23.5 Weight of all equipment dimensions and weight of any oversize package to be
transported shall be indicated in the form set forth in Schedule-D.

23.6 Water and power requirement per shift and water balance, total energy consumption
charts and operation time chart shall be enclosed with the bid.

23.7 All deviations from the specification shall be clearly listed in the form set forth vide
Schedule-E.

23.8 List of tests the bidder proposes to carryout in shop and at site after installation
including those pertaining to their sub contractors shall be clearly brought out in their
proposals in the form set forth vide Schedule-H.

23.9 Bought out materials (pumps, pipes, valves, instrumentation etc) shall be furnished
as per approved vendor list vide Annexure-IV.

23.10 Bidder shall furnish all mandatory spare parts with unit prices for all equipment
offered including the bought out materials as per clause 13.0 above vide Schedule
C2. If the mandatory spares for the equipment proposed by the Bidder varies form
the items indicated against Clause No 13.0, the same shall be clearly indicated in
the Bid.

23.11 Bidder shall furnish recommended spare parts for three years operation vide
Schedule-C3.

23.12 A bar chart of design, engineering, procurement, manufacture, testing, delivery,
installation, commissioning at site, testing of the equipment proposed shall be
furnished.

23.13 The motor data sheet as per Annexure-I to the enclosed Standard technical
Specification for Induction Motors shall be duly filled in.

24.0 BID DRAWINGS

24.1 Bid shall include flow diagrams giving complete schematic arrangement of the plant
operation and scope of equipment offered.

24.2 Drawings showing equipment and systems clearly indicating layout, pipes route in
trenches/ pipe rack/aboveground.

24.3 Dimensioned outline drawings of water and slurry pumps along with drives and other
equipment offered showing dimensions, net weight, shipping weights, loads and
thrusts on the foundation with descriptive literature.

24.4 Equipment cross-sectional drawings for proposed equipment.

24.5 All offered pumps performance curves indicating to head, NPSH, Kilowatt rating and
efficiency shall be furnished.

24.6 Unless otherwise specified herein, after the work is awarded, the contractor shall
furnish the following drawings and details along with design calculations for the
Engineer's approval:

Sheet - 40

a) Civil Works Drawings

i. Excavation drawings

ii. Plant arrangement drawings indicating the details of the columns,
beams, foundations etc

iii. Reinforcement concrete constructional drawings including bar
bending schedule.

iv. Dimensional details and location of the inserts on the concrete walls,
pipe rack/pipe pedestals foundation details etc.

v. Bill of material for various items involved

vi. Architectural drawings

vii. Any other drawings as required by the Engineer for proper
co-ordination of work

b) Other Drawings

i. Flow diagrams for fly ash, ash disposal and water systems.

ii. Dimensioned layout drawings for offered system indicating the details
of the equipment and its maintenance facilities.

iii. Dimensioned arrangement drawings indicating the details of
trenches, equipment foundations, foundation bolt hole centers, loads
etc.

iv. Detailed dimensioned arrangement drawings, cross-sectional
drawings, performance curves, data sheets etc for various equipment
offered.

v. Any other detailed drawings to completely co-ordinate the work with
other works as per Engineer's directives.

24.7 Marked erection prints identifying the component parts of the equipment, with its
assembly drawings.

24.8 Detailed dimensioned assembly and cross-sectional drawings and description of all
auxiliaries and drawings identifying all spare parts for re-order.

25.0 INSTRUCTION MANUALS

At least one (1) month prior to the dispatch of the equipment, one (1) soft copy and
ten (10) hard copies of installation, operation and maintenance manuals shall be
furnished. These manuals shall be sturdily bound volumes and shall contain every
drawing and information required for installation, testing, setting and information
required for components after installation. Separate tabs shall be used for such
instructions concerning each equipment. The data shall include the following

Sheet - 41

particulars, besides other data needed for servicing the components and ordering
their spare parts.

26.0 POST CONTRACT DATA AND DRAWINGS

26.1 Drawings enclosed with the specification are only indicative. Actual design and
drawing work shall be started only the basis of "Released for Construction Drawings
duly approved by Purchaser.

26.2 Within four weeks of issue of letter of intent the contractor shall commence
submission of design calculations and detailed drawings to Consultant/ Purchaser,
for the complete work tendered.

26.3 The Purchaser shall accord his approval after the Contractor has incorporated in
his drawings all the modification required by the Purchaser/Consultant. Thereafter
the contractor shall furnish in duplicate final design computations and detailed
drawings to the Consultant and to the Purchaser. Contractor shall also furnish to
Purchaser one of each of the final approved drawings in soft copy as per distribution
schedule enclosed with GCC.

26.4 Drawings will normally be approved/commented upon within two weeks of their
receipt by the Purchaser/Consultant. No claim shall be entertained due to any delay
in approval of drawings.

26.5 All modifications suggested by the Purchaser/Consultant to meet sound
engineering practice shall be incorporated by the Contractor at no extra cost to the
Purchaser. In this respect the decision of the Purchaser shall be binding on the
Contractor.

26.6 Construction works shall commence only after the written approval of the drawing
by the Purchaser. However, approval of the contractor's drawings shall not absolve
the Contractor of his responsibility regarding adequacy of design, correctness of
dimensions, loadings, detailing and to the safety and stability of the structures
including foundations, accessories, performance etc.

27.0 PROGRESS OF WORKS

27.1 Within fifteen (15) days of issue of letter of intent, the contractor shall submit for
approval a program and PERT chart covering all the work, to be done by the
Contractor from the date of issue of letter of intent till handing over the offered
system duly constructed, commissioned and performance tested to Purchaser's
acceptance.

27.2 The program/pert shall indicate the inputs to be provided by the Purchaser and the
dates by which these are needed.

27.3 The chart shall show, for each significant item of the contract, the time required and
the time allowed for various phases of work such as design, preparation of
construction drawings, material procurement, site establishment, construction at site
and any other significant phase of the work. Once the program is finalized, the
Contractor shall strictly adhere to the same. Monthly progress reports in a prescribed
form shall be submitted by the Contractor.


Sheet - 42

27.4 For every item, in which a delay in a phase of the work had occurred the contractor
shall indicate the cause of the delay, what action is being taken to minimize the
effect of with remedial measures to cover the delay.

27.5 Provisions to the program sections of the chart will not be accepted as extending the
contractual times for completion of the work unless the Purchaser specifically revises
the dates.

27.6 The Pert Chart shall be updated by the Contractor's site representative at one month
interval and submit to the Purchaser. The CPM diagram shall be accurately revised
and redrawn at three (3) monthly intervals or at such intervals as may reasonably be
required by the Purchaser to meet the commissioning schedule.

27.7 The construction activity shall show the following:

a) Expected date of delivery to site of required material and accessories of the
offered system that will materially affect the erection program if not delivered
on time.

b) The time required and the number of man months necessary for each activity.

c) The expected start date of the first activity in each series of activities.

d) The dates of important key events

28.0 DEVIATIONS

28.1 Normally the tender should not deviate from the technical specifications for this work.
Minor deviations from the specifications, if any, proposed by the bidder will be
considered on merit, provided they are manufacturer's proven standards or are
necessary to improve utility, performance and efficiency or to secure overall
economy but provided further that these do not affect competitive comparison of the
proposal. The Purchaser has the right to evaluate any or all deviations in
accordance with his judgment. The Purchaser also reserves the right to reject any
deviation without any consideration.

28.2 All technical and commercial deviations shall be specifically mentioned in
Schedule-E with justifications. Unless specifically mentioned in the Schedule of
Deviations, the bids will be deemed to be inconformity with the specification.

29.0 DELIVERY AND COMPLETION PERIOD

The Purchaser's desired delivery and commissioning of the complete Ash handling
system from the date of Letter of Intent shall be within eighteen (18) months.

30.0 FORCE MAJEURE

If at any time, during the pendency of this contract, the performance in whole or in
part by either party of any obligations under this contract shall be prevented or
delayed by reasons of any war, hostilities, public enemy, strikes, and lockouts, civil
commotion, sabotage, fires, floods, explosion epidemics, warrantine, restrictions or
acts of God (hereinafter referred to as 'events') then provided notice of the
happening of any such event is given by either party to other within 21 days from the

Sheet - 43

date of occurrence thereof, neither party shall by reason of such event be entitled to
terminate this contract nor shall either party have any claim for damage against the
other in respect of such non-performance and the work and services under the
contract shall be resumed as soon as possible after such event has come to an end
or cease to exist and the decision of APGENCO as to whether the work and services
have been so resumed or not shall be final and conclusive. If the performance in
whole or part of any obligation under this contract is prevented or delayed by reason
of any such event, claim, for extension of time shall be granted for periods
considered reasonable by APGENCO subject to prompt notification by the
Contractor to APGENCO of the particulars of the event and supply to APGENCO, if
required of any supporting evidence. Any waiver of time in respect of partial
installment shall not be deemed to be a waiver in respect of remaining portion of
work.

31.0 INSPECTION

Inspection shall be arranged for the equipment mutually agreed by APGENCO and
the bidder. The representative of APGENCO reserves the right to inspect any
equipment and material furnished or used by you under this contract and to reject
any equipment/material which is found defective in workmanship or design, or
otherwise unsuitable for the use and purpose intended or which is not in accordance
with the intent of this contract. Contractor shall, on demand by APGENCO, rectify or
replace at contractors expense, any such defective or unsuitable equipment.
Contractor shall advise APGENCO, 10 days in advance as to when the equipment
will be ready for inspection at shop and those of sub-vendors. APGENCO officers
shall at all times have access to all parts of shop where the equipment is being
manufactured and also shall be provided with all reasonable inspection facilities by
contractor and/or his sub-vendors. None of the equipment to be furnished or used in
connection with this contract shall be dispatched until inspected and cleared for
dispatch. Such inspection of the equipment shall not however, relieve the contractor
from full responsibility for furnishing equipment conforming to the requirements of
this contract, non prejudice any claim right or privilege which APGENCO may have
because of the use of defective or unsatisfactory equipment. Should APGENCO
waive the right to inspect any equipment such waiver shall not relieve the contractor
in any way from your obligation under this contract.

32.0 OPERATION & MAINTENANCE FOR A PERIOD OF THREE (03) MONTHS:

32.1 The Operation & Maintenance of complete Wet Fly ash handling system for a
period of three (3) months from the date of performance testing of the offered
system and training of APGENCOs Engineers/personnel at site during this period
is included in bidders scope.

32.2 Operating Engineer along with adequate skilled / unskilled labour shall be
provided by you in each shift for trouble free operation and maintenance of the
offered system during 03 months O&M period.

32.3 The O&M period commences after completing trail and test runs and system is
satisfactorily commissioned. The Wet Fly ash handling system shall be operated
and maintained by you during this O&M period.


Sheet - 44

32.4 The bidder shall train APGENCO Engineers / Personnel during this period for

i) Proper operation of the complete Wet Fly ash handling system.
ii) Routine maintenance and check on equipments and instruments.
iii) Problem study and trouble shooting.
iv) Procedures for overhauling of equipment at site.

32.5 It is your responsibility to arrange insurance of the plant during the above O&M
period. All other inputs such as oils, lubricants, consumables etc for testing, initial
fill, flushing, cleaning and topping up required during above O&M period of the
Wet Fly ash handling system are in your scope.

32.6 The Wet Fly ash handling system will be taken over only after completing the
O&M period to the satisfaction to the APGENCO.

DESEIN Specification # 4125, Schedule-A, Sheet-1 of 2

Sheet - 1

SCHEDULE - A

SCHEDULE OF GENERAL PARTICULARS

1.0 GENERAL

1.1 Name of Bidder :

1.2 Postal Address of Bidder :

1.3 E mail & fax numbers :

1.4 Place of Manufacturer :

1.5 Service Facilities :

1.6 Availability of spare parts :

1.7 Name and designation of an :
officer at Supplier's works
to whom reference shall be
made for expeditious
technical co-ordination

1.8 Supplier's proposal No. :
and date

1.9 Proposal validity period :

1.10 Completion time in months : _________ months
from the date of issue of
letter of Intent/order

1.11 Is completion period in clause : Yes/No.
1.10 above guaranteed with
specified penalties ?

1.12 Estimated man-hours or
personnel required for
erection, testing and
commissioning of ash
handling plant along with
all accessories
Unloading
& storage
Installation Testing and
adjustment
Commis
sioning
Perform
ance
testing

a. Erection Engineers :

b. Testing & Commissioning
Engineer's :

DESEIN Specification # 4125, Schedule-A, Sheet-2 of 2

Sheet - 2

c. Erection Supervisors :

d. Testing & Commissioning :
Supervisors

e. Skilled Labour :

f. Semi-skilled Labour :

g. Unskilled Labour :

1.13 Whether the terms of payment laid : Yes/No
down in the general conditions of contract
agreeable ?

1.14 Whether earnest money of the desired : Yes/No
value and in the form mentioned in
Instructions to bidder submitted ?

1.15 Current Registration Number :
with DGS&D

Name of the Firm : ______________

Signature : ______________

Name : ______________

Designation : ______________

Date : ______________

Seal of Company
DESEIN Specification # 4125, Schedule-B

Sheet - 1

SCHEDULEB

SCHEDULE OF TECHNICAL PARTICULARS

1.0 Branch Isolation Valves

1.1 Quantity :

1.2 Type and size :

1.3 Method of valve operation :

1.4 Quantity, type and make :
of limit switch

1.5 Type and connections :

1.6 Valve working pressure (MWC) :

1.7 Are worn out parts easily : Yes/No
replaceable

1.8 Construction materials &
hardness

a) Body :

b) Slide gate :

1.9 Is valve cross section : Yes/No
drawing enclosed

2.0 Vacuum Breaker

2.1 Quantity :

2.2 Type and size :


2.4 Are all worn out parts easily : Yes/No
replaceable ?

2.5 Materials of construction
and hardness (BHN)

a) Body :

b) Slide gate :


Sheet - 2

2.6 Are necessary interlocks : Yes/No
provided ?

2.7 Is cross section drawing : Yes/No
enclosed ?

3.0 Knife Gate Valves :

3.1 Quantity :

3.2 Type and size :


replaceable?

3.5 Air quantity and pressure :
needed for valve operation
(Nm
3
/hr & MWC)

3.6 Materials construction and
hardness (BHN)

a) Body :
b) Valve seat :
c) Gate :
d) Deflection cone :
e) Stem :
f) Packing :

3.7 Is valve cross section : Yes/No
drawing enclosed ?

3.8 Are all specified and/or : Yes/No
needed interlocks provided ?

4.0 Collector Tanks

4.1 Quantity per unit :

4.2 Type and size :

4.3 Quantity of replaceable liners/ :
impingment plate

4.4 Size and type of slurry :
inlet connection

4.5 Size and type of slurry :
outlet connection

Sheet - 3

4.6 Materials of construction and thickness :

a) Tank shell :

b) Liners :

c) Impingement plate :

5.0 Sumps Ash Slurry Sump Water Drain
Common Compart- Sump Sump
Trough ment
5.1 Type :

5.2 Capacity (M
3
) :

5.3 Overall dimensions (mm) :

5.4 Sump liners:

a) Type and size :

b) Liner thickness :

c) Material of construction :
and hardness (BHN)

d) Total area with liners (M
2
) :

5.5 a) Is the sump provided with : ......... Yes/No ..........
overflow and drain
connection? (with valves)

b) If so, furnish details ? :

5.6 Is the sump covered at top : ......... Yes/No ..........
with MS grating & its size?

5.7 Is hand railing provided all : ......... Yes/No ..........
around & its size ?

6.0 Agitating Nozzles

6.1 Manufacturer :

6.2 Type & Size :

6.3 Quantity & Location :

6.4 Material of construction :
and hardness (BHN) of nozzle
and nozzle tips

Sheet - 4

7.0 Plug Gate Valves

7.1 Manufacturer :

7.2 Quantity (Nos.) :

7.3 Type & size & make :

7.4 Method of gate operation :

Replaceable

7.6 Construction material and hardness :

a) Gate/stand :

b) Plug gate :

c) Gland :

d) - Stem (submerged portion) :
- Stem (Exposed portion)

e) Seal :

f) Lead screw :

g) Hand wheel :

h) Seat :

8.0 Pumps (Bidder shall fill in the data for each type of pump)

8.1 Manufacturer :

8.2 Number of pumps offered :

8.3 Number of pumps operating :

8.4 Number of pumps standby :

8.5 Number of pumps connected :
in series (as applicable)

8.6 Type of pumps and Model :
Number

8.7 *Rated capacity (cum/hr) :

8.8 *Total dynamic head (TDH), MWC :

Sheet - 5

at rated capacity

8.9 Type of suction :
(flooded/ suction lift)

8.10 Shut-off head, MWC/MLC (as :
applicable)

8.11 Number of stages :

8.12 Pump internal losses (MWC/MLC) :

8.13 *Efficiency at rated capacity :

8.14 Tolerance on (+)% efficiency :

8.15 Pump input power at rated :
capacity and head (KW)

8.16 Power required at motor input :
terminals at rated capacity
and head (KW)

8.17 Power required at shut-off :
head (KW)

8.18 Motor rating (KW) :

8.19 Max. power required at :
any point on characteristic
curve (KW)

8.20 Pump Speed (RPM) :
(rated/maximum/minimum)

8.21 Impeller tip speed (metres/sec) :

8.22 TDH variation possible with :
the pump offered

a) (-) ........ MWC/MLC :

b) (+) ........ MWC/MLC :

8.23 Cooling water required :
for bearing jackets (LPM)

8.24 Materials of Construction :
(specify hardness BHN of
each item along with materials)


Sheet - 6

8.24.1 Pump casing (shell) :

8.24.2 Impeller :

8.24.3 Discharge flange :

8.24.4 Base plate/Skirt base :

8.24.5 Wearing rings (Impeller/casing) :

8.24.6 Casing liners :

8.24.7 Suction sleeve :

8.24.8 Impeller nuts :

8.24.9 Shaft units :

8.24.10 Couplings :

8.24.11 Bolts and nuts at corrosive :
location

8.24.12 Bolts and nuts at other locations :

8.24.13 Shaft :

8.24.14 Bushings :

8.24.15 Stuffing boxes :

9.0 Motors
(Bidder to furnish details of all the motor driven equipment here)

9.1 Quantity :

9.2 Motor rating at 50 deg.C :
(KW)

9.3 Guaranteed input to motor :
with pump operating at
rated flow & TDH (KW)

9.4 Type of enclosure :

9.5 Class of insulation :

9.6 Voltage (Volts) :

9.7 No. of phases :


Sheet - 7

9.8 Type of bearings :

10.0 Jet Pumps

10.1 Manufacturer :

10.2 Quantity :

10.3 Type and size :

10.4 Ash removal capacity :
(Tonnes/hr)

10.5 Water requirement quantity :
(cum/hr) and pressure (MWC)

10.6 Quantity and type of jetting :
nozzles

10.7 Material of construction :

a) Inlet piece :
b) Nozzle body :
c) Nozzle tips :
d) Throat :
e) Tail Piece :

10.8 Weight of each jet pump :

10.9 Feed sump - Size, Material :
and Thickness

10.10 Minimum guaranteed life of :
throat and nozzles.

Name of Firm : __________________
Signature : __________________
Name : __________________
Designation : __________________
Date : __________________
Seal of Company
DESEIN Specification#4125, Schedule-C1, Sheet-1 of 2

KAKATIYA TPP Stage-I, Unit # 1, (1 X 500 MW)

SCHEDULE - C1

SCHEDULE OF PRICES

S.No. Description Qty <------------------------------------------Rupees------------------------------------------------->
Ex-works Excise
duty
CST Any
other
taxes
Freight Transit
Insurance
Any
other
prices
Total
FOR site
price
Unit Total
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
1.0 Price for design and engineering for the
offered Wet Fly Ash Handling System

2.0 Price for manufacturing, supply ,testing at
manufactures works, inspection, packing &
forwarding of equipment, transit insurance,
delivery FOR site of wet fly ash handling
system

3.0 Price for loading/unloading at site, handling,
storage, erection, fabrication, structural
works, storage & erection insurance, testing,
commissioning & performance test at site

4.0 Price for Mandatory spares at clause 13.0
(Please furnish breakup of price in Schedule-
C2 attached)

5.0 Price for maintenance tools and tackles at
clause 12.0. (Please furnish breakup of price
in Schedule C4 attached)

DESEIN Specification#4125, Schedule-C1, Sheet-2 of 2


Ex-works Excise
duty
CST Any
other
taxes
Freight Transit
Insurance
Any
other
prices
Total
FOR site
price
Unit Total
6.0 Price for all civil works
7.0 Price for operation and maintenance 3 months
8.0 Total Lump sum price(sum of items 1.0 to 7.0)

Name of Firm : _________________
Signature of Bidder : _________________
Name of Bidder : _________________
Designation : _________________
Date : _________________
Seal of company
DESEIN Specification # 4125, Schedule-C2, Sheet-1 of 1


SCHEDULE C2

SCHEDULE OF PRICES FOR MANDATORY SPARES

Ex Works Excise
duty
CST Any
other
taxes
Freight Transit
Insurance
Any
other
prices
Total
FOR site
price
Unit Total

Name of Firm : _________________


Name of Bidder : _________________

Designation : _________________

Date : _________________
Seal of company
DESEIN Specification # 4125, Schedule-C3, Sheet-1 of 1


SCHEDULE - C3

SCHEDULE OF PRICES FOR RECOMMENDED SPARES

Ex Works Excise
duty
CST Any
other
taxes
Freight Transit
Insurance
Any
other
prices
Total
FOR site
price
Unit Total

Note: These prices will not be taken into account for price evaluation.

Name of Firm : _________________


Name of Bidder : _________________

Designation : _________________

Date : _________________
Seal of company
DESEIN Specification # 4125


SCHEDULE C4

SCHEDULE OF PRICES FOR MAINTENANCE TOOLS AND TACKLES

Ex Works Excise
duty
CST Any
other
taxes
Freight Transit
Insurance
Any
other
prices
Total
FOR site
price
Unit Total

Name of Firm : _________________


Name of Bidder : _________________

Designation : _________________

Date : _________________
Seal of company


SCHEDULE - D
SCHEDULE OF WEIGHTS

S. No. Description Quantity Weight (Tonnes)
Unit Total

1.0 Branch isolation valves :

2.0 Collector Tanks :

3.0 Wetting Heads :

4.0 Air Washers :

5.0 Plug Valves :

6.0 Knife Gate Valves :

7.0 Ash slurry pumps :

8.0 Seal Water pumps :

9.0 Drain pumps :

10.0 HP Water Pumps :

11.0 11 kV/3.3kV/415 V transformers :

12.0 11 KV switch gears :

13.0 415 V MCCs :

14.0 PLC Panel :

Name of Firm : ______________

Signature : ______________

Name : ______________

Designation : _____________

Date : ______________

Seal of Company


SCHEDULE - E
SCHEDULE OF DEVIATIONS
We confirm that following are the only deviations and variations from any exception to
specifications and tender documents for the above mentioned subject supplies under
Technical Specification which are irrespective of what-so-ever has been stated to the
contrary anywhere else of our offer. These deviations and variations are exhaustive. Except
for these deviations, the entire supplies shall be executed as per specifications and tender
documents. Further, we agree those additional conditions, if any, found in our offer other
than those stated below, save that pertaining to any rebates offered shall not be given
effect to.

S.No. Description of
deviation
Ref of Page, Clause of
Bid Document
*Monitory implications of the
conditions in case of withdrawal
Rs (in figures) Rs (in words)

1 2 3 4

*Note: Here the bidder shall indicate the amount of money, if any, which he would, charge
extra (i.e. in addition to the rates quoted by him) for withdrawal of his
conditions/deviations and accepting the condition as stipulated in tender documents.
(Use additional sheet of the same size and format if necessary).

Name of Firm : ______________

Signature of Bidder : ______________

Name : ______________

Designation : ______________

Date : ______________

Seal of Company


SCHEDULE - F

SCHEDULE OF GUARANTEED PERFORMANCE

1.0 Pumps - (Bidder to fill data for each type pump)

1.1 Rated flow (M
3
/hr) :

1.2 Head at rated flow :
(MWC/MLC) (As applicable)

1.3 Shut-off head (MWC/MLC) :

1.4 Pump efficiency (percent) :

2.0 Power Consumption Power requirement Installed
at motor terminals motor
(KW) rating (KW)

2.1 Ash Disposal pumps :

2.2 Drain pumps :

2.3 Seal Water Pumps :

2.4 HP Water Pumps :

Name of Firm : ______________

Signature : ______________

Name : ______________

Designation : ______________

Date : ______________

Seal of Company


SCHEDULE - G

SCHEDULE OF DRAWINGS ENCLOSED WITH THE BID

_______________________________________________________________
S.No. Drawing No. Title
________________________________________________________________

Name of Firm : ______________


Name : ______________

Designation : ______________

Date : ______________

Seal of Company


SCHEDULE - H

SCHEDULE OF TESTS

Tests as per the specification shall be performed. Detailed list of test shall be indicated in
the Schedule

Note: The tests shall not to be limited to those given in this Schedule. All other relevant
tests not mentioned herein but required to be carried out as per relevant standards
shall deemed to be automatically included in Bidders Scope of work.

Name of Firm : ______________


Name : ______________

Designation : ______________

Date : ______________

Seal of Company


SCHEDULE I

SCHEDULE OF SELF MANUFACTURED ITEMS

S No. Description Place of Manufacture

Name of Firm : ______________


Name : ______________

Designation : ______________

Date : _____________
Seal of Company


SCHEDULE J

SCHEDULE OF REINFORCEMENT STEEL AND CEMENT REQUIREMENT

Binding quantity of reinforcement steel and cement required for the offered plant
shall be indicated in this schedule:

S. No. Reinforcement steel quantity (MT) Cement Quantity (MT)
1 2 3

Name of Firm :

Signature of Bidder :

Name of Bidder :

Designation :

Date :

Seal of Company



SCHEDULE K

SCHEDULE OF STRUCTURAL STEEL REQUIREMENT

Binding quantity of bidders scope of steel materials section wise required for
fabrication/manufacture of various structures shall be indicated in this schedule

S No Section Size of structural steel Quantity
(Tonnes)
1 2 3 4

Name of Firm :


Name of Bidder :

Designation :

Date :

Seal of Company


SCHEDULE L

SCHEDULE OF BIDDERS WORK EXPERIENCE

S.No. Ultimate
purchaser
(indicate full
address)
Location Brief
description
of work
Value of
work
Date of
award
Date of
commissioning
1 2 3 4 5 6 7

Name of Firm :


Name of Bidder :

Designation :

Date :

Seal of Company


ANNEXURE- I

PROJECT DATA & AUXILIARY SUPPLIES

1.0 Purchaser : Andhra Pradesh Power Generation
Corporation Limited.
Vidyut Soudha,
Hyderabad 500 082
Andhra Pradesh, India

2.0 Consultant : Desein Private Limited,
Desein House,
Greater Kailash II,
New Delhi 110 048
India

3.0 Project Title : KAKATIYA Thermal Power Project,
Stage-I, Unit # 1 (500 MW)

4.0 SITE CONDITIONS

4.1 Location : KAKATIYA Thermal Power Project site is
located at Chelpur (Village), Ghanapur
(Mandal), Warangal Dist, of Andhra
Pradesh, India. The power plant is
surrounded by Dubbapalli village on the
West, Mehabubpalli on the north, State
Highway (SH-7) on the east and
Bakkaganipalli on the south. The site is
located at a distance of 170 KM from
Hyderabad.

4.2 Climate : Tropical-Hot-Humid

4.3 Type of Atmosphere : Tropical conducive for fungus growth and
highly humid.

4.4 Altitude : Above mean sea level varies from 174.0
M to 186.0 M

5.0 AMBIENT TEMPERATURE (
O
C)

5.1 Ambient temperature, Extreme : High : 45.7
Low : 9.9

5.2 Mean ambient temperature : High : 34.5
Low : 22.3

5.3 Design ambient temperature : 50.0

Temperature Load for Structural
Design
: For temperature loading, the total
temperature variation shall be


considered as 2/3 of the average
maximum annual variation in
temperature. The average maximum
annual variation in temperature for
this purpose shall be taken as the
difference between the mean of the
daily minimum ambient temperature
during the coldest month of the year
and mean of daily maximum ambient
temperature during the hottest month
of the year. The structure shall be
designed to withstand stresses due to
50% of the total temperature
variation.

6.0 HUMIDITY (%)

6.1 a. Maximum :

81
b. Minimum :

23
c. Mean - Morning (8.30am)
- Evening (5.30pm)
:

64
63
d Average :

55
6.2 Maximum wet bulb (
o
C) : 26

7.0 RAINFALL (mm)

7.1 Maximum per annum : 1775

7.2 Minimum per annum : 509
7.3 Average per annum : 1005
7.4 Tropical monsoon : June to October

7.5 Average number of rainy days : 60

8.0 WIND VELOCITY & PRESSURE

a. Mean wind speed : High : 9.0 KMPH
Mean : 5.7 KMPH
Low : 3.4 KMPH
b. Basic wind velocity : 47 meter/sec

c. Wind pressure (kg/sq.m) : As per IS:875 (part-3)-1987

d. Damping : Welded steel structure - 1%
Bolted steel structure - 2%


RCC structure - 1.6%
9.0 SEISMIC FACTORS

9.1 Horizontal Seismic : Seismic zone: III
As per 1893 (Part-I) 2002

9.2 Zone factor (Z) : 0.16 as per IS:1893 (Part-I):2002

9.3 Importance factor (i) : 1.5

9.4 Response reduction factor :

5.0
9.5 Damping : a) 5% for concrete structure

: b) 2% for steel structure

10.0 Auxiliary Power Supply : Auxiliary electrical equipment shall be
suitable for operation on the following
supply system :

(a) For motors 1500kW & above : 11000V, 3 phase, 3 wire, 50 Hz medium
resistance earthed AC
(b) 175 kW & upto 1500 kW 33000V, 3 phase, 3 wire, 50 Hz medium
resistance earthed AC (upto 1500 KW)
(c) For motor control center : 415V, 3 phase, 3 wire solidly earthed AC

(d) For motor rated 175 kW and
below
: 415, 3 phase, 3 wire solidly earthed AC

(e) DC motor starters, DC
solenoids, DC alarm, control
and protections

: 220 V DC, 2 wire, unearthed DC
(f) AC control & protective devices : 110 V resistance. The single-phase 110V
AC supply shall be derived by Contractor
by providing 415V/110V control
transformers of adequate rating with
MCCB / MCB on both the primary and
secondary sides.

(g) Uninterrupted power supply : 230 V, 1 phase, 50 Hz, 2 wire AC supply
from UPS system for I&C (including
indicator recorders) and UCMS only

(h) Space heaters (for motors
rated 30 KW and above)
: 240V, 1 phase, 2 wire, 50 Hz AC system
with effectively earthed neutral. The
power supply shall be derived by
CONTRACTOR by providing 415V / 240V
transformer of adequate rating with
MCCB / MCB on primary / secondary
sides.


(i) Solid state controls (including
solenoid valves)
: 24 V DC, 2 wire (24V DC derived from
UPS supply).

(j) Lighting fixtures; and space
heaters in panels
: 240V, 1 phase, 2 wire, 50 Hz system

(k) The above voltages may vary as follows

All devices shall be suitable for continuous operation over the entire range of
voltage and frequency indicated below without any change in their performance.
i) AC supply : Voltage variation + 10%
Frequency variation + 5%
Combined voltage & frequency variation
+ 10%

ii) DC supply : Voltage variation + 10%
- 20%



ANNEXURE II

PIPEWORK, VALVES, SPECIALITIES AND INSTRUMENTATION

Pipe work shall include whether specifically mentioned or not, all the piping,
valves, specialties, fittings, hangers, supports and special wall fittings as may be
required. All fabricated pipe work shall be in accordance with latest ASA codes
for piping.

For water and air pipe work, the construction materials shall conform to the
following:

1.0 Water Pipe work

1.1 All water piping for sizes 150mm NB and smaller shall be black continuous
welded pipes, heavy quality to IS: 1239 latest edition. For sizes 200mm NB and
larger, pipes shall be ERW steel pipes to IS: 3589, thickness not less than
6.4mm.

1.2 All elbows for sizes 65mm NB large shall be long radius, hot bend out of carbon
steel pipes having butt welding ends. These shall be true to angle and radius
and maintain a true circular cross-section of pipe without deformation or undue
stretching or thinning of pipe walls. All tees and reducers shall be formed out of
carbon steel pipes. Mitre-cut construction fittings are not acceptable.

1.3 For size 50mm NB and smaller, all elbows shall be long radius, forged carbon
steel to A-105 or IS:1875 : Gr. II with socket welding ends. All other fittings for
these sizes such as couplings, unions, tees, reducers shall be forged carbon
steel similar to elbows.

1.4 All flanges/adaptors shall be IS: 2062 plate fabricated, slip on type 150 # ASA
rating, flat faced and drilled to ASA B-16.5 or approved equivalent. Flanges for
pressure rating 300 # ASA and larger shall be forged carbon steel to A.105 or
approved equivalent, flat faced and drilled to ASA B-16.5 or to match with the
connected equipments flanged connections. All flanged valves should match the
flanged pipe work, wherever applicable in regard to the drilling details, bolt holes
and faces. All pipe flanges and contact surfaces shall be concentric with axis of
piping. All flanges shall be accurately machined and drilled true to template.

1.5 Pipework shall be designed for the maximum pressure (pump shut off) and
corrosion margin of 1.0mm. All piping shall be internally cleaned and flushed by
the bidder before and after erection in a manner suited to the service and to the
complete satisfaction of the Engineer. All the piping systems shall be
hydrostatically tested at a pressure equal to 1.5 times the design pressure of the
system. For hydrostatic test pumps, equipment and instruments, piping etc.
Purchaser will provide water at one (1) mutually agreed point to which bidder
shall connect temporary piping. The bidder shall blow and clean all impulse lines
to instruments.

1.6 It shall be the bidders responsibility to route and erect all pipes to avoid
interference with structure, cable trays, equipment and to provide sufficient
headroom at all places where operators move. The design and fabrication of


hangers and supports shall conform to the requirements of chapter-I: Fabrication
of pipes. Hangers, Supports, Sections of ASA-B-36. 1-1962: Piping code for
pressure piping USIS latest issue. The hangers and supports shall be adequate
to support the piping and valves in a workman like manner rigid enough to
prevent excessive vibration and anchored and/or guided sufficiently to prevent
undue strains on equipment served. Minimum diameter of the hanger rod shall
be 12mm. All concrete inserts shall be furnished to install in the concrete
structure wherever required for fastening supporting devices. Any modifications
required for the piping including the field run pipes shall be done by the bidder at
no extra cost to the Purchaser.

1.7 The design, supply and installation of all pipe supports and hangers including
pipe clamps, turn buckles, hanger rods, auxiliary steel etc. shall be furnished by
the bidder along with the associated pipework. The bidders work shall terminate
at the final tube or pipe connections including the final connections. The bidder
shall furnish all bolting materials, companion flanges, nuts, gaskets etc. Required
at all terminal connections.

1.8 The pipework for various duties shall be sized generally considering the following
limits of velocities (meters/sec) specified below :

Service Pipe size

50mm & smaller 65mm to
150mm
200 NB &
larger

Suction

0.6 to 0.9

0.75 to 1.4

0.9 to 1.5

Discharge

0.9 to 1.8

1.5 to 2.5

1.5 to 2.5

1.9 All gaskets shall be 3mm thick red rubber gaskets or approved equivalent.
Carbon steel machined bolts to ASTM-A-307 Gr. B or IS: 1367: Class 4.6 or
approved equivalent shall be used with hot forged carbon steel nuts to ASTM A
194-Class-I or IS: 1367: Class 4.6 or approved equivalent.

1.10 Air Pipework

1.10.1 All compressed air piping for sizes 15 NB and larger shall be ERW pipes (heavy
quality) to IS: 1239 (latest edition). For instrument quality air, the pipes sizes 15
NB and larger shall be ERW galvanized pipes (heavy quality) to IS: 1239 (latest
edition). For sizes 10 NB and smaller, pipes shall be flexible annealed soft
copper tubing minimum 18 BWG thick.

1.10.2 All galvanized pipe fittings shall be heavy quality malleable iron `R brand or
approved equivalent to BS: 1740, screwed ends to match the pipe threads under
para 1.10.1 above. For copper tubing, the fittings shall be approved forged brass
compression fittings.

1.10.3 All air headers shall be sloped and drained through trap stations. Crosses shall
be used where tees and elbows are required and the unused ends of the
crosses shall be plugged for blowing out the header or branch pipe connections.


All branch connections shall originate from the main header only. All screwed
pipe joints shall be tightened with Teflon tape only.

1.10.4 Adequately sized air filter sets with stand by provision (capacity to suit the
requirement) at the Purchasers terminal point on compressed air line shall be
furnished. The bidder shall furnish all instrument impulse tubing from the
Purchasers terminal connection up to various instruments and control panel
within the bidders scope.

1.10.5 The velocity in the air piping shall not exceed 15 m/sec.

1.11 Valves

1.11.1 For sizes 50mm and smaller, design pressure of 8 kg/cm
2
150 # ASA bronze
body, stainless steel trim, union bonnet, inside screw and yoke, back seated
gate and globe valves having tapered female screwed ends to ISPT or BST shall
be furnished. For design pressure of 8 kg/cm
2
and higher, sizes 50mm NB and
smaller,800 # ASA forged carbon steel body, stainless steel trim, bolted bonnet,
outside screw & yoke, rising stem, back seated gate and globe valves for socket
ends shall be furnished. Check valves for these sizes shall be piston lift type or
dual plate type having construction and materials same as per gate & globe
valves.

1.11.2 For sizes 65 NB larger, design pressure of 11 kg/cm
2
, 125 # ASA cast iron body,
bronze trim, bolted bonnet, outside screw & yoke, rising stem, back seated gate
and globe valves having flanged ends machined, faced and drilled to 150 # ASA
B-16.5 shall be furnished. For design pressure between 11 kg/cm
2
and 18
kg/cm
2
; sizes 65mm NB and larger, 150 # ASA cast carbon steel body, stainless
steel trim, bolted bonnet, outside screw and yoke, rising stem, back seated, gate
& globe valves having flanged ends, machined faced and drilled to ASA-B-16.5
shall be furnished. For design pressure of 18 kg/cm
2
and higher, sizes 65mm NB
and larger, 300 # ASA Cast Carbon Steel body, stainless steel trim bolted
bonnet outside screw and yoke, rising stem back seated gate and globe valves
having flanged ends machined faced and drilled to ASA B-16.5 shall be
furnished. Check valves for the sizes shall be dual plate type with body materials
same as per gate and globe valves with stainless steel discs.

Design pressure as specified above is normal working pressure of the system.

1.11.3 All valves of 300mm NB and above shall be of butterfly valve type designated to
AWWA/BS standards.

1.11.4 Plug valves shall be regular pattern, standard type, wrench operated (up to
150mm NB size only) and of semi steel construction suitable for maximum
working pressure of 11 kg/cm
2
. The valves shall be provided with double flanged
ends machined faced and drilled to 150 # ASA B-16.5.

1.11.5 Pressure relief valves shall be angle pattern type, double flanged cast iron or
cast steel body construction (to suit the pressure rating as indicated above,
similar to gate, globe valves) with stainless steel (type 304) internals ad carbon
steel spring. Ends shall be machined, faced and drilled ASA B-16.5.



1.11.6 All control valves shall have materials and construction similar to para 1.11.1 &
1.11.2 above but to the Engineers approval for specific application.

1.11.7 All gate and globe valves shall be furnished with vertical stems. The valve design
shall ensure a steam lined passage and low pressure drop. The seats and discs
shall be easily renewable and /or shall be suitable for easy re-facing and grinding
while in service. The globe valves shall be capable of being closed against
pressure. All globe valves and gate valves shall be provided with back seating
arrangement so that the gland packing can be replaced while the valve is in
service.

1.11.8 The valves shall have permanent name plate indicting the primary pressure,
temperature rating and Purchasers tag number. Valves shall be suitable for
operation in all stem positions including horizontal, inclined and upside down.
The body seating surfaces and hinge pin seats shall be machined and the body
and seat rings shall be tight fit on the mating surfaces. Necessary precautions
shall be taken to ensure that the seats will not be lifted away from its seating
surfaces during the flow of the fluid.

1.11.9 All instrument air service, needle valve for sizes 15mm and smaller shall be 300
# ASA stainless steel (type 304) body, bar stock valves, inside screw with female
screwed ends to tapered ISPT or BST.

1.12 Specialties

1.12.1 Sight flow indicators for size 50mm NB and smaller shall be 150 # ASA single
window type, bronze body, toughened unbreakable glass, with direction
indicators, graphite asbestos and brass ring gaskets having female screwed
ends to tapered ISPT. For sizes 65mm NB and larger, the sight flow indicators
shall be of 125 # ASA double flanged cast iron body construction, other details
same as above except the needs shall be machined, face drilled to 150 # ASA
B-16.5.

1.12.2 Strainers for sizes 50mm NB and smaller shall be 150 # ASA Y-type, bronze
body with replaceable bronze internals having 0.033 inch perforated screen,
female screwed tapered ISPT or BSPT ends. Each strainer shall be provided
with plugged drain connection.

1.12.3 Filter pressure regulators shall be suitable for maximum operating parameters of
8 kg/cm
2
at 80 deg. C. These shall be constructed of bronze body, bronze trim
with powder metallurgy metallic strainers with 5 micron filter sections, drain cock
and integral pressure gauges. The regulators shall have interchangeable
automatic drain or manual drain, clear, non shuttering transparent bowl and built
in to ensure rapid response to circuit-induced pressure changes. The bowl shall
be threaded, easily removal type suitable for disassembly and service without
tools. The end connection shall be tapered BST or ISPT to suit the line sizes.

1.12.4 The pressure/compound gauges shall be of 150mm dial with black figures on
white dial of suitable range (operating pressure shall be at the middle of the
complete dial range) complete with approved isolating globe valves and fittings
as required. Graduations shall be one tenth of the maximum value of the gauge
and inter graduations shall be one-tenth of the graduations. Pressure gauges


and command gauges shall be glycerine filled snubbers shall be provided
wherever required.

1.12.5 The pressure switches for automatic start/stop control shall be of approved type
suitable for operation across 240/110 Volts, single phase, 50 c/s AC supply
having 3 amps contact rating range adjustable as required. Pressure switches
operated across 240/110 V 50 Hz AC, 24 V DC 5 amps contact rating.

1.12.6 The temperature indicators shall be industrial type glass thermometers with
mercury in glass enclosed in metal casing and mercury should read in red
colour. Alternatively thermometers of bimetallic construction with dial type
indicators are also acceptable.

1.12.7 The vacuum transmitter shall be of non indicating type, approved make providing
3 to 15 psi (g) output signal sensed at the primary element and should be
suitable for universal mounting and outdoor installation. Vacuum transmitters/all
transmitters shall have indicators displays of readings.

1.12.8 The Vacuum recorder should be two pen receiver type with liner chart drive of 6
inches per hour and chart drive should be rated for 240/110V, 50 Hz, AC supply.

1.12.8.1 150 # ASA bronze gauge glass fittings with isolating and drain cocks, flanged
ends shall be provided wherever required. The length of each gauge type
assemble shall not be more than 450mm. Where required multiple gauge glass
assemblies shall be provided on a common header having isolating connections
with valves from the tank.

1.13. Motor Actuators

1.13.1 The drive motors for the motor operators shall be 415V, 3-phase, 50 cycles
direct on line starting type constant speed squirrel cage induction motors, rated
for continuous operation in a maximum ambient temperature of 50
0
C. The motor
shall comply with the requirements of the enclosed Desein specification
`Standard Technical Specification for Induction Motors. Make of the actuators
shall be AUMA/Beacon Rotork/Antrieb only.

1.13.2 The motor operator shall be designed to close the valve in maximum thirty (30)
seconds from the full open position.

1.13.3 Motors gearing and disengaging hand wheel shall be adequate to open and
close valves under full unbalanced design pressure and shall be completely
assembled on there respective valves and shop tested prior to dispatch.

1.13.4 The hand wheel, when engaged should cut off the motor power and control
circuits. A three-pole heavy duty load break switch shall be provided on the
motor operator for use as a locking switch to disconnect the motor from power
source. The switch shall be provided with a lockable handle to prevent
unauthorized operation.

1.13.5 The limit switches shall function to stop the motor when the valve disc has
attained the full open or closed positions and shall have the following additional
contacts for indication lights and interlocking circuits.


a) One contact to open when valve is fully closed.
b) One contact to open when valve is fully open.
c) One contact to close when valve is fully open.
d) One contact to close when valve is fully closed.

1.13.6 The torque switch shall function to stop the motor on closing or upon actuation
by the torque clutch when the valve is restricted in its attempt to open or close
there by causing an overloading torque. Torque switch shall have adjustment for
operating torque and shall be provided with two (2) normally open and two (2)
normally closed contacts.

1.13.7 Torque and limit switches shall be suitable for breaking the current of 110V AC
contactor coils. The bidder shall provide necessary stop-down transformers for
converting 415V to 110V AC supply. Other contacts of the torque and limit
switches shall be suitable for operation at 110V AC or 220V DC.
DESEIN Annexure-III, Sheet - 1 of 23


ANNEXURE-III

STANDARD TECHNICAL SPECIFICATION FOR INDUCTION MOTORS

0.00 SCOPE

This specification is intended to cover design, manufacture, assembly and testing
of AC Squirrel Cage Induction Motors for use in Thermal Power Plants and is
supplement to the driven equipment specifications under which these motors are
being procured for the project.

1.00 SITE CONDITIONS

1.01 Site conditions are covered in 'Project Data', contained in specification of the
driven equipment.

1.02 Gases, Fumes & Dust Particles

1.02.01 General ................. Sulphur dioxide and/or trioxide fumes mildly present. Climate
is tropical, conducive to fungus growth.

1.02.02 Dust Particles

.1 Outdoor locations Heavily dusty with abrasive dust and
coal particles of size five (5) to hundred (100) microns present in
atmosphere in large quantity.

.2 Indoor Locations.

.21 Millbay & coal conveyors . As for outdoor as per clause
1.02.02.1 above.

.22 Other locations Lightly dusty with abrasive dust and coal
particles of size five (5) to twenty (20) microns present in atmosphere.

1.02.03 Special Fumes

.1 Water treatment plant and acid cleaning room .. Acid and alkali
fuses present.

.2 Fuel oil pumping areas & Hydrogen generation plant .. Explosive
fuses (flameproof motors required).

2.00 LOCATION OF MOTOR ..................................... As required

3.00 SPECIFICATIONS & STANDARDS........................ Motors shall comply with the
latest revisions of all relevant standards of BIS (IS-325, IS-900, IS-996, IS-1231,
IS-1885, IS-2148, IS-2223, IS- 2253, IS-2254, IS-2848, IS-3202, IS-4029, IS-4691,
IS-4722, IS- 4728, IS-4889, IS-6362, IS-7816, IS-8223, IS-8789 and IS:12615)
except as modified herein or in driven equipment specification.



Motors conforming to BS or IEC Publications, which ensure equivalent quality
shall also be acceptable. Motors conforming to any other National Standards,
which ensure equivalent quality, are also acceptable but in such cases, the Bidder
shall clearly indicate the standards adopted and furnish two (2) copies of the
English Translation of these standards alongwith the Bid. In case of any difference
between IS Specification/International Standards (IEC;NEMA etc.), this motor
specification prevails.

