Technical Specifications of CHP NTPC 3x500 MW

NTPC TAMIL NADU ENERGY COMPANY LTD.
(A Joint Venture Company of NTPC and TNEB)

NTECL POWER PROJECT (3 X 500 MW)
(Vallur Thermal Power Project - 3 x 500 MW)

SECTION VI

TECHNICAL SPECIFICATIONS
FOR
IN PLANT COAL HANDLING SYSTEM

BIDDING DOCUMENT NO.: CS-0260-156-2(R)


SECTION VI

FOR


This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred,
reproduced or otherwise used for purposes other than that for which it is specifically issued.
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NTPC TAMIL NADU ENERGY CO LTD.
POWER PROJECT (3X500 MW)
SECTION -VI
BID DOC. NO.:CS-0260-156-2(R)
CONTENTS

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TABLE OF CONTENTS

PART SECTION NO TITLE

PART-A Sub Section- I Project Synopsis

Sub Section II : Scope of Supply & Services
Intent of Specification
Scope IIA-01
Terminal Points & Exclusions
IIB-01 PG Test Procedure
PART-A

IIC-01 Spares
PART-B
Sub Section III : Technical Parameters
III-A MECHANICAL
IIIA-01 System Parameters and Operation & Control
Philosophy
IIIA-02 Brakes & Clamps
IIIA-03 Monorails and Hoists
IIIA-04 Chutes & Hoppers
IIIA-05 Belt Conveyor System
IIIA-06 Drive Equipment
IIIA-07 Belt Scale
IIIA-08 Dust Control & Miscellaneous System
IIIA-09 Ventilation System
IIIA-10 CHP Building
IIIA-11 Vibrating Screening Feeder
IIIA-12 Ring Granulator and VMS
IIIA-13 Travelling Tripper & Bunker Sealing Arrangement
IIIA-14 Inline Magnetic Separator
IIIA-15 Metal Detector
IIIA-16 Coal Sampling Unit
IIIA-17 Elevator
PART-B
IIIA-18 Stacker and Reclaimer

PART-B III-B ELECTRICAL
IIIB-01 Motors
IIIB-02 LT Switchgear & Bus Duct
IIIB-03 LT Power Cables
PART-B
IIIB-04 Control Cables
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PART SECTION NO TITLE
IIIB-05 Instrumentation cables
IIIB-06 Illumination System
IIIB-07 Cabling, Earthing & Lightning Protection
IIIB-08 Transformers
IIIB-09 Measuring Instruments
IIIB-10 HT Load Break Switch and Junction Box
IIIB-11 Battery
IIIB-12 Battery Charger
IIIB-13 Control Panel

PART-B III-D CIVIL
IIID-01 CHP System - Civil Works
PART-B IIID-02 Foundation System and Geotechnical Data
(Turnkey)

PART-B III-E QA & I SECTION
III E-01 Coal Handling Plant
III E-02 Motors
III E-03 LT Switchgear & Busduct
III E-04 LT Power Cables
III E-05 LT Control Cables
III E-06 Instrumentation Cables
III E-07 Station Lighting
III E-08 Cabling, Earthing & Lightning Protection
III E-09 Control Panels
III E-10 Control Desk with PLC
III E-11 Battery Charger
III E-12 Indoor Transformer (Dry Type)
III E-13 Electrical Actuator with Integral Starter
III E-14 Auxiliary Transformer
III E-15 Measuring Instruments (Primary & Secondary)
PART-B
III E-16 Sampling, Testing and Quality Assurance for
Civil Works
III E-17 Field Quality Plan (FQP)
PART-C General Technical Requirements