4.00 VOLTAGE (NOMINAL)

4.01 LT Motors

4.01.01 For motors below 200 W ..................... Two hundred forty (240) V Single phase or
Four hundred fifteen (415) V 3 phase.

4.01.02 For motors 200 W and Below 175 KW .................. Four hundred fifteen (415) V.

4.02 HT Motors

4.02.01 For motors from 175 KW and Upto 1500 KW ................. Three point three (3.3) KV

4.03 All motors are to be designed for system grounding described in "System
Particulars" under site information of the Driven Equipment Specification.

5.00 FREQUENCY (NOMINAL) ................. fifty (50) Hertz

6.00 NUMBER OF PHASES .......... Three (3) except for single phase 240 V motors

7.00 SPEED ................................ As required by the driven equipment

8.00 TYPE OF STARTING ............................ Direct on-line

9.00 DUTY

9.01 Continuous motor rating shall be at least fifteen (15) percent above the load
demand of driven equipment at design point.

9.02 Motor rating shall be such that it is not overloaded at any operating point of driven
equipment from zero to full load.

9.03 The break-away torque, pull-up torque and pull-out torque of the motors shall be
properly coordinated with the requirements of driven equipment to ensure smooth
and rapid starting and steady operation. The torque-speed characteristics of
motor super imposed thereon on driven equipment torque-speed characteristics at
100%, 90%, 80% shall be furnished.

9.04 Maximum torque shall not be less than 200% of full load torque.

9.05 All motors shall be designed to withstand hundred twenty (120) percent of rated
speed without any mechanical damage for two (2) minutes.

9.06 Motors shall be designed to keep torsional and rotational natural frequencies of
vibration of the motor and driven equipment at least twenty five (25) percent above


or below, preferably above the motor operating speed (to avoid resonance in
vibration over the operating speed) range.

9.07 All motors shall be energy efficient type having high power factor. LT motors up to
37 KW shall have performances conforming to IS: 12615. LT & HT motors rated
above 37 KW shall have full load efficiency of 91% minimum and rated full load
power factor of 0.81 minimum. The required power factor shall be achieved
without using external capacitors.

10.00 SUPPLY VARIATIONS ...................... Motors shall be capable of running
continuously at full load under following variations in power supply :

10.01 Voltage (percent of nominal voltage) .......... Plus minus (+) ten (10)

10.02 Frequency (percent of nominal frequency) ........ Plus minus (+) five (5)

10.03 Combined voltage & frequency (percent) .............. Ten (10) (sum of absolute
percentage value of voltage and frequency variation)

11.00 ABNORMAL CONDITIONS CAPABILITY...................Motor shall have following
capabilities as specified design ambient temperature:

11.01 The motors shall also be capable of running up again after voltage collapse to
about 40% for approximate duration of 0.5 sec. Subsequent rise in voltage to 70%
and further to 80% and 100%, the total duration not exceeding 20 sec.

11.02 Low Voltage Running .................... Motor shall be capable of running satisfactorily
at seventy five (75) percent nominal voltage for five (5) minutes.

11.03 Momentary Low Voltage Withstanding ................. Motor, when running at full load,
shall not stall when voltage drops down to seventy (70) percent nominal voltage
for one (1) minute.

12.00 STARTING CAPABILITY

12.01 Low Voltage Starting .......................... Motor shall be capable of starting and
accelerating to full speed at full load (including loaded equipment eg mills and
conveyors etc) at eighty (80) percent nominal voltage at motor terminals.

12.02 Cold Motor Starting ................... Under specified voltage variations two (2) starts in
quick succession and third start five(5) minutes thereafter, all with full load
(including loaded equipment eg mills and conveyors etc) of driven equipment. No
additional start will be made till lapse of further thirty (30) minutes.

12.03 Hot Motor Starting ............... Under specified voltage variations, one (1) immediate
and two (2) fifteen (15) minutes interval starts all with full load (including loaded
equipment eg mills and conveyors etc) of driven equipment. No additional start
will be made till lapse of further thirty (30) minutes.

12.04 Motor shall also be suitable for three (3) equally spread starts per hour when the
motor is under normal service condition.



12.05 Break-away Starting Current .................. Breakaway starting current as percent of
full load current for various motor ratings shall not exceed the values given below :

12.05.01 Motors up to 1000 KW .................... 600% subject to IS Tolerance of plus 20%.

12.05.02 Motors (above 1000 KW upto 2500 KW).............. 600%. Not subject to any
positive tolerance

12.05.03 Motors above 2500 KW ................. 450% Not subject to any positive tolerance

13.00 SAFE STALL TIME

13.01 To avoid problem in selecting standard protective relays without using speed
switches, safe stall time under hot conditions (corresponding to 110% nominal
voltage at motor terminals) shall be more than the accelerating time
(corresponding to 80% nominal voltage at motor terminals) by the following
minimum values :

13.01.01 Three (3) seconds, where accelerating time (at 80% nominal voltage) does not
exceed 20 seconds.

13.01.02 Five (5) seconds, where accelerating time (at 80% nominal voltage) exeeds 20
seconds.

13.01.03 At no stage, speed switch shall be provided to achieve the above requirements
mentioned under Clause No.13.01.01 & 13.01.02 above.

14.00 CLASS OF INSULATION

14.01 LT Motors ..................................... Class F.

14.02 HT Motors ..................................... Class F Epoxy enriched insulation shall be
provided for motors having possibility of oil/moisture ingress into windings from
the lubricating system.

14.03 However temperature rise shall be restricted to limits corresponding to Class 'B'
insulation for both HT & LT motors. The temperature under abnormal running
conditions shall be limited to 5
o
C above class B limits.

14.04 The value of the polarisation index for motors above 180kW should not be less
than 2 when determined according to IS:7816.

15.0 TEMPERATURE RISE UNDER NORMAL CONDITIONS........... Temperature rise
over specified design ambient temperature when motor is running with full load at
nominal supply voltage & frequency shall not exceed the values given below:



_______________________________________________________________________
S.No. Specified Design Thermometer Method Resistance Method
Ambient
Temperature
_______________________________________________________________________

15.01 50
o
C 60
o
C 70
o
C
15.02 46
o
C 65
o
C 75
o
C
15.03 40
o
C 70
o
C 80
o
C

16.00 BUS TRANSFER WITHSTAND CAPABILITY

Motors will be connected to an automatic bus transfer system and hence may be
subjected to one hundred and fifty (150) percent of the nominal voltage during
changeover of buses due to the vector difference between the residual voltage
and incoming supply voltage and the duration of this condition may be one
second. Motors shall be capable of withstanding the voltage and torque stresses
developed under such conditions without damage. The manufacturer/vendor shall
indicate the special precautions taken to meet the above requirements and
confirm.

16.01 That about 5000 bus transfers, in life time of motor, shall not puncture its
insulation.

16.02 That motor shall be capable of withstanding heavy inrush transient current caused
by such bus transfers without damage.

16.03 That the motor windings shall be adequately braced to satisfactorily withstand
mechanical stresses under these conditions.

16.04 The motor and driven equipment shafts shall be adequately sized to satisfactorily
withstand transient torques under these conditions.

17.00 TYPE OF ENCLOSURE

17.01 Outdoor Motors ...................... IPW 55 (Totally enclosed weather protected)

17.02 Indoor Motors ....................... IP 55 (Totally enclosed)

17.03 IP-55 degree of protection shall be achieved without application of any compound,
putty etc.

18.00 METHOD OF COOLING

18.01 Method of cooling shall be IC 411 (TEFC), IC 511 (TETV) or IC 611 (CACA)

18.02 Large capacity motors not available with above types of cooling may be accepted
with IC 81 W for IC 91 W (CACW) cooling subject to the approval of the Owner.

19.00 TYPE OF MOUNTING ..................... As required for the driven equipment.



20.00 MAXIMUM MECHANICAL VIBRATIONS

20.01 For motors with shaft heights upto 355 mm; the limits of vibration severity shall
be in accordance with Table-1 or Table-2 of IS:11575 (Normal Class).

20.02 For motors with shaft heights above 355 mm ; the limits of vibration severity shall
be stated by the Manufacturer and shall be subject to agreement by the Owner..

20.03 Noise level

The noise level of motors shall not exceed 85 db (A) at 1.5 m from operating motor
measured in accordance with IS:10265.

21.00 INSULATION

Insulation shall be treated, impregnated, coated and tropicalised to withstand site
conditions as per Cl. 1.00 above. Entire motor assembly, after coils are placed in
slots and connections made, shall be completely immersed in suitable insulating
compound or varnish followed by baking. This would be repeated thrice.

Winding shall then be painted with epoxy paint to withstand heavily salt polluted
atmospheric conditions.

22.00 DIRECTION OF ROTATION

22.01 As needed by driven equipment.

22.02 The 3 phase motor shall, however, be suitable for operation in both directions of
rotation. A plate showing direction of rotation as determined by the phase
sequence on the terminals marking shall be screwed at non-driving end of the
body of the motor.

22.03 If, in the case of HT motors, fan is suitable for only one direction of rotation, the fan
shall be so designed that with the slight modification work, it can be made suitable
for other direction of rotation also. No extra material shall be required for doing
above modification work.

23.00 BEARINGS

23.01 General .............. Greased ball, roller and/or sleeve bearing shall be rated for
minimum standard life of 15,000 hours taking bearing and driven equipment loads
into account. Loss of grease shall be scarce and it shall not creep along shaft into
motor housing.

Bearing shall be effectively sealed against dust ingress and shall be pressure
grease gun lubricated.

If the bearings are oil lubricated, a drain plug shall be provided for draining
residual oil and oil level gauge shall be provided to show precisely oil level
required under standstill and running conditions.



Unless otherwise approved, bearing lubricating system shall be such that no
external forced oil or water is necessary to maintain required oil supply to keep
bearing temperature within design limits.

For HT motors, the bearings shall be insulated wherever necessary to prevent
damage to motor bearings from shaft current.

When pressure oiling is required for horizontal motors, bearings shall be sleeve
type arranged for pressure oiling supplied from lubrication system of driven
machine, with ring oiling for starting and emergency duty. Ring oiling system shall
be adequate for starting and continuous operation of motor for at least half an
hour, without pressure oiling system in operation. Oil sight flow gauges shall be
provided to indicate oil flow through each bearing.

Lubricants shall be selected for prolonged storage and normal use of motors in
tropical climate and shall contain corrosion and oxidation inhibitors. Greases shall
have suitable bleeding characteristics to minimize setting. The selected lubricants
shall be indiginously available.

Sleeve bearings for use with motors having flexible coupling with limited end play,
shall have adequate axial end play to prevent transmission of thrust from driven
equipment to motor bearings.

Bearings shall be of reputed make subject to the approval of the Owner/Consulting
Engineer.

23.02 Large motors .................... Large motors shall preferably have spherically seated
babitted, ring forced, feed lubricated, water cooled bearings. If anti-friction
bearings are provided, these shall be roller bearings rated for a minimum standard
life of 30000 hours taking all bearing and driven equipment loads into account.

24.00 SHAFT EXTENSION ............ Key slotted bare shaft extension of required length
with key on driving end.

25.00 DRAIN HOLES ................... Two (2) drain holes with plugs, one (1) on either end
of motor at the bottom most point.

26.00 LIFTING DEVICES ................. Motors shall be provided with eye bolts, lugs or
other means to facilitate safe lifting.

27.00 DOWEL PINS........... It shall be possible to drill holes vertically inclined through
motor feet or mounting flange for installing dowel pins after assembling motor and
driven equipment, before despatch (for completed driving + driven equipment
assembly) or at site after erection (for separate supplies of above equipment).

28.00 CENTERING SPIGOT................... Flange mounted motor shall have centering
spigot to match driven equipment socket.

29.00 EASE OF MAINTENANCE............... Motor shall be so constructed that it can be
deassembled and reassembled with ease.

30.00 NAMEPLATES................. Motor shall have nameplate(s) showing diagram of
connections, all particulars as per IS:325 and following additional information :


In addition, an arrow block shall be screwed on to the body of motor on the
non-driving end to indicate direction of rotation of motor.

30.01 Temperature rise under normal/abnormal conditions.

30.02 Type of bearing and recommended lubricants.

31.00 FINISH.................. Motor shall have glossy, light grey finish No. 631 as per IS:5
for withstanding site conditions as per Clause 1.00 above.

All sharp edges and scales shall be removed from the surface, which shall then be
thoroughly degreased, derusted and given two (2) coats of primer and two (2)
coats of finish paint. It is preferred that a phosphate coat is given to motor prior to
application of primer coat. Motors for water treatment plant shall have Zinc
Chromate base with acid resistant Epilex 4 paint.

32.00 TERMINAL BOXES

32.01 General ............................ Motors shall be provided with separate terminal boxes
for main, space heaters, embedded temperature detectors, bearing temperature
indicators and moisture detectors terminals. When it is not possible to provide LT
motors with separate terminal box for space heater terminals, space heater
terminals shall be adequately segregated from the main terminals in the single
box. Terminal boxes shall be weatherproof and water-tight confirming to minimum
IP-55 degree of protection with removable front cover for making connections.
IP-55 degree of protection shall be achieved without application of compound.
Space between and around terminals shall be adequate for easily connecting
aluminium conductor cables. Terminal box arrangement shall be to the approval
of the Owner/Consulting Engineer. All terminal boxes shall be suitable for proper
termination of the type and tentative size of cables specified in Clause 33.00
below, however, exact size of cables shall be furnished by Owner during
engineering stage.

The terminal boxes shall be complete with cable glands and termination accessories
as required. Suitable non-magnetic material construction shall be adopted for
terminal boxes where single core cables are to be terminated. All HT motors shall be
provided with phase segregated terminal box.

Terminal bushings and clamps shall be non-absorbent, non- inflammable, insulated
material for connecting with cable.

32.02 Main Terminal Box

32.02.01 LT Motors ........ Main terminal box shall be capable of being turned through 360
degrees in steps of 90 degrees.

32.02.02 HT Motors ........... Motor shall be provided with two (2) terminal boxes for stator
terminals. One (1) terminal box shall be for phase terminals while other one for
forming star connection. These should be interchangeable to facilitate cable routing.

Neutral terminal box for HT motors rated 1000 KW and above shall be suitable for
mounting of three (3) Nos. wound/bar primary/ring type cast resin insulated current


transformers for differential protection. These transformers shall be supplied and
mounted in the motor terminal box. In addition to above, 3 Nos. of identical current
transformers shall be supplied loose for mounting in the switchgear. Stator phase
terminal box may either be phase segregated of standard terminal box suitable for
both top and bottom entry of cables.(i.e. they should be capable of being turned
through 180 Degrees). The terminal box shall be designed for termination of XLPE
cables using heat shrinkable or push on type terminating Kit. Terminal leading shall
be stud type or leading wire type.

32.02.03 Cable End Boxes.................Terminal Boxes shall be provided with cable end boxes
and cable glands for cables of sizes as specified in Clause 33.00 below.
32.02.04 The terminal boxes shall be capable of withstanding at the
terminals the system fault level (as indicated below) without rupture for a duration
of atleast 0.25 seconds.

Min. fault level for HT Motors - 40 KA
Min. fault level for LT Motors - 50 KA

32.02.04 Minimum clearance to be provided between phase to phase and phase to earth
shall be as under ::

Voltage Rating of Motor

Min. Phase to Phase & to Earth
Clearance

0.415 KV

3.3 KV

6.6 KV

11.0 KV
25 mm

65 mm

127 mm

140 mm
In case it is not possible to maintain
these clearances the live parts shall be
totally insulated from earth and other
phases. Adequate clearance shall be
provided for cable connections.

32.02.05 Terminal Accessories................Each terminal end shall be furnished with
bimetallic washers, spring washers, nuts and crimp type aluminium (preferably
tinned) lugs suitable for cables of sizes as specified in Clause 33.00 below.

33.00 TYPE AND SIZE OF CABLES

33.01 Space Heaters

33.01.01 For LT Motors: Two point five (2.5) mm
2
, two (2) core copper conductor XPE
insulated, armoured and FRLS PVC sheathed heavy duty 650/1100 V grade cable
to IS:1554 (Part-I).

33.01.02 For HT Motors: Six (6) mm
2
two core aluminium conductor XPE insulated
armoured and FRLS PVC sheathed heavy duty 650/1100V grade cable to IS:1554
(Part-I).

33.02 For Embedded Temperature Detectors two sets of six (6) Twisted triad 0.5 mm
2

ATC copper conductor armoured, shielded cable, 650/1100 V Grade IS:1554
(Part-I). For bearing temperature, RTDS, two (2) sets of four (4) twisted triad 0.5
mm
2
, ATC copper conductor armoured shielded 650/1100 V Grade, IS:1554
(Part-I).


33.03 Bearing Temperature Indicators - For each indicator, 0.5 mm
2
six (6) tarnished
triad ATC copper conductor, XPE insulated, shielded armoured and FRLS PVC
sheathed heavy duty 650/1100 V grade cable as per IS:1554 Part-I. Two (2)
cables one (1) for each bearing temperature indicator.

33.04 For Moisture Detectors...................As for space heaters as per Clause 33.01.01
above.

33.05 For Main Terminals

33.05.01 LT Motors

.1 Three (3) core cables: Stranded aluminium conductor, XLPE insulated,
colour coded, laid up, PVC sheathed, GI wire / strip armoured, FRLS PVC
jacketed overall, 650 / 1100 V grade, heavy duty cables as per IS:1554
(Part-I).

.2 Single core cables: Stranded aluminium conductor, XLPE insulated, hard
drawn aluminium wire /.strip armoured FRLS PVC jacketed overall, 650 /
1100V grade, heavy duty cable as per IS:1554 (Part-I).

33.05.02 HT Motors

.1 Three (3) core cables: stranded aluminium conductor, XLPE insulated,
screened colour coded, laid up, PVC sheathed, GI wire/strip armoured
FRLS PVC jacketed overall, 6.6 KV / 11 KV grade, heavy duty cables as
per requirement for unearthed system as per IS:7098 (Part-II).

33.05.03 Power cable sizes are given in Sheet-15.

34.00 GROUNDING

34.01 General: Two (2) grounding terminals one (1) on either side at the bottom suitable
for connecting mild steel/GI flat/GI wire grounding conductor of size given Clause
2 Grounding Conductor Sizes, shall be provided.

34.02 LT Motors: At each earthing point, two (2) drilled and tapped holes with hexagonal
head bolts, plain washers, spring washers and tinned lugs (for motors upto 5.5
KW) for size of conductor specified shall be provided.

34.03 HT Motors: Non-corrodible metallic grounding pad shall be welded or brazed at
each earthing point. The size of grounding pad shall be 75x65x25 mm.
Grounding pad shall have 40 mm apart two (2) drilled and tapped holes with
hexagonal head bolts, plain washers and spring washers for size of conductor
specified. In addition, one suitable earthing terminal shall be provided inside the
stator phase terminal box for earthing metallic shield of XLPE cables.

35.00 EMBEDDED TEMPERATURE DETECTORS..................HT motor shall be
provided with six (6) resistance temperature detectors (RTDs) embedded in stator
winding at locations where high temperatures are expected. In addition one (1)
RTD shall be provided in each bearing. The RTDs shall be 3 wire duplex platinum
resistance type having a value of 100 ohms at 0 Deg.C


36.00 BEARINGS TEMPERATURE INDICATORS......... HT motors shall be provided
with dial type two (2) bearing temperature indicators and will have two (2) sets of
contacts, each set having 2 NO + 2 NC contacts rated for 5A at 240V AC and 0.5A
at 220V DC. One set will be set to operate at lower value to give alarm and other
set at a higher value to trip the motor.

37.00 SPACE HEATERS........Valve / Damper actuator motors; and Motors above 30
KW shall be provided with one (1) or two (2) space heaters suitable for 240V, 50
Hertz single phase AC supply and of adequate capacity to maintain motor internal
temperature above dew point to prevent moisture condensation or deterioration of
insulation during shut down. Heaters shall be mounted inside the motor in
accessible locations so that their removal and replacement is simple.

The terminals of space heaters shall be brought out to a separate totally enclosed
dust proof and weather proof terminal box.

38.00 HOT AIR TEMPERATURE DETECTOR
If the motor is of CACA or CACW enclosure, a thermometer with alarm contracts
in hot air circuit shall be provided.

39.00 WATER FLOW INDICATOR
If the motor is of CACW enclosure a provision shall be made for visual indication
of water flow and flow switch shall also be provided with alarm contacts.
Thermometers shall be provided in water inlet and outlet circuits.

40.00 MOISTURE DETECTORS..................Motors with type of cooling 1C 81W or 1C
91 W shall be provided with moisture detectors for raising alarm in the event of
water tube failure.

41.00 BED PLATE............Whenever motor is supplied with driven equipment the
Supplier shall ensure that bed plate suits both motor and driven equipment and is
adequately braced to keep vibration and misalignment within allowable limits to
the approval of driven equipment and motor manufacturers.

42.00 OTHER ACCESSORIES......... Motor shall be supplied with all accessories and
parts other than those, specified above which are necessary and/or useful for
efficient operation.

43.00 TESTS

43.01 Type Tests ........... Type test certificate as per ISS of atleast one (1) motor of each
type to establish that proposed motor conforms to the needs of this specification
shall also be furnished with the Proposal. On award of contract, type tests on
each type of motor shall also be conducted in presence of customer's
representative and test certificates for the same shall be furnished for approval of
customer.

43.02 Routine Tests......... Every motor shall be routine tested in presence of customer's
representative as per IS:325 to the extent necessary to establish that it is identical
to the type tested motor. Routine test certificates shall be furnished for approval.

Following tests shall also be conducted :


1. Over speed test on all Motors
2. Vibration test on HT Motors
3. Polarization Index test for HT Motors.
4. Noise level test for each type of Motor
5. Impulse test by 1.2/50 micro sec. on sample coil of HT motor stator
winding insulation as type test as per IEC.

Voltage Rating of Motor Impulse Test Voltage

3.3 KV 18 KV
6.6 KV 36 KV
11.0 KV 49 KV

6. Test for suitability of IP-55 as per IS: 4691 as type test.

7. Temperature rise test on each type and rating.

8. Degree of protection test for second (2nd) numeral shall be conducted on
all HT motors only.

9. Tan-Delta charging current and dielectric loss measurements on each
phase of HT motor winding as routine test.

43.03 Witnessing of Tests...............The Owner reserves the right to depute his
representative(s) to the Manufacturer's works to witness tests. To enable the
Owner to depute his representative(s), the Supplier shall inform atleast thirty (30)
days in advance about the readiness of motor for testing.

44.00 INFORMATION WITH PROPOSAL

44.01 Motor Data Sheet as per Sheet 16 of 24 of this Annexure.

44.02 Dimension Drawing/Foundation load details of motor and driven equipment.

44.03 Manufacturer's catalogue showing constructional details.

45.00 INFORMATION ON AWARD OF CONTRACT..................Within six (6) weeks
from the date of award of the Contract, following shall be furnished :

45.01 Motor Data Sheet as per Sheet 16 of 24 of this Annexure

45.02 Certified binding dimension drawing of motor complete with all accessories and
fittings specifically showing terminal boxes, terminal spacing and sizes, earthing
connections and sizes thereof, mounting details, lifting lugs, final foundation loads
and dimensions with tolerances of centering spigot (where needed), shaft
extension and key.

45.03 Following characteristics curves :

45.03.01 Torque-speed curves for motor at eighty (80), hundred (100) and hundred ten
(110) percent rated voltage as well as torque-speed curve for driven equipment.



45.03.02 Current-speed curves at eight (80), hundred (100) and hundred ten (110) percent
rated voltage

45.03.03 Current-time curves at eighty (80), hundred (100) and hundred ten (110) percent
rated voltage.

45.03.04 Thermal withstand curves for hot and cold at eighty (80), hundred (100) and
hundred ten (110) percent rated voltage.

45.03.05 Efficiency, power factor, current and speed versus power output curves.

45.03.06 Speed-time curves at eight (80), hundred (100) and hundred ten (110) percent
rated voltage.

45.03.07 Negative phase sequence current withstand characteristics.

46.00 SPARE PARTS..................Proposal shall include unit prices for following spares
and any other spare required for three (3) years normal operation and emergency
needs of the motor :

46.01 One (1) set of bearings.

46.02 One (1) sets of seals and gaskets if any for each motor.

SPECIFICATION FOR CABLES

1.00 CABLE SIZES

1.01 Size of main power cables for various motors shall be as follows:

1.01.01 415V three (3) phase motors
___________________________________________________________

RATING CABLE SIZE
ABOVE UPTO

___________________________________________________________

5.5 KW 3 core - 6 mm
2

5.5 KW 11 KW 3 core - 10 mm
2

11 KW 22 KW 3 core - 35 mm
2

22 KW 37.5 KW 3 core - 70 mm
2

37.5 KW 55 KW 3 core - 150 mm
2

55 KW 75 KW 3 core - 300 mm
2

75 KW 110 KW Two (2), 3 core - 150 mm
2



110 KW 175 KW Two (2), 3 core - 300 mm
2

___________________________________________________________

1.01.02 For 3.3 KV three phase motors

--------------------------------------------------------------------------------------------------
RATING CABLE SIZE
ABOVE UPTO
__________________________________________________________

176 KW 1000 KW 3 core - 240 mm
2

1000 KW 2000 KW Two (2), 3 core - 240 mm
2

2000 KW 4500 KW Two (2), 3 core - 300 mm
2

4501 KW 10000 KW Nine (9), 1 core -1000 mm
2

__________________________________________________________

1.02 Cable size may be increased in some cases because of larger number of cables
laid in under-ground ducts or because of voltage drop consideration. The Supplier
shall supply motors with terminal box and cable accessories suitable for such
higher size of cable at no extra cost.

2.00 GROUNDING CONDUCTOR SIZES

2.01 Size of grounding conductors for various motors shall be as follows :
___________________________________________________________

RATING CONDUCTOR SIZE
ABOVE UPTO
___________________________________________________________

5.5 KW 4 SWG

5.5 KW 22 KW 25 mm x 4 mm

23 KW 55 KW 40 mm x 6 mm

56 KW 175 KW 50 mm x 8 mm

176 KW & ABOVE 75 mm x 10 mm

___________________________________________________________



MOTOR DATA SHEET

(To be furnished along with the bid)

1.00 GENERAL

1.01 Application :

1.02 Quantity (Nos.) :

1.03 Make :

1.04 Frame Size :

1.05 Application Standards :

2.00 TYPE AND RATING

2.01 Type of Motor :

2.02 Service

i) Outdoor/indoor :

ii) Hazardous area classification :
if any

2.03 Duty Cycle/Designation :

2.04 Rated Current Output

i) at 40 deg. ambient KW :

ii) at 50 deg. ambient KW :

2.05 Rated Speed RPM :

2.06 Rated Voltage & % Variation Volts :

2.07 Rated Frequency & % Variation Hz :

2.08 Full Load Current Amps :

2.09 No load current Amps :

2.10 Rated Power Factor :

2.11 Efficiency at rated voltage and
frequency :

i) Full load % :

ii) 3/4 load % :


iii) 1/2 load % :

3.00 PERFORMANCE

3.01 Method of starting :

3.02 Starting current at rated % of FLC :
voltage

3.03 i) Starting torque at % of FLT :
rated voltage

ii) Pull-out torque at % of FLT :
rated voltage

3.04 Starting time at 80% 100% for
fans motors and 90% 100% for
mill motors :

i) With load Sec. :
ii) Without load Sec. :

3.05 Safe stall time at 110% rated
voltage :

i) Hot condition Sec. :

ii) Cold condition Sec. :

iii) Safe stall time at Hot(Sec.) :
100% / 80% for fans & Cold(Sec.) :
100% 90% for Mill Motors

3.06 Thermal Time Constant

i) Heating Min. :
ii) Cooling Min. :

3.07 Starts

i) Equally spread/Hour Nos. :

ii) Successive cold Nos. :

iii) Successive hot Nos. :

3.08 Permissive running time at Min. :
full load at minimum allow-
able voltage



4.00 CONSTRUCTION

4.01 Degree of protection of enclosure :

4.02 Method of cooling :

4.03 Insulation class :

4.04 Temperature rise over 50 deg. Deg.C :
ambient (by resistance)

4.05 Tropicalised Yes/No :

4.06 Mica with epoxy treatment Yes/No :
for insulation

4.07 Winding connection :

4.08 Bearing

i) Make :

ii) Type DE/NDE :

iii) Recommended lubricant :

4.09 Motor Terminal Box

i) Type, phase segregated Yes/No :

ii) Location as seen from NDE :

iii) Fault withstand

a) Current KA :
b) Time Sec. :

iv) Cable lugs and Glands Yes/No :
furnished

v) Type and Range/size of cable :

5.0 ACCESSORIES

5.01 Space Heaters

(i) No. x Watt(Total) Watts :

(ii) Volts, Phase, Frequency :

(iii) Separate terminal box :

5.02 Winding Temperature Detector :


(i) Type :

(ii) Nos. and locations where provided :

(iii) Resistance at 0 deg. Ohm :

5.03 Bearing Temperature Indicator

(i) Type :

(ii) Nos. furnished :

5.04 Temperature Indicators:

(i) Type :

(ii) Nos. provided :

(iii) Locations :

5.05 Temperature Alarm Contacts

(i) Nos. provided :

(ii) Locations :

(iii) Contact Rating :

5.06 Flow Switch

(i) Nos. provided :

(ii) Locations :

(iii) Contact Ratings :

5.07 Current Transformer for Differential
Protection

(i) Nos. provided :

(ii) Current Ratio :

(iii) Class of accuracy :

(iv) Dimensional Drawing :

5.08 Accessory Terminal Box

(i) Nos. provided :

(ii) Cable Glands/lugs furnished :


(iii) Type and Range/size of cable :

6.00 GROUNDING

6.01 Nos. of grounding pads provided

(i) On Motor Body :

(ii) On Terminal Box :

7.00 MISCELLANEOUS

7.01 Type of Mounting :

7.02 Overall Dimensions :

Length mm :

Breadth mm :

Height mm :

7.03 Moment of Inertia

(i) Driven Equipment Kg-M
2
:

(ii) Rotor Kg-M
2
:

(iii) Total Kg-M
2
:

7.04 Weight

(i) Stator with winding Kg :

(ii) Rotor(with winding) Kg :

(iii) Total Kg :

(iv) Copper used in motor Kg :

(v) Base plate Kg :

(vi) Cooler Kg :

7.05 Cooling Water System(if provided)

(i) Water Temperature

(a) Inlet Deg.C. :

(b) Outlet Deg.C. :



(ii) Water pressure required Kg-mm
2
:

(iii) Air Temperature Deg.C. :

7.06 Direction of rotation viewed from NDE :

7.07 Method of coupling with driven equipment :

7.08 Sealing arrangement for bearing :

7.09 Details of painting :

7.10 Details of extra precautions taken :
in motor design to meet 150% of normal
voltage during high speed bus transfer

7.11 Special features if any :

7.12 Total guaranteed losses comprising
Iron loss ,friction, windage and stray
losses KW :

Break-up Iron loss KW :

Cu loss KW :

Friction windage & stray KW :
losses

7.13 CT's for Differential protection :
(For motors more than 1000KW)

(i) Type and Make :

(ii) Ratio & Accuracy class :

(iii) Class of insulation :

(iv) Rated voltage and frequency :

(v) Knee point voltage :

(vi) Applicable standards :

(vii) Dimensions of CT's :

(viii) Separate terminal box for CT's
provided Yes/No :

(ix) If Yes ,Dimension of box :



7.14 Motor Bearings

(i) Permissible temperature
rise deg.C. :

(ii) Design ambient temperature
assumed for above deg.C. :

(iii) Manufacturers reference no. of
catalogues attached :

7.15 Motor bearing lubrication system whether :
self lubricated or forced lubricated

7.16 Forced lubrication(if provided) Whether Yes/No :
this is compatible with forced oil
lubrication system of driven equipment.
If so, furnish the details

(i) Type, Make & specification of oil :

(ii) Flow Rate Liters/Sec :

(iii) Pressure Kg/ mm
2
:

(iv) Quantity of lube oil pump
sets provided for each motor No. :

(v) Location of control panel provided
for forced oil lubrication system for
each motor :

(vi) Make, type & Name plate particulars
of lube oil pumps and 415 volts
3phase 50Hz motor :

(vii) Coolers-material :

(viii) Filters-Make & Type :

7.17 Quick disconnecting type terminal
connection provided Yes/No :
If provided then

(i) Make and Type :

(ii) Operating voltage :

(iii) Current Rating :

(iv) Oil filled/Air insulated :



(v) Reference No of manufacturers :
catalogue attached

7.18 Stator core temperature detectors

(i) Make and Type :

(ii) No & Locations, Where :

(iii) Resistance at 0 deg.C. Ohm :

(iv) Reference literature attached Yes/No :

7.19 Permissible vibrations limits microns :

7.20 Vibration detectors provided Yes/No :

(i) Make and Type :

(ii) No. and Locations :

(iii) Reference catalogues attached Yes/No :

7.21 Vibration recorder provided Yes/No :

7.22 Magnetising current of motor at
rated voltage and frequency Amps :

7.23 Motor Reactances Ohms/phase :

(i) Sub transient reactance PU :

(ii) Transient reactance PU :

(iii) Steady state reactance PU :

7.24 Surge impedance per phase Ohms/phase :

7.25 Capacitance per phase to earth microfarads :

7.26 Winding resistance per phase at
20 deg.C. Ohms :

7.27 Winding resistance between terminals
at 20 deg.C. :

7.28 Shaft orientation
Horizontal/Vertical/Hollow Vertical :

7.29 Whether half coupling required Yes/No :

7.30 Whether bed plate required Yes/No :


7.31 Whether rails required Yes/No :

8.00 CHARACTERISTIC CURVES FOR MOTOR ATTACHED

(i) Speed Vs current at rated
voltage Yes/No :

(ii) Speed Vs Torque at 110%,100%
90%& 80% 0f rated voltage Yes/No :

(iii) Thermal withstand curve for hot
and cold condition Yes/No :

(iv) Effeciency vs load Yes/No :

(v) P.F. Vs Load Yes/No :

(vi) Current Vs Time Yes/No :

(vii) Negative phase sequence Yes/No :

DESEIN Annexure-IV, Sheet - 1 of 1


ANNEXURE-IV

LIST OF APPROVED SUB VENDORS FOR BOUGHT OUT ITEMS

(List to be added by APGENCO)
DESEIN Annexure-V, Sheet - 1 of 53


ANNEXURE V

SPECIFICATION FOR ELECTRICAL AND C&I WORKS

1.0 OPERATION, CONTROL AND INTERLOCKS

1.1 General

1.1.1 The basic operation and control related to the Ash handling System will be
independent for the two unit 5 and will be carried out in co-ordination from
different remote panels either in automatic interlocked sequential mode or
remote/local de-interlocked manual mode as explained in the following
paragraphs.

1.1.2 All instruments like vacuum gauges, vacuum switches, vacuum transmitters,
pressure indictors, pressure switches, pressure transmitters, level control
instruments, level indicators, level switches with alarm contacts, level
transmitters, level control valves, flow indicators etc. as indicated in the
specification and enclosed single line flow diagrams to facilitate effective control
of the system shall be furnished by the bidder. Any other instruments not
categorically shown in the flow diagrams or mentioned in this specification but
considered necessary by the purchaser for the safe and satisfactory operation of
the system shall also be furnished by the bidder.

1.1.3 All air/electric valves will be operated/ controlled from respective remote control
panel. Local operation shall also be possible through manual override to be
provided on locally mounted airline equipment (solenoid valves) for the
actuators.

1.1.4 The operating procedures described here under are tentative for bid purpose
only. However, the offered electrical and control systems shall cater to actual
working conditions and procedural requirements to be decided during detail
engineering.

1.1.5 Operation locations: It is primarily envisaged to operate complete ash handling
system through CRT key board and other desk operations. How ever, provisions
shall also be made to operate and control from MCC as well as local equipment/
stations.

1.1.6 The bidder shall take into consideration all I/O signals from field equipment for
proposed integrated operation of total ash handling system from control room.
The PLC offered shall be adequately sized including expandability if required
during detail engineering.

1.1.7 Necessary interfaces for interoperability with the existing Stage-I and Stage-II
ash handling system with the proposed ash handling system for Stage-III shall
be included in the scope of work.



1.2 Control/Operation Philosophy of Ash Handling System

Technical Details and Philosophy of PLC

1.2.1 The Control & Instrumentation shall be through microprocessor based with
redundant processor Programmable Logic Controller (PLC) system covering the
total functional requirements of sequence control, interlock & protection,
monitoring, alarm, data logging, fault analysis etc.

1.2.2 The design of the control system and related equipment shall adhere to the
principle of fail safe operation at all system levels i.e., loss of signal, loss of
power or failure of any component should not cause a hazardous condition and
at the same time prevent occurrence of false trips and provide reliable and
efficient operation of the plant under dynamic conditions and attainment of
maximum station availability.

1.2.3 The system will mainly include but not be limited to the following:

a) 32-bit processor with 64 MB RAM in hot standby mode. It shall not be loaded
more than 60%.

b) The loop cycle time from input signal to output signal including logic
processing shall be less than 100 m sec. The switchover from main controller
to redundant controller shall be bump less.

c) Input cards up to 16 channels can be non-redundant, but for more than 16
channels, redundancy should be provided.

d) Output cards up to 8 channels can be non-redundant, but for more than 8
channels, redundancy should be provided.

e) On-Line testing facility including self-diagnosis up to I/O level and
programming facility.

f) The operating station shall comprise of two TFT 21size, high resolution
1280 x 1024 pixels, keyboards, mouse and printer. Display update time shall
be 1 to 2 sec. One of the operating station shall be configured as engineering
station cum operator station.

g) Laser printer (one A3 size and one A4 size) shall be provided. Failure of the
printer shall be indicated on the monitor.

h) All field instruments like gauges, switches, transmitters etc. along with
erection hardware and cables on as required basis, with suitable tags.

i) A suitable sized 2x100% UPS with output of 220 V AC, 1 phase, 50 Hz shall
be provided. The UPS shall be in redundant mode with two sets of battery
banks & back-up time of 60 minutes. An emergency bypass with a static
switch shall be provided. On failure of UPS, the supply shall changeover to
emergency through static switch.

j) Desk cum Control panel for mounting following items:


- TFT / kbd, mouse, PC, printer
- Hardwired PBs for back up operation
- Indicating lamps
- Annunciation
- Semi-graphic display of the respective plant system
- Hard wired annunciation system drives for PLC
- Annunciation windows on control desk/ panel in the control room
in addition to the soft annunciation on HMI system.

1.3 Design Considerations

1.3.1 The design of the safety interlocking system is based on the following basic
principles and is intended to shut down the ash handling plant and/or disconnect
the ash handling equipment from the electric power supply under certain
abnormal operating conditions.

1.3.2 To trip the minimum equipment in the sequence during abnormal operating
conditions leaving all the other equipment running which may safely be permitted
to continue operation.

a) To annunciate and indicate initiating cause for equipment which is tripped.

b) To prevent restarting of equipment until safe conditions are restored.

c) To retain as much flexibility of operation as is consistent with safety.

d) To operate from rugged, reliable initiating elements independent of normal
control or alarm devices.

e) To prevent mal-operation of equipment on interruptions and restoration of
control voltage.

f) To eliminate the necessity for any normal bypassing of an interlock to permit
starting and stopping of equipment.

g) To emphasize eliminating false trips by providing component reliability.

1.4 Operation Philosophy

1.4.1 A microprocessor based programmable logic control (PLC) system with
TFT/Keyboard interface shall be provided for the safe operation, control and
monitoring of the Wet Fly Ash Handling System from the Control room. These
operator/ engineering stations shall be used during start-up and commissioning.
Bidder shall furnish PLC system with OPC connectivity or equivalent links to be
provided from the PLC for data communication to main control room in the TG
building for monitoring.

1.4.2 Fly ash shall be removed from various hoppers through vacuum and conveyed
to collector tank tower for conveying wet ash to ash slurry sump. Suitable
interlocks with the existing system shall be provided by the bidder.

In auto mode of operation, selection of hopper shall be based on vacuum mode.



1.4.3 All the HT drives (wet and dry fly ash system) bearing temperature
measurements shall be directly connected to proposed wet fly ash PLC
system I/O cards.

1.5 PLC Based Control System

1.5.1 The microprocessor based PLC shall be configured with Hot redundant
processor, dual redundant communication bus, power supply units and
communication ports. In the event of failure of operating processor, the control
shall be transferred to standby processor automatically. The system shall
provide for sequencing of automatic start up/shutdown, bringing standby
equipment into operation on failure of main equipment, and manual intervention
facility for all the equipment. Provision for online replacement of defective
modules like processors, PSU, I/O cards should be possible.

1.5.2 The PLC shall be provided with two (2), 21 colour TFT Monitor/keyboard for
operation. One of the PC/CRT shall be configured as engineering cum operating
station. The system shall be provided with peripherals like medium speed
printer, CD read/write drive unit etc.

1.5.3 Complete licensed software for PLC based system including the communication
software system shall be supplied and implemented to meet completely the
specification requirements. Application software shall be built based on approved
logic diagram, graphics, etc.

1.5.4 The system shall be provided with the following, as required

- System cabinets
- Input/Output/Conditioning Cards
- Power Supply Cards (Redundant)
- Processor Cards (Redundant)
- Communication Cards (Redundant)

Any other associated hardware to make the system complete.

The PLC shall have extensive self-diagnostic features to monitor completely the
software and hardware faults in the system. Hardware diagnostics up to card/
component level shall be provided.

1.5.5 The vendor shall conduct integrated test at manufacturers works to Purchasers
satisfaction and inspection, checking and pre-commissioning tests at site to meet
completely the specification requirements.

1.5.6 The system shall include the following features for efficient operation from TFT.

i) Individual overview, plant group displays, plant control displays, unfulfilled
criteria display.
ii) Plant schematics (mimic diagrams), bar graph display. This shall include
mimic display of the entire ash handling system including the electrical
systems.
iii) Alarm displays
iv) Trend plots and X-Y plots


v) Logs and reports. An exclusive log shall be provided for evacuation time for
each of 65 hoppers in each evacuation cycle and the memory shall be 72
hours.

1.5.7 OPC connectivity or equivalent links to be provided from the PLC for data
communication to main control room in the TG building for monitoring and
control.

1.5.8 CRT based annunciation shall be provided to annunciate abnormal operating
conditions of the offered plant. The annunciation shall also be provided to
annunciate status of electrical power requirement.

1.5.9 The necessary modifications in the logics and hardware required in the existing
dry fly ash system are in the scope of bidder. The bidder shall visit the site and
understand the existing PLC system before quoting. The necessary interface
required from the existing dry fly Ash handling PLC system shall be in the scope
of bidder. Bidirectional communication link between the existing dry fly ash
handling system and the proposed dry fly ash handling system shall be provided.

1.5.10 Location of Proposed PLC System (wet Fly ash system) control room shall be
indicated and it shall be preferably in the existing PLC control room (Dry Fly ash
System).

1.5.11 The existing fly ash PLC system is GE fanuc system. For better co-oridnation,
control and effective utilization of the existing data with the proposed wet fly ash
system, it is proposed to have the PLC system which is compatible to the
existing system i.e, GE-fanuc PLC system.

1.5.12 The processors/ Controllers and IO cards of GE fanuc PLC system for the
proposed wet fly ash PLC system shall be PACs(Programmable Automation
Controllers) RX3I series, and the communication between the existing and the
proposed wet fly ash PLC system shall be Ethernet communication.

1.6 The power supply used for control shall be derived from two independent 415 V,
feeders, so that trip of one of the feeders does not affect the functioning of the
control and monitoring system. Stand alone redundant UPS (2 x 100%) with
sixty (60) minutes battery backup shall be provided for PLC, TFT, peripherals,
etc. All required power supplies shall be derived and distributed by the bidder.

1.7 Not Used.

1.8 Local Instruments

1.8.1 In order to ensure safe operation of the equipment covered in this system, the
following minimum protective features and safety interlocks shall be provided.

1.8.2 Protective Interlock arrangement for Water Pumps:

It shall be possible to keep any Water Pump as standby. Selected standby Water
Pump shall be arranged to start automatically when any one of the working Water
pump trips or Water Line Header Pressure falls below pre-set value. These pumps
operation shall also be linked with normal and low level of the water tank, as
applicable and if the tank level falls below preset danger low level, then all water


pumps should trip and pumps should start if the water tank level is at or above
preset operating level.

1.8.3 Level Detection Equipment for Ash slurry sumps and Drain sump:

The bidder shall furnish the following equipment for detection of Level in sumps:

1.8.3.1 High Level & Low Level Alarms

Necessary Sump level switches shall be furnished for providing annunciations in
Control Panels. Switch assembly of the above level switches shall be located
outside water space.

1.8.3.2 Very Low Level Switches for Tripping of Pumps

Low level switches shall be provided for tripping of slurry pumps, and Drain Pumps
for extreme low level (danger level) of sumps. Switch assembly of these Level
Switches shall be located outside water space.

1.8.3.3 Safe Operation Level Switches for providing Starting Permissive to Pump:

Sump Level switches, set at a level which will permit safe and trouble free
operation of the pumps shall be provided in respective sumps.

1.8.4 Protective Interlock arrangement for Ash Disposal Pumps

It shall not be possible to start Ash Disposal Pumps unless the following conditions
are satisfied:

a) Pre-set Gland Seal Water Pressure is available.

b) Up stream Pumps can be started only if the Down Stream Pump of this
stage is running (Applicable to series pumping).

c) Suction Valve is Open.

d) Respective Ash Slurry Sump level is at or above the preset safe
operating level.

e) Starting of Disposal Pumps shall be with Suction valve open and
Discharge valve in close condition.

Ash Disposal Pumps shall trip in the event of following emergency conditions :

a) Gland Seal Water Pressure falls below a preset value (for any stage of
pumping).

b) Respective Ash Slurry Sump level falls at or below preset dangerously
(low) level.

c) Pump Suction Valve is not full Open.



d) Discharge Valve is not in Full Open position after preset time of starting
first Ash Disposal Pump in Series.

e) If any pump in series is tripped then the other running pumps in
series should trip.

Discharge Valve of Ash Disposal Pumps shall close as soon as associated Ash
Disposal Pump has tripped. Discharge Valve will open only after running of Ash
Disposal Pump after a preset time.

1.8.5 Slurry Sump Make-up Water Valve

The bidder shall supply adequate size valves for installation in the Make-up Water
Line to Ash Slurry Sump. These valves shall be complete with device for
operation from Remote Control Panel located in MCC room as well as Local
Control Stations.

1.8.6 Drain Pump Controls

There are two (2) Nos. Drain Pumps. Both of them can be started either manually
or automatically from Central Control Panel and only manually from Local Control
Station.

Remote Automatic Operation shall be achieved by selection of either Automatic -
Main or Automatic - Standby duty. Generally one pump shall be selected for
Remote Automatic-Main Operation and the other Pump for Remote
Automatic-Standby Operation.

There shall be two (2) additional Level Switches in the Sump. One of which shall
initiate Automatic-Main Operation and the other Automatic-Standby Operation. In
case of rising level of Sump, the Pump Selected for Automatic-Main Operation
shall start first and continue to operate. This Pump shall automatically stop when
Sump Level falls bellow pre-set LOW LEVEL.

In case Sump Level continues to rise further and reaches Automatic-Standby
Operation level, the Pump Selected for Automatic-Standby Operation shall start
operating irrespective of the condition whether the Pump Selected for
Automatic-Main Operation has started or not. This Pump shall stop automatically
when Sump Level falls below preset LOW LEVEL. This Pump (Remote
Automatic-Standby Selected Pump) shall also start automatically immediately after
tripping of Remote Automatic-Main Selected Pump even when Sump Level has
not risen to start Remote Automatic- Standby Operation.

1.9 Pressure Gauge/Indicator

Air/water lines shall be provided with Local Pressure Gauge as well as Control
Panel Mounted Pressure Indicator so that no water connections should come on
the panels.

1.10 Other Instruments

Pressure indicators, pressure switches pressure transmitters, flow indicators,
slurry sump level indicators, level switches, temperature indicators, temperature


switches, temperature transmitters, vacuum gauges, vacuum switches, vacuum
transmitters, limit switches etc as required for safe and satisfactory operation of
the plant shall be provided subject to Purchaser's/Consultant's approval.

1.11 Control panels with mimic diagram, local control stations etc shall be
manufactured as per specification for control panels.

1.12 Cables

All instrumentation and control (I&C) cables related to the entire plant are under
bidders scope. Preparation of Interconnection schedule for all the I&C cables is
included in bidders scope.

1.13 General

1.13.1 Degree of protection for all field instruments, limit switches, solenoids, panels,
local panels, junction boxes shall be as follows: IP54 for indoor and IPW 55 for
outdoor areas and IP 65 for dusty areas..

1.13.2 All junction boxes, power supply distribution boards, marshalling cabinets,
instrument erection materials, interposing relays, accessories and process hook-
up hardware shall be supplied.

1.13.3 Individual pair shielded and overall shield twisted pair copper cables shall be
used for analog signals and overall shielded cable shall be used for digital
signals. Individual and overall screened triplex shall be used for RTDs. All the
cables shall be armoured. The wire size shall be 0.5 mm
2
and the colour coding
shall be as per IEC. The insulation including overall sheath shall be FRLS
quality.

1.13.4 The makes, model and technical features of all major instruments, PLC etc.
supplied by Contractor shall be subject to Owners approval.

1.13.5 Local push button station with de-interlock switches shall be provided for all
equipment to enable maintenance of the equipment.

1.13.6 Any other control and instrumentation equipment not specifically mentioned but
required for the successful operation of the plant and system shall be supplied
as required.

1.13.7 Technical features of all instrumentation and control equipment included in
bidders scope are subject to purchasers approval.

1.14 Impulse pipes / tubes & fittings

Impulse pipes, fittings and air supply and signal piping / tubing shall be supplied
for all the instruments under the scope of this specification.

1.15 Selection of Ranges for Instruments

The ranges of the instruments shall be selected based on the following
philosophy:



a) For all pressure measurements, the maximum operating pressure will be
within 70% to 80% of the maximum scale range.

b) For pressure switches set points shall fall within 40% to 70% of the scale
range selected.

1.16 Training of Purchasers Personnel

The contractor, as a part of contract shall train Purchasers engineers, regarding
the PLC based system. These engineers shall be given special training in
design, office & shop, regarding design, operation, testing, installation and
maintenance to enable the engineers to become fully familiar with the system
supplied.

Additional performance test points for testing purpose shall be provided by the
bidder on the offered equipment and pipe work as necessary.

1.17 Instruments for Performance Testing

Additional instruments (if any, other than installed for the system) required for
performance testing to prove the guaranteed performance of the instrumentation
and control equipment as specified shall be loaned to Purchaser by the bidder,
at no extra cost, for the duration of the performance test. These test instruments
shall have test certificates from reputed test house, valid for the duration of the
performance test.

2.0 CONTROL PANEL

2.1 General

2.1.1 Control panels shall be totally enclosed dust and vermin proof with Enclosure
Protection Class of IP-54 as per IS: 2147. These shall be made of at least 10
SWG cold rolled, cold annealed sheet steel, reinforced to provide rigid flat level
surfaces, resistant to vibration during transportation and installation. Non Load
Bearing doors or removal covers may be 14 SWG sheets. No welds, rivet hinges
or bolt threads shall be apparent from outside. All panels/cabinets meant for
installation of outdoor location shall be provided with canopy. All door hinges shall
be concealed type.

2.1.2 Equipment and relays mounted on the panels shall be easily accessible for
repair and replacement without disturbing other equipment and connected
wiring. All Special tools and tackles required for repair and replacement shall be
supplied without any extra cost and at least 10 mm clear space shall be provided
all around each equipment.

2.1.3 The Panels shall be supplied completely wired up to terminal blocks for connecting
external cables entering the panels/cabinets/desk from the bottom unless
otherwise approved. Blank removable plate shall be provided with cable
glands/conduits knockout along with the Panel.

2.1.4 Separate terminal blocks of 650V grade with twenty (20) percent spare terminals
with a minimum of 10 Nos. shall be provided for controls and metering circuits.


Terminals for control and metering shall be tinned stranded suitable for termination
on each side two (2) nos. of 2.5 mm
2
copper conductors.

2.1.5 For control, panel wiring 2.5 mm
2
tinned stranded copper 650V grade, PVC
insulated wire shall be used.

2.1.6 All wiring shall be properly supported and laced and shall run in channels. Both
ends of wiring shall have numbered ferrules for proper identification.

2.1.7 Relays, Timers and other devices mounted on or inside the Panels shall have
identification marking beside the device clearly visible on opening the door.
Devices mounted on the front of Panels shall also be labelled on from the inside of
the panel. HRC fuses provided for protection of various circuits shall be
accessible for replacement. Fuse bases shall be provided with circuit labels,
rated fuse current and voltage.

2.1.8 All fuses shall be HRC link & removable type of at least 45 KA rupturing capacity.
Similarly all control circuit neutral link shall be removable plug in type.

2.1.9 Control panels shall be designed with a flat bearing surface for mounting on 14
mm thick, approved shock absorbing material which shall be supplied along with
the Panel. Cabinets shall be suitable for mounting on wall or structure.

2.1.10 Control panels shall be provided with one (1) 50x6 mm tinned copper earthing
strip running throughout the length of the Board at the Bottom. One (1) earthing
terminal with accessories shall be provided at each end for connecting GI earthing
strip.

2.1.11 Panels interior shall be provided with sufficient Space Heaters with Isolating SPN
MCB, and Thermostats. Fluorescent Illuminating Lights, complete with Door
Switches; 3 pin 10 Amps Sockets with SPN MCB for maintenance minimum two
(2) Nos. shall be provided.

2.2 Mimic Diagram

The Control Panel shall be provided with Coloured Mimic with lamps wherever
asked for along with lamps and switches, push buttons; indicating lamps,
annunciators, indicating instruments, interlock/de-interlock switches etc required
for the complete system.

The indicating lamps should be designed so that proper brightness is maintained
at the panel though switching operations takes place at the farthest location.

2.3 Annunciation System

This specification is applicable in all cases except where a separate annunciation
system is specified for the subject plant/auxiliary plant.

2.3.1 The annunciation system shall consist of panel mounted audiovisual windows.

2.3.2 Each window shall be nominally 36 mm high by 75 mm wide and shall be provided
with two white lamps wired in parallel and capable of replacement from the front.
The life expectancy of each lamp shall be a minimum of 7000 hours of operation.


2.3.3 Each window or group of windows shall be provided with solid state logic which
shall plug in directly behind the window/group of windows.

2.3.4 Initiating contacts may be either NO or NC. A jumper or switch shall be provided
in each card to make it suitable for either type of contact.

2.3.5 One set of acknowledge, reset and test push buttons shall be provided for each
panel. These shall be mounted separately on the panel at convenient height.

2.3.6 All printed circuit boards shall be of epoxy fibre glass construction. Plug in
contacts shall be gold plated.

2.3.7 The sequence of annunciation shall be as follows:

Condition Visual Audible

Normal OFF OFF
Alarm Flashing ON
Acknowledge Steady OFF

Return to normal

a) Before acknowledge Flashing ON
b) After acknowledge Steady OFF
Reset:
a) Alarm condition No change No change
b) Return to normal OFF OFF
Note: Pitch and volume of audible tone shall be adjustable.

2.3.8 The annunciation system shall operate satisfactorily in the temperature range 0 to
50
0
C and 95% humidity. Suitable environmental resistant coating shall be
provided for all printed circuit boards to ensure satisfactory operation in tropical
climate and corrosive atmospheres.

2.3.9 The annunciation system shall operate on 220V, 50 Hz supply. One no. window
operating on 220V DC along with Flasher/ Buzzer/ Accept/ Reset/ Test push
button shall be provided to annunciate Annunciator Supply Fail Alarm.

2.3.10 The annunciation system shall include all electrical equipment required to supply
power continuously to the systems, relays & other accessories required for
duplication of any annunciation point for annunciation of supply failure condition.

2.3.11 The number and distribution of annunciation points shall be in accordance with the
specification of the subject plant.

2.3.12 The system, shall be tested for continuous operation for a minimum of one
hundred(100) hours in an ambient temperature of 50
0
C


2.3.13 Minimum ten (10) per cent spare windows shall be provided.

2.4 Local Control Station

2.4.1 Local Control Station shall be provided for repair, testing and maintenance of all
Motor operated/Solenoid Operated feeders. Stop Push Buttons shall be lockable
in Off/Pressed position. Local Control Station shall be housed in Cast Alloy or Cast
Iron corrosion proof enclosure having degree of protection IP-55.

These shall be suitable for mounting on Wall/Column/Structure. All Local Control
stations for outdoor location shall be provided with canopy. Local Control stations
shall have concealed hinges.

2.4.2 In case Local Control Station is fabricated from sheet steel, it shall be CRCA
Grade and at least 14 SWG thick.

2.5 Indicating Instruments

Standards IS: 1248.

2.6 Push Buttons

Green : For Motor-START; Breaker-CLOSE; Valve OPEN commands

Red : For Motor-STOP; Breaker-Open; Valve CLOSE commands

Yellow : Intervention to suppress abnormal circumstances or cancel
unwanted working cycle.

Blue : Any function not covered by the above colour i.e. Green; Red &
yellow & for clinker grinder reverse.

Black : For Annunciator function Test; Overload Relay Reset; Single phase
Preventor Relay-Reset and miscellaneous commands including
clinker grinder reverse.

All push buttons on panel shall be located in such a way that 'RED' Push button
shall always be to the right of 'GREEN' Push Button.

2.7 Indicating Lights

Red : For Motor-ON; Valve - Open; Breaker close

Green : For Motor-OFF; Valve - Close; Breaker-Open

White : Motor-Auto Trip; Trip Relay-Healthy

Blue : For all healthy conditions (e.g. control supply; lube oil pressure;
and also breaker spring charged) & for grinder motor reverse.

Amber : For all alarm conditions (e.g. pressure-low; overload) and also for
Service and Test position indications and overload operated.


2.8 Type of Painting & Finish

All surfaces to be painted including interior and exterior of panels, mechanisms
and enclosures and other metal parts shall be shot or sand blasted or chemically
treated to remove all rust, scale, grease and other adhering foreign matters. Steel,
surface, exposed to weather shall be given two (2) coats of zinc chromate and two
(2) coats of approved colour or epoxy based paint of accepted manufacturer. If
not specified or approved otherwise later, colour of finishing paint shall be opaline
green shade no. 275 as per IS:5 with semi glossy finish for exterior portion and
brilliant white finish for interior portion and as well as equipment mounting plate.

2.9 Name Plate

Each panel shall be provided with Main Name Plate both on Front as well as on
Rear of the panel. Each vertical panel or relay panel shall be provided with panel
number both on front and rear in addition to main name plate. Panels shall be
serially numbered.

Each equipment/device shall be given specific device number and this shall be
clearly painted beside the equipment/device so that it can be seen without any
hindrance.

All name plate located on the external side of the panel shall be of engraved
anodized aluminium material.

2.10 Data Sheet for Control Panels

2.10.1 Location : MCC Room

2.10.2 Construction : Totally enclosed, IP-54 Degree of protection complete with
anti-vibration mounting pad.

2.10.3 Steel Metal : Cold rolled Cold Annealed sheet- steel conforming to IS.

2.10.4 Thickness of : 10 SWG for load bearing members and 14 SWG for
Sheet Metal Doors and covers only with no cut out or equipment
mounted on it.

2.10.5 Shape : Desk type Control Panel

2.10.6 Colour of : Outside semi glossy opaline green Shade No. 275 as per
Panel IS: 5 and Inside/Equipment Mounting Plate: brilliant White
Paint shall be used.

2.10.7 Type : Mimic Type Control Panel - one piece Coloured Mimic shall
be provided for complete Ash Handling System

: Complete system shall be provided on Vertical Front
surface of panel. All the required PLC system, relays,
transformers etc shall be provided inside the panel and
shall be approachable easily.



: Operating equipment/devices shall be located within a
distance of 850 mm and 1800 mm from operating floor
level. Indicating Instrument/ devices and Annunciation facia
shall be located at eye level from operating floor but not
more than 2050 mm from operating floor.

2.11 Mimic Diagram

2.11.1 Location : One piece Mimic diagram for complete system indicating
Wet Fly Ash Handling System for Unit # 1 shall be
screened on vertical surface of the Panel. Mimic shall have
ON/OFF Indicating Lamps for all motors. OPEN/CLOSE
indicating lamps for all Motor Operated/Solenoid Operated
valves.

2.11.2 Material of mimic : Mimic shall be made of 10 mm thick Acrylic Sheet of
Mimic approved fast colour material which can be easily
cleaned.

Layout of various equipments on Mimic shall be subject to
Purchaser/ Consultant's approval.

Mimic shall be engraved on the INSIDE SURFACE and painted after engraving.

Colour : All colours on Mimic for the representation of various
equipments shall be subject to Purchaser approval.

2.11.3 Equipment to be provided:

Various Control : Approved by purchaser/consultant
Switches, selector for all drives
Switches

Auxiliary Relay : As required

Various Start/Stop, : As required & approved by
Forward/Reverse, push Purchaser/Consultant
buttons indicating lamps etc

2.12 List of Minimum Annunciations for Control Panel

1. HP Water pump : Tripped (separately for each pump)

2. HP Water pump discharge : Low
header pressure

3. HP Water to Wetting Head : Low
pressure

4. Seal water pump : Tripped (separately for each pump)

5. Seal Water Pump Suction : Low
pressure


6. Seal water pump discharge : Low
header pressure

7. Ash Slurry pump : Tripped (separately for each pump)

8. Drain Sump : High

9. Drain Sump : Low

10. Wet/FA system : In operation

10. Following Electrical Annunciations to be incorporated on the panel:

a) For each HT Motor : Motor tripped on electrical fault
(contact shall be provided
from 3.3 kV switchgear)

b) 3.3 kV Incomer No.1 to : Tripped
3.3 kV switchgear

c) 3.3 kV Incomer No.2 to : Tripped
3.3 kV Switchgear

d) Tie breaker of 3.3 kV : Tripped
Switchgear

e) Under voltage on 3.3 kV : -
Bus A

f) Under voltage on 3.3 kV : -
Bus B

g) Auto change over initiated between 3.3 KV Bus A & Bus B.

h) Ground fault on Bus A/Bus B.

i) Healthiness of UPS and power supplies

j) 3.3/0.433 KV AHP Transformer : Tripped (for each transformer)

k) Auto change over initiated between 415 V Bus A & Bus B.

l) 415 V Incomer : Tripped (For each Incomer)

At least ten percent (10%) spare annunciation windows with minimum fifteen (15)
numbers shall be provided for annunciation.

2.14 Indicating Lamps

2.14.1 Drive ON/OFF/Open/Close : As required and approved by Owner/
indication Consulting Engineer



2.14.2 Drive Trip Indication : As required for all the feeders and approved
by Owner/Consulting Engineer. This lamp
shall be mounted along with RED/GREEN
LAMP above RED/GREEN PUSH
BUTTONS or CONTROL SWITCH.

2.15 Terminal Blocks

2.15.1 Type : Clip-on type

2.15.2 Size : 10 mm
2

2.15.3 Quantity : As required including termination of all spare
contacts of each and every Push Button;
Control Switch; Selector Switch, Contactor,
Timer etc. + 20% spare with a minimum of
ten (10) nos.

2.16 Panel shall be provided with suitable 415/240 V dry type control transformer. The
rating of transformer shall be as required plus at least twenty (20) percent margin.

2.17 Audible Alarm for Fault : Electronic hooters of 96 mm x 96 mm
Annunciator (Semi flush mounting type) of
different sound as per requirement.

2.18 Separate Mounting Channel : To be provided if required. This shall be sent
to site while construction of floor and within
15 days of approval of Control Panel GA
drawing.

2.19 Anti vibration mounting pad : To be provided

2.20 Termination Accessories : Each terminal shall be provided with Tinned
Copper Lugs & necessary numbers of
Chrome Plated Double Compression Brass
Cable Glands.

2.21 Insulating Material : All insulating material e.g. separation sheet
support shall be of GRP/FRP. No Hylam/
SRBP material shall be used.

2.22 Local Control Stations/Push Button Stations

2.22.1 Location : To be furnished by bidder

2.22.2 Supply : 415V AC/240V AC/110V AC/ 220V DC; As
per Scheme Requirement.

2.22.3 Construction : Totally enclosed, IP-55 deg. of protection
for Indoor and IP-55 weather poof protection
Wall/Column mounting type, hinged front
door.



2.22.4 Material : Cast iron/cast aluminium alloy suitable for
corrosive atmosphere

2.22.5 Size : As required. Minimum 150 mm clear space
shall be provided between cable gland plate
and Terminal block.

2.22.6 De-interlock/OFF/Interlock : One (1) on each Local Control Selector
Switches Station/Push Button Station

2.22.7 Terminal blocks : As required plus ten (10) percent spare with
a minimum of four (4) Nos. All spare
contacts of Push Buttons, Selector Switch
shall be wired up to terminals.

2.22.8 Wiring : 2.5 M
2
stranded tinned copper flexible
conductor PVC insulated wires.

2.22.9 Colour : Outside: Semi-glossy Light grey: Shade No.
631 as per IS-5

Inside/Equipment Mounting : Glossy White
Plate

2.22.10 Accessories : Epoxy based paint shall be used. Each
terminal shall be provided with tinned copper
lugs and necessary numbers of chrome
plated doubled compression brass cable
glands.

Notes:

1. Colour of various lamps shall be decided during detailed engineering
other than start/stop and tripped indication lamps which shall be Red,
Green, Amber.

2. Colour of various push buttons shall be decided during detailed
engineering except start/stop Push Buttons which shall be Green and
Red respectively.

3.0 3.3 kV SWITCHBOARD

3.1 Technical Specification

3.3 kV switchgears with vacuum breakers shall be as follows:.

3.2 Technical Particulars

3.2.1 Rated Current 1250 A

3.2.2 Short Circuit Current 40.0 KA

3.2.3 Main bus bar 1250 A


3.2.4 Type of circuit breaker Vacuum Breaker

3.2.5 Rated Voltage 3.3 KV

3.2.6 Maximum Permissible voltage 3.65 KV voltage corresponding
to rated current.

3.2.7 Voltage for spring charging motor 220 V DC

3.2.8 Voltage for closing & trip coils 220 V DC

3.3 Technical Details

3.3.1 The type of switchgear shall be metal enclosed, vertical single front, draw out type
suitable for indoor installation, Triple pole single/double break high speed
Vacuum circuit breaker.

3.3.2 The trolley shall have three distinct positions i.e. service, test and isolated with the
provision for locking. The panel shall have door interlock such that door cannot be
opened unless the Circuit breaker is switched OFF. Suitable limit switches shall be
included for the above safety.

3.3.3 Each Incomer with line PTs and 0.5 Class energy meters, Outgoing feeder panel
shall have adequate cabling space to terminate 3.3 KV cables as specified
elsewhere.

3.3.4 3.3 KV S/G shall be provided with O/C & E/F protection for transformer feeder &
sequence instantaneous O/C, negative sequence O/C, locked rotor & E/F relay
protection (composite multi-function) motor protection relay.

3.3.5 3.3 KV S/G shall be provided with VCB. Switchgear shall be provided with 2 Nos
Bus PT Panels one on each section. Facility for live transfer of load shall be
provided. During the planned outage, the breaker to be brought in closed and the
breaker to be taken out will be tripped out through a trip selector switch. In the last
closed event of selected breaker fails to trip, the breaker shall be tripped after a
time delay. During the normal running conditions, shall any of the incomers to AHS
tripped due to tripping or failure of station switchgear supply, the bus coupler
breaker shall be automatically closed after ensuring bus no voltage. This auto
changeover however be inhibited in the event of AHS incomer tripping on fault.

3.3.6 One (1) current transducer and one (1) voltage transducer for each incomer and
three (3) nos, voltage transducers for each bus shall be provided for remote
metering.

3.3.7 DC supply will be 220 V DC.

4.0 CONSTRUCTIONAL DETAILS

4.1 Panel

4.1.1 Panel shall be totally enclosed dust and vermin proof with IP 54 degree of
protection as per IS: 3427. The Switchgear housing shall be fabricated from cold


rolled sheet steel and shall be rigid self supporting free from mechanical
vibration & heating. It shall be made out of at east 2.00 mm sheet steel, suitably
reinforced to provide flat level surfaces, resistant to vibration and rigid during
transportation and installation. Doors or removable covers may be of 2.00/1.6
mm sheet. No welds, rivets, hinges or bolt shall be apparent from outside. Vent
openings shall be provided with inaccessible grills. Each panel shall have
stationary and removable sections. Circuit breaker, switch isolator, voltage
transformers, movable self aligning spring controlled main disconnect contacts,
and two (2) sliding silver plated copper contacts for earthing switchgear truck
through earthing rails in housing shall form the removable section. Rest of the
components shall form the stationary section.

4.1.2 Panel shall have separate compartments for circuit breaker, bus bars, current
transformers, voltage transformers, relays/instruments, terminal blocks and cable
end boxes. All the breaker panels of switchboard shall be of uniform depth.
Relays, meters and control equipment shall be mounted on the front portion of
the panels. No component shall be mounted on rear of relay chamber.

4.1.3 Compartments with doors/covers for access to equipment mounted in the panel
shall be so arranged as not to expose any high voltage part or circuit to
operation/maintenance crew. Assembly shall be such that components are
easily accessible for inspection and maintenance. Circuit breaker compartment
shall have front hinged door with lock and key. The front door shall be designed
so as to allow the breaker to be withdrawn up to test and isolated position
without opening the front door. It shall be possible to charge the breaker without
opening the front door. It shall be possible to close the door when circuit breaker
trolley is in isolated position inside the panel. Dummy panels, if any needed, to
clear switchgear room floor beams shall be supplied at unit rates to be quoted
along with the bid.

4.1.4 Fixed main disconnect contacts in panel housing shall be provided with
automatic safety shutters to cover the high voltage circuit with padlocking
arrangement. Shutter operating mechanism shall be interlocked with-drawable
truck to prevent incorrect operation.

4.1.5 Panel shall have following interlocks :

.1 Circuit Breaker truck cannot be withdrawn or inserted when breaker is
closed

.2 Circuit Breaker can be operated only in service, test, isolated and
withdrawn position of circuit breaker truck

.3 Tie breaker and associated switch isolator/dis-connector shall be
provided with key or electro magnetic interlock to prevent operation of
switch isolator/dis-connector when circuit breaker is in service position

4.1.6 Each circuit breaker shall have three positions: Service, test and withdrawn. It
shall have provision for locking the breakers in any of these positions. These
three positions shall be available for each bus bar system. PTs shall be mounted
on breaker trolleys wherever asked. Auxiliary switches for breaker positions shall
be furnished and shall be so connected as to permit circuit breaker operation:



.1 In test position from local control switch only but testing of all auxiliary
and control should be possible

.2 In service position from remote and local control switch

.3 Breaker can be tripped from any position.

.4 Auto Changeover Scheme for 3.3 KV Switchboard (2 Incomers V/S Bus
Coupler)

4.1.7 The current transformers shall be mounted on the stationary part of the cubicle.

4.1.8 All circuit breakers of same rating shall be interchangeable in all respects.

4.1.9 Arc Quenching Device and Contacts

4.1.10 Main contacts shall be generously sized for low contact pressure and to carry
rated current and short time rated current so that there is no excessive
temperature rise which may cause pitting or welding after repeated usage.

4.1.11 Main as well as arcing contacts shall be easily renewable and adjustable to allow
for wear. The whole contact surface of arcing and main contacts shall either be
silver plated or made of tungsten alloy. Arc quenching device shall not require
any critical adjustment and shall be easily removable for access to circuit
breaker contacts. It shall satisfactorily interrupt low value, low power factor,
inductive and capacitate currents at rated voltages.

4.1.12 Multi break interrupters, where used, shall be arranged so as to ensure fairly
uniform voltage distribution across them.

4.2 Gasketed Joints

All the joints shall be made of dust proof by using gaskets. All gasketed joints
shall remain perfectly air/oil/water tight. Gasket shall have appropriately located
mechanical stops to prevent crushing and be so placed that they shall not be
exposed to weather. Damaged gasket shall not find way into equipment.

4.2.1 Bushings and Insulators

4.2.1.1 The supporting insulators used in the panel should withstand the short circuit
forces and shall not support combustion. The supporting insulators/bushings
shall be of Epoxy resin cast/porcelain. Porcelain used in bushings and insulators
shall be homogenous, free from laminations, cavities or any other flaw which
may effect its mechanical and dielectric qualities and shall be thoroughly vitrified,
tough and impervious to moisture. The creepage distance shall be 300mm.

4.2.1.2 Glazing of porcelain shall be of uniform brown colour, free from blisters, burns
etc.

4.2.1.3 Bushings and terminal fittings shall carry full rated current continuously and the
temperature rise of any component shall not exceed the specified values.



4.2.2 Fittings and safety shutters

Circuit breaker shall have mechanical ON-OFF indicators, automatic closing
shutters to prevent accidental contact with fixed contacts, auxiliary contacts, control
fuses, operation counter, space heaters and any other items required for safe and
efficient operation.

4.2.3 Temperature rise of bus bars & connections

Temperature rise of bus bars & connections when carrying normal rated current
at rated frequency shall not exceed 45
0
C over an ambient of 45
0
C.

4.2.4 Bus bar Ratings

Each board shall have air insulated with Electrolytic copper sleeved bus bars
designed with current density not exceeding 1.25 A/mm
2
. Phase barriers between
the bus bars shall be provided. The Bus bar shall be designed considering entire
loads including spare modules/breakers.

4.2.5 Control Bus Bars

Adequately rated, high conductivity and electrolytic copper bus bars of minimum
8 mm dia for specified DC & AC control supplies and motor space heating supply
shall run throughout the length of switchgear. Control supply for each panel
shall be tapped-off from these buses through double pole load breaking
switches. All control, breaker spring charging motor and alarm circuits shall be
protected with HRC fuses of rupturing capacity not less than the value specified
in terms of K for fault level in the system concerned.

4.2.6 Inter panel Wiring

Inter panel wiring between the panels of each switchgears is to be provided by
the Contractor as required and as per schemes finally approved during
engineering. However, the connections between different switchgears/other
panels shall be done through cables.

4.2.7 Ground Bus and Connection

Adequately rated copper ground bus of cross-section not less than 50x6 mm
shall run throughout the length of switchgear. Panels, circuit breakers, relays,
instruments and all equipment shall be connected to ground bus for complete
safety.

At each end of ground bus, one (1) earthing terminal with non ferrous bolt, nuts,
washers suitable for the purchaser's grounding conductor shall be provided.

4.2.8 Power Terminals

Power terminals shall be brought out near the bottom of panel for connecting the
power cables of sizes as finally selected, entering from the Bottom. A provision
of non-ferrous gland plate at the bottom of the panel is to be provided.
Adequate space shall be provided for cablng



Cable termination kits (heat shrinkable/cold shrinkable type for connecting power
cable shall be supplied. Each panel shall have adequate cabling space and
channel supports for clamping of cables.

4.2.9 Wiring and Terminal Blocks

4.2.9.1 Panels shall be supplied completely wired upto terminal blocks for connecting
external cables entering panels from the bottom. All interconnecting cables to be
used in panel should be stranded copper of minimum 2.5 mm
2
cross sectional
(except CT Connection which shall be of min 4.0 mm
2
cross section). Terminal
blocks shall be complete and provided with necessary terminal accessories for
cable ends. Blank removable plate shall be provided with cable glands at the
bottom of the panel.

4.2.9.2 Separate 1100 V grade terminal blocks with twenty (20) percent spare terminals
shall be provided for 240V AC, 220V DC control, interlocks, metering and
protection instrumentation, Current transformers and voltage transformers, PLC
circuits. Terminals for control interlock and metering shall be suitable for two (2),
2.5 mm
2
copper conductors and those for protection circuits shall be suitable for
four (4), 2.5 mm
2
copper conductors.

4.2.9.3 All the terminal strips shall be located within the panel at the front at a suitable
height for ease of termination, duly segregated for termination of CT and PT wires,
external interface wiring of plant PLC and external interlocks. HT fuses shall be
placed within the panel providing adequate clearances for maintenance.

4.2.9.4 Disconnecting type terminals with shorting facility will be used for CT circuits.

4.2.9.5 All internal wiring shall also be numbered with suitable ferrules. Engraved core
identification plastic ferrules marked to correspond with panel wiring diagram and
shall be fitted at both ends of each wire. Number 6 and 9 shall not be used for
wire identification.

4.2.9.6 Wiring shall be properly supported and shielded to prevent any sagging or
damage in transit and/or in operation.

4.2.9.7 Hinged doors or panels shall be provided for access to all internal wiring.

4.2.9.8 Disconnecting devices shall be provided for connecting control circuit between
panel unit and breaker draw out truck. Disconnecting device shall get engaged
in "Service" position of breaker. On trolley withdrawal, it shall get disengaged
and re-engaged in "test" position. On further moving out, it shall again get
disengaged. However, it shall be possible to connect control circuit with test
jumpers. Alternately bidder may provide suitable plug and socket arrangement
with adequate number of pins between fixed position of the cubicle and circuit
breaker carriage along with proper interlocks.

4.2.9.9 For 220V DC control supply bus bars running in Switchgear, (2) entries through
adequately rated double-pole switch fuse unit shall be provided in each
switchgear for the cables entering in different panels. Similar arrangement shall
also be provided for 240 V AC auxiliary supply.



4.2.10 Instrumentation

Instruments along with associated CTs and VTs as specified shall be supplied,
mounted and wired on switchgears.

4.2.11 Auxiliary Contacts

In addition to the circuit breaker auxiliary contacts provided on breaker trolley for
circuit breaker operation, a mechanically operated switch shall be provided on
stationary part of switchgear. This switch shall be positively operated by the
breaker mechanism when the breaker is in service position. Switch shall provide
at least six (6) normally open (NO) and six (6) normally closed (NC) potential
free contacts rated for 10A, 240V AC and 2; 220 V DC auxiliary contacts for
each circuit breaker for interlocking. Provision of additional contacts also be met
by providing contact multiplication relays. However Aux. Contactors shall not be
used for this purpose.

4.2.12 Operating Mechanism

4.2.12.1 Breaker shall be trip free and provided with anti-pumping device.

4.2.12.2 Each circuit breaker shall be power operated by stored energy spring
mechanism for both closing and opening operations.

4.2.12.3 Spring mechanism complete with opening spring, closing spring and other
accessories shall operate the circuit breaker normally by the circuit breaker
local/remote control switches. Once charged, the springs, shall be capable of at
least one (1) B-M-B operation of the circuit breaker. Accidental failure of any
spring shall not trip or close the breaker, charging shall be automatic by a
Universal motor which shall keep spring fully charged at all times. Maximum
charging time of fully discharged spring shall not exceed thirty (30) seconds. If
spring charging takes place either after a closing operation or after tripping
operation, it shall not take more than ten (10) seconds.

4.2.13 Closing Mechanism

4.2.13.1 Circuit breaker shall be motor operated (220 V DC), spring charged electrically
released (coil voltage 220V DC) stored energy type, true trip free closing
mechanism.

4.2.13.2 The coils shall be designed to operate over range of 85% to 110% of rated
voltages.

4.2.14 Tripping Mechanism

4.2.14.1 Circuit breaker shall be provided with 220 V DC shunt trip coil. The trip coil
should operate satisfactory at all voltages between 70 to 110% of rated voltage.

4.2.14.2 Circuit breaker shall close, upon closing a contact in its closing circuit
momentarily. A second closing impulse shall have no effect on closing
mechanism.



4.2.14.3 Manually operated lever or push buttons shall be provided to 'Trip circuit breaker
mechanically. However, access to this shall be possible only after opening panel
door. Means shall also be provided to slowly open and close circuit breaker for
maintenance.

4.2.14.4 The circuit breaker shall not close through control switch of the switchgear in
case of failure of DC supply.

4.2.15 Panel Illumination

Each panel shall be provided with one (1) 240V, 20 Watt guarded fluorescent
lamp fixture with tube with door limit switch in an accessible place inside the
panel.

4.2.16 Equipment for Drive Motor Space Heaters

HT motors controlled by the switchgear will have space heaters suitable for 240V
single phase AC supply. These shall be 'put-on' automatically when motor is
idle. Circuits shall be provided in Switchgear panels and terminals brought out
for the cable. Terminals and accessories shall be suitable for two (2) core,
6.0 sq. mm copper conductor PVC insulated armoured and PVC sheathed
heavy duty 1100V grade cables.

4.2.17 Panel Space Heater

Adequate panel heaters of approximately 200 W capacity with ON/OFF switch at
appropriate location of the panel shall be provided with suitable thermostat for
temperature control.

4.2.18 Control and space heater supply

4.2.18.1 The switchgear shall receive two (2) DC feeders for the control supply and
distribute to each panel. Each panel shall receive power supply through copper bus
and shall be tapped off through switch fuse/MCB provided in the respective panel.
It shall be possible to isolate any panel without disturbing the power supply to other
panels. Each sub circuit shall have separate MCB/fuse. Potential circuits for
protection and metering shall also be protected by separate MCB. All DC circuits
shall have MCB on both poles.

4.2.18.2 An under voltage relay to monitor each of the control supply and auto change
over shall be provided. A contact of the relay shall be wired to the terminal for
external use. A common indication `Control Supply Failed for both the supplies
shall be provided.

4.2.18.3 The Switchgear shall receive two feeders of 415 V/240 V AC supply feeders.
Necessary MCB to receive, isolate and distribute to each panel shall be provided.

4.2.19 Power Cable Termination

Cable termination compartment shall receive XLPE insulated, screened, armoured,
PVC sheathed, single core/three core aluminium conductor power cables(s).
Adequate interphase clearance and phase to phase clearance shall be provided to
accommodate termination kits of specified cable sizes. Cable termination


compartment shall be complete with power terminals and associated hardware
and removable undrilled gland plates. For all single core cables gland plates shall
be of non-magnetic material.

4.2.20 Nameplates and Labels

All panels shall also be identified on front as well as backside by larger engraved
nameplates giving the distinct feeder description along with panel numbers. All
enclosure mounted equipment shall be provided with individual engraved name
plate & labels for clear equipment identification Nameplates shall be of non-rusting
metal or 3-ply lamicoid with white engraved lettering on black background.

4.2.21 Foundation Channel

Special foundation channel/bolts for mounting shall form part of the
supply.

5.0 DRY TYPE TRANSFORMER

5.01 Design Criteria

5.01.1 The transformer will be installed in hot, humid and tropical atmosphere. All
equipment accessories and wiring shall be provided with tropical finish to prevent
fungus growth.

5.01.2 The transformer shall be capable of continuous operation at specified rating
under the following conditions:

a) Voltage variation - 10%

b) Frequency variation - 5%

c) Combined voltage and frequency variation - 10%
(absolute sum)

5.01.3 The transformer shall be capable of withstanding the short circuit stresses due to
a terminal-fault on any one winding with full voltage maintained on the other
winding for minimum period of three (3) seconds. Necessary calculations
confirming thermal ability shall be submitted with bid.

5.01.4 The dry type transformer shall be completely encapsulated cast resin type,
naturally cooled (AN) non inflammable and moisture proof. Flux density of all
transformers shall not be more than 1.55 Webers/Sq.m at the rated voltage &
frequency. Current density for H.V. and L.V. windings of all transformers should
not exceed 2.5 A/Sq. Mm. The transformer shall be free from annoying hum or
vibration. The design shall be such as not to cause any undesirable interference
with radio or communication circuits.

5.01.5 In addition to the above, MVA rating and impedance of the transformer shall be
chosen such that the largest motor can be started with 80% base load.



5.02 Specific Requirements

Each transformer shall be provided with one set of flat type bi-directional rollers
for rolling the transformer parallel to either centre line. Jacking pads, lifting eyes
and pulling lugs shall be provided to facilitate movement of the transformer. All
heavy removal parts shall be provided with eye bolt for ease of handling.

5.03 Enclosure for Dry Type Transformer

5.03.1 The transformer shall be housed in IP 43 enclosure fabricated from sheet steel
of minimum 2 mm thickness. The screen shall be perforated sheet steel type.
The enclosure shall be adequately reinforced to ensure rigidity so as to permit
transportation of transformer within enclosure.

5.03.2 Double leaf access doors shall be provided with concealed hinge and neoprene
gaskets for easy access to H.V. links and also for withdrawal of core and coil
assembly, if required. Enclosure shall be provided with lifting lugs and grounding
terminals; and the enclosure door shall have provision of pad locking in door
close position.

5.04 Core and Coils

5.04.1 The transformer shall be of either core type or shell type. The core shall be built
up with high grade, non-aging, low loss, high permeability grain oriented cold-
rolled silicon steel laminations especially suitable for core material. The
laminations shall also be free of all burrs and sharp projection.

5.04.2 The coils shall be manufactured from electrolytic copper conductor and fully
insulated for rated voltage. Both HV and LV windings shall be completely
encapsulated.

5.04.3 Insulating material shall be of proven design. Coils shall be so insulated that
impulse and power frequency voltage stresses are minimum and to withstand
even extreme of temperature fluctuations. The insulating material shall be glass
fibre reinforced with epoxy resin conforming to class F. Separate encapsulation
for HV and LV winding shall be provided.

5.04.4 All leads from the windings to the terminal board and bushings shall be rigidly
supported to prevent injury from vibration or short circuit stresses. Guide tube
shall be used where practicable.

5.04.5 The core and coil assembly shall be securely fixed in position so that no shifting
or deformation occurs during movement of transformer or under short circuit
stresses. Core coil assembly shall be provided with locking arrangements, lifting
lugs, and earthing terminals.

5.04.6 The insulating structure for the core to bolts, core to clamp plates and core to
structural steel works shall be such as to withstand voltage of 2 KV A.C for one
minute. No strip conductor wound on edge shall have a width exceeding six-
times its thickness. Winding shall not contain sharp bends which might damage
insulation and produce high di-electric stresses.



5.05 Tapping

Off-circuit taps as specified shall be provided on the high voltage winding. The
transformer shall be capable of operation at its rated KVA on any tap provided
the voltage does not vary by more than +/- 10% of the rated voltage
corresponding to the tap. The winding including the tapping arrangement shall
be designed to maintain electromagnetic balance between HV and LV windings
at all voltage ratios.

5.06 Off-Circuit Tap Changer

The off-circuit tap changing shall be effected by 3-phase by change of links for
dry type transformers. All contacts shall be silver plated and held in position
under strong contact pressure to ensure low contact drop and avoid pitting. The
design of tap changing link shall be such to ensure that same tap is set on all the
three phases at a time.

5.07 Bushing

Bushing shall be resin moulded type of appropriate voltage class.

5.08 Terminal Arrangement

5.08.1 Terminals for L.V connection shall be brought out through side wall mounted
bushings to a detachable adaptor box with disconnect link suitable for bus duct
connection. Adaptor box shall be self-supporting, weatherproof, air filled type
with sufficient space inside for termination and connection of bus duct flexible
links.

5.08.2 A separate L.V Neutral bushing shall be provided on tank for connection to 415
V neutral grounding as detailed below:

The transformer neutrals grounded through resistance shall be brought out
through 1.1. KV bushing suitably protected and equipped with terminal clamps
suitable for connection to 415 V Neutral grounding resistors by ground
conductor. The neutral bushing shall be enclosed in the dust and water tight
enclosure. Necessary cable gland along with removable gland plate suitable for
the cable shall be provided in the Neutral terminal box.

5.09 Marshalling Box

5.09.1 A sheet steel, weatherproof, IP54, marshalling box shall be provided containing
all auxiliary devices such as winding temperature indicators except those must
be located directly on the transformer.

5.09.2 All terminal blocks for Purchasers cable connection shall be located in this box.
The terminal blocks shall be ELMEX 10 sq.mm. or approved equal. The
marshalling box shall be provided with cubicle lamp with door switch, space
heater, with thermostat & switches and removable cable gland plate. For
isolation for incoming supply switch fuse /MCBs shall be provided.



5.10 Wiring

5.10.1 All control alarm and indication devices provided with the transformer shall be
wired up to the terminal blocks.

5.10.2 Wiring shall be done with PVC wires in conduit of PVC. Minimum wire size shall
be 2.5 sq. mm. copper. Not more than two wires shall be connected to a
terminal. 10% spare terminals shall be provided.

5.10.3 All devices and terminal blocks within the marshalling box shall be identified by
symbols corresponding to those used in applicable schematic or wiring diagram.

5.11 Grounding

5.11.1 A ground bus of 50x6 mm G.I. flat shall be run all along the transformer
enclosure. Grounding pad shall have clean buffed surface with two tapped holes,
M10 G.S. bolts and spring washers for connection to 50 x 6 mm G.S. flats.

5.11.2 The core coil assembly shall be directly connected to this ground bus by
removable bolted link for effective grounding. Ground terminals shall also be
provided on cable end box and marshalling box to ensure its effective earthing.

5.12 Additional Requirement

5.12.1 The external steel /surfaces, of transformers after cleaning shall be given a coat
of high quality red oxide or yellow chromate primer followed by filler coats. The
transformer enclosure shall be finished with two coats of Siemens grey RAL
7032 synthetic enamel paint.

5.12.2 In addition to the IS routine tests, following shop tests shall be carried out:

a) Excitation loss and current measurement tests at 90%, 100% and 110%
of the rated voltage.

b) Resistance of each phase of each winding shall be measured at principal
tap as well as 2 extreme taps and corrected to 75 deg. C.

c) Impedance voltage measurement at principal tap; & 2 extreme taps and
corrected to 75 deg. C.

5.12.3 The transformer shall be fully type tested as per IS and special tested in respect
of the following:

a) Impulse withstand test on each limb including chopped wave test as per
clause no.13 of IS:2026 (Part III) 1981.

b) Temperature rise test

c) Dynamic Short circuit test as per IS, clause no.16.11 & 16.11.4.5 of IS
2026.

d) Thermal withstand test for 3 sec. to be followed after dynamic short
circuit test


e) No load loss and excitation current measurement at rated voltage and
frequency both before and after the Impulse test.

f) All routine tests as per IS both before and after short circuit test.

g) Partial discharge test

5.12.4 All component parts and auxiliary equipment such as bushings, CTs etc shall be
routine tested as per relevant Indian Standards. Dimensional general
arrangement drawing showing all parts with fittings, space for withdrawal of core-
coil assembly etc.; Bus duct/cable termination arrangement. Control schematics
& wiring diagrams; Scheme for measurement of maximum winding temperature
through temperature monitoring device.

5.12.5 The transformer shall be equipped with fittings and accessories as listed below :

a) Maximum winding temp. monitoring device with electrically separate sets
of contacts for trip and alarm, along with temperature sensing element
embedded in L.V. winding of all three phases.

b) Jacking pad for core coil assembly

c) IP 54 marshalling box

d) Ground bus

e) Door handle safety limit switch 1NO+1NC contact

f) Inspection Cover for cable end box

g) Handling and lifting lugs for core coil assembly.

h) Flat type bi-directional rollers with locking arrangement for core coil
assembly.

i) Rating and terminal marking plates.

All indication, alarm, trip contacts provided shall be rated for 0.5 A at 220 V D.C.
and 5A at 240 V.A.C.

6.0 415 V SWITCHGEAR

6.1 415V switchgears shall have two equally rated incomers and a bus coupler. Equal
loads shall be connected to each of the bus sections. 415 V switchgear shall be
provided with two no Bus PT panels one on each section. Facility for live transfer
of load shall be provided. During the planned outage, the breaker to be brought in
closed and the breaker to be taken out will be tripped out through a trip selector
switch. In the event of selected breaker fails to trip, the incoming breaker shall be
tripped after a time delay. During the normal running conditions, should any of the
incomers to AHS tripped due to tripping or failure of 3.3 KV AHS switchgear supply,
the bus coupler breaker shall be automatically closed after ensuring bus no
voltage. This auto changeover however be inhibited in the event of incomer tripping


on fault. The 415 V incomer breakers short circuit/over current protection shall be
through external CTs only, the inherent short circuit protection of the incomer
breakers shall be made disable. During normal operation both the incomers would
be in service and the bus coupler would be kept open. The feeders shall be
complete and wired with all the hard wares as per schematics approved during
detail engineering. The selective tripping scheme is meant for the changeover
between incomers.

6.2 Each incoming breaker shall be capable of catering the complete load connected
to the 415V switchgear when panels for additional breaker and associated
equipment have been added in future. The type of MCC shall be draw out type.
Each 415 V section having control transformer of 415/110 V AC for control supply.

6.3 Circuit and components for winding heating of motors up to 37.5 KW by
connecting motor winding to 24V AC supply and for motors above 37.5 KW by
space heaters shall be provided. 24V AC supply for winding heating and 240V
AC supply for space heating should be created inside the switchgear through
415/240V and 415/24V space heater transformers, one on each bus section and
having interconnected through auto changeover facility.

6.4 The switchgear shall have following feeders:

1 Two (2) incomers of adequate rating

2 One (1) bus coupler breaker of equal rating of incomers

3 Required number of outgoing feeders for unidirectional motors.

4 Required number of outgoing feeders for reversible motors and motor
operated valves.

5. Required number of switch fuse unit outgoing feeders for lighting
distribution board, control cabinets. As many feeders as required and of
required ratings should be provided.

6. Bus PT panel for each bus section with necessary voltmeter selector
switch and voltmeter. The bus PT panel shall be of draw out design.

7. 415/240V space heating transformer in each bus section and rating of
the transformer as needed.

8 415V/24V winding heating transformer, rating of the transformer as
needed.

9. Ten (10) percent but at least one (1) spare feeders of each type and size
of outgoing feeder. The quantity is minimum requirement, at the time of
handing over of the system, any additional Qty required for any
increase/changes during detailed engineering stage also shall be
considered.

10. 415 V switchgear air circuit breakers control shall be operated with 220 V
DC.



11. One (1) current transducer and one (1) voltage transducer for each incomer
and three (3) nos, voltage transducers for each bus shall be provided for
remote metering.

12. One (1) alarm module for DC supply alarm.

6.5 Details for various types of feeders are given in subsequent paras. Any other
items needed, other than those specified shall be included.

6.6 Each incomer shall have a fully draw out electrically operated circuit breaker
suitable for local and remote operation. The breaker panel shall be complete and
wired with all the hard wares.

6.7 Bus coupler breaker shall have a fully draw out electrically operated circuit breaker
suitable for local & remote operation. The bus coupler panel shall be complete
and wired with all the hard wares.

6.8 Each feeder for unidirectional motor shall be of fully draw out design. The feeder
shall be complete and wired with all the hard wares. Motors of 100 KW rating and
above shall be provided with air circuit breaker. The panel shall be complete and
wired with all the hard wares.

6.9 Each feeder for reversible motor shall be of fully draw out design. The panel shall
be complete and wired with all the hard wares.

6.10 Each switch fuse unit feeder shall be of draw out design and shall have one (1)
switch fuse unit.

6.11 Each feeder module shall be provided with two nos. interposing relays.

6.12 Circuit breaker

1. Each breaker shall be power operated by stored energy charged spring
mechanism for both closing and opening operations. The mechanism
complete with opening spring, closing spring and other accessories shall
operate the breaker through local/remote control switches. Once
charged, the springs shall be capable of B-M-B operation of the breaker.
Accidental failure of any spring shall not trip or close a breaker.

Charging shall be automatic by a DC motor complete with accessories
and the motor shall keep the springs fully charged at all times. The
maximum charging time of fully exhausted springs shall not exceed fifteen
(15) seconds. Charging motor and closing coil shall operate between
eighty five (85) and hundred ten (110) percent of 220 V DC/ and trip
coil between Fifty (50) and hundred and ten (110) percent of 220V DC.

2. Breaker shall close upon closing a contact in its closing circuit
momentarily. A sustained closing impulse shall have no effect on the
closing mechanism

3. Red lamps, indicating Breaker closed shall be wired to supervise shunt
trip circuit. Green lamps mounted on remote panels indicating


'Breaker-open' shall be wired to light up only when remote/local switch is
on 'Remote' position.

4. Manual operated lever or push buttons shall be provided to close and trip
the breaker mechanically without opening the door. Means shall be
provided for emergency manual operation of electrically operated breaker
without opening the door. Means shall also be provided to slowly open
and close the breaker for maintenance.

6.13 Main Switches

1. Main switches shall be air break type three (3) pole group operated
units for three phase AC supplies and two (2) pole units for single phase
AC and DC power and control supplies.

2. The switches shall be capable of making, carrying and breaking safely
and without any deterioration the rated full load and motor starting currents
of the associated circuit. The switches shall be capable of withstanding
thermal stresses caused by overloads, locked rotor and short circuit
currents of values associated with protective relay settings. The switches
shall also be capable of withstanding the mechanical stresses caused by
the peak short circuit current of value equal to the cut off current of the
associated fuse. Switches contacts shall be of silver alloy or silver plated
and contact springs shall be of stainless steel. The switches shall be
capable of withstanding the let through fault current of the back up fuses.
Switch handles shall have provision for locking in both fully closed and
fully open position. The switches shall be tested for making and breaking
capacity for AC - 23 duty application as per IS - 4064 (Part-1) 1978.

3. All main switches shall be operable from outside the cubicle by an
operating handle. The operating handle of the switch shall be fully
insulated from circuit and earthed to ensure safe operation. Whenever
solid links are used for the connections between switches and fuses such
links shall be fitted with insulated sleeves. All live parts of the switch shall
be shrouded. 'ON' and 'OFF' position shall be engraved clearly. An
interlock shall be provided between the cubicle door and the switch such
that

- Cubicle door cannot be opened when the switch is closed

- The switch cannot be closed when the cubicle door is open. It
shall be possible to defeat both the interlocks. Switch design shall
be such that all components needing maintenance, viz., contacts
etc shall be approachable by loosening/opening minimum number
of fixing screws.

6.14 Fuses

1. All fuses shall be of high rupturing capacity (HRC) cartridge plug-in type
conforming to IS: 2208.

2. The fuses shall be mounted on the front of the base plate in vertical plane
and provided with visible indicator to show that they have operated.


Fused indicator of fuse link shall be visible after opening compartment
door by defeating door interlock without need to switch off the feeder.
They shall be held under spring pressure. It shall be possible to remove
the fuses using an insulated fuse pulling handle.

3. Fuse ratings shall be so chosen that they do not operate during motor
starting. They shall also not operate before the associated motor thermal
overload relay for 1.1 times the motor rated current.

4. Fuse ratings chosen by bidder for application in various circuits shall be
subject to Purchaser's approval.

6.15 AC Contactors

1. Motor starter contactors shall be direct on line, air break, single throw
electro magnetic type.

2. The main contacts of the contactor shall be silver faced. The quantity of
silver facing shall be such that after carrying out one tenth of the total
number of operations specified for the mechanical duty test there is still a
continuous layer of silver on the contacts.

3. Each main contactor shall be fitted with at least 2 NO and 2 NC auxiliary
contacts of adequate rating for control, indication and alarm requirements.

4. Contactors shall not dropout when a fault occurs on an adjacent feeder.

5. For all motor feeders, auxiliary contactor shall be provided as indicated in
the enclosed drawing.

6. The contacts of the auxiliary contactors and the auxiliary contacts of
main contactor shall be rated for making, carrying and breaking 10A,
110V AC and 0.5A, 220V DC (inductive circuit). All spare contacts shall
be independently wired to the terminal block for external connections.

6.16 Over Load Relays

1. The overload relays for all motor and valve feeders shall be three (3)
elements positive acting, ambient temperature compensated, time
lag thermal bimetallic type with adjustable settings. This shall be hand
reset, and reset push buttons shall be flush with front door of the
module and be suitable for resetting with the door closed.

2. Relays shall be either direct connected or CT operated depending on the
motor rating. In the latter case, the required CTs shall be provided by the
Bidder.

6.17 Current Transformers

1. Technical details of the current transformers shall be as given in
Technical Particulars.



2. Current transformers shall be arranged such as to withstand open circuit
secondary with primary under rated load for a short duration to be stated in
the bid.

3. CTs shall have polarity markings indelibly marked on each transformer at
the lead terminations and at the associated terminal block. Facility shall be
provided for short circuiting and grounding the CT secondary at the
terminal blocks.

4. C.T shall have a short time withstand rating equal to the short time
withstand rating of the associated switchgear for one (1) second.

5. Test links shall be provided in both secondary leads of the CT is to
facilitate current and phase angle measurement tests.

6. All CT secondaries shall be earthed through a separate earth link on the
terminal block to permit easy measurement of the C.T insulation
resistance (CT's built in with the thermal relays of the contactors are
excluded)

7. All CT secondary leads should be wired upto shorting type terminal
blocks. The neutral point of the CTs should be formed only on these
terminal blocks.

6.18 Voltage Transformers

1. Technical details of the voltage transformers shall be as given in
Technical Particulars.

2. Current limiting HRC fuses shall be provided on the primary and
secondary sides of the VT. Facility for visual indication of rupturing of
the fuses shall be provided. It shall be possible to replace a fuse safely
without having to de-energise the main bus bars.

3. It should be possible to replace V.T.'s without having to de-energize the
main bus bars.

6.19 Relays

1. Technical details of the relays shall be as given in Technical Particulars.

2. Numerical relays shall be supplied.

3. Rated continuous, short time thermal and dynamic currents for coils shall
be suitable for service involved.

4. Rated continuous, making and breaking currents for contacts shall be
suitable for service involved.

5. Relay shall provide reliable, sensitive and selective circuit and equipment
protection at all times while maintaining supply to healthy circuits. False
tripping shall not take place.



6. Relays shall be rectangular in shape with dust tight covers.

7. Relays shall be equipped with externally reset, positive action operation
indicator.

8. No control relay tripping a circuit breaker on being de-energised shall be
used in control schemes.

9. Access to setting devices shall be possible only after the front covers are
removed. Access to resetting devices shall be external to the case.

10. Each relay shall be provided with at least two (2) separate voltage free
contacts.

6.20 Auxiliary Relays

Auxiliary relays shall be designed for operation at 220V DC/110V AC and shall
operate satisfactorily between seventy (70) percent and hundred and ten (110)
percent of the rated voltage.

6.21 Single Phasing Preventor Relays

1. All three (3) phase motor circuits, rated above 37.5 KW shall be provided
with single phasing preventor relays as a positive protection against single
phasing. The relays shall be of current operated type. The relays shall
operate on sense of negative sequence current principle. It shall detect
single phasing conditions for all motor loads including no-load, and shall
operate before the motor is damaged. It shall withstand without damage
all let-through currents of the associated motor fuses and overload relay,
and shall not operate for current unbalance of less than ten (10) percent.

2. The relay shall be suitable for use in specified ambient temperature
(outside the panels).

3. After sensing a single phasing, the relay shall operate with a time delay of
at least two (2) to three (3) seconds. It shall be hand reset type with hand
reset push button.

4. The relay shall be suitable for both reversible as well as unidirectional
motors. The relay operation shall be fail safe type and shall operate to
trip the motor when the relay internal wiring is accidentally open circuited.

5. The relay shall not operate for current unbalance of up to 10% and its
operation shall be independent of motor speed and the load conditions
prior to the occurrence of the single phasing.

6. Visual indication for the operation of the relay shall be provided and on
resetting this indication shall go off.

7. The relay shall be fitted with one (1) NO and One (1) NC, independently
wired contacts, each rated to make, break and carry 10A at 110V AC.



8. Above 100 KW and up to 160 KW motor feeder, it shall be provided with
motor protection relay having locked rotor feature.

9. For motors below 37.5 kW, the thermal relays shall have in built single
phase preventing feature.

6.22 Indicating Instruments

1. Indicating instruments shall be square shape, flush mounting type. Make
shall be AE. Preferred size 96x96 mm
2
.

2. Indicating instruments shall have provision for zero adjustment outside
the cover

3. AC instruments shall be suitable for connection to 1A CTs and 110V
VTs and series resistors wherever necessary.

4. Ammeters provided on the motor circuits shall be provided with a
suppressed extended scale to indicate motor starting current.

6.23 Space/Winding Heating Transformer

Each switchgear/MCC shall be provided with adequate rated 415/240 V and
415/24V single phase transformers for space as well as winding heating etc; one
each on each bus section of the switchgear

6.24 Local Control Cabinets for Exhaust Fans

Local control cabinets for group control of exhaust fans shall include the following:

a) Incoming switch fuse units

b) Starters and overload relays

c) Push buttons and indicating lamps

d) Complete wiring of the starters.

Not more than four exhaust fans shall be controlled from each cabinet. The
cabinet shall be metal clad fabricated from 2mm thick cold rolled sheet steel and
painted similar to the LT switchgear. It shall be a wall mounted type and mounted
at convenient location for easy operation and maintenance. The cabinet shall be
dust tight, water tight and vermin proof.

6.25 Constructional Details

6.25.1 Panel

1. Switchgear shall be of metal enclosed, sheet steel cubicle indoor,
floor mounting, free standing type. Cubicles shall be totally enclosed,
dust and vermin proof with IP-54 degree of protection as per IS: 2147.
These shall be made out of at least 2.0 mm thick cold rolled sheet steel,
suitably reinforced to provide rigid flat level surfaces, resistant to


vibration during transportation and installation. Non load bearing
members shall be at least 1.6 mm thick. No welds rivets, hinges or bolt
threads shall be apparent from outside.

2. Switchgear shall be assembly of a series of floor mounting, identical
cubicle type panels placed side by side. They shall be capable of being
easily extended at site on either side. The panels shall be fully
compartmentalized, with separate totally metal enclosed compartment for
every module, in their formation. Hinged covers for easy inspection and
maintenance of equipment in each cubicle shall be provided. Separate
chamber shall be provided in each panel to house bus bars.

3. Panels supporting framework shall be sturdy fabricated using suitable
mild steel structural sections or pressed and shaped cold rolled sheets
steel of, thickness not less than 2.5 mm and suitable base channels
shall be provided complete with anchor bolts, nuts and levelling
attachments. Maximum operating height shall preferably be limited to 2.0
metres. All opening for incoming and outgoing cables shall be at the
bottom only. Necessary blank plates with cable glands shall be
provided individually for each feeder. Name plates shall be provided
individually for each feeder and for complete switchgear and shall consist
of black perspex with white engraving to approval.

6.25.2 Circuit Breakers

1. Breakers shall be mounted on cradles which shall be designed and
constructed to permit smooth withdrawal and insertion of the breaker into
the compartment. The movement shall be free of jerks, easy to operate
and shall be on steel rails/rollers and not on the flat surfaces.

2. The circuit breaker shall have following distinct and separate positions on
the cradle viz.:

a. Service, in which all power and control circuits are connected

b. Test, in which the power circuits are disconnected while the control
circuits remain live.

c. Isolated maintenance, in which both the power and control circuits
are disconnected and circuit breaker is fully outside the cubicle
preferably on self supporting telescopic rails which are integral with
the draw out mechanism.

3. The first two (2) positions shall be positively achieved through the
turning/racking motion of the draw out mechanism and not by trial and
error. There shall be a positive mechanical indication clearly showing the
above first two (2) positions and visible from the front without opening the
front door. It shall be possible to close the cubicle door when the breaker
is in either of the first two positions.

4. The third position may be achieved by manually drawing out the circuit
breaker beyond the 'test' position, complete access shall be available in


this position for removal of arc chutes, arcing contacts and other routine
maintenance on the breaker which shall be recommended by the Bidder.

5. The breaker shall be provided with lock in isolated position and door
interlocking to ensure that the door can only be opened when the
breaker is in off position. However interlock defeat shall also be provided
for examination by competent personnel. It shall not be possible to plug in
a closed breaker or to draw out a circuit breaker in closed position.

6. Air circuit breaker, employing magnetic blow-out or dry type for arc
extinction shall consist of three (3) identical single pole units linked
together electrically. Insulating barriers shall be provided to segregate
interrupting units from each other so as to isolate phases and each phase
to earth. Interrupters shall have an integral assembly consisting of arc
chute with arc runners and blow out.

7. Components of operating mechanism shall be of corrosion resisting
material. Bearings which require grease shall be equipped with pressure
type grease fittings, bearing pins, bolts, nuts and other parts shall be
adequately fixed or locked to prevent loosening or changing adjustments
with repeated operations.

6.25.3 Arc Quenching Device and Contacts

1. Main contacts shall be generously sized for low contact pressure and to
carry rated current and short time rated current so that there is no
excessive temperature rise which may cause pitting or welding after
repeated usage.

2. Main as well as arcing contacts shall be easily renewable and adjustable
to allow for wear. The whole contact surface of the arcing and main
contacts shall either be silver plated (25 microns thick) or made of tungsten
alloy.

3. Arc quenching device shall not require any critical adjustment and shall
be easily removable for access to breaker contacts. It shall satisfactorily
interrupt low value, low power factor, inductive and capacitive currents at
rated voltages.

4. Multi-break interrupters, where used, shall be arranged so as to ensure
fairly uniform voltage distribution across them.

6.25.4 Module

1. Approved quality and make equipment/components like switches, fuses,
contactors, overload relays, control transformer, control fuses, voltage
transformer, ammeters, voltmeters terminals blocks, etc. needed for
complete circuit of each module shall be provided.

2. Built-in interlock between switchgear components and main switches
shall be provided.



3. All modules shall be withdrawable type and the minimum size of module
shall not be less than 1/8th of the height of panel.

4. For the draw out modules the phase connections to bus bars shall be
plug in type. These contacts shall be self-aligning, spring loaded, silver
plated copper-to silver plated copper and of robust design. All outgoing
power wiring connections shall be plug in type. Removable multi plug
disconnect contacts shall be provided for outgoing control wiring
connections. The cable connection to the fixed end of removable plug shall
be soldered. The plug shall be manually operable with locking device.

5. Inter phase projected insulation barrier shall be provided in the power
contact in draw out module.

6. The Bidder shall elaborate draw out design offered by him clarifying
the number of screws to be loosened/opened after the switch fuse units
have been made off, and features for correct alignment and reliable
contact.

7. It shall be ensured that the with drawl and insertion of modules is always in
switch off mode.

8. The trolley shall have distinct 'Service', 'Test' and isolated position.

9. Each module shall have the independent earthing facility such that it
makes before the main contacts close and breaks after the main contacts
open.

10. No meters, indicating lamps, start/stop push buttons and springs of
breaker/switch shall be mounted on the hinged door covering the starter
compartment and these shall from a part of the Chassis. Suitable
glass covers shall be provided on the hinged covers for the indicating
lamps, meters etc.

11. The Coils of all contactors, their moving and fixed contacts should be
replaceable from the front.

12. Each section of the switch gear shall be provided with an independent
control transformer of adequate rating to derive control supply. Control
supply through common control transformer shall be acceptable with
changeover facility.

13. Identical module shall be interchangeable. For the identical module,
the door related components shall also match in all respects for
ensuring total inter changeability.

6.25.5 Wiring

1. All needed internal wiring shall be properly dressed and supported
over cable ways of adequate width. All equipment shall be completely
shop wired and be ready for external connections at site. PVC insulated
flexible aluminium wires for power circuits and 650/1100V grade PVC
insulated flexible copper wires of minimum 2.5 sq. mm. size for


control, metering, CT and PT wiring circuits shall be used with
identification ferrules at each end. Colour code shall be used for CT/PT
circuit wiring.

2. The panels shall be supplied completely wired up to terminal blocks
for connecting external cables entering the panels from the bottom.
Terminal blocks shall be complete and provided with necessary terminal
accessories for cable ends.

6.25.6 Terminal Block

1. Separate terminal blocks of 1100 V grade with twenty (20) percent spare
terminals shall be provided for 415V, 240V, 110V AC, 220V DC Control,
metering, protection, CTS and VTs circuits. Terminals for control,
metering, protection and VTs shall be suitable for connecting two (2) 2.5
sq. mm copper conductors on each side. CTs and VTs terminals shall
have disconnecting, connecting and earthing facilities for the purpose of
testing.

2. The power and control terminal shall be separated by a barrier in order to
avoid accidental touch of power terminal while working on control
terminal. Terminals shall be suitably labelled for identification.

3. All terminals for secondary wiring shall be with stud and shall be of hard
brass and not less than 6 mm diameter. The stud shall be securely
locked within the mounting base to prevent turning. Substantial
insulation shall be provided between adjacent terminals. The
spacing clearance between terminal blocks when put in parallel shall
not be less than 100 mm and last terminal shall not be less than 220 mm
away for the associated cable gland plates.

4. Terminal blocks shall be sturdy and made of good quality moulded
phenolic resin or other suitable synthetic insulating materials.
These shall be suitable for connecting the crimped lugs to avoid loose
connections. Terminal shall be designed to avoid bimetallic corrosion.
Change or making of site connections for external wiring should be
possible without disturbing the internal wiring. The bakelite should be
heat resistant.

6.25.7 Bus bar

1. The bus bars shall be of high conductivity aluminium conforming to
IS:5082, liberally sized for the specified current ratings (both short
circuits and continuous currents). Maximum temperature of the bus
bar and bus bar connections when carrying rated normal current shall
not exceed 85 deg. C.

2. Bus bars shall be of uniform section throughout the length of the
switchgear and up to the incoming circuit breaker/switches.

3. Bus bar shall be adequately supported and braced to withstand the
stresses due to short circuit currents. All the bus bar supports shall be
made of glass reinforced thermo setting plastic having anti tracking


design. Bus bar including vertical droppers shall be encased in heat
shrunk PVC sleeves which shall be snug fit not capable of being
removed without destruction. The sleeving shall safely withstand
operating temperature of bus bars during normal service. Main bus bar
joint shall be provided with removable thermosetting plastic shrouds.

4. Separate support shall be provided for each phase of the bus bars. If
a common support is provided for all three phase, anti tracking barrier
shall be incorporated.

5. The bus bars shall be housed in totally enclosed bus bar chambers
completely shrouded from the feeder units and cable chambers. The
incoming connections from the bus bars to various feeders shall be so
designed as not to disturb the cabling connection, to ensure safety of
operating and maintenance personnel and facilitate work on the
outgoing side of a particular unit there being no necessity to switch of
the adjacent feeders of the incoming units as far as possible.

6. The bus bar shall be designed for the entire loads connected including
spare modules/feeders.

6.25.8 Earth Bus

A flat copper earth bus of suitable size and capacity shall be provided running
along the entire length of each switch board. At each end of ground bus one (1)
earthing terminal for connection to the station earthing grid shall be provided. The
earthing termination shall be identified by means of the sign ( ) marked in legible
and indelible manner on or adjacent to the terminal.

6.25.9 Cable Alley

A cable alley preferably 250 mm wide shall be provided in each vertical section
for taking cables into the compartments.

6.25.10 Space/Winding Heating

1. Adequately rated, high conductivity and electrolytic copper bus bars for
240/24V space/winding heating supply shall run throughout the length
of switchgear. Tap off from these buses to each panel shall be through
double pole load breaking switch.

2. Switchgear and motor control centres shall be provided with sufficient
number of a space heaters with isolating switch, fuse and thermostat.
These shall be provided with at least one (1) three (3) pin, 240V AC
sockets with switch for every four (4) panels or one (1) shipping section
for connecting to hand lamp for maintenance purpose.

3. The provision of space heater shall also be made in the dummy panels if
required.



6.26 415V BUS DUCT

The LT or secondary side of the transformers shall be connected to the two (2)
incoming panels by adequately rated, segregated phase bus duct.

7.0 CABLING

7.1 Power, Control and Instrumentation Cables shall meet with the following
specification in general and also relevant clauses of Indian Standards/IEC etc.
The bidder shall clearly identify their compliance with the following specifications
in the offer. All items used in cabling work such as cable trays, cable covers,
cable bends, rigid steel conduits, conduit fittings etc shall be clearly identified in
the bid including their sizes. All these items shall be subject to the approval of
the Purchaser. In addition to the Instrumentation cables specified below, if the
bidder wishes to use some other types of Instrumentation cable, the
specifications for such cables have to be approved by the Purchaser.

7.2 3.3 kV HT Cables

HV system (3.3 kV system) cables shall be unearthed grade suitable for use in
medium resistance earthed system, with stranded &compacted aluminium
conductors, extruded semi-conducting compound screen, extruded XLPE
insulated, extruded semi-conducting compound with a layer of non-magnetic
metallic tape for insulation screen, extruded PVC (Type ST-2) inner sheath,
aluminium/galvanized steel round wire armoured extruded PVC (type ST-2)
FRLS outer sheathed, single/ multicored confirming to IS 7098(Part-II) IEC-
60502 for constructional details and tests.

7.3 LT Power Cables

LV Power Cable shall be 1100 V grade, single/multicore, stranded aluminium
conductor, XLPE insulated, with PVC inner sheath and outer sheath made of
FRLS PVC compound. The armouring shall be of Aluminium / galvansied steel
round wire. The cable used for DC system shall be of single core type. All other
details shall be as applicable. Minimum conductor cross section of power cables
shall be 4 Sq.mm.

7.4 Control Cables

Control cables shall be 1100 V grade, multicore, minimum 2.5 sq.mm cross
section, stranded copper conductor, PVC insulated, inner PVC sheathed /
galvanized steel wire armoured and outer sheath made of FRLS PVC compound.
In situations where accuracy of measurement or voltage drop in control circuit,
warrant, higher cross sections as required shall be used. 4 Sq.mm copper
conductor cables shall be used for CT circuits all other specifications remaining
same.

7. 5 Instrumentation Cables

Instrumentation cables shall be with stranded high conductivity annealed, tinned
copper, twisted pair (with min. 20 twists for meter) extruded PVC insulated with
overall and / or individual screening, extruded PVC inner sheathed, extruded


outer sheathed with FRLS PVC compound. The conductor size shall be minimum
0.5 sq.mm.

Triplex cables similar to instrumentation cables can be used for RTDs.

7.6 Lighting Wires

1100 V grade, single core, stranded, copper conductor, PVC insulated wires
conforming to IS-694-1990 / IEC-60227 part 1 to 5 (1979) / IEEE-719 (1981).
Minimum cross section of copper wires shall be 2.5 sq.mm for lighting circuits
and 4 sq.mm for receptacle circuits.

7.7 The factory tests to be conducted:

i. Type tests to IS:1554 Part-I and IS:9968 Part-I as the case may be.

ii. Acceptance tests in respect of each lot of cable to IS:1554 Part-I and
IS:9968 Part-I as the case may be.

iii. Routine tests in respect of each length of cable as per IS:1554 Part-I and
IS:9968 Part-I as the case may be.

iv. Flammability tests on finished cable: The cable should pass the
requirement of IEEC 383, IEC 332-I and SS 4241475.

v. Smoke generation by sheath under fire: When tested as per ASTM-D-
2943/77 the cable shall meet the requirement of light transmittance of
minimum 40% after the test. In case of Instrumentation cable, the value
shall be minimum 80%.

vi. Oxygen Index test: The oxygen index when tested as per ASTM-D-
2863/77 shall be minimum 30 at ambient temperature. The oxygen index
value at 250
o
C should be minimum 21.

vii. Acid gas generation test: When tested as per IEC-754-I, the maximum
acid gas generation shall be 20 percent by weight. In case of
Instrumentation cables, the value shall be maximum 2 percent by weight.

viii. The factory tests to be conducted: The Outer sheath of FRLS PVC
compound Cables shall pass ultraviolet tests as per DIN 53387.

ix. Any other tests as required by the Purchaser.

7.8 Compression type cable lugs shall be used for terminating the cables at
equipment. The lugs shall be of sufficient size and have ample contact surface
after drilling the fixing holes, to carry the rated current continuously without
increase in temperature beyond that determined by the conduction of the cable.

7.9 The straight through joints on cables shall not be done except where those are
unavoidable and with the prior approval of the Purchaser to an approved design.
For terminating the cables, control panels desks and equipment etc, suitable
cable glands shall be used so as to grip the cable securely and sufficiently to
prevent ingress of water, condensation, vermin, insects etc into them.


7.10 The cable glands shall not damage or deform in any way the insulation of the
cores. To limit compression, glands shall be provided with seals.

7.11 Each cable, whether power or multi core control shall be identified by the label or
tag of an approved type, bearing a cable reference number indicated in the cable
and conduit list, prepared by the contractor, at both ends of the cables adjacent
to the terminations and also where cables enter and leave ducts. Cable route
markers shall be provided at every 15 M intervals and at bends. Also Joint
markers shall be provided at each joint.

7.12 Bidder shall prepare a Cable and Conduit list showing length, size and routing
of each cable and conduit laid by the bidder and shall submit it for the Engineers
approval. Cable and conduit laying shall be done strictly in accordance with this
list.

7.13 Power and control cables shall be laid above ground in most cases; unless
otherwise absolutely needed when these may be routed in trenches. All cables
shall be laid on cable trays fixed to angle iron supports which shall be suitably
treated against acid fumes etc. Cable trenches shall only be provided below
MCC & control panel as specified.

7.14 Ducts shall be provided by the contractor wherever the trench crosses roads.
Ducts shall be capable of withstanding the load of 8 tonnes truck passing over
the roads. Iron supports shall be treated/ painted with anti-corrosion
(methods/paints).

7.15 All civil works, viz., ducts, excavation, foundations, trenches, riddling of soil
cable ducts under roads associated with cabling work shall be done by the
contractor within the limits.

7.16 The contractor shall supply and install all surface mounted, embedded, rigid and
flexible conduits and associated clamps, bushings, lock nuts, caps and flexible
conduit connections required in the cabling work.

7.17 All conduits and accessories upto sizes 50 NB shall be made of galvanized
heavy gauge steel with conduit threads as per ISS; and for sizes 50 NB & above
shall be of GI pipe with threads as per ISS. However, the internal bore of all
pipes shall be smooth and suitable for pulling cables without damages. All
conduits and accessories shall be galvanized.

7.18 The contractor shall also supply all fittings, required to make the conduit
installation complete including but not be limited to inspection and/or ordinary
tees and elbows, check nuts, male and female reducers and enlargers, wooden
plugs, caps, pull boxes, junction boxes, conduit outlets, outlet boxes, splice
boxes, all supporting steel work and necessary grounding arrangements.

7.19 The scope of the bidder shall also include all supporting steel work and all other
miscellaneous materials required to make a complete conduit installation.

7.20 Junction boxes, conduit boxes and conduits shall be shop pre-fabricated of
malleable iron or steel plates with galvanized finish and shall have galvanized


malleable iron or steel plates covers with rubber gaskets. These shall be
corrosion resistant.

7.21 The bidder shall supply and install cable raceways, cable trays and accessories,
supporting brackets, hangers and all other miscellaneous materials required to
make a complete cable tray installation.

7.22 Cable vertical raceways and trays shall be completely installed before any
cables are laid in raceways or trays.

7.23 The bidder shall also supply and install all needed fasteners for vertical cable
raceway installation.

7.24 The bidder shall supply and install all angles, straps, hangers, clamps, clips,
nuts, bolts and other anchorage material for installation of cable trays and
raceways.

7.25 Cable trays shall be of 2.5 mm thick sheet steel. Cable trays and raceways shall
be galvanized and all supporting steel shall be primed with red lead and oil
primer followed by finish coats of anti-corrosive paints.

7.26 Cables shall be tested at works and at site after installation as per applicable
Indian Standards.

7.27 All metal parts like cable racks, earth risers etc susceptible to corrosion due to
acid or other chemical fumes should be painted with anti-corrosion paints.

7.28 Cables shall be routed neatly and clamped to cable trays by using trifoil clamps
for single core cables nylon ropes for horizontal runs of cables. For clamping of
cables in vertical runs, prefabricated GI clamps shall be used.

7.29 For direct burial of cables where applicable, cables shall be laid and buried as
per the standard drawings enclosed for direct burial. Complete works including
excavation, cable laying and backfilling etc shall be provided by the contractor.

7.30 Cables/Cable tray openings in walls and floors or through pipe sleeves from one
area to another or one elevation to another elevation shall be sealed by a fire-
proof sealing system as per standards. The FPSS shall effectively prevent the
spread of fire from the flaming to the non-flaming side, in the event of a fire.

7.31 Firebreak shall be provided by applying a suitable fire-resistant coating on cables
for the required length to meet the fire rating of two hours and as per standards.

8.0 EARTHING

8.1 The earthing system shall be designed for 50 KA for 1 Sec. The earthing
system conductors shall be as follows:

a) Conductors above ground level : GS
and in trenches

b) Conductors buried in soil : MS



c) Conductors embedded in concrete : GS

d) Electrodes : GS Pipe/rod

e) Lightning protection air termination : GS Flat
and down conductors for buildings

8.2 Buried conductor shall be provided around the building. Main grids shall be
provided on floor of the building, for equipment earthing and connected to the
buried grid.

8.3 Interconnection with Purchasers earth grid shall be made at as many points as
necessary by using test electrodes.

8.4 A minimum of two earthing connections shall be made for all electrical
equipment each of which shall be connected separately to the main earthing
grid.

8.5 Metallic sheaths, screens / shields and armour of all power / control cables shall
be earthed at both the ends of the equipment, where the cables are terminated.
Instrumentation cables shall be earthed at one end only. Suitable earthing clips
shall be provided as required.

8.6 The connection between the earthing GS flat / wire conductors shall be welded
type.

8.7 The main earth grid shall be buried at a depth of 600 mm below ground.

8.8 The resistance to earth of the Ash handling system earthing as measured shall
not exceed 1 ohm.

8.9 The electrodes wherever mandatory as per codes/regulations, shall be provided
by the contractor.

8.10 The necessary electronic earthing required for Proposed PLC system (PLC
Panels) shall be provided by bidder.

8.11 Test pits with disconnecting facilities shall be provided at all interconnection with
purchasers grid.

8.12 The Contractor shall design and provide a complete earthing system as needed
for Ash Handling Plant. Earthing grid and earth mats conforming to IS: 3043 shall
be of 40 mm dia. MS rod with 40 mm MS round bar, 3 M long earthing electrodes.
Earth mat shall be connected to the Purchaser's main earth mat at least at two (2)
points, through test pits by MS round bars embedded in soil.

8.13 Each piece of equipment and structure shall be bonded to the earthing system at
two (2) points. Earthing conductor of MS flats/GS flats with a minimum 450 gm/M
2

zinc coating (wherever applicable) shall be of suitable size, required from the
consideration of safety, mechanical strength and electrical current carrying
capacity and shall not be less than the following sizes.

a. Push button stations : 8 SWG GI wires


b. Motors up to 5.5 KW : 4 SWG GI wire

c. Motors above 5.5 and up to 22 KW, : 25x4 mm MS flat
miscellaneous equipment and lighting
panels

d. Motors above 22 and up to 55 KW : 40x6 mm GS flat

e. Motors above 55 and up to 160 KW : 50x8 mm GS flat

f. Motors 160 KW and above : 75x12 mm GS flat

g. Switchgears, motor control centres, : 75x12 mm GS flat
lighting distribution boards, steel columns
and structures

h. Control panels & control desks etc : 40x6 mm GS flat

i. Earth buses and risers : 75x12 mm GS flat

j. Cable trays : 40x6 mm GS flat

k. Earth pads : 300x250x12mm GS flat

8.14 Earth mat conductor shall be laid either at a depth of 600 mm below finished grade
level or 300 mm below bottom of concrete whichever is more.

8.15 Whenever the earth bus conductor is buried in concrete floor it shall have a
minimum clear cover of 25 mm.

8.16 Length of the earthing conductor of each piece shall not be more than 10 metres.
All the joint portions in the earthing connections shall be thoroughly cleaned before
welding. All metal parts shall be protected and painted against acid & other
chemical fumes corrosion.

8.17 Earthing resistance of the earthing system shall be less than one (1) ohm. In case
of testing if it is found that the earth resistance is more than one (1) ohm or more,
the Contractor shall provide additional earthing electrodes and/or mat so as to
bring down the earthing resistance to a value less than 1.0 ohm.

8.18 Earthing system shall meet the requirement of Indian Standards and Indian
Electricity Rules and Act and shall be to the approval of Purchaser/ Consulting
Engineer.

8.19 Lightning Protection System

Lightning protection system as required for different areas/equipment shall be
provided in accordance with the requirements of IS 2309. Lightning protection
system roof / down comer conductors shall be 25x6 mm GS flats.



9.0 CABLE INSTALLATION AND ACCESSORIES

9.1 All material and accessories including cable trays, covers, conduits / pipes, etc.
shall be hot dip galvanized. Support steel shall be painted as specified. All
requirements of cable carrier system are included in bidders scope of work.

9.2 The tray support structures shall be fabricated from standard structural steel
section. The trays shall be prefabricated of the following sizes 150/300/450/
600/800 wide.

9.3 All the supporting structures, inserts conduits, pipes required to be embedded in
concrete work shall be supplied well in advance so that civil work is not held up.

9.4 Cables shall not be buried.

9.5 The junction boxes and cable glands/ terminations shall be of dust proof / dust
tight design. Cable trays shall be mounted in vertical formation, as these will
collect Ash dust in course of time, if mounted in horizontal formation.

Separate trays shall be provided for HT power cables, LT power cables and
control / instrumentation cables. Instrumentation cables shall be laid in
perforated trays. Tray covers shall be provided for all vertical raceways. Cable
trays shall be installed in horizontal configuration in the switchgear room.

9.6 Cable Trays and Covers

Cable trays shall be of ladder/perforated type. Cable trays and the associated
accessories such as coupler plates, tees, elbows, etc., shall be fabricated from
14 gauge (2 mm thick) mild steel sheets. Cable tray covers shall be fabricated
from 16 gauge (1.7 mm thick) MS sheets. All sheet steel shall be of hot dig
galvanized.

9.7 Steel Supports

Cable tray mounting supports shall be fabricated from standard structural steel
sections. These supports shall be given a coat of suitable primer followed by
two finishing coats of epoxy paint. It shall be the vendors responsibility to size
these supports adequately, considering safety margins and the maximum cable /
tray load.

9.8 Conduits / Pipes

a) Steel conduits shall be hot dip galvanized both inside and outside and shall
conform to IS:1653, 2667 & 3837. Conduits shall be used for sizes up to 63.5
mm.

b) The pipes shall be of the heavy duty type as per Clause C of IS 1239 (Part-I) and
shall be hot dip galvanized both inside and outside.

All the cable entries to the equipment shall be from bottom. Switchgear / control
room shall be provided with cable trenches. Top entry shall not be adopted for
any equipment located outdoor.



10.0 LIGHTING SYSTEM

10.1 The lighting system fixtures, equipment and installation shall comply with
specification. Lux level and the fitting type to be used in various areas are as
follows:

10.2 Lux Levels

The following lux levels shall be considered for designing the lighting system in
various areas.

Sl. No Area Minimum Lux
levels
i) Ash slurry pump house 300
ii) Switchgear/ control rooms 300

10.3 Lighting fixtures

The following type of fixtures shall be considered:

Area Type of fixture
Switchgear
rooms
2x40W Fluorescent lamp, industrial type with vitreous
enamelled reflector
Control Room 2x40W Fluorescent lamp, recessed / ceiling mounted with
wide angle mirror optic anti-glare type
Ash Slurry
pump house
1x70/150 W HPSV Industrial medium bay.
General Area
Lighting
1x70/150W HPSV lamp dust proof & dust tight well glass
fixture with reflector, wire guard & integral mounted control
gear.

10.4 Emergency lighting MCC/Switchgear room shall be provided.

10.5 All buildings shall be provided with adequate perimeter lighting. All lighting
fixtures shall be provided with lug type terminals. Temperature rise of any part of
the external surface of the light fittings shall comply with IS 4013.

10.6 Lighting Distribution System

The lighting distribution system shall generally comprise a lighting distribution board
(LDB) and adequate no. of lighting panels (LPs) fed from the LDB. A lighting
distribution transformer, to reduce the fault levels at the LPs shall be included in the
LDB. The lighting distribution board shall consist of a lighting distribution
transformer with switches / fuses on the incoming circuit and MCBs / MCCBs on
outgoing feeders. The Lightning Distribution system shall also comprise of
Voltmeter, Ammeter etc.

10.7 Lighting Panels

a) The lighting panels shall generally comply with the specification. Lighting
panels shall be in dust proof and dust tight enclosures.



b) Lighting panels shall be provided with one TPN 63 Amp with ELCB.
Incoming switch, required number of 15 Amp. Single phase MCBs with
neutral links for each outgoing circuit.

c) Lighting panels shall be factory fabricated by the MCB manufacturer.
The makes of these panels shall be subject to purchasers approval and
all panels shall be of same make.

d) Provision shall be made in lighting panels in terms of space & wiring for
adding ELCBs in future, in each outgoing circuit.

10.8 Receptacles

Following receptacles shall be provided for the Ash handling system:

a) 3 phase, 4 pin 63 A receptacles with interlocked switches, scrapping
earth connection, male and female units and cover.

b) Single phase, 3 pin 15A receptacles with switches, adequate numbers
shall be provided in each area. These shall be used for DC emergency
lights (Initializes) as well.

c) Receptacles for welding purpose shall be provided at appropriate
locations.

d) For every 10 Mtr radius 1 No. 5/15 A 3 Pin receptacles shall be provided.
15 A receptacles shall be commercial/industrial type.

All the switches, receptacles, JBs, TBs, etc. shall be of dust proof and dust tight
type. In addition, all the above items located outdoor shall be of weather proof
type.

10.9 Lighting Design & Installation work

10.9.1 Adequate DC lighting shall be provided in the control room and switchgear room
fed from 220V DC supply. Distribution board for distribution of the supply shall
be provided.

10.9.2 Area lighting shall be provided around all ash handling system structures as
necessary. Street lighting for streets in ash handling system area shall also be
carried out by the bidder.

10.9.3 Lighting fixtures/receptacles shall be distributed so that the loads on the three
phases are nearly equal.

10.9.4 Maximum wattage of lamps connected to any single lighting switch shall not
exceed 250 watts except in the case of floodlights. Each flood light shall be
controlled by an independent switch.



10.10.5 Mode of Cabling/Wiring

a) Cabling between lighting distribution board and lighting panels shall be
carried out by 1100 V grade, single or two core LT, power cables with
specification as given under clause 9.3 above.

b) Wiring between lighting panels and lighting fixtures / receptacles shall be
carried out with 1100 V grade, stranded copper conductor, PVC insulated
wires in screwed steel conduits conforming to IS 1653 provided with
heavy protection ( hot dip galvanized). When conduit wiring is adopted,
minimum size of conduit used shall be 19 mm and same shall be of the
reliable and reputed make and shall be subject to PURCHASERS
approval.

Copper wire size employed shall be 2.5 mm2 and 4 mm2 for lighting and
power circuits respectively.

10.10.6 When conduit wiring is adopted, the circuit wires shall be color coded as follows:

AC phase wire - Red, Yellow, Blue
AC neutral wire - Black

10.10.7 The loading in any single phase lighting circuit shall not exceed 2000 watts.

10.10.8 The combined voltage drop between LDB to LP and LP to the last lighting fixture
in the circuit shall be limited to 5%. Cables / wires shall be sized accordingly.

10.10.9 The following loads shall be assumed for fluorescent lamps, HPSV lamps
including the choke losses, when designing the circuit loading:

Fluorescent Lamps Load in Watts

i) 20 W 25
ii) 40 W 50
iii) 65 W 80
iv) 80 W (2x40) 100

HPSV Lamps Load in Watts

i) 70 W 90
ii) 150 W 175
iii) 250 W 280
iv) 400 W 460

10.10.10 The following loads shall be assumed for receptacles while designing the circuit
loads.

Receptacles Load in Watts

15 A 500



The number of 15 Amp receptacles shall not exceed four (4) in each circuit.
The number of 3 phase receptacles connected to each feeder shall not exceed
two (2)

10.10.11 Lighting fixtures to be mounted on ceiling / platforms having considerable
vibrations which can cause damage to the fixtures shall be suitably supported
with rubber pads to limit vibrations in the fixtures.

10.10.12 Joints in the earth continuity conductors shall be made by welding only.

11.0 DISTRIBUTION BOARDS

Vendor shall derive 110 V/240 V as required using step down transformers from
the 415 V switchgear in his scope.

12.0 GENERAL

12.1 An electrical control panel, floor mounted free standing vertical panel complete
with breaker control switches, mimic, indicating lamps, voltmeters with selector
switch for measuring 415 V bus voltage, ammeter for incomers at 415 V bus,
shall be provided.

12.2 All electrical installations shall comply strictly with relevant Indian Electricity
rules, Indian Standard Institution (ISI) codes of practice, fire insurance
regulations and local codes of practice and regulations, if any. It shall be the
contractors responsibility to meet these requirements and no additional costs
will be admissible in future on this account.

13.0 SURFACE FINISH OF ELECTRICAL SYSTEM EQUIPMENT & STRUCTURES:

a) All electrical equipment and structures employed in the system shall be
epoxy painted with proper primer (2+2 coats) after sand blasting the
surfaces.

b) All hardware associated with the system shall be hot dip galvanized.

14.0 TYPE OF ENCLOSURE

Following specific requirements shall be met:

a) Motors: TEFC with IP 55 enclosure.

b) All spark producing equipment like lighting system boards, receptacles, JBs
marshalling boxes, PB stations and similar items shall have dust proof and
dust tight enclosure, if located in the Ash handling plant area other than the
control / switchgear room.

c) All lighting fixtures shall be dust tight and dust proof.

15.0 TESTS

15.1 Tests for all electrical equipment and components shall be carried out at
Manufacturers works as per the relevant standards. Purchaser reserves the


right to witness the tests for any equipment. All test certificates shall be
furnished for purchasers approval.

15.2 All meters, instruments used during testing of equipment at Manufacturers/ Sub
vendors works as well as those used during commissioning at site shall have a
valid calibration certificate.

DESEIN Annexure-VI, Sheet - 1 of- 25


ANNEXURE VI

SPECIFICATION FOR INSTRUMENTS

1.0 GENERAL

1.1 This Standard technical specification is applicable for various instruments and
controls required for Thermal Power Station application. In case of any discrepancy
between this standard specification and specific equipment details covered under
the specifications to be supplied, it shall be referred to Engineer whose decision
shall be final and binding.

1.2 All instruments shall be suitable for reliable operation at the specified site
conditions. All the locally mounted instruments, transmitters and field mounted
controllers shall be provided with weather-proof, dust proof and water tight
enclosures. NEMA IV enclosures shall be provided for all the switches and
instruments having electrical contacts. All receiver type Indicators/Recorders/
Integrators and Electronic Controllers shall be of modular construction with
integrated circuits.

1.3 Name Plates

For all dial type locally mounted indicating instruments, tag number and service
shall be engraved in black letters on the dial itself. For all other locally mounted
instruments, tag number and service shall be engraved in white letters on a black
metallic plate fixed to the body of the instrument.

For all panel mounted instruments, tag number and service shall be engraved in
white letters on a black metallic/plastic plate fixed to the bottom frame of the
instruments. For multi-pen/multi-point recorders, the inscriptions for each pen/point
shall be engraved as above and fixed to the frame/front glass of the instrument.

1.4 Test Certificates

Shop test certificates of all instruments shall be furnished to Engineers approval
prior to dispatch.

1.5 Operation & Maintenance Instruction Manuals

Instruction Manuals containing complete information regarding installation,
testing, calibration, commissioning, operation and maintenance of the
instruments shall be furnished to Engineer minimum twelve (12) months prior to
the commissioning of the Plant as per the Distribution Schedule.

All the instruments shall have proven record of satisfactory operation for Power
Station application.

1.6 Site Calibration & Testing

All instruments shall be tested and calibrated at site prior to their installation.
The results of calibration shall be submitted to the Purchaser in an approved
proforma. This shall be the essential pre-requisite condition for handing over the
instruments to the Purchaser.


2.0 LOCAL / FIELD INSTRUMENTS

2.1 Pressure & Differential Pressure Gauges (PG & DPG)

2.1.1 Applicable standards : IS: 3602-1966 / IS:3624 except as
modified in this specification.

2.1.2 Type/Construction:

i) (-) 760 mmwc to 1.0 Kg/cm
2
: Bellows

ii) Above 1.0 Kg/cm
2
: Bourdon Tube

iii) Suction side of pumps : Compound gauge

2.1.3 Materials

i) Bourdon tube up to : SS 316
60Kg/cm
2
pressure & 300C
Temperature

ii) Bourdon tube above : SS 316
60Kg/cm
2
press. & 300C
Temperature for all steam
services

iv) Bellows : SS 316

v) Case : Die-cast aluminium with stoved
enamel black finish; epoxy coating
for corrosive atmosphere

vi) Protective Diaphragm : Teflon

Vii) Cover glass : Shatter proof

2.1.4 Dial Size

i) 65 NB & below line sizes : 100 mm

ii) all other line sizes : 150 mm

iii) special : 250 mm (as specified)

2.1.5 Scale Details : Graduations in black lines on white
dial. Smallest scale division shall be
two (2) percent of full scale value or
smaller. Pointer stop at max. value.

2.1.6 Accuracy : + 1 %



2.1.7 Instrument Connection : NPT (male), Bottom

2.1.8 Accessories

a) 3 way needle valve : For all gauges

b) Self cleaning type : Pump and compressor discharge
Pulsation dampener lines

c) Siphon : For all steam lines

d) Protective separating : For fuel oil and corrosive liquid
diaphragm lines

2.1.9 Other particulars

a) Zero adjustment : For all gauges

b) Safety devices

i) Range 5 to 20 Kg/cm
2
: Rubber blow out disc with open front
construction.

ii) Range above 20 Kg/cm
2
: Neoprene safety diaphragm at the
back with solid front construction.

iii) Over range protection : Twenty (20) percent of full scale

2.2 Pressure Switches & Differential Pressure Switches (PS & DPS)

2.2.1 Applicable Standards : IS3624 - 1966/ISA-RP-8.1 except as
modified in this spec.

2.2.2 Type/Construction : Bourdon / Sealed Diaphragm [Piston
Actuated preferable]. Indicators with
contacts are not acceptable.

i) (-) 760 mm wc to 1.0 Kg/cm
2
: Bellows

ii) Above 1.0 Kg/cm
2
: Bourdon

2.2.3 Materials

a) Bellows : SS 316

b) Bourdon tube up to : SS 316
60Kg/cm
2
press. & 300C
temperature

c) Bourdon tube above : SS 316
60Kg/cm
2
press. & 300C
temperature for all steam
services


d) Protective Diaphragm : Die-cast aluminium with stoved
& case enamel black finish; epoxy coating for
corrosive atmosphere.

2.2.4 Accuracy : + 1 %

2.2.5 Repeatability : + 0.5 %

2.2.6 Differential : Adjustable

2.2.7 Contacts

a) Number : Two (2)

b) Type : Changeover & snap action micro
switch

c) Rating : 5 Amp, 240V AC
0.2 Amp, 220V DC

2.2.8 Connection - Instrument : NPT (male)

- Electrical : Suitable for NPT(female)
gland conduits

2.2.9 Accessories:

a) 3 way valve : For all switches

b) Self cleaning type : Pump and compressor
pulsation dampeners discharge lines

c) Syphon : For all steam lines

d) Protective separating : For fuel oil & corrosive liquid lines.
diaphragm

2.3 Temperature Indicators (TI)

2.3.1 Applicable standard : IS: 3602, BS: 5235 ISA: RP: 8.1
except as modified in this
specification

2.3.2 Type/Construction

a) Thermometer : Industrial type, Mercury in steel with
separable thermo well

b) Thermo well : Bar stock



c) Cover glass : Shatter proof

2.3.3 Material

a) Thermo well & Bulb

i) Up to 300C : 304 SS

ii) Above 300C : 316 SS

b) Capillary : Armoured stainless steel (applicable
for capillary Type)

c) Bourdon tube : SS 316

d) Bourdon movement : SS 304

e) Casing : Die-cast aluminium with stoved
enamel black finish; epoxy coating for
corrosive atmosphere; 270 degree
dial rotation.

2.3.4 Dial Size

a) 50 NB & below line sizes : 100 mm

b) All other line sizes : 150 mm

2.3.5 Scale Details : Graduations in black lines on white
dial provided with glass cover.
Smallest scale division shall be
two(2) percent of full scale value or
smaller. Pointer stop for all gauges

2.3.6 Accuracy : + 1 %

2.3.7 Connection

a) Pipe : M33 x 2

b) Thermo well : To suit instrument

2.3.8 Other Particulars

a) Capillary length : 5 / 10 Meters

b) Immersion length : Within + 10 mm of centre line of pipe
with adjustable nuts.

c) Extension length : Minimum 50 mm above insulation of
pipe

d) Stop at Maximum value : For all gauges of scale


2.4 Temperature Switches (TS)

2.4.1 Type/Construction

a) Switch : Industrial type Mercury in steel with
capillary and separable thermo well
and contacts directly connected to
Bourdon element.

b) Thermo well : Bar stock

2.4.2 Material

a) Thermo well & Bulb

i) Up to 300C : 304 SS

ii) Above 300C : 316 SS

b) Capillary : Armoured Stainless Steel

c) Bourdon : Phosphor-Bronze

d) Bourdon movement : SS 316

e) Casing : Die-cast aluminium with stoved
enamel black finish; epoxy coating
shall be provided for corrosive
atmosphere.

2.4.3 Accuracy : + 1 % of setting and differential

2.4.4 Repeatability : 0.5 % of setting.

2.4.5 Contacts

a) Number : Two (2)
b) Type : Changeover & Snap action micro
switch

0.2 Amp, 220V DC
2.4.6 Connection

a) Pipe : M33 x 2

b) Thermo well : To suit switch

c) Conduit : Suitable for gland 3/4 inch.

2.4.7 Other Particulars



a) Capillary length : 5 / 10 Meters

b) Immersion length : Within + 10 mm of centre line of pipe

c) Packing glands : Yes

2.5 Flow Indicators (Rota meters)

2.5.1 Type/Construction : a) On-line type Rota meter for
50 NB and below lines

b) Bypass type Rota meter for
above 50 NB lines.

2.5.2 Materials : For On-line type For Bypass type

i) Metering Tube : -------------- Borosilicate glass ----------

ii) Float : -------------- 316 SS ------------------------

iii) Packing : -------------- Teflon --------------------------

iv) End fittings : ------------- 304 SS ----------------------

v) Orifice Plate : - 316 SS

vi) Carrier ring : - 304 SS

vii) Impulse pipe; flanges & : - Same as pipe
mating flanges material

viii) Fittings : - 200 # ANSI, SW
ends to match with
pipe material.
2.5.3 Dial Size/Scale length : 250 mm

2.5.4 Scale Details : Direct reading type engraved on
detachable Aluminium scale

2.5.5 Accuracy : + 2 %

2.5.6 Reproducibility : 0.5 %

2.5.7 Connection : Screwed NPT

2.5.8 Accessories : a) Isolating valves (for Bypass
type only)
b) Bolts, Nuts and Gaskets as
required

2.5.9 Tests : Tested at two hundred (200)
percent of the maximum process
pressure


2.6 Flow Switches (FS)

2.6.1 Type : Differential pressure type/vane
actuator type as per application.

2.6.2 Materials

a) Sensing Elements : 316 SS

b) Case : Die-cast aluminium

2.6.3 Accuracy and Repeatability : + 1 %

2.6.4 Set point : Adjustable through range

2.6.5 Contacts

a) No. of contacts : Two (2)

b) Type : Changeover & Snap action micro
switch

c) Rating : 5 Amp 240V AC
0.2 Amp 220V DC

2.6.6 Connection - Instrument : 1/2 inch NPT(male)
- Conduit : Suitable for gland 3/4 inch

2.6.7 Accessories : As required

2.7 Level Indicators (Gauge Glass) (LI)

2.7.1 Type/Construction : a) Reflex
b) Tubular (For tanks open to
atmosphere only)

2.7.2 Material
a) Glass : Tempered borosilicate resistant to
thermal shock

b) Case : Carbon steel

c) Integral cocks and : i) Forged carbon steel with
drain valves stainless steel internals
ii) Rubber lined corrosion
resistant stainless steel (for
Demineralised and Osmosis
water service)

d) Fittings : i) Forged carbon steel



ii) Rubber lined steel/PVC for
corrosive liquids (DM and
Osmosis water service)

iii) 304 Stainless Steel for
non-corrosive liquids (DM
and Osmosis water service)

e) Packing : Teflon

2.7.3 Dial size/scale : 150 mm 1.5 Meters maximum
length

2.7.4 Scale details : Graduated in mmwc

2.7.5 Connection : 25 NB/40 NB ANSI Flanged

2.7.6 Accessories : a) Integral cocks
b) Drain valves
c) Bolts, nuts and gaskets
d) Illuminating lamps as required
e) Periscope as required

2.7.7 Tests : Tested at two hundred (200) percent
of the maximum process pressure

2.7.8 Other details : For larger lengths, additional gauge
glasses shall be provided with
minimum of 50 mm overlap.

2.8 Level Switches (LS)

2.8.1 Type/Construction : a) External float cage type
with magnetic switch actuator for tanks and vessels.

b) Electrode (for oil tanks)

c) Displacer -Top mounted for
all clean water sumps.
2.8.2 Materials

a) Body : Cast Carbon Steel suitable for
specified pressure and temperature
ratings

: For corrosive liquids, suitable
anti-corrosive coat/lining shall be
provided.

b) Float/Displacer : 316 SS

c) Wire rope : 316 SS



2.8.3 Differential : + 6 mm minimum (Adjustable)

2.8.4 Contacts

a) Number : DPDT

b) Type : Changeover Snap action micro
switch

c) Rating : 5 Amp 240V AC
0.2 Amp 220V DC

2.8.5 Connection - Process : 1 inch NPT(female) or
1 inch ANSI flanged.

- Electrical : Suitable for gland 3/4 inch

2.8.6 Temperature/pressure rating : As per service conditions

2.8.7 Accessories : Counter flanges, still pipe of requisite
length with anticorrosive coating for
sump service.
3.0 CONTROL VALVES (CV)

3.1 Type/Construction

a) For flashing/ : Angle Pattern or Globe
High pressure drop Pattern - Ported Cage Quick
applications trim/Step trim.

b) High flow and low : Butterfly
pressure drop applications.

c) Other applications : Globe

3.2 Material

a) Body

i) Upto 300C : Cast Carbon Steel to ASTM A 216
Gr. WCB

ii) For temperature:
- 300 to 450C : Cast Alloy steel to
ASTM A 217 Gr. WC-6
- above 450C : Cast Alloy Steel to
ASTM-A-216 Gr. WC-9

iii) Above heater drain : Cast Alloy steel to ASTMA 216
valves Gr. WC-9

iv) For butterfly valves : Cast Iron



- Internals : 316 SS Stellited

3.3 Connection

a) Upto 900 #/ASA : ANSI Flanged Ends

b) 1500 #/ASA & 2500 : BW ends to ASA # B 16-9

3.4 Accessories : i) Diaphragm/Piston actuator

ii) Positioner with Input/ Output
Gauge Assembly and
requisite characteriser to suit
valve and control
requirements.
iii) Position Transmitter with 4 to
20 mA signal for Remote
Indication and feedback
signal to control loop.
iv) Local Mechanical Position
Indicator
v) Air Filter Regulator set
vi) Air Locking Relay
vii) Solenoid valve
viii) Limit Switches (2 SPDT for
each end position) of
Honeywell Micro switch
make.
ix) Connecting brass air tubing &
fittings
x) Hand wheel

3.5 Tests : Hydraulic, radiographic and magnetic
particle tests as specified.

3.6 Other Particulars : As per respective control valve data
sheets; IBR certificate as required.

3.7 Accuracy

a) Positioner : +1.0% full scale

b) Position transmitter : +0.5% full scale

4.0 PRESSURE, DIFFERENTIAL PRESSURE, LEVEL AND FLOW TRANSMITTER
(PX,DPX, LX & FX)

4.1 Type/construction : Micro processor based hart Protocol
compatible Sealed Capacitance
type / Inductance /Peizo resistive

4.2 Material



a) Body : Carbon Steel for air and flue gases,
SS for other services

b) Diaphragm : 316 SS

c) Valves : Carbon steel for non-corrosive
applications; Stainless steel for
corrosive applications.

d) Capsule : SS 316

e) Bellows : SS 316

f) Bourdon : SS 316

4.3 Output signal : 4 to 20 m Amp.DC (Two wire)

a) Overall accuracy : + 0.075%

b) Power supply : 24V DC

c) Load impedance : 600 Ohms

4.4 Connection

a) Process : inch NPT (female screwed)

b) Electrical : inch NPT (female screwed)

4.5 Accessories

a) For Pressure Transmitters : Three way (3) valve manifold
& 2 drain valves

b) For Differential pressure : Three way (3) valve manifold
transmitters and two (2) drain valves flow

c) For level & flow transmitters : 5 Valve manifold

d) For oil and corrosive liquids : Separator diaphragm seals

e) For all transmitters : Mounting bracket

f) Enclosure : IP 65

4.6 Other Particulars

a) Type : Smart

b) Local indicating scale : 0 to 100%

c) Suppression and elevation : To be built in feature.



d) Over range protection : Two hundred (200) percent of
maximum range up to 60 kg/cm
2
for
medium pressure; One hundred fifty
(150) percent of maximum range for
high pressure services.

Full static pressure for differential
pressure transmitters

5.0 DIRECT MOUNTED LEVEL TRANSMITTERS (LX)

5.1 Type/Construction : External float (Displacer)

5.2 Material

a) Body : Cast Carbon steel suitable for
specified pressure and temperature
ratings; For corrosive liquids, suitable
anti corrosive coat/lining shall be
provided.

b) Float : 316 SS

5.3 Accuracy : + 0.5 %

5.4 Output signal : 4 to 20 m Amp. DC

5.5 Power Supply : 24V DC

5.6 Connection

a) Type : Side and bottom/side and
side to suit process vessel

b) Process : 2 inch SW/Flanged

c) Electrical : inch NPT (female screwed)

d) Pneumatic : inch NPT (female screwed)

5.7 Accessories : i) Matching flanges with bolts,
nuts and gaskets
ii) Drain valve
iii) Air filter regulator

5.8 Other Details

a) Zero and span adjustment : To be provided

b) Extended Bonnet : For service 200`C and higher

c) Float Movement : Transmitted to the pilot mechanism
by a torque device incorporating a


positive seal between the float cage
interior and the transmitting
mechanism without use of stuffing
boxes.

d) For oil & corrosive liquids : Separate diaphragm seal

e) For level transmitter : Five valve manifold

6.0 THERMOCOUPLES WITH THERMO WELLS

6.1 Applicable standard : ASME PTC 19.3-
for Thermo well Latest Revision

6.2 Element : Duplex

6.3 Sheath : 8 mm OD

6.4 Sheath Material : 316 SS

6.5 Spring loaded provision : Yes

6.6 Nipple/Union : Yes

6.7 Packed connector : Compacted magnesium oxide
ungrounded

6.8 Type : ISA,K (Chromel-Alumel)/
Platinum Rhodium-Platinum
with limits of error according to
ANSI-96.1 - 1982.

6.8.1 Gauge : 18 AWG; 16SWG for Type K

6.8.2 Head : Forged Aluminium

6.9 Well or Tube

a) Construction : Tapered Drilled from Bar stock

b) Material : 316 SS for water/steam services

c) Process Connection : (i) M 33 x 2
(ii) Flanged with mating flanges.
d) Extension : Threaded union inch NPT
(female) with two (2) nipples of SS
316 having inch NPT(male)
threads at both ends

6.10 Accuracy : + 1.1
0
C (for 0 to 277C)
+ 0.4 percent (for 277 to 1280C)

6.11 Accessories : Bolts, nuts and gaskets for


flanged connections.

6.12 Immersion length : Within + 10 mm of centre line of
pipe

6.13 Extension neck length : Minimum 50 mm above
insulation of pipe; and minimum
160 mm on un insulated pipe

6.14 IBR Certification : For high pressure service as per
IBR regulations

7.0 RESISTANCE TEMPERATURE DETECTORS (RTD)

7.1 Applicable Standard : ASME PTC 19.3
for Thermo well - Latest Revision

7.2 Complete assembly with nipples/ : Yes
union provision

7.3 Element : Duplex, Pt 100

7.4 Leads : Standard

7.5 Sheath material/insulation : 316 SS/Compacted Magnesium
Oxide

7.5.1 Sheath O D : 8 mm

7.5.2 Connection : 3 wire

7.5.3 Calibration : As per DIN Standard - 43760

7.5.4 Element : Duplex

7.6 Accuracy

a) PRT : + 0.35C

b) CRT : + 0.35C

7.7 Insulation resistance : RTD leads to body more than
5 Meg Ohms at 100V DC.
7.8 Well/or Tube

a) Construction : Tapered drilled from Bar stock

b) Material : 316 SS - water and steam
services

c) Process connection : i) M33 x 2
ii) Flanged with mating


flanges.

7.9 Other Details:

All sensors shall be compacted magnesium oxide insulated with spring loaded
sensing element forged aluminium head assembly screw cap and galvanised
chain. Thermo wells/tube for air/flue gas/mill services shall be with adjustable
flanges.

7.9.1 Accessories : i) Junction boxes with terminal
blocks as required.

ii) Shielded and twisted triads
upto junction boxes

iii) Flexible conduits upto
junction box of silica make or
approved equal

7.9.2 Immersion length : Centre line of pipe + 10 to 15 mm

7.9.3 Extension neck length : Minimum 50 mm above pipe
insulation.

8.0 RECEIVER INDICATORS

8.1 Type : Fluorescent display - Receiver
Single channel or dual channel

8.2 Input

a) Electrical : 4 to 20 mA DC

b) Scale : Vertical

c) Accuracy : + 0.2% for digital display

d) Resolution : 0.5% Span

e) Dead band : + 0.2% of span

f) Repeatability : 0.2% of span

g) Full scale response time : Less than two (2) seconds

8.3 Power Supply : 240V, 50 Hz

8.4 Mounting : Single or Multiple Unit flush
mounting; If bin mounted, along with
bin.

8.5 Dimensions : 72 x 144 mm as per DIN



8.6 Power & Signal Connection

a) Electronic : Plug in type rear connection with
adequate cable length to permit full
withdrawal of indicator with cables
connected.

b) Accessories : Mounting Bracket

8.7 Other Particulars : i) The instrument shall also
display the input value as
digital display in engineering
units.

ii) If the instrument does not
contain specified number of
contacts, suitable alarm cards
shall be supplied for this
purpose.

iii) If rating of the instrument
contact is not adequate, then
these should be suitably
updated to meet the specified
rating.

9.0 RECORDERS

9.1 Type

a) Principle : Indicating type microprocessor
based

b) No. of pens/points : One (1), two (2), or three (3)
continuous recording and 6/12/24
point recording as per schedules.

9.2 Input Signal : 4 to 20 m Amp DC / mV / RTD

a) Chart

i) Type : Strip chart with fan fold designed for
ease of replacement.

ii) Speed : Adjustable

b) Standard : 20 mm/hr for horizontal chart

c) Special requirements : 120 mm/hr or higher for specified
application with a switching


arrangement to be actuated using
external contacts.

d) Drive : Electrical operated

9.3 Accuracy : + 0.5 percent

a) Zero Adjustment : + 20% of span

b) Span Adjustment : From 85% to 115% of rated input
span as minimum

c) Temp. effect : + 0.02% per C

d) Dead band : + 0.2% of span

e) Full span response time : 2 Seconds

9.4 Power supply : 240V, 50 Hz

9.5 Mounting : Flush mounting

9.6 Dimensions : 72 x 144mm or 144 x 144mm

9.7 Power & signal connection

a) Electronic : Plug in type rear connection with
swing door.

b) Accessories : i) Mounting Bracket
ii) Chart for 2 years operation.
Consumption as per selected
chart speed.
iii) Spare ink pots for 2 years
operation
iv) Spare pens for 2 years
operation in addition to
maintenance spares specified
elsewhere.

9.8 Other particulars : i) If the instrument does not
contain specified number of
contacts, suitable alarm
cards shall be supplied

ii) If rating of the instrument
contacts is not adequate,
then these should be
suitably updated to meet the
specified rating.

iii) 'SUPPLY ON' indicating
lamp shall be provided.


iv) Service, units and time in
hours shall be printed on
every chart roll

v) For Multi pen recorder, each
service shall be identified by
different colours.

10.0 PANEL MOUNTED ACCESSORIES

10.1 Auto-manual station (Electronic)

a) Type : Desk mounted

b) Dimensions : Miniaturised to DIN standards

c) Particulars : Two (2) maintained action push
buttons for Auto-manual selection
and Two (2) momentary action push
buttons for Raise-lower operation
with illuminated coloured lamps -
Green for closing/stop and Red for
opening/start.

10.2 Setter (Electronic)

a) Type : Suitable for Desk Mounting

b) Dimensions : Miniaturised to DIN standards

c) Particulars : Electronic-pulse type with 2 PB for
increase/decrease of set point
values.

d) Range : Actual range

e) Accuracy for

i) Setting : +0.3%

ii) Indication : +1.5%

10.3 Setter (Pneumatic)

a) Type : Integral with controller

b) Dimensions : As per Manufacturer's standard

c) Range : Actual range

d) Accuracy : +0.5% of actual value


e) Position Indicator
(Electronic only)

i) Type : Desk mounted

ii) Dimensions : Miniaturised to DIN standard
iii) Range : Actual range

iv) Indication accuracy : +1.5% of range

10.4 Electro-pneumatic convertor
(Electronic only)

a) Type : Field mounted

b) Dimensions : Manufacturer's standards

c) Input : 24V AC Pulses/4-20 mA DC as
required by the design of control
system

d) Output : 0.2 to 1 Kg/cm
2

e) Calibration capability : + 0.5 percent span

f) Repeatability : 0.2 percent span

g) Ambient temp.effect : 1.0 percent of span from
-20 to + 60C

h) Action : Direct or reverse field selectable.

10.5 Selector Switches (SS)

a) Type : 3, 4, 6, or 12 position rotary
maintained or spring return action
depending upon requirement

b) Material

i) Mechanical housing : Oil tight, Fire resistant material with
dust proof enclosure

ii) Switch pack : Self-extinguishing plastic compound

iii) Engraving details : As required

c) Contacts

i) Number & Type : Two, SPDT

ii) Breaking capacity : 1 Amp, 250V DC


10 Amp, 600V AC

iii) Dimensions : Miniaturised to DIN standards
(preferred) 48x48 mm or multiples of
24mm.
iv) Handle : Pistol grip for large contacts small
knob upto 4 position as per schedule.

10.6 Push Buttons (PB)

a) Type : Momentary/maintained action

b) Material: Mechanical Housing : Oil tight, fire resistant material with
dust proof enclosure

c) Color/Engraving

i) Valve Actuators : RED/OPEN
GREEN/CLOSE

ii) Motors : RED/START
GREEN/STOP

d) Contacts

i) Number & Type:
- Breaking capacity : 1 Amp, 220V DC
10 Amp, 600V AC

e) Dimensions : Miniaturised to DIN standards

10.7 Illuminated Push Buttons (ILPB)

10.7.1 Type : Momentary/Maintained action

10.7.2 Material: Mechanical housing : Oil tight, fire resistant material with
dust proof enclosures

10.7.3 Colour:

a) Valve & damper : RED - OPEN

b) Actuators : GREEN - CLOSE

10.7.4 Engraving: Type : On transparent film sandwiched
between diffuser and top transparent
cover

10.7.5 Contacts:

a) Number & Type : 2 x SPDT

b) Rating : 10 Amps, 600V AC


2 amps, 220V DC

10.7.6 Lamp details

a) Voltage : 60 Volts nominal

b) Supply : 240V AC/110V AC/control system
power supply.

c) Accessories : Series resistors/transformers

10.7.7 Dimensions : Miniaturised to DIN standards

10.8 Indicating Lamps (IL)

10.8.1 Type : Miniaturised

10.8.2 Colour:

a) Valves : RED - OPEN
GREEN - CLOSE

b) Motors : RED - ON
GREEN - OFF
YELLOW - TRIP
WHITE - AUTO - START

10.8.3 Engraving: Type : On transparent film sandwiched
between diffuser and top
transparent cover

10.8.4 Voltage : 60V nominal/control system power
supply.

10.8.5 Supply : 240V AC/110V AC
220V DC

10.8.6 Accessories : i) Dropping resistors/transformers

ii) Lamp holder

10.8.7 Dimensions : Miniaturised to DIN standards

10.9 Ammeters (AMM)

10.9.1 Type : Moving iron type/moving coil type

10.9.2 Input : 4 to 20 m A DC

10.9.3 Mounting : Flush panel

10.9.4 Face Dimensions : 96 x 96 mm (for generator current)


96 x 48 mm (for thers)

10.9.5 Scale : horizontal

10.9.6 Zero adjustment : Screw on meter face

10.9.7 Accuracy : + 1.0 percent

10.9.8 Over range protection : To suit service. Six times normal
range minimum marking in red.

11.0 TEMPERATURE MONITORS/ SCANNERS

11.1 Type : Electronic Indicating

11.2 Input : 3 wire RTD Pt-100/Cu-53/other

11.3 Number of Channel : 8 / 12 / 16 / 20

11.4 Measurement range : 0 to 200C

11.5 Accuracy : + 1.0% F.S.D

11.6 Display for values : 7 Segment LED

a) Channel No.
b) Measured value

11.7 Dwell time : Adjustable

11.8 Alarm Display : Through LEDs Two per channel

a) Alarm
b) Trip

11.9 Sensor Status : Open/Short status to be displayed

11.10 Alarm Contacts : Adjustable over span

a) Number : One per group of 6, 2, 4 inputs.

b) Type : Change over snap action

0.2 Amp, 220V DC

11.11 Trip Contacts : Adjustable over span

a) Number : One per Group of 6, 2, 4 inputs

b) Type : Change over, Snap action



0.2 Amp, 220V DC

11.12 Operator Interface : Auto/man Mode Selection

- Alarm Limit
- Trip limit
- Reset
- Advance

11.13 Common mode voltage : 120 dB

11.14 Series mode voltage : 60 dB

11.15 Termination : Rear through terminal block for direct
connection of temperature sensor

11.16 Ambient Temperature : 0 to 50C

11.17 Power supply : 240V AC, 50 Hz, single phase

11.18 Mounting : Flush panel

a) Dimension : 144 x 144 mm.

b) Accessories : Mounting brackets

c) Other features : Alarm contacts shall not be
activated/deactivated during power
on instance.

d) Application : Mounting and generation of Alarm
and Trip Contacts of winding and
Bearing Temperatures of HT motors.

12.0 DIGITAL INDICATOR

12.1 Type : Electronic digital indicator with
floating point decimal.

12.2 Input : 4 to 20 mA DC/1-5V DC/RTD/TC.

12.3 Number of inputs : One

12.4 Range : As per schedule

12.5 Number of digits : Four plus sign

12.6 Digit height : 12 mm or larger

12.7 Display : Fluorescent red/green

12.8 Display mode:


a) Input over range/open : All digits to flash
sensor (T/C)

b) Input hold time : 0.7 seconds max.

c) Accuracy : + 0.05% of span

12.9 a) Power supply : 240V AC, 50Hz

b) Mounting : Flush panel

c) Bezel size : 96 x 48 mm

13.0 SOLENOID VALVES

13.1 Type and Construction

a) Control valves : 3-way single solenoid

b) Power cylinders : 5-way dual solenoid

13.2 Material:

a) Body : Brass

b) Seat : Stainless Steel

c) Bonnet gasket : Teflon

d) Solenoid internal parts : 304 SS

13.3 Coil details:

a) Rating : Continuous

b) Voltage : 240V AC or 220V DC
as applicable

13.4 Connection : 1/4 inch NPT (female screwed)

DESEIN Annexure-VII, Sheet - 1 of- 77


ANNEXURE VII

SPECIFICATION FOR CIVIL WORKS

1.00 SCOPE

The scope of work covered under this sub-specification includes the complete
design, engineering, coordination and construction of the civil works and
structures, required for the completion of the proposed Ash Handling System
including furnishing of designs, construction drawings, bar bending schedules,
bill of materials, materials and labour etc. Finishing items for the works shall
include plastering, painting, protection treatment, provision of insert plates &
misc. structural steel work, plinth protection, sheeting, sewage, drainage and
further site clearance and protection of existing structures/ foundations during
the construction of the civil works.

The various structures/equipment/arrangements etc., for which civil and
structural works are to be provided for in this turnkey contract shall be as per
detailed scope of work specified.

Any other civil works required for structures/equipment other than those
mentioned above for the completion of the turnkey contract shall be deemed to
be covered under this specification even though not specifically mentioned
herein.

2.00 SURVEYING AND SOIL INVESTIGATION

2.01 The Contractor shall survey, layout and establish baselines, bench marks and
grades for all work areas and also shall make his own survey of the site, to
the satisfaction of the Engineer.

2.02 The bidder shall carry out his own investigation at his own cost in order to fully
determine and satisfy himself with the site conditions as those exist at the time
of bidding. No claim after the award of work shall be entertained for the bidders
inadequate knowledge of the site.

3.00 JUNGLE CLEARANCE

3.01 The Contractor shall furnish all labour, materials and equipment required for the
jungle clearance of the site for the works mentioned in clause 1.00. This shall
include loading, unloading, transportation and stacking, cleaning and grubbing
materials to specified lead.

3.02 The area shall be cleared of all trees, shrubs, stumps, roots, rubbish and all
other objectionable material as directed by the Engineer. Trees of specified girth
and/or any other cleared materials shall be stockpiled or handed over to the
Engineer if he so desires.


4.00 EARTH WORK

Disposal of surplus from excavation is to be carried away from the excavation
site to designated disposal area selected by the Engineer-in-Charge. All goods
excavated from the pits and all assorted materials of dismantled structures shall
be the property of the purchaser.

4.01 EXCAVATION

4.01.1 The Contractor shall perform entirely on his own initiative and at his own cost all
and any earth work required for the civil works. This shall include the loading,
unloading, transportation and stacking of excavated material up to a lead of
within five (5) kilometres crow fly distance from site as directed by the Engineer-
in-Charge. Before commencing the earthwork, the Contractor shall prepare the
excavation drawings based on the final RCC. Approved for Construction
drawings and submit to the Engineer. If any modifications are made in the final
RCC drawings, the Contractor shall modify the excavation drawings accordingly
and perform the work according to them.

4.01.2 The area to be excavated / filled shall be cleared of fences, trees, plants, logs,
stumps, bush, vegetation, rubbish, slush, etc. and other objectionable matter. If
any roots or stumps of trees are met during excavation, they shall also be
removed. The materials so removed shall be burnt & disposed of as directed
by Engineer. Where earth fill is intended, the area shall be stripped of all
loose/soft patches, top soil containing objectionable matter/ materials before
base fill commences.

4.01.3 If during excavation, the Contractor comes across some facility/ structures/
system, he shall immediately intimate the Engineer and carry out the excavation
with care under the Engineers guidance and provide suitable supports/
protection required. The Contractor shall include the cost of these in his lump
sum price. However, in case the Engineer requires the dismantling of such items
and/or diversion facility for the same, it shall be paid for separately.

4.01.4 The Contractor shall perform excavation in such a way as to prevent immediate
or future sliding or caving in of the ground, he shall be held fully responsible
for damage to persons, works or things and entirely liable for all an any changes
entailed in removal of material collapsed or for other works or supplies
eventually required for re-conditioning.

4.01.5 The earthwork in excavation shall include the removal of all materials to properly
execute the work. Sides and bottoms of excavation shall be cut sharp and
trimmed to the required levels.

4.01.6 Any excavation taken out to a depth greater than required for any reason
whatsoever, shall be filled by the Contractor with nominal mix M15 grade of
concrete at his own cost. Excavation for bottom 300 mm depth shall be done
just before concreting to avoid weathering action.

4.01.7 Should the bottom of any excavation appear to be soft, unsound or unstable,
the Contractor shall report the matter to the Engineer; and if the Engineer so


directs, shall excavate it to directed depth. Such extra excavation shall be filled
up with nominal mix M15 grade of concrete as directed by the Engineer.

4.02 DEWATERING

4.02.01 The Contractor shall dewater and maintain the water table 0.5m below the
lowest level of the excavated area during excavation and concreting till back
filling. For lowering of water table, the proposed schemes shall be submitted by
the Contractor to the Engineer for prior approval.

4.02.02 The Contractor shall provide and operate all pumps or other equipment
necessary to drain and keep all excavations, pits, trenches free from water,
mud or slush during he continuance of the contract and as directed.
Necessary standby diesel and electric sets shall also be maintained by the
Contractor to be used in cases of emergency. The Contractor shall make
suitable arrangement/provisions to dispose this water into the project drainage
system. Dewatering shall be continued up to 7 days after the completion of the
last pour of concrete in the foundation.

4.03 SHORING AND STRUTTING

The Contractor shall provide all necessary shoring and strutting required for the
proper execution of earth work after getting approval from Engineer. The
Contractor shall also provide design of shoring and strutting for prior approval of
Engineer. The details of any special arrangements like sheeting, cofferdams,
diaphragm walls, etc. shall be submitted to the Engineer.

4.04 BENCH MARKS

Throughout the construction, the contractor shall at his own cost establish,
construct, protect and maintain all bench marks and reference points to the
satisfaction of the Engineer and provide necessary assistance in taking and
recording of all measurements by the Engineer.

4.05 PROTECTION

The Contractor shall provide and maintain required decking, guard fencing,
roping, planks, sign boards, red lights etc. required to maintain safe pedestrian
and vehicular traffic and for safety of persons and property.

4.06 PRECIOUS OBJECTS, RELICS, OBJECTS OF ANTIQUITY ETC.

All gold, silver, oil, minerals, archaeological and other findings of importance,
trees cut or other materials of any description and all precious stones, coins,
treasures, relics, antiquities and other similar things which may be found in or
upto the site shall be the property of the Purchasers; and the contractor shall
duly preserve the same to the satisfaction of the Purchaser and from time to
time deliver the same to such person or persons as the Purchaser may from
time to time authorize or appoint to receive the same.

All fuses shall be cut to the lengths required before being inserted into the holes.
Joints in fuses shall be avoided. Where these are unavoidable, a semicircular


niche shall be cut in one piece of the fuse about 2 cm deep from the end and of
the other piece inserted into this niche, and the two pieces then wrapped
together with a string. All joints exposed to dampness shall be wrapped with
rubber tape. Fuses and detonators shall be kept separate from the explosives.

4.07 Excavation in rock requiring drilling

4.07.01 General

Hard rock is available below the RCC paving in the entire area proposed for wet
fly ash system. No blasting is permitted as important structures viz., Chimney,
ESPs and ESP building are in the vicinity.

4.07.02 Wherever rock is encountered, excavation is to be carried out by rock drilling
and removal of rock by excavator.

4.07.03 During the execution of work, any damage to the existing structures and any
dismantling required for taking up the work, shall be made good to the
satisfaction of the engineer in charge.

4.07.04 Personnel

4.07.05 Excavation by drilling will be permitted only under personnel supervision of
competent and licensed persons and trained workmen.

4.07.06 All supervisors and workmen in charge of make up, handling, storage and
drilling work shall be adequately insured by the contractor.

4.07.07 The storage shall be in charge of a very reliable person, approved by the
Engineer, who may if necessary, cause police enquiries being made as to his
reliability antecedents etc. The contractor shall have to produce a security for
the person in charge of the drilling, if and as required by the Engineer.

4.07.08 The contractor shall make sure that his supervisors and workmen are fully
conversant with all the rules to be observed in storing, handling and use of the
equipments. It shall be assured that the supervisor in charge is thoroughly
acquainted with all the details of the handling and the drilling operations.

4.08 Back Filling

The contractor shall include in his lump sum price, the cost of earth and sand fill
required including cost of materials, transportation consolidation etc, complete.
The earth used for back filling shall be free from salts, organic or other
impurities. All clods of earth shall be broken or removed. As soon as the work in
foundations up to original ground level has been accepted by the Engineer, the
space around the foundations shall be cleared of all debris, brick-bats etc and
backfilled with approved earth in layers not exceeding 200 mm in thickness.
Every layer shall be watered, rammed and properly compacted by Mechanical
Compactors or if approved, by manual tamping to 90% proctor density at
optimum moisture content (OMC) before the next layer is laid. The compaction
shall be to the satisfaction of the Engineer. Outside filling shall be done with
excavated material brought from within the project area as directed by the


Engineer, properly compacted. The sand filling required shall be done with local
sand. The used shall be clean, medium grained and free from impurities.
Maximum compaction shall be assured by dumping sand and flooding with water
for sufficient time. On reaching required level of compaction, the surface water
shall be drained out and the top dressed as per profile required.

5.0 CONCRETE FORMS AND REINFORCING STEEL WORK

5.01 General

The Contractor shall furnish all labour, materials and equipment required for the
construction of all concrete and associated work required as mentioned in clause
1.00. All cement concrete, reinforced or plain shall conform to Indian Standard
Code of Practice IS:456, with latest amendment, unless otherwise specified
herein. The concrete mixes used in various civil works shall be of the following
grades; the proportions of fine and coarse aggregate shall be determined in the
field, at the instance of the Engineer and at the cost and arrangement by the
contractor.

Proportion of
Grade
Composition Use
5.01.01 Nominal M15 240 kg of Portland cement
per each actual cubic
meter of finished vibrated
concrete with sand and
crushed and graded
coarse aggregate of size
not exceeding 40 mm.
Filling in sub-grade, mud mat
concrete for foundation work
mud mat below 0.000 floor
min. 100 mm thick.
5.01.02 M20
(controlled)
Minimum 320 kg of port
land cement per each
actual cubic meter of
finished vibrated concrete
and graded coarse
aggregate of size 40 mm
and down/ 20 mm and
down
Paving, grade floor slab &
misc. works
5.01.03 M25 Minimum 340 kg of
Portland cement per each
actual cubic meter of
finished vibrated concrete
with sand and crushed and
graded coarse aggregate
of size 40 mm and down/
20 mm and down
Foundations, RCC building
superstructure works for RCC
silos, ash slurry cum ash water
pump house, ash water tank,
compressor room, mechanical
exhauster room, MCC room
and control room

5.01.04 No extra payment shall be made for variation in several ingredients. The
engineer shall have the right to inspect the source of materials used, its storage
and order for any tests found necessary. The work shall be carried out to the
engineers satisfaction at the contractors cost. Any change in the source of


aggregates shall require the redesigning of the concrete mix for the engineers
approval.

5.02 Materials

5.02.01 Ordinary Portland Cement

Ordinary Portland cement conforming to IS:269 shall be used. The contractor
shall be fully satisfied with the quality and properties of cement used irrespective
of its source. Cement shall be kept in clean, dry, damp proof covered stores. It
shall be adequately protected from condensation, rising damp and atmospheric
moisture. Should at any time, the engineer have reasons to consider any
cement defective, then irrespective of its origin and/or manufacturers test
certificate, such cement shall be tested immediately at an approved laboratory
and until the results for such test are found satisfactory, it shall not be used in
any work. The contractor shall not be entitled to any claim of any nature on this
account.

5.02.02 All aggregates shall conform to IS:383. The natural aggregates shall be
chemically inert, strong, hard, durable, of limited porosity, free from adherent
coatings, clay lumps, coal and coal residues; and shall contain no organic or
other admixtures that may cause corrosion of reinforcement or impair the
strength or durability of the concrete. The limits of the content of deleterious
materials in aggregate, are indicated below:-

Limits of the content of deleterious materials*

Deleterious
substances
Fine Aggregates Coarse Aggregates
Uncrushed Crushed Uncrushed Crushed
Coal and lignite 1.00 1.00 1.00 1.00
Clay lumps 1.00 1.00 1.00 1.00
Soft fragments - - 3.00 -
Material passing 75
micron IS sieve
3.00 15.00 3.00 3.00
Shale 1.00 - - -

percent by max. weight of aggregates.

Note: The sum of percentages of all deleterious materials shall not exceed
three (3).

Approved natural and crushed granite for structural concrete and well washed,
thoroughly cleaned and graded natural gravel for lean and back fill cement
concrete shall be used as aggregates. Representative samples of selected
aggregates shall be tested at the contractors cost for sieve analysis from time to
time as required by the engineer for approval.

The source of materials shall be ascertained by the contractor before submitting
his offer. The contractor shall not be entitled to any claim of any nature on this
account.



5.02.021 Fine Aggregates

Fine aggregates (sand) shall be clean, sharp, coarse sand with a fineness
modules between 2.2 and 3.2 (fineness modulus is the sum of cumulative
percentages retained on the IS sieves given below for gradation divided by 100).
The contractor shall check and ensure that local sand satisfies this requirement;
and if necessary, shall include for and supply materials from other sources which
comply with the specifications. It shall be graded as follows:

Designation of IS Sieve
zone
Percentage passing for
Grading
Zone-I
Grading
Zone-II
Grading
Zone-III
10 mm 100 100 100
4.75 mm 90-100 90-100 90-100
2.36 mm 60-95 75-100 85-100
1.18 mm 30-70 55-90 75-100
600 micro9n 15-34 35-59 60-79
300 micron 5-20 8-30 12-40
150 micron 0-10 0-10 0-10

The objectionable foreign matter in sand shall be removed by screening or
washing or both as required.

5.02.022 Coarse Aggregates

Coarse aggregates shall be procured/used only from approved quarries. Coarse
aggregates shall conform the following grading limits.

IS Sieve Designation Percentage retained for graded aggregate
of nominal size
40 mm 20 mm 16 mm 12.5 mm
80 mm - - - -
40 mm 0-5 0 - -
20 mm 30-70 0-5 0 0
16 mm - - 0-10 -
12.5 mm - - - 0-10
10 mm 65-90 45-75 30-70 15-60
4.75 mm 95-100 90-100 90-100 90-100

The pieces shall be angular in shape and shall have granular or crystalline
surfaces.

5.02.0221 Friable, flaky and laminated pieces, mica and shale, if present, shall be only in
such quantities that will not, in the opinion of engineer, affect adversely the
strength and durability of concrete. The max. size of aggregate shall be as
specified. The maximum size of coarse aggregate shall be the maximum size
specified, but in no case greater than of the minimum thickness of the
member, provided that the concrete can be placed without difficulty so as to
surround all reinforcement thoroughly and fill the corners of the form. For heavily
reinforced concrete members, the nominal maximum size of the aggregate shall


be 5 mm less than the minimum clear distance between the reinforcing main
bars or 5 mm less than the minimum cover to the reinforcement whichever is
smaller.

5.02.0222 Crushing Value

The aggregate crushing value, when determined in accordance with IS:2386
(Part-IV) shall not exceed 45 percent for aggregate used for concrete other than
for wearing surfaces, and 30 percent for concrete for wearing surfaces, such as
roads pavements and floor finishes.

5.02.0223 Impact Value

As an alternative to 5.02.0222 the aggregate impact value may be determined in
accordance with the method specified in IS: 2386 (Part-IV). The impact value
shall not exceed 45 percent by weight for aggregates used for concrete other
than for wearing surfaces and 30 percent by weight for concrete for wearing
surfaces, such as roads, pavements and floor finishes.

5.02.0224 Abrasion Value

Unless otherwise agreed to between the Purchaser and the supplier, the
abrasion value of aggregates, when tested in accordance with the method
specified in IS: 2386 (Part-IV), using Los Angeles machine, shall not exceed the
following values:-

a. For aggregates to be used in concrete Thirty(30)
for wearing surfaces

b. For aggregates to be used in other Fifty(50)
concrete (structural)

The amount of fine particles occurring in the free state or as loose adherents
shall not exceed 1% when determined by laboratory sedimentation tests as per
IS:2386. After 24 hours immersion in water, a previously dried sample shall not
have gained more than 10% of its even dry weight in air, as determined by
IS:2386.

All aggregates shall be stored on approved planking or sloping, flat, well drained
brick soling; and shall at all times be protected from injurious contamination.
Different sizes shall be stacked sufficiently apart or separated with approved
wooden bulk heads.

Should at any time, the engineer have reason to consider any aggregate
defective or of poor quality, then irrespective of any previous approval or tests,
representative samples of such materials shall be immediately tested and until
the results of such tests prove the material to be satisfactory, it shall not be used
for any work. The contractor shall not be entitled to any claim of any nature on
this account. The cost of these tests (including collection of samples and
transportation) shall be borne by the contractor.



5.02.0225 Storage of Aggregates

All coarse and fine aggregates shall be stacked separately in stock piles to avoid
mixing of different aggregates. While heaping the materials, contamination with
foreign materials and earth shall be avoided. The aggregates must be of
specified quality not only at the time of receiving at site but particularly at the
time of loading into mixer. Rakers shall be used for lifting the coarse aggregates
from stock piles. The coarse aggregates shall be piled in layers not exceeding
1.20 meters in height to avoid segregation; each layer shall cover the entire
stock piled area before placing the next layer. Aggregates that have become
segregated shall be rejected; however, rejected material may be accepted after
remixing if subsequent tests demonstrated conformance with required gradation.

5.02.03 Water

5.02.031 Water for all work shall be fresh, clean and free from injurious or deleterious
materials and conforming to IS:3025. The contractor shall provide at his own
cost for distribution, storage, filtration and/or treatment, as necessary of the
required quantity of water. Quantity of water to be used in concrete shall be
such as to obtain the consistency specified. This quality of water shall be
subject to approval by the engineer on the basis of test finding and shall in no
case be changed without permission. The suitability of water for making concrete
shall be ascertained by the compressive strength and initial setting time test
specified in IS:456. The sample of water taken for testing shall be typical of the
water proposed to be used for concreting, due account being paid to seasonal
variation. The sample shall not receive any treatment before testing other than
that envisaged in the regular supply of water proposed for use in concrete. The
sample shall be stored in a clean container previously rinsed out with similar
water.

5.02.032 Average 28 day compressive strength of a at least three 15 cm concrete cubes
prepared with water proposed to be used shall not be less than 90% of the
average strength of three similar concrete cubes prepared with distilled water.

5.02.033 The initial setting time of test block made with the appropriate test cement; and
the water proposed to be used shall not be less than 30 minutes; and shall not
differ by more than 3 minutes from the initial setting time of control test block
prepared with the appropriate test cement and distilled water. The test blocks
shall be prepared and tested in accordance with the requirements of IS:4031.

5.02.0334 The water used shall also conform to the following:

a. To neutralize 200 ml sample of water, using phenolphthalein as indicator,
it should not require more than 2 ml of 0.1 normal NaoH. The details of
test shall be as given in IS:3025.

b. To neutralize 200 ml sample of water, using methyl orange as an
indicator, it should not require more than 10 ml of 0.1 normal HCL. The
details of test shall be as given in IS:3025.

c. Percentage of solids, when tested in accordance with IS:3025 shall not
exceed the following:-


Description Percent

Organic 0.02

Inorganic 0.30

Sulphate (as SO
4
) 0.05

Alkali chlorides 0.10

Suspended matter 0.20

5.03 CONTROLLED CONCRETE

5.03.01 In proportioning concrete, the quantity of both cement and aggregates should
be determined by weight. Cement shall be measured by weight but aggregates
may be converted into their volumetric equivalent to facilitate work. Water
should be either measured by volume in calibrated tank or by weight. All
measuring conditions and the accuracy may be periodically checked. It is
most important to maintain specified water cement ratio constant at its correct
value, due allowance being made for the moisture content of coarse and fine
aggregates.

5.03.02 No substitution in material used on the work or alteration in the established
proportions as given above shall be made without prior approval of Engineer.

5.04 COMPRESSIVE STRENGTH OF THE CONCRETE

5.04.01 Minimum compressive strength shall be as specified under para 5.04.02 below.
All the related tests for this shall be at the Contractors expense. These tests
shall be witnessed by the Contractor or his representatives and those of the
Engineer. Where the work concerned requires it, concrete permeability tests
shall also be done.

5.04.02 Minimum compressive strength of 15 cm cubes shall be as follows:

Comprehensive strength in N/mm
2
Work Test

Grade of Concrete at seven (7) days at twenty eight
(28) days

M15 15 15
M20 13.5 20.0
M25 17.0 25.0

5.04.021 Preliminary Test

A test conducted in a laboratory on the trial mix of concrete produced in a
laboratory with the object of:



- designing a concrete mix before the actual concreting operations start.

- determining the adjustments required in the designed mix when there is
a change in the materials used during the execution of work.

- verifying the strength of concrete mix.

5.04.022 Test specimens shall be prepared with at least two different water/cement
ratios for each class of concrete consistent with workability required for the
nature of work. The materials and proportions used in making preliminary tests
shall be similar in all respects to those to be actually employed in the works as
the object of these tests is to determine the proportions of cement, aggregate
and water necessary to produce concrete of required consistency and to give
specified strength. It shall be the Contractors sole responsibility to carry out
these tests. He shall furnish to the Engineer a statement of proportions
proposed to be used for the various concrete mixes.

5.04.023 For the preliminary tests, the concrete shall be mixed by hand or in a small
batch mixer as per IS 516 in such a manner as to avoid loss of water. The
cement and fine aggregate shall first be mixed dry until the mixture is uniform
in colour. The coarse aggregate shall then be added, mixed and water added
and the whole batch mixed thoroughly for a period not less than two minutes
until the resulting concrete is uniform in appearance. Each batch of concrete
shall be of such a size as to leave about 10% excess concrete, after moulding
the desired number of test specimens.

5.04.024 The consistency of each batch of concrete shall be measured immediately
after mixing by the slump test in accordance with IS:1199. The concrete test
cubes shall be moulded by placing fresh concrete in the mould and compacted
as specified in IS 516. Curing shall be as specified in IS:516. The compression
tests of concrete cubes shall be carried out as per IS 516 on 15 cm cubes.

5.04.025 The strength shall be determined based on not less than 5 cubes test
specimens for each age and each water cement ratio. All these laboratory
test results shall be tabulated and furnished to the Engineer.

5.04.026 The test results shall be accepted by Engineer if the average compressive
strengths of the specimens tested is not less than the compressive strengths
specified for the age at which specimens are tested, subject to the condition
that only one out of the 5 consecutive tests may give a value less than the
specified strength for that age. Engineer may direct contractor to repeat the
tests if the results are not satisfactory and also to make such change as he
considers necessary to meet the requirements specified. All these preliminary
tests shall be conducted by Contractor at his own cost in an approved
laboratory. All testing shall be carried out as per IS:516.

5.04.03 Work tests shall be performed according to the following schedule:

5.04.031 Frequency of sampling shall be as per IS: 456: 2000 Clause No 15.2.2.
Concrete shall be considered unsatisfactory if the average strength of three-
28 days cubes is below the specified value. However, only one of the three


consecutive tests may give a value less than the specified strength but this
shall not be less than 90% of the specified strength.

5.04.032 Samples shall be taken while concrete is being poured in the presence of
representatives appointed by the Engineer and the Contractor. Proper record of
work tests shall be maintained and signed jointly. The preliminary test and
works tests shall be at the Contractors expense.

5.04.04 MIXING OF CONCRETE

5.04.041 Cement, sand and crushed stone shall be measured by weight as directed by
the Engineer; the components of the concrete shall be batched in such a way
that each batch contains a whole number of cement bags. Concrete shall be
mixed in concrete mixers of a size and type previously certified acceptable
to the Engineer. Concrete shall be mixed in the machine for at least one (1)
minute dry and for at least one and half (1.5) minutes after adding water.
Mixed concrete shall be of even colour and uniform consistency.

5.04.042 Concrete shall be mixed only in such quantities as are required for immediate
use. No more concrete shall be mixed in any one let than that can be laid in
position before the initial setting occurs. Partly set or re-tampered concrete
shall not be used. After the finish of each days work, the mixing plants shall
be thoroughly washed and cleaned. On commencing work, the first batch
shall have 10% additional cement.

5.04.043 The mixer and weigh batchers shall be maintained in a clean, serviceable
condition. The accuracy of weigh batchers shall be periodically checked. They
shall be set up level on a firm base and the hopper shall be loaded evenly. The
needle shall be adjusted to zero when the hopper is empty. Fine and coarse
aggregates shall be weighed separately. Volume batching will not be
permitted. However, Engineer may permit volume batching by subsequent
conversions of weights of the aggregates into their equivalent volumes
knowing their bulk densities. Only in the case of small and less important
pours, all concrete shall be mixed in mechanically operated batch mixers
complying with IS:1719 and of approved make with suitable provision for
directly controlling the water delivered to the drum.

5.04.044 The water-cement ratio to be adopted shall be determined in each case by the
Contractor frequently as desired by the Engineer and shall be approved by
him. The water cement (W/C) ratio is defined as the weight of water in the
mix (including the surface moisture of the aggregates) divided by the weight of
cement in the mix.

5.04.05 CONSISTENCY & WORKABILITY OF THE CONCRETE

5.04.051 Consistency and workability of concrete shall be checked by measuring the
slump of a truncated cone of concrete straight from the mixer under normal
working conditions. The conical mould shall be of metal, 300 mm high and 100
mm and 200 mm in diameter at top and base respectively.

5.04.052 Moulds shall be prepared by the Contractor. The slump range of concrete shall
be as mentioned in the Released for Construction drawings.


5.04.053 Slump tests shall be performed as per IS: 456: 2000, Clause 7.10 at intervals
established by the Engineer at the Contractors cost in such a way as to check
that the degree of consistency established by the Engineer for work in
progress is maintained. The table below gives the general slump range to be
followed for various types of construction unless otherwise shown on drawings
or instructed by the Engineer:-

Various types of Construction Slump mm

Max. Min.

Concrete for use on large non- 75 25
Reinforced pours

Reinforced concrete slender vertical 75 25
Horizontal structures

Reinforced concrete: large volume 75 25
Structures

Columns, slabs, beams and reinforced 100 50
walls

5.04.054 COMPACTION FACTOR TEST

the workability test by means of compaction factor tests as per IS:1199 shall
also be carried out by the Contractor at his own cost.

5.05.0 Transporting of Concrete

5.05.01 Mixed concrete shall be conveyed and placed in the forms as rapidly as possible
without segregation or loss of ingredients. Re-handling and flowing shall be
minimum. Total time lapsed between addition of water to mixer to completion of
placing shall not exceed 30 minutes. The concrete which has not been placed in
the final position within such time and the concrete contaminated with foreign
material shall be rejected and disposed off as directed by the engineer.

5.05.02 The means adopted for transportation/carriage/flow of concrete of mixed
concrete shall be wheel barrows, concrete carts, monorails, guided hoists,
concrete chutes or any other method approved by the engineer. The free fall of
concrete to be laid shall not exceed 1.5 M to avoid segregation. In case
segregation does occur during transportation, concrete shall be got remixed
before placing it in final position. An approved intermediate hopper shall be used
for intermittent operations. The concrete chutes or any other device should be
thoroughly cleaned before and after each run.

5.05.03 Placing of concrete

5.05.31 Before placing the concrete, the contractor shall ensure that:

- All mixing and placing equipment is thoroughly cleaned


- All concreting space is free from debris and rubbish
- All forms have been thoroughly wetted or oiled and firmly installed in line
and plumb to engineers approval.

- All reinforcement is cleaned of loose rust, scales and other injurious
adherents and is firmly bound and correctly placed and has been so
approved by the engineer.

- All inserts, sleeves, foundation bolts and embedded parts have been
correctly and firmly installed to conform to the engineers drawings and
have been carefully checked to comply with the drawings. Special care
shall be taken to locate and check sleeves or inserts which may not be
symmetrically placed with respect to center lines.

5.05.32 The contractor and engineer shall separately inspect and check the above
mentioned points and record and sign the results in a register which shall be
maintained by the contractor in an approved form. No concrete shall be placed
without the engineer having inspected and approved in writing. Inspite of
ensuring the above requirements, the contractor shall fill pour cards furnishing
the necessary details of the job, duly signed by the engineer. This however,
shall not absolve the contractor from his responsibility to correctly execute the
work. Pour cards shall contain the following information:

Design Index

- Slump
- Workability
- Work test specimen
- Type of finishing and admixtures used (if any)
- Period for removal of shuttering/props/forms

5.05.33 The concrete pouring method shall be submitted to the engineer for approval;
and shall always be such as to avoid any possibility of segregation of the
components or shifting of the reinforcement.

5.05.34 Special grout or mix shall be used for difficult and intricate locations as specified
by the engineer. During placing, the concrete shall be thoroughly worked around
reinforcement, embedded parts and corners of the formwork.

5.05.35 Greatest possible care shall be taken by the contractor that reinforcement and
embedded parts, particularly foundation bolts and sleeves are not displaced
during placement of concrete. While concreting mats and other such locations
where top and bottom reinforcement are adopted, top reinforcement shall be
thoroughly cleaned of all slurry and mortar sticking to them at the time of
concreting top layers.

5.06.0 Jointing

5.06.01 Concrete shall be cast, as far as possible, continuously until the parts of the
structure to be built are finished. Should this not be feasible, the type, number
and location of construction joints shall be approved by the engineer prior to
placing concrete.


5.06.02 All such joints shall have continuous square bond grooves to produce a
substantial and water tight key; and the exposed faces of joints shall be
monolithic with the main mass of concrete formed and completed under
substantially shuttered faces. The contractor shall take all the necessary steps
by means of timber edging etc to ensure an exact horizontal straight finish to
outside edge of any lift of concrete. Subject to the approval of engineer, the
contractor is at liberty to arrange his own construction joints but the following
restrictions shall be observed:

a. There shall be no vertical construction joints in the vertical direction.

b. Concrete pouring shall be reasonably large, but in no case shall the
height of pouring concrete exceed 2.0 metres without the engineers firm
approval. Such approval shall not in any way relieve the contractor of his
responsibility to ensure that no segregation takes place.

5.06.03 Laitance shall be removed from the surface of concrete before it has set hard by
washing and wire brushing so as to expose the stones of the top layer without
undue erosion of the mortar or damage to the underlaying concrete.

5.06.04 All beds and joints in concrete faces, which have become set shall be picked all
over and all loose materials removed before fresh concrete is deposited thereon.
The indentations shall be at least 12 mm deep and no less than 75 percent of
the area of the existing concrete face to be covered over, care shall be taken
that the indentations are not nearer than 38 mm to the exposed edge of the
concrete.

5.06.05 Immediately before depositing fresh concrete, the exposed surfaces shall be
cleaned of foreign matter by further wire brushing, if necessary. It shall then be
thoroughly washed and surplus water removed. The surface while still moist
shall be covered with layer of 1:1 cement mortar which must be vigorously
stippled into the surface by means of a stiff brush, the depositing of the fresh
concrete following on closely. Pockets to form keys shall be left in the surface of
the concrete at construction joints; 75 mm deep and approximately equal to 20
percent of the exposed surface.

5.06.06 All costs in connection with the forming of construction joints shall be
contingency of the contract.

5.06.07 Concrete in beams and slabs shall be placed throughout without a joint.

5.07.00 Vibration

Concrete to be vibrated shall be placed in level layers of suitable thickness not
greater than the effective length of the vibrator needle. The concrete at the
surface shall be distributed as horizontally as possible. The vibration shall not
be done in the neighbourhood of slopes. The internal vibrator shall not be used
to spread the concrete for filling. It is advisable to deposit concrete well in
advance of the point of vibration. When the concrete is being continuously
deposited to a uniform depth along a member, vibrator shall not be operated too
near to the free end of the advancing concrete, usually not within 1.20 metres of


it. Every effort shall be made to keep the surface of the previously placed layer
of concrete alive so that the succeeding layer can be amalgamated with it by
vibration process. Following points shall be kept in mind while vibrating
concrete:-

5.07.01 The concrete shall be placed in shallow layers consistent with the method being
used to place and vibrate the concrete. Usually concrete shall be placed in
thickness not more than 300 mm and on initial placing in thickness not more than
150 mm.

5.07.02 The vibrator head shall be dipped through filling which shall be consolidated to
further depth of 10 to 20 mm in the lower layer which the already been
consolidated.

5.07.03 Vibration shall be carefully controlled, the internal vibrator being systematically
inserted at points minimum 450 mm apart and maintained in position for a fixed
time. Immersion for periods of 5 to 15 seconds should normally be sufficient.
The limit of action is judged by surface appearance. The surface shall neither be
honey combed nor shall it contain excess mortar.

5.07.04 The vibrator shall be inserted vertically. With inclined or haphazard insertion, it
shall be impossible to regulate the degree of compaction in all portions of the
concrete. Care shall be taken to prevent contact of immersion vibrators with
formwork, reinforcement steel and finished surfaces. Immersion vibrators shall
not come in contact with reinforcement steel if initial set of concrete around it has
started.

5.07.05 The vibrator shall be allowed to penetrate on its own accord and should be
withdrawn quite slowly, at the rate of about 75 mm per second, whilst still
running, so as to allow the redistribution of the concrete in it wake.

5.08.0 Curing

5.08.01 Curing shall start from the time of final set of concrete. Concrete shall be kept
damp for as long a period as practicable. Concrete surfaces that are
approximately horizontal shall be cured by ponding, water being maintained at a
depth of at least 25 mm for a minimum period of 14 days.

5.08.02 Arrangements shall be made by the contractor for a standby supply of water in
case of failure of the normal supply. The contractor shall see that the sump/
water retaining structure are water tight and as such shall take all precautions to
ensure a thorough and dense concrete. On completion of the curing, the work,
as necessary, shall be filled with water. The water shall be maintained at the
same level for a period of 7 days, after which time, it shall be emptied. Any parts
which show signs of leakage shall be marked during the test and shall be traced
to the inside face of the pond after emptying and sealed with bitumen or other
suitable material and retested to the satisfaction of the engineer. This shall be
deemed to have been included in the lump sum amount of the contractor.



5.09.00 Sub Standard Concrete

Should the work strength of controlled concrete fall below the specified strength,
the engineer will decide.

5.09.01 To reject the work, in which case the contractor shall replace the defective work
with concrete of required strength and bear all costs for dismantling and
replacing including the cost of associated formwork, reinforcement, embedded
parts and associated works.

5.09.02 To accept the work at a reduced rate, in which case the unit rate payable for
substandard work will be reduced by the Purchaser directly in proportion to the
work strength as compared to the specified strength. The Purchaser may, in
addition, require other tests performed on the respective structural member so
accepted prior to its acceptance with or without necessary corrective measure
and in each such case the contractor shall bear all costs for all such tests or
corrective measures, besides the reduction in the unit rates as specified herein.

5.09.03 Concrete of strength below 10 percent of the specified strength will not be
accepted.

5.09.04 The test load shall be 125 percent of the maximum superimposed load for which
the structure was designed. Such test load shall not be applied before 56 days
after the effective hardening of concrete. During the test, struts strong enough to
take the whole load shall be placed in position leaving a gap under the members.
The test load shall be maintained for 24 hours before removal.

5.09.05 If within 24 hours of the removal of the load, the structure should not show a
recovery of at least 75 percent of the maximum deflection shown during the 24
hours under load, the test loading shall be repeated after a lapse of at least 72
hours. The structure shall be considered to have failed to pass the test if the
recovery after the second test is not at least 75 percent of the maximum
deflection shown during the second test. If the structure is certified as failed by
the engineer, the cost of the load test shall be borne by the contractor.

5.09.06 Optional Tests

Engineer, if he so desires, may order tests to be carried out on cement, sand,
coarse aggregate, water in accordance with the relevant Indian Standards.

Tests on cement shall include (i) fineness test (ii) test for normal consistency (iii)
test for setting time (iv) test for soundness (v) test for tensile strength (vi) test for
compressive strength (vii) test for heat of hydration (by experiment and by
calculations) in accordance with IS: 269.

Tests on sand shall include (i) sieve test (ii) test for organic impurities (iii)
decantation test for determining clay and silt content (iv) specific gravity test (v)
test for unit weight and bulkage factor (vi) test for sieve analysis and fineness
modulus.

Tests on coarse aggregates shall include (i) sieve analysis (ii) specific gravity
and unit weight of dry, loose and rodded aggregate (iii) soundness and alkali


aggregates reactivity (iv) petrographic examination (v) deleterious materials and
organic impurities (vi) test for aggregate crushing value.

Any or all these tests should normally be carried out only if the engineer feels the
materials are not in accordance with the specification or if the specified concrete
strengths are not obtained; and shall be performed by contractor or at an
approved test laboratory at his cost.

5.09.07 Concrete in Alkali Soils and Alkaline Water

Where concrete is liable to be attacked from alkali salts or alkaline water, special
cements containing low amount of tricalcium aluminate shall be used, if so
specified on the drawings. Such concrete shall have a minimum 28 days
compressive strength of 250 kg/cm2; and shall contain not less than 400 kg of
cement per cubic metre of concrete in place. If specified, additional protection
shall be obtained by the use of a chemically resistant stone facing or a layer of
plaster of paris covered with suitable fabric, such as jute thoroughly impregnated
with tar.

5.09.08 Rain or Wash Water

No concrete shall be placed in wet weather or on a water covered surface. Any
concrete that has been washed by heavy rains shall be entirely removed if there
is any sign of cement and sand having been washed away from the concrete
mixture. To guard against damage which may be caused by rains, the works
shall be covered with tarpaulins immediately after the concrete has been placed
and compacted before leaving the work unattended. Any water accumulating on
the surface of the newly placed concrete shall be removed by approved means
and no further concrete shall be placed, thereon until such water is removed. To
avoid flow of water over/around freshly placed concrete, suitable drains and
sumps shall be provided.

5.09.09 In case the engineer so desires, the contractor shall get the quality of cement
tested as per relevant codes and submit the report for the approval of the
engineer. The contractor shall not be entitled for any extra claim on this account.

5.09.10 In case the cement issued to the contractor by the department stores has been
stored for more than 90 days, the contractor shall get the quality of the cement
tested as per relevant Indian Standards and submit the report for the approval of
the engineer. The contractor shall not be entitled for any extra claim on this
account.

5.10.00 Concreting in Hot Weather

Concrete shall not normally be placed when the atmospheric temperature
exceeds 40 degrees centigrade in the open. If, in spite of programming concrete
work in the cooler hours of early morning, evening or night placement is
necessary in too hot a weather, then the contractor shall take the following other
precautions:

- Stockpile aggregates in shade.
- Do not use fresh factory hot cement


- Use cold water/ice as directed by engineer.
- Cool formwork by sprinkling chilled water without collecting water inside.
- Reduce to minimum the time interval between mixing and placing
- Place, vibrate and finish as quickly as possible
- Initiate curing as soon as concrete hardens
- Use retarders as directed by Engineer-in-charge.

5.11.0 Concrete in Cold Weather

Special precautions as per IS:456 shall be taken, should concreting be
necessary when atmospheric temperature in the open is below four (4) degrees
centigrade.

5.12.0 Formwork

5.12.01 All formwork shall be of steel or plywood, made mortar proof and sufficiently
strong and well anchored to withstand the loads they have to bear without any
distortion.

5.12.02 Before constructing forms, the contractor, if required, shall submit detailed
drawings and design wherever necessary in critical areas of proposed formwork
for examination by the engineer,. Safety against buckling of any member shall
be investigated in all cases. If such drawings are not satisfactory to the
engineer, the contractor shall make such changes as may be required prior to
start of the work. The engineers approval of the drawings as submitted, or as
corrected shall in no way relieve the contractor of his responsibility for
adequately designing constructing and maintaining forms and the safety of
formwork so that they will function properly under applicable conditions of work.

5.12.03 Formwork shall be built with great care; all forms not found skill fully and
perfectly made or lacking in rigidity will be rejected.

5.12.04 Support shall be of the required dimensions for the work concerned and of first
class materials.

5.12.05 False work shall be so constructed that vertical adjustments can be made to
compensate for take up and settlement. Wedges shall be used at the top or
bottom of shores to facilitate vertical adjustment or dismantling of the formwork.
To permit easy removal, the maximum load per wedge shall be 15 tonnes when
located at the top and 20 tonnes when located at the bottom.

5.12.06 When wire is used to position the forms and reinforcement and it remains
embedded in concrete, it shall be cut. Once the formwork is dismantled, to a
depth of 10 mm from the concrete surface, then the hole shall be sealed in 1:1
cement mortar. When reused formwork is employed, it shall be perfectly
cleaned, straightened and oiled.

5.12.07 Formwork shall be such that the finished structures are true to shape and size as
shown on drawings.

5.12.08 It shall be noted by the Contractor that no through bolts will be permitted to be
used in the formwork.


5.12.09 The vertical loads assumed shall consist of the dead load plus allowance for live
load. The weight of formwork together with weight of freshly placed concrete
shall be considered dead load. The live load consisting of the weight of
workmen, equipment, runways and impact hall be taken as not less than 500
kg/m
2
of horizontal projection.
5.12.10 Forms, ties and bracing must be designed for a lateral pressure of fresh concrete
of maximum of 3 to 4 tonnes/m
2
unless higher loads are likely to occur in any
special cases as may be specified on the drawings. Braces and shores must be
designed to resist all forceable lateral loads such as wind, cable tensions
inclined supports, dumping of concrete, and starting and stopping of equipment.
In no case, should the assumed value of lateral load due to wind, dumping of
concrete and equipment acting in any direction at each floor line be less than
150 kg/metre of floor edge or two (2) percent of total dead load of the floor,
whichever be greater. Wall forms should be designed for maximum wind load at
least 50 kg/m
2
; and bracing for wall forms shall be designed for a lateral load of
at least 150 kg/metre of wall applied at the top.

5.12.11 The formwork must be designed for any special conditions of construction likely
to occur, such as unsymmetrical placement of concrete, impact of machine
delivered concrete, uplift, and concentrated load. Imposition of construction load
on the partially completed structure shall not be allowed except with the written
approval of the engineer.

5.12.12 A design analysis will not be required for formwork for structures less than 5
metres in height if all loads are transmitted directly to the ground by vertical
supports. However, safety against buckling of any member shall be investigated
in all the cases. For heavy construction and for all other cases, design analysis
shall be made and got approved by the engineer. The formwork system shall be
designed to transfer all lateral loads to the ground in such a manner as to ensure
safety at all times. Diagonal bracing shall be provided in vertical and horizontal
planes where required to provide stiffness and to prevent buckling of individual
members.

5.12.13 The internal dimensions of the forms shall conform precisely to the structure to
be built; they shall have smooth surfaces and their corners shall be rounded with
20 mm side triangular wooden stats, unless otherwise specified on drawings.
Forms shall be sufficiently rigid to hold without distortion the fresh concrete, the
vibrations ensuing from transit and distribution of the concrete, with a minimum
factor of safety of 1.5.

5.12.14 Beams forms shall be provided with ties to avoid horizontal distortion; formwork
for columns shall be reinforced with square braces and those of considerable
cross-section or height shall be bound with spirals of twisted wire.

5.12.15 All forms shall be generously nailed; boards for slab work shall have atleast two
(2) nails on each supporting tie-rod. Boards shall be of uniform thickness; edges
shall be at right angles and smooth for easy jointing.

5.12.16 The number of supports shall be such as to safely support the loads specified;
the engineer may demand that their number of increased whenever it is
considered necessary. A load spreading plate shall be placed on the top of the
supports; their base shall rest on a dual wooden wedge arrangement.


5.12.17 Prior to the concreting as well as after concreting the exposed surfaces of the
shuttering or moulds shall be cleaned of all adhering concrete before depositing
of fresh concrete. Details of construction joints shall be arranged so that a
Starter is provided to which the forms for the next pour can be tightly clamped
and suitable baulking shall be used to prevent leakage of grout from the
concrete.

5.12.18 Wherever concreting of narrow members is required to be carried out within
forms of considerable depth temporary openings in the sides of the forms shall, if
so directed by the engineer, be provided to facilitate the pouring and
consolidation of concrete.

5.12.19 Small temporary openings shall be provided if necessary at the bottom of forms
for columns, walls and deep beams to permit the expulsion of rubbish etc.
Shuttering must be used for all slopes exceeding 15 degrees to the horizontal, to
enable the concrete to be properly rammed.

5.12.20 No load shall be put or any weight suspended from slabs, for one month after
casting and temporary props shall be left in for the support of the underside of
slabs, beams etc for as long as is reasonably practicable after stripping
shuttering.

5.12.21 No shuttering or temporary props shall be removed without permission of the
engineer and being recorded in the contractors Log Book under the engineers
signatures.

5.12.22 Form stripping shall be performed slowly and gradually, after the minimum
period for striking formwork as per clause 5.12.24.

5.12.23 The formwork in contact with concrete shall be clean and well coated with mould
oil. Mould oil used shall be insoluble in water, non-staining and non-injurious to
concrete. It shall not become flaky or be removed by water.

5.12.24 The minimum period for striking formwork shall be as under:

a. Walls, columns and vertical sides 24 hours as directed
of beams by the engineer

b. Slabs (props left under) 3 days

c. Beam soffits (props left under) 7 days

c. Removal of props to slabs

i) Spanning up to 4.5M 7 days
ii) Spanning over 4.5M 14 days

d. Removal of props-beams and arches

i) Spanning up to 6M 14 days
ii) Spanning over 6M 21 days


5.12.25 Concrete surface shall not normally be patched or otherwise treated after the
removal of forms. Where the surface exposed on stripping is not of a
satisfactory nature, owing to the contractors failure to take necessary precaution
before, during or after the concrete placing, such surfaces shall be worked and
finished in accordance with the instructions of the engineer, at the cost of the
contractor. The pores may be filled in with a weak solution of cement and water
applied by brush and when dry the surface rubbed down with carborundum
stone. The cost of the above treatment shall be deemed to be included in the
lump sum price quoted by the contractor. The top surface of the reinforced
concrete slabs shall be screeded-off unless otherwise specified, to the required
levels. There must be no surface grouting or treating up which might draw the
fines to the top. All shuttered surfaces shall be left as they strip without
removing board or panel marking. Any serious honey combing will render the
concrete work liable to rejection and cutting out and reconcreting wholly or partly
as the engineer directs. All costs involved in repairing defects shall be borne by
the contractor.

5.12.26 The contractor shall submit the design of staging and hoisting arrangement for
engineers approval.

5.13 Admixtures

5.13.01 General

Admixtures shall be used in concrete only with the approval of engineer for the
works specified based upon the evidence that, with the passage of time, neither
the compressive strength nor its durability is reduced. Calcium chloride shall not
be used for accelerating set of the cement for any concrete containing
reinforcement, or embedded steel parts. When calcium chloride is permitted to
be used, such as in mass concrete work, it shall be dissolved in water and added
to the mixing water in an amount not to exceed 1.5 percent of the weight of the
cement in each batch of concrete. When the admixtures are used, the designed
concrete mix shall be corrected accordingly. Admixtures shall be used as per
manufacturers instructions and in the manner and with the control specified by
engineer.

5.13.02 Air Entraining Agents

Where specified and approved by engineer, neutralized vinyl resin or any other
approved air entraining agent shall be used to produce the specified amount of
air in the concrete of mix and these agents shall conform to the requirements of
ASTM standard 6-260, air entraining admixtures for concrete. The
recommended total air content of the concrete shall be 4% 1%. The method of
measuring air content shall be as IS:1199.

5.13.03 Retarding Admixtures

Where specified and approved by engineer, retarding agents of CICO make or
approved equivalent shall be added to the concrete mix in quantities specified by
engineer.



5.13.04 Water Proofing Agent

Where specified and approved by engineer, water proofing agent conforming to
iS:2645 of CICO make or approved equivalent shall be added in quantities
specified by engineer.

5.13.05 Other Admixtures

Engineer may at his discretion instruct contractor to use any other admixtures in
the concrete.

5.14 Reinforcing Steel

5.14.01 Reinforcement shall consist of any of the following types but shall conform to
requirements as shown on the drawings:

- Plain mild steel bars (IS-432 Part-I)

- Cold twisted or deformed bars (IS:1786) Grade Fe 500.

- Medium tensile steel bars (IS:432 Part-I)

5.14.02 The contractor shall check and ensure that appropriate test certificates of
materials drawn are available for engineers inspection; otherwise necessary
tests shall be made by the contractor at his own cost to ensure that the quality
and physical properties of materials used conform to the specifications. No
complaints or claims shall be entertained on this account.

5.14.03 All reinforcing material, before its final use shall be free from loose mill scale,
rust, dust, oily or bituminous coatings or injurious adherents. Pitted and
otherwise defective bars shall not be used. Re-rolled scrap steel, bars shall not
be used.

5.14.04 The contractor shall check, ensure and procure in time as necessary the
reinforcing materials required for the continuous scheduled progress of work till
completion. All reinforcing steel shall be suitably stacked and stored by the
contractor to protect it from damage by corrosion and to prevent from distortion
of section in long lengths.

5.14.05 The reinforcement shall be sent in accordance with IS:2502 and as approved by
the engineer. Bars shall be bent cold except bars larger than 25 mm in size
which may be bent hot at cherry red heat (not exceeding 850 degrees
centigrade).

5.14.06 Those bars which depend for their strength on cold working shall be bent cold.
Hot bars shall not be cooled by quenching. Any type of equipment may be used
for bending of bars with the prior approval of the engineer.

5.14.07 All reinforcement shall, as far as possible, shall be furnished in full lengths,
shown in the drawings. The length of laps in bars shall be as per clause 26-2-1
of IS:456:2000.


5.14.08 Welding by electricity or gas may be permitted with the written approval of the
engineer, provided the carbon content of steel used is less than 0.3 percent.
Welding so permitted shall be in accordance with IS:816. Substitution of
differential size bars shall be permitted only when authorized by the engineer.

5.14.09 No part of the reinforcement, irrespective of whether the concrete work is under
construction or completed, shall be used for conduiting electrical currents.
Electrical grounding connections shall be carefully isolated from reinforcement.

5.14.10 The number and size of all steel bars, ties, stirrups and other members of the
reinforcement shall be in exact accordance with the drawings and the rods shall
be bent cold by the gradual and uniform application of force to the shapes and
dimensions given in the bar bending schedule. These schedules shall conform
to IS:1566. The size of the hooks if not specifically dimensioned shall be as per
IS:456.

5.14.11 Bars which have been bent wrongly shall not be straightened, rebent and used
without the permission of engineer.

5.14.12 Reinforcement shall be suitably supported by steel or concrete spacers, care
being taken during the concreting operation to maintain the concrete cover
specified. All hooks, links and strirrups shall be sent so that the bars then tired
together shall be properly braced. If possible, the reinforcement shall be
fabricated with frames or mats before being fixed in the forms. Good quality
ductile binding wire of 1.6 mm shall be used to fix and secure the
reinforcement so that no bars will be disturbed or displaced when the concrete
is placed. Alternative tack welding shall be carried out to secure and fix the
reinforcement instead of binding wire. No concreting shall be commenced until
the bars have been properly fixed and tied at their specified locations and have
been inspected and approved by the engineer.

5.14.13 Cover

Unless indicated otherwise on the drawings, clear concrete cover for
reinforcement (exclusive of plaster or other decorative finish) shall be as follows:-

a. At each end of reinforcing bar, not less than 25 mm nor less than twice
the diameter of the bar.

b. For a longitudinal reinforcing bar in a column or pedestal not less than 40
mm, nor less than the diameter of the bar.

c. For longitudinal reinforcing bars in a beam, not less than 25 mm nor less
than the diameter of the bar.

d. For tensile, compressive, shear or other reinforcement in a slab or wall
not less than 15 mm, nor less than the diameter of such reinforcement.

e. For any other reinforcement not less than 15 mm, nor less than the
diameter of such reinforcement.



e. For footing where the concrete is deposited directly against the ground,
cover to the bottom reinforcement shall be 100 mm. If concrete is poured
on a layer of lean concrete, the bottom cover may be reduced to 75 mm.

f. For concrete surfaces exposed to the weather or the ground after
removal of forms, such as footing sides and top, etc. not less than 50 mm
for bars larger than 16 mm ; and not less than 40 mm for bars of 16 mm
or smaller.

g. Increased cover thickness shall be provided, as indicated on the
drawings, for surfaces exposed to the action of harmful chemicals (or
exposed to earth contaminated by such chemical), acid, alkali, saline
atmosphere, sulphurous smoke etc.

h. Protection to reinforcement in case of concrete exposed to harmful
surroundings shall also be given by providing a dense impermeable
concrete with approved protective coating as specified on the drawing. In
such a case, the extra cover, mentioned in (h) above, may be reduced by
engineer to those shown on the drawings.

i. The correct cover shall be maintained by cement mortar briquettes or
other approved means. Reinforcement for footings, and slabs on sub
grade shall be supported on precise concrete blocks as approved by
engineer. The use of pebbles or stones shall not be permitted.

j. The minimum clear distance between reinforcing bars shall be in
accordance with IS:456 or as shown in drawings.

5.15 Tolerances

5.15.01 Tolerance specified shall be permissible variation from lines grade or dimensions
given in drawings. No tolerances specified for horizontal or vertical building lines
of footing shall be construed to permit encroachment beyond the legal
boundaries. Unless otherwise specified, the following tolerances will be
permitted:

5.15.02 Variation in the sizes and locations of sleeves,
openings, in walls and floors except in the case
of anchor bolts
5 mm
5.15.03 Variation in cross sectional dimensions of
columns and beams and in the thickness of slabs
and walls
- 5mm
+ 10 mm
5.15.04 Variation in steps

a) In a flight of stairs 3 mm rise
5 mm tread

b) In consecutive steps 1.5 mm rise
3 mm tread

5.15.05 Variation from level of grade indicated on
drawings in slab, beams, soffits, horizontal



grooves and visible arises

a) In 2.5 m 5 mm
b) In 7.5 m or more 10 mm
c) In buried construction Twice the above
amount

5.15.06 Variation in cross-sectional dimensions of
columns beams, buttresses, piers and similar
members
- 5mm
+10mm

5.15.07 Variation in the thickness of slabs, walls, arch
sections and similar members
-5 mm
+10 mm

5.15.08 Tolerances in fixing anchor bolts shall be as
follows:

a) Anchor bolts without sleeves 1.5 mm in plan
b) Anchor bolts with sleeves 5.0 mm in elevation

i) For bolts upto 32 mm dia 5 mm in all direction

ii) For bolts 32 mm dia and above 3 mm in all direction

c) Embedded parts 5 mm in all direction

5.15.09 Tolerances in other types of structures shall generally conform to those given in
clause 2.4 of Recommended practice for concrete for work (ACI-347).

5.16.00 Finish for Concrete Surfaces

5.16.01 Exposed concrete, other than floors or slabs to view, upon completion shall have
a smooth finish.

5.16.02 A smooth finish shall be obtained with the use of lined or plywood forms having
smooth and even surfaces and edges. Panels and form linings shall be of
uniform size; and shall be as large as practicable and installed with closed joints.
Upon removal of forms, the joint marks shall be smoothened off and all
blemishes, projections, etc removed, leaving the surfaces reasonably smooth
and unmarked.

5.16.03 Concrete surfaces shall not normally be patched or otherwise treated after the
removal of forms. Where the surface exposed on stripping is not satisfactory
owing to the contractors failure to take necessary precautions before, during or
after the concrete placing, such surfaces shall be worked and finished in
accordance with the instructions of the engineer at the cost of the contractor.
The pores may be filled in with a weak solution of cement and water applied with
brush and when dry the surface rubbed down with carborundum stone. The cost
of the above treatment shall be deemed to have been included in the rates
entered by the contractor in the bill of quantities. The top surface of the RC
slabs shall be screeded off unless otherwise specified, to the required levels.


There must be no surface grouting or treating up which might draw the fines to
the top. All shuttered surfaces shall be left as they strip without removing boards
or panel markings. Any serious honey combing shall render the concrete work
liable to rejection and cutting out and reconcreting wholly or partly as the
engineer directs. All costs involved in repairing defects shall be borne by the
contractor.

5.16.04 Concrete surfaces shall be finished as follows:-

5.16.041 Inside and outside surfaces, except as specified shall generally be left as they
come off the forms but fins and other irregularities on the surface of the concrete
shall be removed by rubbing with fine carborundum stone. No plastering of any
description shall be allowed except with the permission in writing of the engineer.

5.16.042 The exposed faces of all concrete work shall be made true to line, fair and
smooth without rendering; and should any part of the face work present a rough,
uneven, honey-combed of imperfect appearance when shuttering is removed, it
shall be picked out to such a depth and refilled and properly refaced with such
class of concrete, as the engineer will direct, all at the contractors expense.
Particular care must be taken on all exposed work that no irregularities or
roughness occurs between the successive sections of the shuttering; and the
finished faces must be perfectly smooth and to such shapes as shown on the
drawings, free of board or shutter marks.

5.16.43 Horizontal construction joints shall be true and regular as specified herein
before.

5.17.00 Pre-cast Reinforced Concrete Slabs

5.17.01 The pre-cast reinforced concrete slabs shall be capable of supporting a live load
of 150 kg per metre square, in addition to its own weight. Suitable allowances
shall be made for erection and handling stresses. The concrete used shall be
grade M-20. All slabs shall have a standard approved width, except when
specially required for the geometry of the trenches. All slabs shall be un-warped,
free from cracks and broken edges. Defective pieces shall be rejected. The
joints shall fit snugly together and shall be pointed, made flush on the upper side
with an approved asphalt, cement, fine sand filler. Completed roof surface shall
be smooth and even, ready for the application of the roof insulation and
covering.

5.17.02 Holes and openings shall be provided during casing or cut afterwards as
required, without any extra charges. After installation of pipes, vents, sleeves
etc., the openings shall be plugged with concrete of original grade. The work
during manufacture at contractors site shall be subject to the engineers
inspection. Test specimens shall be loaded to destruction; and loading tests
shall be made at the contractors cost on specimen slabs received at site.

5.17.03 Pre-cast units shall be kept protected from direct rays of the sun for at least
seven (7) days after casting; and during this period each unit shall be kept in
vats completely immersed in water.



5.17.04 All pre-cast units shall be provided with edge angles of minimum 6 mm thickness
all along the edges.

5.18.00 Applicable Codes and Standards

5.18.01 The following standards and codes of practice are made a part of this
specification. All standards, codes of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions as
applicable on the date of opening of the bids.

5.18.02 In case of discrepancy between this specification and codes/standards referred
to herein, this specification shall govern.

5.18.03 Materials

1. IS:269 Specification for ordinary, rapid hardening
and low heat Portland cement
2. IS:455 Specification for Portland blast furnace
slag cement
3. IS:1489 Specification for Portland pozzolana
cement
4. IS:4031 Methods of physical tests for hydraulic
cement
5. IS:650 Specification for standard sand for testing
of cement
6. IS:383 Specification for coarse and fine
aggregates from natural sources for
concrete
7. IS:2386 (Part-I to
VIII)
Methods of test for aggregates for
concrete
8. IS:516 Method of test for strength of concrete
9. IS:1199 Method of sampling and analysis of
concrete
10. IS:3025 Methods of sampling and test (physical
and chemical) water used in industry
11. IS:432 (Part-I & II) Specification for mild steel & medium
tensile steel bars and hard drawn steel
wire for concrete reinforcement
12. IS:1139 Specification for hot rolled mild steel and
medium tensile steel deformed bars for
concrete reinforcement
13. IS:1566 Specification for plain hard drawn steel
wire fabric for concrete reinforcement
14. IS:1785 Specification for plain hard drawn steel
wire for pre-stressed concrete
15. IS:1786 Specification for cold twisted steel bars
for concrete reinforcement
16. IS:2090 Specification for high tensile steel bars
used in pre-stressed concrete
17. IS:4990 Specification for plywood for concrete
shuttering work
18. IS:2645 Specification for integral cement water


proofing compounds
19. IS:4461 Cold worked steel bars for the
reinforcement of concrete
5.18.04 Equipment

1. IS:1791 Specification for batch type concrete
mixers
2. IS:2438 Specification for roller pan mixer
3. IS:2505 Specification for concrete vibrators
immersion type
4. IS:2506 Specification for screed boar concrete
vibrators
5. IS:2514 Specification for concrete vibrating tables
6. IS:3366 Specification for pan vibrators
7. IS:4656 Specification for form vibrators for
concrete
8. IS:2722 Specification for portable swing weigh
batchers for concrete (single and double
bucket type)
9. IS:2750 Specification for steel scaffolding

5.18.05 Codes of Practice

1. IS:456 Code of practice for plain and reinforced
concrete
2. IS:1343 Code of practice for pre-stressed
concrete
3. IS:457 Code of practice for general construction
of plan and reinforced concrete for dams
and other massive structures
4. IS:3370 (Parts I to
IV)
Code of practice for concrete structures
for storage of liquids
5. IS:3935 Code of practice for composite
construction
6. IS:3201 Criteria for design and construction of
pre-cast concrete trusses
7. IS:2204 Code of practice for construction of
reinforced concrete shell roof
8. IS:2210 Criteria for the design of BC shell
structures and folded plates
9. IS:2751 Code of practice for welding of mild steel
bars used for reinforced concrete
construction
10. IS:2502 Code of practice for bending and fixing of
bars for concrete reinforcement
11. IS:3558 Code of practice for use of immersion
vibrators for consolidating concrete
12. IS:3414 Code of practice for design and
installation of joints in buildings
13. IS:4014 (Part-I & II) Code of practice for laying in situ cement
concrete flooring


14. IS:2751 Code of practice for laying in situ cement
concrete flooring

5.18.06 Construction Safety

1. IS:3696
(Part-I&II)
Safety code for scaffolds and ladders

5.18.07 In the event that Andhra Pradesh State, Cuddapah district or other governmental
bodies have requirements more stringent than those set forth in this
specification, such requirements shall be considered part of this specification;
and shall supersede this specification where applicable.

5.19.0 Grouting

5.19.01 Standard Grout

5.19.011 Grout shall be provided as per the drawings.

5.19.12 The proportions of grout shall be such as to produce a flow able mixture
consistent with minimum water content and shrinkage. The grout proportions
shall be limited as follows:-

Use Grout
thickness
Mix proportions W/C
ratio(max)
a. Fluid mix Under 25 mm One part Portland cement
to one part sand
0.44
b. General 25 mm and
over but less
than 50 mm
One part Portland cement
to 2 parts of sand
0.53
c. Stiff 50 mm and
over
One part of Portland
cement to 3 parts of sand
0.53

5.19.013 a. Sand shall be such as to produce flow able grout without any tendency to
segregate.

b. Sand, for general grouting purposes, shall be graded within the following
limits:

Passing IS 2.36 mm sieve 95 to 100%
Passing IS 1.18 mm sieve 65 to 95%
Passing IS 300 micron sieve 10 to 30%
Passing IS 150 micron sieve 3 to 10%

c. Sand for fluid grouts, shall have the fine material passing the 300 and
150 micron sieves at the upper limits specified above.

d. Sand, for stiff grouts, shall meet the usual grading specifications for
concrete.


5.19.014 a. Surface to be grouted shall be thoroughly roughened and cleaned of all
foreign matter and laitance.

b. Anchor bolts, anchor bolt holes and the bottom of equipment and column
base plates shall be cleaned of all oil, grease, dirt and loose material.
The use of hot, strong caustic solution for this purpose will be permitted.

5.19.015 a. Prior to grouting, the hardened concrete surfaces to be grouted shall be
saturated with water.

b. Water in anchor bolt holes shall be removed before grouting is started.

5.19.016 Forms around base plates shall be reasonably tight to prevent leakage of the
grout.

5.19.017 Adequate clearance shall be provided between forms and base plate to merit
grout to be worked properly into place.

5.19.018 Grouting, once started, shall be done quickly and continuously to prevent
segregating, bleeding and breakdown of initial set. Grout shall be worked from
one side of one end to the other to prevent entrapment of air. To distribute the
grout and to ensure more complete contact between base plate and foundation;
and to help release entrapped air, link chains can be used to work the grout into
place.

5.19.019 Grouting through holes in base plates shall be by pressure grouting.

5.19.20 Variations in grout mixes and procedures shall be permitted if approved by
engineer.

6.00 WATER PROOFING OF SUBSTRUCTURES EXPOSED TO SUBSOIL WATER

6.01 Scope

The contractor shall furnish all materials, labour, equipment etc and carry out all
works for water proofing substructures of the proposed system as per approved
drawings.
6.02 Membrane Water Proofing

6.02.01 Materials

The water proofing membrane shall be 0.30 mm thick polyvinyl sheet of
approved make and quality. The sheet shall have knobs projecting out 10 mm
from the sheet surface in a grid fashion at a maximum distance of 200 mm
centres on both faces. The sheet shall be made from compounded resin of
grade MP/DP/CR-02 and the chemical composition of the sheet shall be
designed for underground use.

6.02.02 A minimum of 2440 mm wide polyvinyl sheet shall be used without joint. This
sheet shall be joined at shop to achieve a minimum total width of 7320 mm
before using it for actual execution at site. A overlap of 50 mm shall be provided


between two adjacent sheets. Suitable adhesive as recommended by the
manufacturer shall be used to achieve a bond strength of at least 10 kg/cm width
and the elongation at break shall not be less than 130%.

6.02.03 Application

6.02.31 Vertical surfaces

The treatment shall be carried out on the vertical surface by fixing the polyvinyl
chloride sheet with the formwork. The knobs shall project towards the concrete.
After the removal of shuttering (on completion of concreting), shuttering tie rod
holes, cuts, etc shall be patched with an additional sheet. The job shall be
carried out by an approved agency to the utmost satisfaction of the engineer.
After completion of the testing of the vertical face, 115 thick brick masonry in1:6
cement mortar shall be provided on the outer face to protect the membrane
protection treatment from backfilling; future excavation etc.

6.02.32 Horizontal Surfaces

After laying the lean concrete for mud mat and when t is still green, the polyvinyl
sheet shall be laid with the knobs downwards, pressing into the green concrete.
Over this sheet, 40 mm thick PCC/lean concrete shall be laid to protect it from
damage from reinforcement steel, etc. Before laying 40 mm thick protection
layer, the polyvinyl sheet shall be electronically tested and repaired with
additional sheets for puncture if any. For roof slabs of underground tunnels, the
polyvinyl sheet shall be laid over the completed RCC slab, with knobs facing
downwards into the green concrete shall be laid as a protection layer.

6.02.04 Membrane water proofing treatment shall be provided for all underground tunnel,
transfer points etc.

6.03 Joint Treatment

A 300 mm wide 20 mm thick bank of cement plaster 1:1 with non-shrink water
proof compound shall be provided on external surfaces of all construction joints
after hacking the surface for proper bonding.

6.04 Water Proofing Agent

Where specified and approved by engineer, water proofing agent conforming to
iS:2645, shall be added in quantities recommended by the manufacturer and as
directed by the engineer.

7.0 ROOF INSULATION AND WATER-PROOFING

7.01 Scope

The contractor shall furnish all labour, materials and equipment required for
insulation and water proofing to be done for the civil works mentioned in clause
1.00 for the complete construction of the proposed system as per approved
drawings.


7.02 Foam Concrete

The foam concrete shall be laid cast-in-situ/pre-cast to 75 mm average
thickness. The insulation density shall not exceed 400 kg per metre cube.
Thermal conductivity of foam concrete shall be 0.85 mw/cm/degree C at 50
o
C.
Broken and other pieces damaged in any way shall not be used. Materials shall
be check tested and approved to ensure that insulation qualities are complied by
each lot. The slab base and/or insulating slabs shall be laid to necessary slope
for drainage. The insulation shall conform to Type 2, Code B of IS:6598.

7.03 Water Proofing

Over the cured Foam concrete, Isothane EMA high solid content polyurethane
based cold liquid applied waterproof coating of 1.5mm as per ASTMC-836-89
and shall comprise of urethane pre-polymer extended with flexible material,
which cure by reaction with atmospheric moisture to give a continuous
impervious jointless film, which is rubbery and elastic. The product final finish will
be in aluminium colour. The material shall come in a single pack system to site.
The material shall not be diluted. The coating shall have physical features like
high viscosity, min.80% solids, high resistance to impact, abrasion and cracking,
superior tensile strength, min.300% elongation and forming a perfectly smooth
permanently flexible seamless membrane which should have good adhesion to
PUF insulation and roof substrates. The cured film should have a very low water
absorption rate. The material shall not be older than 11 months after the date of
manufacturing and packing. Reinforcing layer of non-woven polyscrim cloth (40
gsm/m2) of 3-4 mm thick APP Membrane felt shall be used at vulnerable point
like drainage areas and high foot traffic/ mechanical equipment movement areas,
for providing extra protection to the insulation. Over the cured membrane,
min.40mm thick cement screed treatment mixed with water proofing compound
to be provided with metal mess reinforcement uniformly and finished in panels of
2.5x2.5 mtrs. The grooves formed for making the panels shall be subsequently
filled with an elastomeric compound.

7.04 Applicable Codes

IS:2645 : Integral cement water proofing compounds

IS:1580 : Bitumen primer for use in water proofing
and damp proofing

IS:1580 : Bituminous compounds for water proofing
And caulking purposes

IS:1346 : Code of practice for water proofing of roofs
with bitumen felts


8.0 BRICK MASONRY

8.01 Scope

The contractor shall furnish all labour, materials and equipment required for the
construction for all brick masonry work required on the construction of the
proposed system. The bricks shall be fly ash bricks.

8.02 Materials

8.02.01 Bricks

Bricks of Class-II conforming to IS:1077 shall be of uniform colour, strength and
size with minimum crushing strength of 75 kg/cm
2
. The bricks shall have smooth
surfaces with corners straight; they shall not be twisted or chipped; when broken,
they shall reveal a fine, uniform, non-vitreous grain; they shall emit ringing sound
when tapped with a hammer; they shall absorb water on immersion (not more
than one sixth of its original weight after soaking for 15 minutes) and dry
sufficiently quickly. The bricks shall not show any sign of efflorescence after
soaking and drying in shade. If the bricks show any sort of efflorescence, the
contractor shall do the necessary treatment at his own cost to the satisfaction of
the engineer.

8.02.02 All bricks shall be subjected to inspection & approval; and representative
samples shall be submitted before ordering out. The bricks supplied shall
conform to approved samples; and shall be subjected to tests as required by the
engineer.

8.03 Mortar

Mortar shall be prepared with the materials as specified in clause 1.02 of sub-
section-6D; and the mortar shall conform to IS:2250. The type of mortar to be
used shall be as mentioned on drawings.

8.04 Brick work

8.04.01 Soaking of bricks

Bricks required for masonry in cement mortar, shall be wetted to saturation point
by prolonged immersion, but never by spraying. The cessation of bubbles, when
the bricks are immersed in water, shall be an indication of thorough soaking of
bricks. The soaked bricks shall be kept on wooden plank to avoid earth being
smeared on them.

8.04.02 Laying

8.04.21 Brick work shall be laid with best skill land the greatest care & diligence, each
brick shall be pressed on the layer of the specified mortar so that this spreads all
around it and fill the joints which shall never be more than 10 mm nor less than 5
mm wide. Mortar ingredients shall be of proper grain size to permit joints within
these limits.


8.04.22 The whole of the brick work shall be built in English bond unless otherwise
directed. No four brick courses shall rise more than 25 mm above the same laid
dry. No brick bats shall be used except where required as closers. The bricks
shall be thoroughly bedded on cement mortar during each layer. After every
third course, reinforcing steel consisting of 2 nos. of 6 mm dia mild steel bars
shall be provided; and these shall be anchored to the structural steel or RCC
columns as directed by the engineer.

8.04.23 The work shall be done in a proper manner in the first instance only and no
grouting shall be resorted to. String courses, cornices and mouldings shall not
generally be provided unless as shown on the drawings or as directed by the
engineer. The architectural features and treatment if required as per the
drawings or as may be finalized before execution and such items whether in
large or small quantities and any shape and size, shall have to be provided by
the contractor at the quoted rates. The contractor shall not be eligible to claim
any extra rate on this account. The brick work must be laid true to lines and
level with horizontal courses and vertical perpendicular faces and corners etc.

8.05 Non-bearing walls

Non-bearing walls (dividing walls) shall be built of choice bricks, for both header
and stretcher course. No broken bricks or bricks with chipped corners will be
accepted.

8.06 Curing

Green work shall be protected from rain by suitable covering. Brick work in
cement mortar shall be kept constantly moist on all the faces for a minimum
period of ten (10) days. The top of masonry work shall be left flooded at the
close of the day.

8.07 In case of discrepancy between this specification and those referred to herein,
this specification shall govern:

IS:1077 : Common burnt clay building bricks

IS:3102 : Classification of burnt clay bricks

IS:2180 : Burnt clay building bricks, heavy duty

IS:3495 : Method of sampling and testing clay
Building bricks

IS:2691 : Burnt clay facing bricks

IS:2212 : Code of practice for brickwork

IS:2185 : Load bearing hollow concrete blocks

IS:5498 : Lime-cement-cinder hollow concrete blocks



IS:3115 : Lime-cement-cinder solid blocks

IS:12894-1990 : Code of practice for fly ash bricks

9.00 STEEL DOORS, WINDOWS & VENTILATORS

9.01 Scope

9.01.01 The contractor shall furnish all labour, material and equipment required for
supply, transportation and fixing in position, all the doors, windows and partitions
required for the civil works for the proposed system.

9.01.02 All windows and door frames of any kind and size shall be made of standard
steel shapes and be of the tight closing type; double contact, stiffened. Windows
shall be partly hinged and partly fixed.

9.01.03 Hinged windows shall be actuated by means of special easy to adjust and
operate devices, smoothly operating. All the doors shall be of standard
construction, with shape and size of openings as indicated in the drawings. All
standard steel doors, windows and ventilators of approved best quality shall
conform to iS:1038 and IS:1361 unless otherwise stated.

9.01.04 All fittings shall be of superior chrome plated quality or anodized aluminium as
required. The contractor shall submit samples of all fittings and provide only the
selected/approved fittings.
9.02 Each steel door shall be provided with:

a. A superior quality rim lock or mortice lock with handles on both sides and
two (2) 150 mm tower bolts to close the door from inside.

b. An approved brass door closer

c. Necessary lugs for fixing

9.03 Each steel window shall be provided with peg-stay arms; handles; and tower
bolts.

9.04 Each steel ventilators shall be provided with bronze cup pivots and spring catch
closer.

9.05 All glazing for doors and windows shall be as per relevant drawings and work
shall conform to IS:1081 (latest). Glazing for doors, windows, ventilators and
partitions shall be 5.5 mm thick plate glass patent, flattened sheets or 6 mm thick
wire plate glass panels & of approved quality conforming to IS:1761 (latest
edition). All glass panes or panels shall be free from flaws, specks, bubbles &
wavy surfaces; and shall have a uniform refractive index. All panels shall have
properly squared corners and straight edges; putty shall be fresh and ready mix
of superior approved quality conforming to IS:400 (latest). Necessary glazing
clips, putty, mastic cement etc shall be supplied by the contractor.

9.06 All steel doors, windows and ventilators shall be given a coat of shop paint after
thorough cleaning. This shall be touched up during installation as necessary.


9.07 Doors shall be completely or partly sheeted. Doors of toilets, wash rooms, etc
shall be fully sheeted with the bottom portion constructed as a louvered
ventilator. Kick plates shall be provided. Two (2) keys shall be provided for
each door and in addition master and sub-master keys shall be provided, as
required.

9.08 Installation

After the masonry work has been constructed, the contractor shall install the
doors, windows and ventilators framed in line and plumb; and shall firmly anchor
these to the masonry with approved metal anchors. The contractor shall ensure
that variations in building dimensions (contraction, expansion etc) will not cause
the doors, windows or ventilators to jam or not close properly. Work not properly
anchored or out of plumb shall be rectified to the engineers satisfaction. After all
civil works under this and other sections have been completed, the contractor
shall carefully inspect all doors, windows and ventilators and make necessary
adjustments to ensure efficient operation.

10.0 ALUMINIUM DOORS, WINDOWS & PARTITIONS

10.01 Scope

The contractor shall furnish all labour, material and equipment required for
supply, transportation and fixing in position, all aluminium doors, windows &
partitions including glass required for the proposed system.

10.02 Doors & Windows

The doors & windows shall be built from extruded aluminium sections. The
panels shall be of aluminium sheet of not less than 16 gauge thickness, unless
otherwise specified. The finished work shall be plumb in line and free from
corrugation, depression or wavy appearance; and any defects shall be rectified
to the satisfaction of the engineer. Field connections of all works may be made
with concealed screws or approved type of fasteners or may be welded as
approved by the engineer. All glazing shall be of high approved quality and shall
be 12 mm thick. Glazing work shall be as per specification.

10.03 Partitions

The partitions shall be in hollow anodized aluminium section of 65 x 40 mm 16
gauge (with infilled timber of silver oak) frame work, fully glazed or as per
drawings. Glazing shall be fixed to the framework with anodized aluminium
section and preformed rubber beading all round.

11.00 WOODWORK IN DOORS, WINDOWS, PARTITIONS, LOUVRE, RAILING ETC

11.01 Scope

The contractor shall furnish all labour, material and equipment required for
supply, transportation and fixing in position, all the wood work including flush


doors inclusive of glazing, painting/polishing and relevant masonry work required
for the civil works for the proposed system.

11.02 Wood used for all work shall be the best of the respective class specified, and
properly seasoned by at least 6 months air drying, suitable for joiners work,
should be of natural growth, uniform in texture, straight grained, free from
sapwood, dead knots, open shakes, boreholes, rot, decay and any and all other
defects and blemishes.

11.03 The thickness specified for joiners wrought timbers are, unless otherwise
specified, prior to planning; and 3 mm will be allowed from the thickness stated
for each wrought faces.

11.04 All joining shall be wrought on all faces and finished off by hand with sand paper,
with slightly rounded arises.

11.05 The joints shall be pinned with hard wood pins and put together with white lead.
Jointing shall be by means of mortice and tenon or dovetailed joints as
approved.

11.06 Any joiners work which shall split, fracture, shrink or show flaws or other defects
due to unsoundness, inadequate seasoning or bad workmanship, shall be
removed and replaced with sound material at the contractors expense.

11.07 Doors, windows and ventilator frames, transoms and mullions shall be rebated.
All dimensions shall be as per drawings. The top framing member of doors and
top & bottom framing of windows and ventilators shall project about 150 mm in
brick work. The verticals of door frames shall project about 50 mm below
finished floor. Surface coming in contact with brick work shall be painted with
bitumen as directed by engineer. Each of the door and window frames shall be
provided with 3 nos. MS 225x25x6 flat split hold fasts on each side. These hold
fasts shall be embedded in masonry or concrete work. The work shall conform
to IS:4021.

11.08 The doors shall be paneled as per relevant drawings. All doors shall be supplied
with approved fittings such as hinges, mortice lock of approved make with
handles on both sides, oxidized brass tower bolts and latch arrangements, door
stops etc and as shown in drawings but exclusive of door closers.

11.09 Doors will generally have no sills but if a few have to be provide, the contractor
shall do so at no extra cost to the Purchaser.
11.10 The type of window shall be as specified. Each shutter shall have one pair of
hinges, two tower bolts (one 225 mm long and another 150 mm long), one
handle and one hook with eye and pegstay. Ventilators shall have two MS hold
fasts and hinges, one handle and one hook and eye at each end and one small
tower bolt in the centre. Where so directed by the engineer, the doors and
windows shall be provided with parliamentary type hinges at no extra cost.

11.11 The workmanship of all doors and windows shutters shall conform to the
requirements of IS: 1003 (Part I & II) and IS:2202 (Part-I).



11.12 Cupboards, almirahs and shelves shall be provided as shown in drawings. The
doors could be of either hinged type or sliding type as approved by the engineer.
All dimensions as furnished in the drawings shall be followed. Fixtures and
fittings as shown on drawings or as directed by engineer shall be used.

11.13 Railings and architraves shall conform to the shape shown on drawings or as
approved and fixed by means of screws (counter sunk or otherwise) or bolts.

11.14 The finish expected shall be of very high order; and the work shall be all
inclusive whether or not all detailed specifications have been spelt out and the
work shall be free from blemishes.

11.15 Glazing shall be as per clause 10.05 of this subsection. Glazed windows,
louvers, ventilators and doors shall be provided with either clear or pinheaded
glass 5.5 mm thick which shall be free from all blemishes and shall conform to
IS:1761. It should be clearly understood that glass which does not have uniform
refractive index or which is wavy, will be rejected.

11.16 Woodwork shall not be painted, oiled or otherwise treated before it has been
approved by the engineer.

11.16.01 Painting/Polishing for Woodwork

Paint/polish to be used for various items of wood work shall be of best quality;
and shall be obtained ready mixed in sealed containers from approved
manufacturer. The contractor shall obtain the engineers approval for the make
and colour of the paint he proposes to use. If required, polish for woodwork shall
be tested as per IS:5807 (Parts I & III).

11.16.02 A priming coat without colouring matter shall be first applied after which all holes,
cracks etc shall be stopped with putty and all knots properly filled with quick lime.
Workmanship shall conform to IS:1477 (Parts I & II) and 2338 (Part I).

11.16.03 Three coats shall be applied and at least 24 hours shall elapse between the
application of successive coats. No painting shall be carried out on exterior work
in wet weather or on surfaces which are not entirely dry.

12.00 ROLLING SHUTTERS

12.01 The rolling steel shutters shall be of an approved design and make. The
dimensions shall be as shown in the engineers drawings. Wicket gates shall be
provided, where required.

12.02 The curtains shall be made of interlocking scrolls made of hot rolled double
dipped galvanized steel lathe sections of 18 SWG tested mild steel strips at 75
mm rolling centres, locked with galvanized malleable iron clips. The bottom
lathe shall be coupled to a lock plate fabricated from 3 mm thick galvanized steel
plate and securely riveted with stiffening angles. The guides shall be hot rolled
mild steel galvanized channel sections. These shall be embedded securely into
concrete or masonry face or anchored to steel stanchions with necessary lugs in
an approved manner. Latches shall be provided at both ends of the bottom bolt
plate of the curtain and provisions shall be made for locking from both sides.


12.03 Where required, wicket doors shall be provided with a safety lock, tower bolt and
handle. The hood covers shall be double dipped hot galvanized 20 gauge steel
adequately reinforced to prevent sag. The shutters shall, where necessary, be
operated by means of an AC. Motor driven power operator placed inside the
building. Each motor shall be controlled by a push button station with three (3)
raise, stop and lower push buttons. A safety edge with limit switches shall be
provided to automatically stop the shutter upon touching any interference or
ground. Motor shall be A class insulation totally enclosed type and shall
operate on 415 volts, 3 phase, 4 wire, 50 cycle system. They shall be
adequately sized not to overheat with quick successive operation of the shutter.
Necessary motor starters and push button stations shall be furnished. Apart
from the power drive, provision shall be made for manually operating the
shutters by an auxiliary endless chain gear operator.

12.04 All steel parts of the door shall be double dipped hot galvanized.

12.05 The shutters shall be given (1) coat of zinc based primer paint before installation.

12.06 Installation

The shutter shall be erected complete with all necessary hardware, operation
mechanisms, equipment, wiring and materials to suit the sizes of the openings.
All electrical works shall be in accordance with the Indian Electricity Regulations.

12.07 Tests

After the equipment has been installed, tests shall be made by the contractor in
the presence of the engineer to ensure efficient operation of the equipment.
These tests shall be repeated after all civil works have been completed and the
contractor shall make necessary checks and adjustment to ensure efficient
operation.

12.08 Applicable Codes and Specifications

12.08.01 The following latest codes and standards are made a part of this specification.
All standards, codes of practices referred to herein shall be the latest edition
including all applicable official amendments and revisions.

12.08.02 In case of discrepancy between this specification and those referred to herein,
this specification shall govern:

IS:4021 Tiber door, window and ventilator frames

IS:2202 Wooden flush door shutters (solid core type) Part I

IS:1003 Timber panelled and glazed shutters (Part I & II)

IS:4020 Methods of tests for wooden flush doors: Type tests

IS:1761 Transparent sheet glass for glazing and framing purposes.



IS:4351 Steel door frames

IS:1038 Steel doors, windows and ventilators

IS:1081 Code of practice for fixing and glazing of metal (steel and
aluminium) doors, windows and ventilator

IS:5807 Method of test for clear finishes for wooden Furniture
(Part I to III)

13.0 PLASTERING

13.01 The contractor shall furnish all labour, materials and equipment required for
plastering all the walls and ceilings required for the civil works for the proposed
system.

13.02 Materials

13.02.01 Cement and water used for this work shall be as per this specification. Sand for
plaster shall have the characteristics as per IS:1542. The sand shall not contain
any harmful impurities, as per clause 3.3 of IS:2116. The maximum quantities of
clay, fine silt, fine dust and organic impurities in sand shall not exceed the
following limits:-

a. Clay, fine silt and fine dust : Not more than three(3)
(determined in accordance percent by weight
with IS:383 Appendix-C and
also IS:2386 (Part-II)

b. Organic impurities (determined): Below that indicated by
in accordance with IS:2386 comparison with standard
(Part-II) specified in clause 6.2.2 of
IS:2386 (Part-II)

13.02.02 Plastering Work

13.02.21 Plastering shall be done with 1:4 cement plaster to the following finished plaster
thickness; 13 mm for all even surfaces, 20 mm for all uneven and outside
surfaces and 25 mm for rough textured faade plastering. Plaster shall be
applied only when walls are perfectly dry. Jutting or recessed edges shall have
sharp or suitably rounded corners, as specified by the engineer. Plaster of all
kinds, either smooth or rough finished, shall never show cracks, faulty alignment
either in horizontal or vertical planes, detachment from walls, blisters or other
faults and shall have a uniform and perfectly smooth appearance. However, the
new plaster shall not be towelled to a glazed surface since white wash would not
adhere to it.

13.02.22 Any fault plastering shall in any event be removed and replaced at the
contractors expense at the sole discretion of the engineer.

13.02.23 The joints of brick work and masonry shall be raked out 10 mm deep with mortar
still green to form key for the cement plaster and surfaces to be plastered, if not


sufficiently rough, shall be thoroughly picked and roughened to provide a good
bond for the plaster. The rates for plastering shall be inclusive of preparing the
surface as above.

13.02.24 Cement and sand shall be mixed dry and then just enough water added to form
an easily workable paste. In no case shall mortar which has been allowed to
stand more than 20 minutes after mixing, be used.

13.02.25 The surface of brick work, stone, concrete and other structures to be plastered
shall be thoroughly cleaned from dust, dirt, oil, salt and bituminous spots, wetted,
as directed before the application of the rendering coat.

13.02.26 All scaffolding log holes shall be properly filled in advance of plastering as
scaffolding is being taken down Patches of plaster nearly 150x150 mm should
be put 3 metres apart horizontally and vertically to correct plane and to the
specified thickness. In case of floors and ceilings, the mortar slab shall be truly
horizontal or to specified slope and shall be provided 3M apart in both directions.

13.02.27 The plaster shall then be laid in single coat correct to the line connecting the
150x150 mm patches laid before hand. This shall be beaten with thin strips of
bamboo about one metre long to ensure thorough filling of the joints; and then
brought to a true surface by working a wooden straight edge reaching across the
patches with small upward and sideways movement at a time. The surface shall
be finished smooth with wooden floats and shall be of first class workmanship of
required texture to the overworking the float shall be avoided. During this
process a solution of live putty shall be applied on the surface to make it
workable. In case of internal walls, the plaster shall be left off in a straight lien
225 mm above the floor level. This plastered together, the junction being curved
to a radius of 35 mm or larger if so specified on drawings.

13.02.28 For any increase in plaster thickness due to irregularities in brick work face,
contractor will not be entitled for any extra payment.

13.02.29 Proper precautions shall be taken to see that each coat of plaster is cured for a
maximum period of 7 days by an approved method. Curing shall be done as
soon as the applied plaster has hardened enough so as not to be damaged.
The dates on which the plastering is done shall be legibly marked on the various
sections plastered so that curing for the specified period can therefore be
watched.

13.02.30 The contractor shall take every precaution, right from the commencement of
plaster work to prevent any defects that may appear on the surface of the
plasters, and shall be responsible to make good any portion of the work which in
the opinion of the engineer requires removal and/or redoing.

13.02.31 For the uneven face plastering, 20 mm thick shall be applied in two layers, the
first coat 14 mm thick with the second coat 6 mm thick applied after the under
coat has sufficiently set but not dried and in any case within 48 hours. The
plaster of under coat when brought to a true surface with a wooden straight
edge, the surface shall be left rough and furrowed 2 mm deep with a scratching
tool diagonally both ways to form key for the finishing coat. Faade plastering 25
mm thick shall be done in 3 coats with the first 2 coats as above and the third


rough texured coat 5 mm thick of cement and black marble chips (2-3 mm size)
in 1:1.5 ratio.

13.02.32 Plastering of the ceiling shall be done before wall plastering which shall be done
from the ceiling downwards.

13.02.33 In suspending work at the end of the day, the plaster shall be left, cut clean to
line both horizontally and vertically. When recommencing the plastering, the
edge of the old work shall be scraped, cleaned and wetted with lime putty before
plaster is applied to adjacent areas to enable the two to properly join together.
Plastering work shall be closed at the end of day on the body of wall and not
nearer than 15 cm to any corners or arises. Horizontal joints in plaster work
shall not occur on parapet tops and copings, as these invariably lead to leakage.
No portion of the surface shall be left out initially to be patched up later.

13.02.34 If directed by the engineer, the contractor shall use approved water proofing
admixture made by reputed manufacturer in the mortar for plaster work. The
quantity to be used shall be in accordance with the manufacturers instructions
subject to the engineers approval. These admixtures shall not contain calcium
chloride unless specifically allowed by the engineer and shall conform to
iS:2645. Payment shall be made for actual quantity of such admixtures used
unless it is already covered in the rates for the work concerned.

14.00 PAINTING

14.01 Scope

The contractor shall provide all labour, materials and equipment necessary to
paint, water proof cement paint, all the items in general covered by this technical
specification. Steel structures shall be painted with synthetic enamel paint over
the primer paint.

14.02 Type of Painting

Exterior emulsion paint of two coats over primer for all exterior surfaces exposed
to weather. Synthetic enamel painting for all structural and miscellaneous steel
work. Dry distempering for all interior surfaces. Plastic emulsion painting for
interior of MCC room/control room.

14.03 Exterior emulsion paint

14.03.01 Exterior emulsion paint shall be of approved brand and manufacture and shall be
applied on the surface to be treated in accordance with the manufacturers
specifications if so directed by engineer. However, for guidance of contractor,
the following specifications are given. The surface shall be thoroughly cleaned
of all mortar dropping, dirt, dust, grease and any other foreign matter by brushing
and washing. The surface shall be thoroughly wetted with clean water before
the Exterior emulsion paint is applied.

14.03.02 Exterior emulsion paint shall be mixed in such quantities as can be used up
within an hour of its mixing as otherwise, the mixture should set and thicken,
affecting flow and finish. Exterior emulsion paint shall be mixed with water in 2


volumes exterior emulsion paint and one volume of water stirred thoroughly and
allowed to stand for 5 minutes. Care shall be taken to add the exterior emulsion
paint gradually to the water and not vice-versa. The second stage shall
comprise of adding further one volume of water to the mix and stirring thoroughly
to obtain a liquid of workable and uniform consistency. In all cases the
manufacturers instructions shall be followed. The solution shall be applied on
the clean and wetted surface with brushes or spraying machine. The solution
shall be kept well stirred during the period of application. It shall be applied on
the surface which is on the shady side of the building so that the direct heat of
the sun on the surface is avoided. The subsequent coat shall be applied after
the previous coat has set for at least 24 hours. Before application of the second
or subsequent coats, the surface of the previous coat shall not be wetted. For
new work, the surface shall be treated with 3 coats of exterior emulsion paint to
get a uniform shade. For old work, the treatment shall be with one or more coats
as found necessary to get a uniform shade. Exterior emulsion paint shall not be
applied on surfaces already treated with white wash, colour wash, distemper dry
or oil bound, varnishes, paints etc. It shall not be applied on gypsum, wood and
metal surfaces.

14.04 Synthetic Enamel Painting

14.04.01 All rust and scales shall be removed by scraping or by brushing with steel wire
brushes. Hard skin of oxide formed on the surface of wrought iron during rolling
which becomes loose by rusting, shall be removed. All dust and dirt shall be
thoroughly wiped away from the surface. If the surface is wet, it shall be dried
before priming coat is undertaken. The priming coat shall be of readymade
primer of approved brand and manufacture. The primer shall be applied with
brushes, worked well into the surface and spread even and smooth. The
painting shall be done by crossing and laying off. The crossing and laying off
shall consist of covering the area with paint, brushing the surface hard for the
first time over; and then brushing alternately in opposite direction, 2 or 3 times
and then finally brushing lightly in a direction at right angles to the same. In this
process, no brush marks shall be left after the laying off is finished. The full
process of crossing and laying off shall constitute one coat.

14.04.02 The priming coat shall have dried up completely before painting is started.
Superior quality ready mixed synthetic enamel paint shall only be used; and shall
be of approved brand and manufacture and of required shades. They shall
conform in all respects to the relevant Indian Standard Specifications.

14.04.03 Where so stipulated, the painting shall be done with spray; spray machine shall
be of approved type; skilled and experienced workmen shall be employed for this
class of work. Spraying should be done only when dry condition prevails. Each
coat shall be allowed to dry out thoroughly and rubbed smooth before the next
coat is applied. This should be facilitated by thorough ventilation. Each coat
except the last coat, shall be lightly rubbed down with sand paper or fine pumice
stone cleaned of dust before the next coat is laid. No left over paint shall be put
back into the stock tins. When not in use, the containers shall be kept properly
closed. No hair marks from the brush or clogging of paint puddles in the corners
of panels, angles of mouldings etc shall be left on the work. In painting doors
and windows, the putty around the glass panes shall also be painted; but care
must be taken to see that no paint stains etc are left on the glass. Tops of


shutters and surfaces in similar hidden locations shall not be left out in painting.
In painting steel work, special care shall be taken while painting over bolts, nuts,
rivets, overlaps etc.

14.05 Dry Distempering

14.05.01 Dry distemper of approved brand and make shall be used with the shade to the
engineers approval. The dry distemper shall be stirred slowly in clean water
using 0.6 litres of water per kg of distemper or as recommended by the
manufacturer. Warm water shall preferably be used. It shall be allowed to stand
for at least four (4) hours (or if practicable overnight) before use. The mixture
shall be well stirred before and during use to maintain an even consistency.
Distemper shall not be mixed in larger quantity than is actually required for the
days work.

14.05.02 Before new work is distempered, the surfaces shall be thoroughly brushed free
from mortar droppings and other foreign matter and sand papered smooth. New
plaster surfaces shall be allowed to dry for at least two (2) months before
applying distemper. In the case of old work, all loose pieces and scales shall be
removed by sand papering. The surface shall be cleaned of all grease, dirt etc.
Pitting in plaster shall be made good with plaster of paris mixed with dry
distemper of the colour to be used. The surface shall then be rubbed down
again with a fine grade sand paper and made smooth. A coat of the distemper
shall be applied over the patches. The surface shall be allowed to dry
thoroughly before the regular coat of distemper is applied.

14.05.02 A priming coat of whiting shall be applied over the prepared surface in case of
new work. Whiting (ground white chalk) shall be dissolved in sufficient quantity
of warm water; and thoroughly stirred to form a thin slurry which shall then be
screened through a clean coarse cloth. Two(2) kg of gum and 0.4 kg of copper
sulphate dissolved separately in hot water shall be added for every cubic metre
of the slurry which shall then be diluted with water to the consistency of mild so
as to make a wash ready for use. No white washing coat shall be used as a
priming coat for distemper. The treated surface shall be allowed to dry before
distemper coat is given.

14.05.03 In the case of new work, the treatment shall consist of a priming coat of whiting
followed by the application of two (2) or more coats of distemper till the surface
shows an even colour. For old work, the surface prepared, shall be applied one
or more coats of distemper till the surface attains an even colour. The
application of each coat shall be as follows:

14.05.04 In the case of new work, the treatment shall consist of a priming coat of whiting
followed by the application of two (2) or more coats of distemper till the surface
shows an even colour. For old work, the surface prepared, shall be applied one
or more coats of distemper till the surface attains an even colour. The
application of each coat shall be as follows:-

The entire surface shall be coated with the mixture uniformly with proper
distemper brushes (ordinary white wash brushes shall not be allowed) in
horizontal strokes followed immediately by vertical) ones which together shall
constitute one coat. The subsequent coats shall be applied only after the


previous coat has dried. The finished surface shall be even and uniform and
shall show no brush marks. Enough distemper shall be mixed to finish one room
at a time. The application of a coat in each room shall be finished in one
operation; and no work shall be started in any room, which cannot be completed
the same day. After each days work, the brushes shall be washed in hot water
and hung down to dry. Old brushes which are dirty or caked with distemper shall
not be used.

14.06 Plastic Emulsion Painting

14.06.01 Plastic emulsion paint of approved brand and make shall be used. The primer
where used shall be in accordance with the manufacturers requirements and
shall be of the same manufacture as plastic emulsion paint and shall be brought
by the contractor in sealed tins in sufficient quantities at a time to suffice for a
fortnights work and the same shall be kept in the joint custody of the contractor
and the engineer. The empty tins shall not be removed from the site of work, till
this item of work has been completed and passed by the engineer. Only
sufficient quantity of paint required for the days work shall be prepared for new
work. The surface shall be thoroughly cleaned of dust, old white or colour wash
if any by washing and scrubbing. The surface shall then be allowed to dry for at
least 48 hours. It shall then be sand papered to give a smooth and even
surface. Any unevenness shall be made good by applying putty made of plaster
of paris mixed with water on the entire surface including filling up the undulation
and sand papering the same after it is dry. The primer coat shall be applied with
a brush on the clean dry and smooth surface, horizontal strokes shall be given
first and vertical stroke shall be applied immediately after. This entire operation
shall constitute one (1) coat. The surface shall be finished as uniformly as
possible leaving no brush marks. It shall be allowed to dry for atleast forty eight
(48) hours, before plastic emulsion paint is applied.

14.06.02 After the primer coat has dried, the surface shall be lightly sand papered to make
it smooth for receiving the paint, taking care not to rub out the priming coat. All
loose particles shall be dusted off after rubbing. One (1) coat of paint properly
diluted with thinner (water or other liquid as stipulated by the manufacturer) shall
be applied with brushes in horizontal strokes followed immediately by vertical
ones which together constitute a coat. The subsequent coats shall be applied in
the same way. Two (2) or more coats of paint shall be applied over the primer
coat to obtain an even shade. A time interval of at least twenty four (24) hours
shall be allowed between consecutive coats to permit the proper drying of the
preceding coat. Fifteen (15) centimetres double bristled distemper brushes shall
be thoroughly washed in hot water with soap solution and hung down to dry. Old
brushes which are dirty and caked with distemper shall not be used on the work.
Plastic emulsion paint is not recommended to be applied within six (6) months of
the completion of wall plaster. Protective measures shall be as described for
white washing.

14.07 General

14.07.01 All painting shall be performed, generally, in accordance with the detailed
description as above. In the selection of colours, agreement shall be made with
the Engineer. All painting/finishing materials (other than whitewash colour wash
etc.) shall be obtained ready mixed in sealed containers from approved


manufactures; these shall be of best quality, of approved make and having
Engineers approval.

14.07.02 Generally, iron and steel work etc. would have received its primary shop coat
being delivered to site. No painting work shall be started, unless specimens and
colours are submitted in advance to the Engineer for approval. Such approval of
paint specimens by the Engineer does not relieve the Contractor of his full and
entire liability as to the lie and quality of paints. No products prepaid in the field
by the workmen shall be used, except for those not available in the market; in
this case, however, the paints shall be prepared with the greatest care and best
methods known in a sufficiently good quantity to assure uniform colouring; they
shall be of a density and body such as to cover perfectly the surfaces to which
they are to be applied. The Engineer may, while work is in progress, take
samples for the products employed in the different operations, in order to have
them analysed and tested as deemed fit, all at the contractors expense.

14.07. 03 The contractor shall be responsible for evident or hidden faults which may
become apparent even after work is finished, upto the time of final inspection
and acceptance. The Contractor shall take into account the conditions of the
surfaces to be painted (for example ageing of plasters, etc.) and adapt the
preparation thereto, using any special operations which in practice may have
proved necessary and which have been approved by the Engineer. All
reconditioning or extra work which the Engineer may deem necessary for the
removal of defects shall be at the Contractors expenses.

14.07.04 all paints shall be of the best type used for that particular purpose, possessing
the highest wear resistance, and shall be submitted for approval to the Engineer,
who is entitled to demand such tests as he may deem fit. The contractor shall
give notice to the Engineer of each stage of painting that is to be performed, and
obtain approval for each in special register prepared for the purpose. Painted
surfaces shall appear absolutely even and free from any trace of brush marks
and a good finish is required for those having pumice treatment.

14.08 Applicable Codes and Specifications

The following codes, standards and specifications shall form part of this
specification. All standards, specifications, codes of practices 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 herin, this
specification shall govern.

IS:2394 Code of practice for application of lime plaster finish

IS:1443 Code of practice for laying and finishing of cement concrete
flooring tiles.

IS:2114 Code of practice for laying in situ terrazzo floor finish

IS:777 Glazed earthenware tiles



IS:427 Distemper, dry, colour as required.

IS:428 Distemper, oil emulsion, colour as required.

IS:2395 Code of practice for painting concrete, masonry and plaster
surfaces

IS:1477 Code of practice for painting of ferrous metals in buildings
and allied finishes

IS:2338 Code of practice for finishing of wood and wood based
materials (Part I)

15.00 PVC WATER STOPS

15.01 These should be of approved good quality PVC highly resistant to tearing,
abrasion and corrosion as well as to alkalies, acid and sulphate likely to come in
contact with, during use. The ribbed 150 mm & 225 mm PVC water stops shall
be 6 mm thick with adequate number of ribs on either side top and bottom of the
central bulb. PVC water stops shall be provided at all construction joints in
underground tunnels, transfer points etc.

15.02 Physical Properties

Physical properties shall generally be as follows:

Sl. No.

Characteristics Unit value
1. Tensile strength Kg /cm
2
116 minimum

2. Ultimate elongation % 300 minimum

3. Tear resistance - 49 kg/ cm
2

4. Stiffness in flexure Kg/cm
2
24.6 minimum

5. Accelerated Extraction

a. Tensile strength Kg /cm
2
105 minimum

b. Ultimate
elongation

% 250 minimum

6.

Effect of Alkali 7 days

a. Weight increase % 0.25 minimum

b. Weight decrease % 1.10 minimum

c. Hardness change Point + 5


Sl. No.

Characteristics Unit value

7. Effect of Alkali 28 days

a. Weight increase % 0.40 maximum

b. Weight decrease % 0.30 maximum

c. Dimensions change % + 1

d. Shore hardness 60 A to 80 A

e. Minimum safe continuous
temperature
70
0
C

15.03 Placing In Position

15.03.01 Water stops shall be cleaned before placing them in position. Any dirt / grease
shall be washed off with water / detergent, as directed by the Engineer. Water
stops shall be procured in ling lengths to avoid joints as far as possible.
Adequate provision shall be made to support the water stops during progress of
work and to unsure their proper embedment in the concreting. The symmetrical
halves of the water stops shall be equally divided between the concrete pours
adjacent to the joints. Maximum density and imperviousness of concrete shall
be ensured by thoroughly working it in the vicinity of joints.

15.03.02 Splices in the continuity or intersection of runs of water stops shall be jointed as
per manufacturers stipulations. It is essential that the material shall not get
damaged during splicing operation and that the continuity of entire water stops
across the sections is maintained.

15.03.03 All water stops installation shall be subject to inspection and approval by the
Engineer before concerting operations encasing water stops are performed.

15.04 Pre-moulded Bituminous Joint Filler And Sealing Compound

15.04.01 Pre-moulded joint fillers shall be of non-deteriorating and resilient type
conforming to IS: 1838. sealing compound shall be Grade A as per IS:1834.
Bitumen primer shall conform to IS: 1384.

15.04.02 The concrete surface shall be made clean, smooth and free from dirt or loose
particles. When the surface is completely, dry a coat of hot blown bitumen
conforming to IS:702 of grade 85/25 shall be given with brush or spray.

15.04.03 When the bitumen is still hot, the pre-moulded joint filler fibre board shall be
pressed against the surface and held in position till the time it automatically
remains fixed in position. Where the joint filler is specified in two layers, the
second board shall be fixed on the board as above with a few tacking patches of
bitumen between the two. After placing the filler in position, the surfaces of the
filler against which further concreting shall given a coat of bitumen. Before


application of the sealing compound, the joints shall be splayed or brushed with
bitumen primer. The primer shall then allowed to dry thoroughly for at least 24
hours; and then mixed a mixture of 30% fine sand & 70% sealing compound by
we weight.

15.04.04 Applicable Codes

The following standards and codes shall form a part of this specification. All
standards, codes of practice referred to herein shall be latest edition including all
official amendments and revisions:

1. IS:454 Concrete Pipes (with and without
reinforcement)
2. IS:554 Dimension for pipe threads where pressure
tight joints are required on the threads.

3. IS:651 Salt glazed stoneware pipes and fittings

4. IS:774 Flushing cisterns for water closets and urinals
(valveless siphonic type)

5. IS:775 Cast iron brackets and supports for wash
basins and sinks

6. IS:781 Sand cast brass screw-down bib taps and stop
taps for water services

7. IS:783 Code of practice for laying of concrete pipes

8. IS:1068 Electroplated coatings of nickel and chromium
on iron and steel

9. IS:1239 Mild steel tubes (Part I) and mild steel
tubulars and other wrought steel pipe fittings
(Part II)

16.0 FLOORING

16.01 The type of flooring for the various area shall be provided as detailed below:

a)

All grade slabs, compressor
room, slurry pump house,
water pump house
: Grade slab with heavy
duty finish

b) MCC room, toilets : Mosaic flooring

c) All RCC floors other than
above
: Cement flooring

d) Toilets : Ceramic tiles

e) Control room : Markrana white marble
flooring



16.02 General

Material of any type and kind shall be perfect in every respect. The individual
elements shall fit perfectly together and be fixed to the underlying floor without
the slightest unevenness at joints; they may be of different shapes and colours
as approved by the Engineer and shall be laid as directed. Floor shall penetrate
about 15 mm into the wall plaster, finished and clean, without stains and
performed to best workmanship. The contractor shall be fully responsible for
damage resulting from abusive treatment; and shall at his own expense rebuild
the portions damaged. Flooring directly exposed to rain shall be cast rough /
grooved to make them non-slippery. The contractor shall submit samples of the
materials to be used to Engineer for approval.

16.03 Grade Slab

16.03.01 The existing earth fill shall be thoroughly compacted so that there are no loose
pockets left. Extra layers of earth shall be deposited to make good the
settlement due to compaction of the existing fill. Each consolidated layer shall
have a thickness not exceeding 450 mm; and shall be consolidated to minimum
90% proctor density at optimum moisture content. The final surface shall be
evenly dressed to the specified level.

16.03.02 RCC paving:

RCC paving in specified areas shall comprise following layers:

1. 225mm thick approved quality boulders shall be placed on well
compacted soil underneath. The interstices of the boulders shall be filled
with sand. These layers shall be compacted to the satisfaction of
engineer.

2. 100mm thick M15 grade plain cement concrete on layer mentioned (1)
above.

3. M20 reinforced concrete with nominal reinforcement 8 Tor @ 250 c/c
both ways top and bottom having thickness 150mm shall be laid over the
layer mentioned (2) above.

16.03.03 For painting structural steel with enamel paint, thickness of painting in DFT shall
be as follows:

2 coats of primer with DFT of each coat 35 microns (minimum). 2 coats of finish
paint with DFT of each coat as 35 microns totalling to a minimum of 150 microns.

16.03.04 Flooring in MCC and control room shall be with vitrified tiles.

16.04 Cement Floor

16.04.01 The cement topping shall consist of one (1) part Portland Cement, one (1) part
fine aggregate and two (2) parts of coarse aggregate, proportioned by volume,
with the addition of not more than eighteen (18) litres of water per bag of cement


unless otherwise approved by the Engineer. The coarse aggregates shall be
graded from 3 mm to 12 mm maximum size. The fine and coarse aggregates
shall be free from injurious quantities of clay, loam, vegetable matter or any
ingredients that may affect their bonding quantities.

16.04.02 Cement topping shall be applied in average thickness of 40 mm after all heavy
construction work has been completed and all machinery, equipment units and
piping have been installed.

16.04.03 All surfaces in areas to receive cement topping shall be broom cleaned and be
free from loose particles; any grease, paint, oil spot, asphalt and /or tar shall be
removed; any projections such as nails, bolts or screws shall be cut off flush with
the concrete slab. Any laitance or scum shall be removed by the use of stiff
bristle brushes.

16.04.04 Immediately prior to placing the cement topping, the base slab shall be
thoroughly moistened and brush coated with a neat cement grout, to provide a
mechanical bond for the surface application. The cement topping shall be
placed immediately following the applied neat cement brush coat. After
screeding the topping to the established grades, the surface shall be compacted
by tamping and rolling, then floated with a wooden float or power floating
machine.

16.04.05 After the topping has partially set, the surface shall be steel trowelled to a
smooth and even finish, free from tool marks. A final steel trowelling shall be
given until the surfaces have set to a hard and uniform finish.

16.04.06 Provision for expansion joints shall be made through the entire depth of the
topping at all intersections with vertical surfaces and at not more than 3 meter
intervals across the floor surface. The expansion joints shall be formed by
placing 20 mm thick wooden strips and after the curing period the wooden strips
shall be removed and all joints shall be filled with bitumen, asphalt or equivalent
material [Curing shall be done by covering with wet sacks for two (2) days and
then by ponding 50 mm water for seven (7) days].

16.05 Heavy Duty Floor

16.05.01 Heavy duty ironite or approved equal artificial stone concrete floor hardner shall
be provided for heavy equipment areas as shown on drawings or as directed by
the Engineer.

16.05.02 The topping shall, if possible, be placed on the base slab before the latter has
taken its final set. When this is not possible, the base slab shall be thoroughly
brushed with stiff brooms, wetted for twelve (12) hours and allowed to dry before
the cement concrete floor topping is laid. Surplus water shall be mopped up;
and a cement grout brushed well into the surface immediately before laying the
screeded bed to a level 12 mm below the finishing level.

16.05.03 The cement floor shall consist of a mix of part cement, one part sand and 2 parts
crushed aggregate 10 mm size, as specified above, but with a slump less than
25 mm. This shall be mixed, placed, thoroughly tamped with a grill hammer and
floated and screeded to receive the 12 mm thick hard topping. Hard topping


shall be applied while the screeded bed is still wet. This shall consist of one part
of a cement- ironite mixture to 2 parts by bulk of well-graded approved crushed
granite of maximum 6/12 mm size. The cement-ironite shall consist of well
mixed dry mixture containing one part ironite to 4 parts cement by weight. Water
shall be added after mixing the aggregate, placing tamping, floating and
trowelling being done in accordance with manufacturers recommendations.
Care shall be taken not to over-trowel until the initial set has taken place.

16.06 Mosaic Tile Floors

16.06.01 Mosaic tiles shall be hydraulically pressed, machine polished, of approved tint,
pattern and size. Each tile shall be printed legibly and permanently on the back
with manufacturers trade name and ISI certification mark. The Tiles shall
conform to IS:1237. Face of the tile shall be free from pin holes and any other
such defects. The contractor shall submit samples of the tiles for the approval of
the Engineer. The tile shall be cured for a minimum period of fourteen (14)
days at the shop before being delivered to the site.

16.06.02 The underbed for horizontal surfaces shall be cement mortar 1:3 and 20 mm
thick, mixed with ample water to form a stiff workable mass.

16.06.03 The tiles shall be kept wet for atleast ten (10) minutes just before laying. The
under bed mortar shall be evenly spread and brought to proper grade. Before
the under-bed mortar is set, cement slurry at the rate of 4.4 Kg of cement per
square metre shall be applied over it. The tiles shall be immediately placed over
it and pressed by wooden mallet till it reaches the desired level. The floor shall
be kept moist for seven (7) days. The joints between the tiles shall be uniform
and as thin as possible but not more than 1.5 mm.

16.06.04 The day after the tiles are laid, all joints shall be carefully cleaned and grouted
with coloured cement to match with the tint of tiles. About a week after laying of
tiles, each tile shall be tapped with a wooden mallet to find out if it gives a hollow
sound. All such tiles and tiles broken shall be removed and replaced by new
tiles till the tiles are fixed to proper line and level and polished. After the joints
have developed sufficient strength, the floors shall be properly polished to a
highly glossy finish with polishing machine. After the final polish, oxalic acid
shall be dusted over the surface at the rate of 33 gms per square meter sprinkled
with water and rubbed hard with a pad of woolen rags. The following day, the
floor shall be wiped with a moist rag and dried with a soft cloth and finished
clean. If any tile is disturbed or damaged, it shall be refitted or replaced properly
jointed and polished. The finished floor shall not sound hollow when tapped with
a wooden mallet.

16.07 Ceramic Tiles

16.07.01 The earthenware tiles shall be of Johnson make or approved equal covered with
glaze of approved colour and design. The tiles 100 x 100x6 mm shall be flat and
true to shape. They shall be uniform in colour, free from any flaws like cracks,
chips etc. The edges and the underside of the tiles shall be free from any glaze
and shall have proper indentations for proper bond. All precautions and
workmanship while doing the work shall be enumerated above.



16.08 Curing

Curing shall be done by covering with wet sacking for two (2) days and then by
ponding with 50 mm water for seven (7) days.

16.09 Dado

Tiles from factory should be practically fully polished. The back of such tiles at
the time of fixing to the mortar backing shall be covered with a thin layer of neat
cement paste; and the tile shall then be jointly tapped against the wall with a
wooden mallet. This shall be done from the bottom of the surface upwards. The
joint shall be as close as possible; and the work shall be truly vertical and flush.
After the work is set, polishing shall be done so that the surface attains a high
glossy.

16.10 Makrana White Marble Floor

16.10.01 The Makrana (Rajasthan) Marble shall be pure white with minimum 25 mm
thickness. It shall be flat, uniform in colour, free from cracks and any such other
defects. The minimum size shall be 500 x 500 mm and of uniform size as for as
possible. The contractor shall submit samples of the marble for approval of
Engineer.

16.10.02 The underbed for the marble flooring / Dado shall be in cement mortar 1:3 and
20 mm thick, mixed with ample water to form a stiff workable mass.

16.10.03 The marble shall be kept wet for at least ten (10) minutes just before laying. The
underbed mortar shall be evenly spread and brought to proper grade. Before the
underbed mortar is set, cement slurry at the rate of 4.4 kg of cement per square
metre shall be applied over it. The marble shall be immediately placed over it
and pressed by wooden mallet till it reaches the desired level. The floor shall be
kept moist for seven (7) days. The joints between the marble pieces shall be
uniform and as thin as possible but not more than 1.5 mm.

16.10.04 The day after the marble is laid, all joints shall be carefully cleaned and grouted
with white cement. About a week after laying the marble, it shall be lapped with
a wooden mallet to find out if it gives a hollow sound. All such marble pieces till
the pieces are fixed to proper line a level and polished. After joint have
developed sufficient strength, joints shall be cleaned properly and floor shall then
be properly polished with wax polish using a soft cloth and finished clear. If any
marble piece is disturbed or damaged, it shall be refitted or replaced, properly
jointed and polished. The finished floor/ wall shall not sound hollow when tapped
with a wooden mallet.

17.00 PIPING AND DRAINS

17.01 Scope

The contractor shall furnish all labour, materials, tools and plant and equipment
necessary for complete installation of permanent storm water drainage system
and sewage disposal system required for the proposed system.



17.02 Storm Drainage / Rain Water Pipes

17.02.01 Rain water pipes shall be adequately provided to drain out the rain water without
overflow. Minimum 100 mm diameter pipe shall be provided to drainout 40
Square meter of roof surface area and minimum 150 mm diameter to drain out
80 square meters of roof surface area. All vertical down spout pipes and pipe
fittings shall run inside the walls. All vertical down spout pipes shall be
connected to water-proof roofing by means of lead funnels protected at the
outside by a cover net of brass wire or by 90 degree bends (elbow).

17.02.02 All covers for water collecting pits, both inside and outside the buildings, shall be
of cast iron, with proper holes and designed to withstand any possible transient
load. Such cast iron covers shall be of commercial size and as far as possible
the closest to-for indoor pits minimum 250 x 250 mm and for outdoor pits 600 x
600mm.

17.02.03 Cast iron pipes shall be straight and perfect in every detail, of uniform thickness
and with smooth internal surface free from any casting faults, and shall comply
with IS:1230. Pipes to be embedded in masonry shall be fixed in the masonry
work as it proceeds. Care shall be taken to keep the pipes absolutely vertical or
to the lines as directed by the Engineer. Pipes shall have a surrounding of 12
mm minimum thickness of mortar at every position of the external surface. The
mortar shall be of the same mix as is used in the masonry. The joints shall be
caulked in with lead as soon as the next length of pipe is placed in position. The
open end (socket end) of the pipe shall be kept closed till the next length of pipe
is fitted and jointed to prevent any brick bats or concrete or pieces of wood falling
in and choking the pipe. The spigot end shall butt the shoulder of the socket and
leave no gap in between. The annular space between the socket and the spigot
shall be first well packed in with spun yarn leaving 25 mm from the lip of the
socket for the load. The joints shall then be lead caulked as per IS:3114.

17.03 Sewerage Pipes

Sewerage piping shall be of vitrified clay of proper diameter as per IS:3006 made
of an opaque compact paste, combined with a feldspar flux, after which the
compound shall be strongly baked. The resulting mass shall be free from lumps,
free of lime and chemically resistant. Pipe sections shall be inside and outside
glazed and the vitreous glaze chemically embodied in the ceramic paste, shall
be resistant to attack by alkali and acids with the exception of hydrofluoric acid.
Vitrified clay pieces shall be most carefully manufactured, shall not be distorted
and shall be free from cracks. They shall have bell-and-spigot coupling; they
shall be cylindrical and straight. In each part, the flare of the bell- and spigot
coupling shall be formed to ensure an excellent connection inside and the
opposite end shall be suitably grooved outside. Pipes shall be practically non-
absorbent, when struck with a metal body, they should ring clearly providing
optimum baking and absence of invisible cracks.

17.04 Cement Concrete Pipes

These pipes shall be with or without reinforcement as required conforming to
IS:485.



17.05 Normal Concrete Pipes

These shall be cast from concrete with high cement content; and shall be well
cured and compact, smooth and perfectly straight with absolutely circular internal
and external sections, of uniform thickness, free from cracks and absolutely
impervious. Internal surfaces shall be smooth finished. On breaking, they shall
reveal a compact structure without cracks and the concrete gravels shall be
intimately mixed with the mortar that grains when hammered shall break up
without detaching from the mortar.

17.06 Reinforced Concrete Pipes

17.06.01 The reinforcement cage for pipes shall consist of main circular bars & secondary
longitudinal steel bars of diameter and spacing as per design. Steel rings for
socket type of pipe-to-pipe joints shall be provided at the 2 ends of each pipe,
and properly fixed and anchored to concrete while casting. The reinforcement
steel shall be completely embedded in the concrete.

17.06.02 Each pipe piece shall be provided with a self- aligning expansion joint equipped
with rubber seal ring, capable of absorbing the relative movements of pipes due
to settlement of ground or due to the effects of temperature variations.

17.06.03 Final diameter of pipes and working pressure shall be as per drawings, pipe
thickness for each different diameter shall be such as to withstand test pressure.
Test shall be performed in accordance with Indian Standards or as directed by
the Engineer. The pipes shall have uniform circular section. Should the actual
diameter of a straight piece of pipe result less than nominal diameter, the
following tolerances will be accepted:

a) For pipe diameter upto and including 1200 mm, the actual pipe diameter
shall not be over 7 mm less than the nominal ones.

b) For pipe diameter over 1200 mm and upto and including 1600 mm, the
actual pipe diameter shall not be over 13.5 mm less than the nominal
ones.

17.06.04 Piping Design

Main circular reinforcement shall consist of one or more cages. The overall
reinforcement steel surface at any point of the pipe shall be so designed as to
withstand the internal operating pressure, keeping the reinforcement steel
internal stress below 900 kg/cm2. in no case shall the surface and number of
reinforcement bars be less than specified by the Indian standards. The
secondary longitudinal reinforcement bars shall consist of atleast 12 mm
diameter steel bars with a maximum bar to bar distance of 75 mm. In any way,
each cage shall consist of not less than six (6) 12 mm diameter bars.

17.06.05 Joints

17.06.051 Joints shall be provided with tight seals by means of rubber ring seals of suitable
shape, such as to hold tight with any operating conditions, as well a with any
pipe movements due to pipe expansion and / or contraction, and due to ground


settlement. Each pipe piece shall be equipped with socket type joint consisting
of steel rings properly fixed and anchored to the reinforced concrete while
casting. The male \section of ring shall have concrete lined internal face. The
female section of ring shall have concrete lined external face.

17.06.052 The steel portion of the rings of which the socket type joint consists- that will
remain exposed after fabrication of the pipe, shall be protected against corrosion
effects by means of a suitable rust preventing compound. The male section of
ring shall be provided with a suitable groove to receive, house, and protect the
rubber seal and the joint surface. Shape and size of joining faces shall be so
designed that joints shall be self-aligning when assembling the pipes, so that the
already erected piping shall not have to bear the weight of the pipes that are
being erected. Special steel shapes for making male sections of joints rings
shall conform oto the provision of the Indian Standards specifications.

17.06.053 Plain steel shapes for making female sections of joints rings, shall be 4.5 mm
thick; and shall be used for pipes upto and including 900 mm diameter, and shall
also be in conformity with the provisions of the Indian Standards specifications.

17.06.054 Female rings for pipe diameters of 1050 mm or larger shall be 6 mm thick
conforming to the provisions of the Indian Standard Specifications.

17.06.055 Joints seal packing shall consist of special compound rubber, designed so as to
provide a tight and long lasting seal; and shall be manufactured by a qualified
firm with atleast five (5) years experience with the production of rubber seals for
pipe joints. The rubber seal shall consist of a solid ring of suitable section and
adequate size to completely fill the male ring groove when the piping is erected.
The rubber seal shall ensure alone the tight seal of the pipe and offer completely
smooth surfaces, without any blowholes, pin holes or any other similar flaw.

17.07 Reinforcing Steel

Reinforcing steel shall be as specified elsewhere.

17.08 Concrete

Concrete shall be as specified elsewhere; and shall be case in vertical steel
forms so constructed that the pipes both in interior and exterior sides, steel rings
of the joints and steel reinforcing cage remain in their proper perfect circular and
concentric positions. During the pouring of concrete, the formwork shall be
continuously vibrated.

17.09 Curves and Special Pieces

Curves of great radius may be obtained, giving a gradual deflection in each pipe
joint or by construction and placing special pipes at the end of which steel rings
should be provide to fit and join to other pieces, with necessary angle of
deflection. Special pieces of pipes shall be so designed that the same can resist
the same pressure as that of the adjoining straight piece. The elbows, tees,
reducers, bends shall be of steel and cylindrical type. Special pieces shall be
provided with rings for the seal in all respects equal to that used for straight


concrete pieces. Along with the bid, the bidder shall produce the detailed
drawings, literature and make, pieces, he proposes to use.

17.10 General

17.10.01 Piping in general of the type and size specified, shall follow the shortest course
compatible with proper orientation and good appearance. As far as possible,
elbows, sharp turns, joints and change of diameter shall be avoided. Pipes shall
be laid so as to cause no hindrance and to be easily inspected, particularly where
there are joints, siphons, etc., drains shall allow rapid and complete discharge of
their contents without clogging, deposits or other drawbacks.

17.10.02 Underground pipes outside the building shall normally be laid at a depth of
atleast one 91) meter beneath road level; horizontal pipes inside the building
shall be laid in accordance with design drawings; vertical columns shall be
placed along the walls in proper chassis sufficiently wide to allow making joints,
take-offs, etc. and fixed with suitable supports, unless otherwise authorised by
the Engineer.

17.10.03 Pipes operating under pressure even for short periods shall be given a pressure
test at one and a half (1-1/2) times the operating pressure, over a period of four
(4) hours. Both pressure pipes and free circulation pipes shall be tested by and
at the expense of the Contractor before operation is commenced; and should
even slight leaks be ascertained, they shall be repaired and sealed at his
expense.

17.10.04 The Contractor shall also be responsible for repairing any leaks or other faults
which may be found in the various pipes, gutters, etc., even after they have
commenced working until the final inspection and acceptance test has taken
place, and to do all reconditioning required. All the above piping not buried shall
be fixed and supported with suitable stirrups, ties, brackets, clamps or the like of
sufficient number to anchor them perfectly; these supports shall be built so as to
allow rapid removal of the pipe and as a rule shall be placed close enough
together to prevent sagging of the pipe, and shall be protected by a carefully
applied coat of paint, or larring.

17.10.05 Small size pipe shall be paid either on isolated brick supports or concrete beds
etc. shaped so as to follow perfectly the outside circumference of the pipe for at
least 60 degree, depending on the Engineers instructions. These supports shall
be sized so as to ensure that the pipes remain in the exact position specified. If
pipes rest on isolated supports, particular care shall be taken in burying them.

17.10.06 The Contractor shall prepare and submit for approval plumbing, drainage and
disposal pipeline drawings and carry out work accordingly.

17.11 Applicable Codes & Standards

IS : 1536 Centrifugally cast (spun) iron pressure pipes, for water, gas
and sewage
IS : 1626 Asbestos cement building pipes, gutters and fittings (spigot


and socket types)
IS : 1703 Ball valves (horizontal plunger type) including floats for water
supply purposes
IS : 1726 Cast iron manhole covers and frames
IS : 1729 Sand cast iron spigot and socket soil, waste and ventilating
pipes, fittings and accessories
IS : 1742 Code of practice for building drainage
IS : 2326 Automatic flushing cisterns for urinals
IS : 2470 Code of practice for design and construction of septic tanks
IS : 2556 Vitreous sanitary appliances (Part I to XV)
IS : 2963 Non-ferrous waste fittings for wash basins and sinks
IS : 3311 Waste plug and its accessories for sinks and wash basins
IS : 5329 Code of practice for sanitary pipe work above ground for
buildings
IS : 5434 Non-ferrous alloy bottle traps for marine use

18.00 STRUCTURAL STEEL WORKS

18.01 Standards

Unless otherwise specified herein, the design, materials and workmanship or the
work shall conform to the latest editions of the following standards or their
approved equivalents :

American Institute of Steel Construction Specification of the Design,
Fabrication and Erection of Structural Steel for Buildings.

American Institute of Steel Construction Specification for Assembly of
Structural Joints using High Strength Bolts.

American Welding Society Code for Arc and Gas Welding in Building
Construction.

Indian Code of Practice for General Construction Steel, Indian Standards
Institute IS:800.

Indian Code of Practice for Use of Metal Arc Welding for General
Construction in Mild Steel, Indian Standard Institute IS:816.

Specification for Structural Steel IS:226 and when specified, IS:2062.



Specification for Black Hexagonal Bolts and Nuts IS:1363.

Specification for Precision and Semi-precision Hexagonal Bolts and Nuts
IS:1364.

Technical Supply Conditions for threaded fasteners IS:1367.

Specification for Covered Electrodes for Metal and Welding of Mild Steel
IS:814.

All structures shall be designed as per IS:800; as well as for wind & seismic
loads as per latest revisions of IS:875 & IS:1893. For seismic loads importance
factor of 1.5 as per IS:1893 shall be considered. Minimum live load on floors,
gallery walkways, platform etc. shall be taken as 500 Kg/m2, besides other
equipment loads. In case designed sections are not available, higher size
sections shall be substituted by contractor with out any extra cost.

18.02 Fabrication

All structural steel work shall be in accordance with IS:800 Code of Practice for
Construction in steel unless otherwise stated; workmanship and finish shall
be of the best quality and shall conform to the best approved method of
fabrication. All materials shall be finished straight and shall be machined true
and square where so specified. Materials at the fabrication shop shall be kept
clean and protected from weather. All holes and edges shall be free form burrs.
Shearing and chipping shall be neatly and accurately done and all portions of
work exposed to view shall be neatly finished.

Fabrication clearance as detailed in Manuals shall be generally followed unless
otherwise directed/ approved.

18.03 Straightening

All steel materials, before being worked shall be straight and free from bends
or twists. If the sections are distorted or twisted, they shall be straightened and
flattened by methods that will not injure the material, (heating/forging shall
not be resorted to). Contractors lumpsum price shall be inclusive of the cost
of all these operations involved in straightening as desired above.

18.04 Cutting and Edge Planning

Cutting may be done by shearing, cropping, sawing, or mechanically
controlled gas cutting torch as permitted by the Engineer. All re-entrant
corners shall be shaped notch free to a radius of at least 12 mm. Sheared or
cropped edges shall be dressed to a neat finish; and shall be free from distortion
and burrs. Hand flame cutting shall be undertaken only if so permitted by the
Engineer and shall only be carried out by an expert in such work. Hand flame
cut edges shall be ground smooth and straight. Edge planning of sheared edge
should not be intended unless the sheared edges are such as to warrant it or
specifically called for, by Engineer whose decision shall be final and binding.
Edges of cropped or gas cut edges shall be planned as directed by Engineer.



18.05 Grinding

All the edges cut by flames shall be grounded before these are welded. Ends
of all bearing stiffeners shall be ground to fit tightly at both top and bottom. In
case of gantry girders, the bottom of the knife-edge support shall be
accurately ground to provide effective bearing on the column bracket with a
clearance not exceeding 0.1 mm locally at any place. The top surface of
column bracket, struts and compression members shall be accurately ground
and closely butted over the whole section with tolerance not exceeding 0.1 mm
locally at any place. Notwithstanding the above, full loads shall be transferred
through welds. Column ends resting on bases shall be ground smooth and
true to ensure minimum 85 per cent contact area with local gap not exceeding
0.1 mm.

The base plate shall be similarly ground over the bearing surfaces and shall
have effective contact with the end of the shaft. The bearing face which is to be
grouted direct to a foundation need not be ground if such face is true and
parallel to the upper face. To facilitate grouting and escape of air, holes shall
be provided wherever necessary in column bases.

18.06 Bending

The bending of plates and sections to specially required shapes shall be done
either on appropriate machine or by angle smithy and black smithy process.

18.07 Rolling & Framing

Plates for chutes, hoppers etc. shall be accurately laid off and rolled or formed
to required profile/shape as called for on the drawings. Adjacent sections shall
be matched for facilitating accurate assembly, welded and erection in the field.

18.08 Drilling and Punching

a. Holes through more than one thickness of material for members, such
as compound stanchion and girders flanges shall, where possible, be
drilled after the members are assembled and tightly clamped or bolted
together; sub-punching may be permitted, by assembly provided the
poles are punched 3 mm less in diameter than the required size and
reamed after assembly to the full size. Punching shall not be adopted
where the thickness of the materials to be punched together exceeds
16 mm.

b. Matching holes for black bolts shall register with each other so that a
gauge of 1.0 mm lesser in diameter than the diameter of the hole will
pass freely through the assembled members in a direction right angle
to such members. Finished holes shall not be more than 1.5 mm or
2.0 mm (as the case may be depending upon the diameter than the
diameter on the black bolt passing through them, unless otherwise
specified by the Engineer.

c. Holes for bolts shall not be formed by gas cutting process.



d. Where reamed members are taken apart for shipping or handling the
respective pieces reamed together shall be so marked that they may
be reassembled in the final setting up. No interchange of reamed
parts will be permitted. Poor matching, over drilling and ovality in holes
shall be a cause for rejection.

e. Burrs shall be removed after drilling holes, where ever horizontal
member is likely to collect water, suitable holes for drainage shall be
provided.

18.09 Notches

The ends of all joints, beams and girders shall be cut truly square unless
required otherwise and joint flanges shall be neatly cut away or notched
away wherever necessary, the notches being kept as small as possible.
Corners of such notches in flanges shall be shaped to a radius of 50 mm.

18.10 Assembly

The component parts shall be assembled in such a manner that they are
either twisted nor otherwise damaged and shall be so prepared that the
specified chamfer, if any, is provided. In order to minimize distortion in a
member, the component parts shall be positioned by clamps, jigs and other
suitable means and fasteners. If the individual components are to be bolted,
parallel and tapered drifts shall be used to align the parts so that the bolts can
be accurately positioned. Items like roof trusses etc. shall be assembled
keeping in view the actual site conditions, prior to despatch to site of erection,
so that they can be conveniently pre-assembled during erection. Necessary
match marks shall be made on these components before disassembling in the
shop and dispatching.

18.11 Connections

The Contractor shall plan out the work right from the preparation of fabrication
drawings stage to have shop connections as well as field connections
effected either by welding, or by black bolts as shown on the design/fabrication
drawings or as specified.

18.12 Bolted Connections

Bolts, nuts and washers and other fastening materials shall be stored in racks
off the ground with coating of suitable protective oil.

Bolts shall be inserted in such a way that they may remain in position under
gravity even before fixing the nut.

The length of the bolt shall be such that at least one thread of the bolt projects
beyond nut. Bolted parts shall fit solidly together when assembled and shall not
be separated by gaskets or any other interposed compressible materials. When
assembled, all joint surfaces including those adjacent to the washers, shall
be free of scales except tight mill scales. They shall be free of dirt, loose
scales, burrs and other defects that would prevent solid seating of the parts.


Contact surfaces shall be free of oil, paint, lacquer or galvanizing. Wherever
necessary, tapered washers or flat washers or spring washers shall be used
under the nut so that no part of the threaded portion of the bolt is within the
thickness of the parts bolted together.

Flat washers shall be circular of a diameter 2-1/2 times that of bolt and of
suitable thickness. Where bolts head/nuts bear upon the beveled surfaces
they shall be provided with square tapered washers of suitable thickness to
afford a seating square with the axis of the belt.

Flat washers shall be circular. All the bolts and nuts shall be of steel with well-
formed hexagonal heads unless specified otherwise, forged from the solid and
shall be dipped in hot linseed oil as soon as they are made.

Notwithstanding anything to the contrary contained in IS:1363, IS1364 and
IS:1367, the unthreaded length of the bolt shank shall be equal to total
thickness of metal being bolted together plus 2 mm. The threaded length shall
be equal to at least the diameter of the bolt plus 6 mm.

Not more than one shop splice shall be provided to make up the full length of
member. This splice shall be within full strength butt weld.

18.13 Welded Connections

a. Manual are welding shall be used, except in case of continuous welds,
use of automatic welding machine shall be necessary for ensuring
satisfactory quality of fabrication. Welding must be done by experienced
and tested welders in proper sequence using necessary jigs and
fixtures to minimize all possible distortions.

b. Welding shall be done by experts in the field who have been qualified
by tests as specified. Surfaces to be welded shall be free from loose
scales, slag, rust, grease, paint and any other foreign materials.

c. The members to be joined by fillet welding shall be brought and held
as close together as possible and in no event shall be separated by
more than 3 mm. If the separation is 1.5 mm or greater, the fillet weld
size shall be increased by the amount of separation. This shall only
apply if the surfaces are completely sealed by welds. In all other cases,
the fit up shall be close enough to exclude water from painting.

d. Before commencing fabrication of members in which welding is likely to
result in distortion or locked up stresses, a complete programme of
fabrication, assembly and welding shall be made and submitted to the
Engineer for approval.

e. Web to flange connections shall be welded by continuous double fillet
welds by automatic or semi-automatic electric are welding process. All
welds shall be free from defects like blow-holes, lack of penetration,
slag and inclusions etc. All fillet welds shall be inspected for flaws.



f. Butt welding in flange plates or web plates shall be complete before
the flanges and webs are welded together.

g. All main butt welds shall have complete penetration unless noted
otherwise.

h. The Contractor shall give timely notice to the Engineer before welding
is taken up at the site. Approval of Engineer shall be undertaken in
writing before welding field connections.

Electrodes

The electrodes used for welding shall be of suitable type and size depending
upon the specifications of the parent material, the method of welding, the
position of the welding and the quality of welds desired eg. Normal
penetration welds or deep penetration welds; and shall conform to IS:814,
IS:1395 or IS:1442 (latest edition) as per requirements.

Only those electrode which give radiographic quality welds shall be used.
Suitable electrodes of Advani Oerlikon, D&H, ESAB, Modi, L&T, Rockweld,
Indian Oxygen or Philips.

Specific approval of the Engineer shall be taken by the Contractor for the
various electrodes proposed to be used on the work before any welding is
started.

Where bare electrodes are used, these shall correspond in specification to the
parent material. The flux used for submerged are welding should be
specifically manufactured for the purpose; and should have such a composition
which does not evolve any appreciable quantity of gases. The electrodes shall
be stored in an oven, strictly in accordance with the manufacturers
requirements as stipulated.

Welding

No welding shall be done when the surface of the member is wet nor during
high winds unless the welding operator and the works are properly protected.

All welds shall be free from defects like blow holes, slag inclusions lack of
penetration, under cutting; crackers etc. All welds shall be cleaned of slag or
flux and show uniform sections, smoothness of weld metal, feather edges
without overlap, freedom from porosity. The ends of the welds shall have full
throat thickness. This shall be obtained on all main welds by the use of
extension pieces shall be removed by matching or by other approved means;
and the ends and surface of the welds shall be smoothly finished.

The sequence of welding shall be carefully chosen to ensure that the
components assembled by welding are free from distortion and large residual
stresses are not developed. The distortion should be effectively controlled
either by a counter-effect or by counter-distortion. The direction of welding
should be away from the point of restraint and towards the point of maximum
freedom.


Each case shall be carefully studied before finally following a particular
sequence of the welding.

Butt-welds in flange plates and/or web plates shall be completed before the
flange and webs are welded together.

The beams and column stiffeners shall preferably be welded to the webs
before the webs and flanges are assembled, unless the web and flanges of
the beam or columns are assembled by automatic welding process.

Approval of welding sequence and the procedure shall not relieve the
contractor of the responsibility for the correct welding and for minimizing the
distortion in the finished structure which in no case shall exceed that laid
down in Indian Standards.

All the welds shall be furnished full and made with correct number of runs,
the welds being kept free from slag and other inclusions, all adhering slag
being removed from exposed faces immediately after such run.

Welding procedure, current, voltage etc. shall be as per electrode
manufacturers instructions.

All main butt welds shall have complete penetration and except where it is
impracticable, they shall be welded from both side. Back surface of the weld
being gauged and cleaned before first run of the weld is given from the back.

Butt welds shall be terminated at the end of joint in a manner that will ensure
soundness. Where abutting parts are 20 mm or more in thickness run on and
run off plates with similar edge preparation and having a width not less than
the thickness of the thicker part jointed shall be used. These extension
pieces shall be removed upon completion of the weld and the ends of the welds
mad smooth and flush with the abutting parts by machining or by other approved
means. Where the abutting parts are thinner than 20 mm, the extension pieces
may be omitted by the ends of the butt welds shall then be chipped or gouged
out to sound metal and side welded to fill up the ends to the required
reinforcement.

18.14 Inspection and Testing

The Contractor shall provide at his coat all testing and inspection services &
facilities to the Engineer. The cost of these tests shall be borne by the
Contractor. The contractor shall also give sufficient advance notice to the
Engineer for inspection of materials or workmanship. The material rejected on
inspection shall be promptly removed and replaced by materials approved by
the Engineer.

The acceptance of test certificates or shop inspection by Engineer does not
relieve the Contractor from the responsibility of providing materials conforming
to specification requirements nor does it invalidate final rejection at site by the
Engineer unless otherwise stated. At all stages of fabrication and assembly,
the structural steel members shall be inspected to check whether the


dimensions, tolerances, alignment, painting and surface finish are within areas
specified. The same standard of supervision and quality control as for shop
work shall be maintained for field fabrication work. Inspection and tests on
structural steel members shall be carried out as follows:

18.15 Mill Tests

Mill tests shall be conducted by the Contractor at his own cost (if the mill test
reports are not available) to the Engineers satisfaction to demonstrate
conformity with the relevant specification.

18.16 Inspection of Welds

The Contractor shall in routine check execution of established technological
processes or general technological instructions. All welds shall be visually
examined and measured for external dimensions by appropriate gauges.
Profile of the weld shall be uniform. In case of butt and corner welds, the
profile shall be convex and in case of submerge arc fillet weld it shall be slightly
concave. He shall also conduct selective examination of welds by ultrasonic
and radiographic method.

The number of these tests shall be per clause 6.03. However, welded joints
in doubt examined by ultrasonic method should be re-examined by X-ray
although this may be beyond the number of such tests specified. The
Contractor shall arrange for examination by ultrasonic, radiographic for
welded joints for high quality control and in areas of doubtful welding as
directed by Engineer.

18.17 Quantum of Tests

i. Visual examination : Hundred percent (100% of welded
joints)

ii. Dye penetration test : As & when directed by the
Engineer.

iii. Ultrasonic : Hundred percent for butt welds.

iv. Radiographic : Ten percent (10%) of the length of
weld for all butt welds.

18.18 Rectification of Defective Welding Work
Whenever defects like improper penetration presence of blow holes, under
cuts, cracking, slag inclusion are noticed, the welds in such location shall be
removed by gauging process. The joints shall be prepared again by cleaning
the burrs and residual matters with wire brushes and grinding, if necessary
and rewelded. The gauging shall be done using gauging electrodes. All
defects shall be rectified, at no extra cost as per direction of the Engineer and
tests shall be conducted again for such cases.



18.19 Acceptance of Welded Structures
The acceptance of the welded work shall depend upon correct dimensions
and alignment, absence of distortion in structure, satisfactory results from the
examination and testing of the joints and the test specimens as per IS,
soundness of weld and upon general workmanship being good. Decision of
Engineer shall be final and binding.
18.20 Testing of Welders
Welding shall be done by experts in the filed who have been qualified by tests
as specified in IS:817 & IS:1181. Welders to be employed for erection work
shall be tested as per ASME Section - IX. Routine testing of all welders shall
be done every six months. The Engineer reserves the right to have any
welder retested at any time.
18.21 Tolerances
The dimensional and weight tolerances for rolled shapes supplied by the
Contractor shall be in accordance with IS:1852 and/or ASTM A1.
Not rolled or fabricated members shall deviate from straightness by more than
1/1000 of the axial length or 10 mm whichever is smaller. The length of
members with both ends finished for contact shall have a tolerance of +1 mm
Members without ends finished for contact bearing shall have a tolerance of
+1.5 mm for members upto 10 metres length and a tolerance of +3 mm for
members over 10 metres in length.
Lateral deviation between center line of web plate and center line of flange
plate at contact surface, in the case of built up sections shall not exceed 3 mm.
The combined warpage and tilt of flanges in welded built up section shall not
exceed 1/200 the of the flange width or 3 mm whichever is smaller.
The deviation from flatness of welded plate girder web in the length between
stiffeners or a length equal to the depth of the girder shall not exceed 1/150 th
of such length.
Deviations from the specified depth of welded girders measured at the center
line of the web shall not exceed +3 mm upto a depth of 1000 mm + 5 mm for
depths above 1000 mm and upto 2000 mm and +8 mm and 5 mm for depths
over 2000 mm.
18.22 Shop Matching
Some steel work, particularly columns, along with the tie beams/bracings, roof
trusses etc. shall be shop assembled to ensure satisfactory fabrication,
obtaining of adequate bearing areas etc. if so desired by the Engineer at no
extra cost to the Purchaser.



18.23 Stairways and Intermediate Landings
All stairways and intermediate landings as shown and/or listed on the drawings
shall be fabricated as a complete unit and shall include steel grating treads,
nosing, landings, hangers, brackets, struts, bracings etc. as detailed or as
necessary for connections to structural steel framing in place.
All stairs, shall be capable of sustaining a safe live load of 500 Kg/m2 of gross
projected area unless otherwise specified or as per Engineers approval.
Treads and landings for stairs shall be suitable for the prescribed loading and
furnished complete with a one piece standard non-slip nosing of approved
type. Nosing at start of stair flights shall also have a non-slip surface of an
approved type.
18.24 Gratings
All gratings shall be designed to sustain a minimum safe load of 500 Kg/cm
2
of
the plain area unless otherwise specified, or as per Engineers approval. The
maximum width of openings in gratings shall not exceed 30 mm. The minimum
thickness of main bars shall be 5 mm. Grating openings larger than 300 mm
diameter shall be bonded with bars of size as cut away. Holes for pipe and
equipment shall be located, but bonded and painted in the field. All gratins shall
be free from wraps, twist and other defects. Gratings shall be adequately
secured to the supporting steel. All grating shall be pressure locked type
manufactured in accordance with applicable standards.
18.25 Hand railing
Hand railing shall be provided on open sides of platforms, around all openings
and along stairways. Hand railing shall be B grade (medium quality)
galvanized steel pipe of flush welded construction, ground smooth using 32
mm NB pipe provided with double rail one (1) metre above platform level and
pipe posts spaced not more than 2000 mm centre to centre.
Smooth uniform curves and bends shall be used at stair returns and wherever
required. Posts connected to curb plates shall have a neat closure at the bottom
and 6 mm plate neatly welded to posts for attachment and curb plates. All
necessary fittings including inner dowels at splices, brackets, bolts flanges and
chains where required shall be furnished. Where hand railing posts have to be
set in concrete, they shall be set in sleeves.
Open ends of all the pipe posts shall be plugged and welded. A minimum radius
of 3 times the pipe diameter shall be provided at all points of direction changes
in the handrail.
18.26 Toe and Curb Plates & Angles
Toe and curb plates/angles shall be at least 6 mm thick extending at least 100
mm above the working surface.



18.27 Chequered Plates
Chequered plates used shall be as required; and shall be capable of carrying a
live load of 5000 Kg/m2. Chequered plates shall be fixed by intermittent
welding as specified on the approved drawings. The chequered plate pattern
shall be approved by the Purchaser. If lifting hooks are necessary the same
shall also be provided by the Contractor. Suitable stiffeners and supporting
structure shall be provided wherever necessary.
18.28 Marking of Members
18.28.01 Before any steel work leaves the Contractors fabrication shop, it shall be
suitably marked in accordance with the approved fabrication drawings.
18.28.02 The erection marks assigned to various components of the structural steel
work excepting cross-beams shall also contain an erection sequence number
indicating the sequence in which the various components are to be erected.
18.28.03 Erection marks shall be clearly painted on the work, each piece being
marked in at least two places. Each piece shall also have its weight marked
thereon.
18.28.04 The centre line of all column bases and girder bearings and important levels
shall be marked on the sections with the utmost care to ensure proper
alignment and assembly of the pieces at the site.
18.28.05 A separate colour code should be adopted for parts 9if any) fabricated out of
steel supplied by the Contractor. Weight of these parts shall also be marked.
18.29 Drilling Holes for Other Works
Holes in members (included in this scope) required for installing equipment or
structures fabricated by other Contractor shall be drilled by the Contractor.
Effort will be made to supply information for these holes by Engineer before
fabrication. However, these may be required to be drilled even after erection.
18.30 Shop Painting
After all inspection and test have been conducted to the satisfaction of the
Engineer the steel surface to be painted or otherwise treated, shall be dried
and thoroughly cleaned as per IS:1477 part-I. All steel work shall be given on
coat of approved metal protection except where encased in concrete. The
metal protection of approved shade and of ICI or British Paints or Jenson
Nicholson or Shalimar Paints shall be used for the work.
Surfaces not in contact, but inaccessible after shop assembly shall receive two
(2) different coats of shop paint. Surfaces to be welded shall not be painted
or metal coated within 50 mm of the edge where welding is to be done since
they may impair the quality of weld. Machined edges and contact surfaces
shall be cleaned effectively but not painted. Machine finished edges shall be
protected against corrosion by a suitable coating.


Red oxide shall be used for shop painting with primer applied by brushing.
The instructions of the manufacturer shall be followed in applying the paint.
18.31 Erection
The Contractor shall complete all preliminary works at site like transporting
fabricated materials, derricks, unloading gantry etc. so as to start erection work
as per schedule. The Contractor shall furnish at how own cost necessary
inflammable staging and hoisting materials or equipment for erection work. The
Contractor shall also provide necessary passage ways, fences, safety belts,
helmets, lights and other fittings to the Engineers satisfaction.
All assemblies shall be carried out on a levelled platform. No dragging of
steel shall be permitted.
The Contractor shall ascertain the correctness of the foundations and carry in
cleaning of foundation at his own cost. Welding shall be done in accordance
with IS:816. Code of Practice for use of metal are welding for general
construction on mild steel and IS:823 Code of procedure for manual are
welding of mild steel. The Contractor shall work in co-ordination with the
other agencies at site. The Engineer shall have free access to inspect any part
of the work during erection; and all erection shall be subject to his approval. In
case of faulty erection, all such dismantling and re-erection required shall be at
Contractors cost. No paint shall be applied to field welds or bolts until these
have been approved by the Engineer.
No Welding or final bolting shall be done until the structures has been
properly aligned and has the approval of the Engineer.
The Contractor shall examine the site conditions and transportation clearances
before deciding whether the building columns are to be fabricated in one
piece or more than one piece. Maximum number of erection joints permitted in
column shall be two i.e no column shall be fabricated and erected in more than
3 pieces. Proper splice material shall be provided at the erection joints and
as indicated in fabrication drawings. When erection joints are provided in
column, their location shall invariably be above floor level and shall be as per
approval of the Engineer.
Nothing extra shall be payable for fabrication/erecting columns in one piece or
more than one piece. The splice material shall, however, be detailed in the
fabrication drawings and shall be past of supply, fabrication and erection of
structural steel.
18.32 Tolerance for Erection
The tolerance limits during erection shall be as follows:-
The shift of column base from the marked axis shall not exceed 5mm.

All column tiers shall be plumb within a tolerance of 1 in 500; and the structure
as a whole plumb within a tolerance of 1 in 1000.



The displacement from plumb of column tiers shall not exceed 10 mm; and the
total displacement of the structure as a whole should not exceed 25 mm for
structures up to 50 meters and an additional displacement of 1 mm for every 2.5
meters additional height shall be permitted subject to a maximum displacement
of 50 mm.

The actual levels of supports of trusses, roller beams, roofing beams, purlins etc.
shall not vary by more than 20 mm from their marked levels.

The sweep of trusses, beams etc. in the horizontal plane shall not exceed
1/1500 of their span subject to a maximum of 10 mm.

The deviation of the upper chord of trusses from vertical plane through centres of
supports shall be within 1/250
th
of the truss height.

Deviation in spacing of purlins shall be within 5 mm.

18.33 Stability

18.33.01 The Contractor shall be responsible for the stability of structure at all stages of its
erection at site; and shall take all necessary measures by the additions of
temporary bracings and guying to ensure adequate resistance to wind and also
to loads due to erection equipment and their operation. Guying and bracing shall
be done in such a way that it does not interfere with the movement of working of
other agencies working in the area. For the purpose of guying, the Contractor
shall not use the structures which are likely to be damaged by the guy. Any
damage caused by the Contractor shall be rectified by him entirely at his own
cost to the satisfaction of the Engineer.

18.33.02 The lump sum price towards supply, fabrication & erection of structural steel
work shall include provision of such temporary bracings and their removal. Such
temporary bracings used shall be the property of the Contractor and may be
removed by him at the end of the job from the site of work.

18.33.03 If work has to be carried out adjacent to switchyards or electrical installations
which are live, Contractor must ensure suitable safety precautions in
consultation with the Engineer.

18.33.04 If a portion of the work or project area cannot be made available to Contractor for
his activities due to operations being carried out by other Contractors works, he
shall suitably modify his sequence of operations so as to continue work without
interruption.

18.34 Defective Work

Any error in work which prevents proper assembling and fitting up of parts in the
field by moderate use of drift pins or moderate amount of remaining shall be
classified by Engineer as defective work. No gas cutting or punching of holes
shall be permitted for erection.

All defective works shall be replaced/rectified as the case may be by the
Contractor at his own cost. Any charges incurred by purchaser either directly or


indirectly because of defective workmanship will be deducted from the amount
due to contractor before payment is made.

18.35 Grouting

Fresh A.C.C. shrinkomp or equivalent make shall be used for grouting of column
bases and foundation bolts in pockets and block outs provided in foundation by
other Contractor. Contractor shall be responsible for bringing the top of concrete
foundation to the desired level by chipping. In case the foundation as cast is
lower than the desired level, the Contractor shall make up the difference by
providing additional shims without extra payment for any such work or material.
Type & grade of the grouting for structural columns and equivalent bases shall
be indicated. Crushing strength of the grout shall generally be one grade higher
than the base concrete. Minimum grade of grout shall be M30.

Top surface of foundation shall be chipped with a chisel to ensure proper bond
between grout and the foundation concrete and shall be thoroughly cleaned.
Normally thickness of the grout is at least 50mm for building columns and
pedestals of major equipment. For others the grout should not be less than
25mm.

18.36 Painting

After all inspection and test have been conducted to the satisfaction of the
Engineer, the steel surfaces to be painted or otherwise treated, shall be dried
and thoroughly cleaned as per IS:1477 Part-I. All steel works shall be given one
(1) coat of approved metal protection except where encased in concrete. The
metal protection of approved shade and of ICI or British paints or Jensen
Nicholson or Shalimar paints shall be used for the work. The instructions of the
manufacturers shall be followed in applying the paint.

18.37 Applicable Codes & Specifications

The following specifications, standards and codes form a part of this
specification. All standards, specifications, codes of practice referred to here in
shall be the latest editions including all applicable official amendments and
revisions.

In case of discrepancy between this specification and those referred to herein,
this specification shall govern :

a)

Materials
1. IS:226 Structural steel (Standard quality)
2. IS:808 Rolled Steel Beam, Channel and Angle Sections
3. IS:961 Structural steel (High Tensile)
4. IS:2062 Structural Steel (Fusion welding quality)


5. IS:1977 Structural Steel (Ordinary Quality)
6. ASIM A6 General Requirements for Delivery of Rolled
Steel Plates, Shapes, Sheet piling and Bars for
Structural use
7. IS:1148 Rivet Bars for Structural Purposes
8. IS:1149 High Tensile Rivet Bars for Structural Purposes
9. IS:1363 Black Hexagonal Bolts, Nuts and Lock Nuts
(diameter 6 to 39 mm) and Black Hexagonal
Screws (diameter 6 to 24 mm)
10. IS:1364 Precision and Semi-precision Hexagonal Bolts,
Screws, Nuts and Lock Nuts (Diameter 6 to 39
mm)
11. IS:1367 Technical Supply Conditions for Threaded
Fasteners
12. IS:3757 High Tensile Friction Grip Fasteners for Structural
Engineering Purposes
13. BS:1083 Precision Hexagonal Bolts, Screws and Nuts
(BSW & BSF Threads)
14. BS:3139 High Strength Friction Grip Bolts for Structural
Engineering
15. ASIM:A325 High Strength Steel Bolts for Structural Joints
16. IS:2016 Plain Washers
17. IS:814 Specifications for covered Electrodes for Metal
Arc Welding for Mild Steel
18. IS:3613 Acceptance Tests for Wire Flux Combinations for
Submerged Arc Welding
19. BS:639 Covered Electrodes for the Manual Metal Arc
Welding of Mild Steel and Medium Tensile Steel
20. AWS:A-5.1 Specification for Mild Steel Covered Arc Welding
Electrodes

21. AWS:A-5.17 Specification for Bare Mild Steel Electrodes and
Fluxes for Submerged Arc Welding
22. IS:1852 Specification for Rolling and Cutting Tolerances


for Hot Rolled Steel Products
23. IS:2074 Ready Mixed Paint. Re Oxide Zinc, Chrome and
Priming
24. IS:102 Ready Mixed Paint, Brushing, Red Lead,
Nonsetting, Priming
b)
Codes of Practice
1. IS:800 Code of practice for use of Structural Steel in
General Building Construction
2. IS:875 Code of practice for Structural
3. IS:1893 Recommendations for Earthquake Resistant
Design of Structures
4. BS:449 The use of Structural Steel in Building
5. AISC Specification for the Design, Fabrication
and Erection of Structural Steel for Buildings
6. IS:919 Recommendations for Limits and Fits for
Engineering
7. IS:4000 Code of practice for Assembly of Structural Joints
using High Tensile Friction Grip Fasteners
8. BS:3294 The use of High Strength Friction Grip Bolts in
Structural Steel Work
9. Research Council on Rivetted and Bolted
Structural Joints Specification for Structural
Joints using ASIM A325 or A 490 Bolts
10. IS:816 Code of Practice for use of Metal Arc Welding for
General Construction
11. IS:4353 Recommendations for Submerged Arc Welding of
Mild Steel and Low Alloy Steels
12. AW Standard code of Welding in Building
Construction
13. IS:823 Code of Procedure for Manual Metal Arc Welding
of Mild Steel
14. IS:817 Code of Practice for Training and Testing of Metal
Arc Welders
15. IS:1181 Qualifying Tests for Metal Arc Welders (engaged
in welding structures other than pipes)


16. IS:1182 Recommended practice for Radiographic
examination of Fusion welding Butt Joints in Steel
Plates
17. IS:2595 Code of Practice for Radiographic Testing
18. IS:3658 Code of Practice for Liquid penetrant Flaw
Detection of Welds
19. IS:5334 Code of practice for Magnetic particle Flaw
Detection of Welds
20. ASIM E 94 Recommended practice for Radiographic Testing
21. ASIM E 109 Dry Powder Magnetic Particle Inspection
22. ASIM E 138 Wet Magnetic Particle Inspection
23. ASIM E 165 Liquid Penetrant Inspection
24. IS:1477 Code of practice for painting of Ferrous Metals in
Buildings and Allied Finishes

18.38 Steel Materials

Steel materials shall comply with the specifications laid down under clause 2.0
above and/or as called for on the design drawings.

Steel to IS: 1977 shall be used only as follows :

St 32-0 for general purposes such as door & window frames, grills, steel gates,
handrails, fence post, tee bars.

St 42-0 for structures not subjected to dynamic loading other than wind loads
such as:

Platform, roofs, foot over bridges, office building, factory sheds etc.

St 42 shall not be used:
a) If welding is to be employed
b) If site is in service earthquake zone
c) If plastic theory of design is used.

19.00 AC ROOF AND SIDE CLADDING

19.01 The Contractor shall provide all labour, materials and equipment required for
supply and erection of AC Roof and cladding including corner pieces, nuts, bolts,
washers etc. required for the works as per clause 1.00 of this sub-section.



19.02 The sheets shall be free from cracks, chipped edges of corners and other
damages and shall conform to IS: 459. The workmanship shall be of higher
order and shall conform to IS: 3007 (Part I & II).

19.03 The side lap shall be half corrugation and end laps shall be 150mm minimum.
For side cladding, corrugation shall be vertical.

19.04 Sheets shall be secured to structural steel by 8 mm dia (minimum) galvanized
iron J or L hook bolts and nuts. These hook bolts shall bear or GI flat washer
which in turn is beeded on a 36 mm dia bitumen washer 1.5 mm thick. Holes for
these hook bolts shall be drilled not punched. Corner of building shall be
properly closed with standard corner piece, butt jointed and battened.

20.00 SANITARY APPLICATIONS

20.01 The Contractor shall furnish all labour, materials and equipment required for
supply and installation of various sanitary appliances required for the works as
per clause 1.00 of this sub-specification.

20.02 Wash Basins

Wash basins shall be of white vitreous china of standard size 550 x 440 mm with
flat back. Wash basin shall be one piece construction including a combined
overflow and a soap holder. Wash basins shall be provided with approved
quality chromium plated pillar taps (15 mm) dia (hot and cold) alongwith chain
and plug stop cocks, brackets, complete. The wash basins shall in all respects
conform to IS: 2556 (Part-IV); and shall be provided with a looking glass, liquid
soap dispenser and tower rail. Wash basins shall be provided with 32 mm dia
CP bottle trap and waste, 75 mm CI Nahani floor trap and connecting pipes.

20.03 Lipped Urinals

The urinals shall be of one piece construction white vitreous china. Each urinal
shall be provided with not less than 2 fixing holes of minimum dia of 6.5 mm on
each side. Each urinal shall have an integral flushing rim and inlet or supply
horn for connecting the flush pipe. The flushing rim and inlet shall be of the self
draining type. It shall have a weep hole at the flushing inlet of the urinal. At the
bottom of the urinal, an outlet for connecting to an outlet pipe shall be provided.
The exterior of the horn shall not be glazed; and the surface shall be provided
with grooves at right angles to the axis of the outlet to facilitate fixing to the outlet
pipe. The inside surface of the urinal shall be smooth throughout to ensure
efficient flushing. The bottom of the pan shall have sufficient slope from the front
towards the outlet such that there is efficient draining of the urinal. For every 3
urinals, there shall be an automatic case iron flushing cistern conforming to
IS:774, stop-cocks, connecting pipe, flush pipe etc. complete for proper
functioning of the urinals. A vitreous china screen shall be provided after every
urinal.

20.04 Indian Type Water Closet

Indian type WC shall be of Orissa pattern of size 580 mm. Each pan shall have
a integral flushing rim of suitable type. It shall also have an inlet or supply horn


for connecting the flush pipe. The flushing rim and inlet shall be of the self
draining type. It shall have weep hole at the flushing inlet of the pan. The
flushing inlet shall be in the front unless otherwise specified. The inside of the
bottom of the pan shall have sufficient slope from the front towards the outlet;
and the surface shall be uniform and smooth to enable easy and quick disposal
while flushing. In all cases, a pan shall be provided with a 100 mm p trap with
approximately 50 mm effective water seal and 50 mm diameter vent horn, where
required by the Engineer. Each pan shall be provided with a cast iron flushing
cistern of 15 liters capacity approved manufacture and quality along with
telescopic flush pipe, stop-cocks, taps, floor traps, connection pipe etc. complete
for proper functioning of the pan and shall conform to IS:2556 (Part-III).

20.05 General

The work shall be carried out, complying in all respects with the requirements of
relevant Indian Standards and Bye-laws of the local authority. Any damage
caused to the building or to electric, sanitary, water supply or other installation
etc. therein, either due to actual requirements of the work, shall be made good
and the building with the installation shall be restored to its original condition by
the Contractor. Nothing extra shall be paid for it, except where otherwise
specified.

For making good the damage to masonry work, concrete work, plastering and
many other items shall be as specified.

All sanitary appliances including sanitary fittings, fixtures, toilet requisites, shall
be of size, make and design as specified in the item work and as per sample
approved by the Engineer. All sanitary and plumbing work shall also be got
approved. On completion of the work, the site shall be cleaned and all rubbish
disposed off as directed by the Engineer.

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