PART-D Erection Conditions of Contract

PART-E List of Tender Drawings

PART-F List of Mandatory Spares

POWER PROJECT (3 X 500 MW)
BID DOC NO.:CS-0260-156-2(R)
TECHNICAL SPECIFICATION
SECTION-VI
PART-A

PART- A

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-A

PART- A
SUB-SECTI ON-I
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1.00.00 BACKGROUND
A memorandum of understanding was signed on 12
th
July 2002 between NTPC and
Tamil Nadu Electricity Board with intent to establish and operate 1500 MW coal
based Thermal Power Project at Ennore in Tamil Nadu. Subsequently, a Joint
Venture Company between NTPC and TNEB, each acquiring 50% share, under the
name NTPC TAMIL NADU ENERGY COMPANY Ltd. (NTECL) was incorporated.
1.01.00 Location and Approach
The proposed power project of NTPC TAMIL NADU ENERGY COMPANY LTD
( NTECL) shall be located between Ennore creek and Kuruvimedu village of Ponneri
Taluk of Thiruvallur district in Tamil Nadu at a Latitude 13
0
13 45 N and Longitude
80
0
18 05E respectively. It is located at a distance of about 20 Kms from Chennai
city. The nearest railhead, Kathivakkam is at a distance of 1Km on trunk route
section of Southern Railway from the project site. The National Highway exists at a
distance of about 14 Kms from project site. The nearest airport, Meenambakkam, is
about 36 Kms from the project site.
Vicinity Plan of the project is placed at Exibit No.-1
1.02.00 Land Requirement
Land comprising of about 415 acres for plant & associated facilities, 500 acres for
ash disposal area, 75 acres for ash based units,35 acres for corridors and 45 acres
for township out of total 1184 acres have been identified for development. Balance
112.35 acres of land which is part of the salt pan plot falls under CRZ and another
1.65 acres is located across Ennore creek.
1.03.00 Water
Desalinated seawater for sweet water make-up and sea water cooling has been
envisaged. Make up water requirement for this project would be about 10000 m
3
/hr
with reverse osmosis process to 12500 m
3
/hr with thermal desalination process.
1.04.00 Coal Availability and Transportation
1.04.01 Coal Availability
Mahanadi Coalfields Ltd. vide letter dtd. 13.06.03 in-principle agreed to supply 5.0
MT/annum of coal fron Talcher/IB Valley coalfield of MCL. Further, long term coal
linkage for project was considered by SLC (LT) in various meetings, however, firm
linkage is still awaited.
Parallely, NTPC TAMIL NADU ENERGY COMPANY LTD has applied for allocation of
Nuggaon- Talisahi coal block of Talcher Coal Fields. MOP vide letter dtd. 15.12.05
has forwarded their recommendation to MOC for allocation of Nuggaon-Talisahi coal
block to NTECL
1.04.02 Coal Transportation
The envisaged mode of coal transportation from the coalmines to the power plant is
by Indian Railways rakes upto the port, thereafter by ships upto Ennore Port and
from Ennore Port to the main plant by conveyor system.

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1.04.03 Coal Quality Parameters and Fuel Oil Characteristics
The Coal quality Parameters and Fuel Oil Characteristics are as specified in Table1,
Table-2 and Table-3.
1.05.00 Capacity : 3 x 500 MW
1.06.00 Meteorological Data
Important meteorological data from nearest observatory at Nungambakkam is placed
at Annexure - I.
1.07.00 Plant Water Scheme
The Plant water scheme is described below.
1.07.01 Condenser Cooling (CW) Water System
It is proposed to provide recirculating type CW system with natural draft type cooling
towers. For the re-circulating type CW system, it is proposed to supply sea water as
makeup. Make up water for the project shall be drawn from the sea. CW system shall
be operated at a C.O.C. of about 1.5. The expected circulating water analysis is
given in Annexure - II of this sub-section. For carrying circulating water from CW
pump house to TG area and from TG area to cooling tower, steel lined concrete
encased duct with internal lining would be provided. For interconnecting CW duct
with CW pump, condenser and cooling towers, steel pipes with internal coating would
be used. Cooled water from cooling tower will be led to CW pump house through the
cold water channel by gravity.
1.07.02 Equipment Cooling Water (ECW) System (Unit Auxiliaries)
The plant auxiliaries of Steam Generator shall be cooled by Demineralised water
(DM) in a closed circuit. The primary circuit DM water shall be cooled through plate
type heat exchangers by Circulating Water tapped from CW system in a closed
secondary circuit. The hot secondary circuit cooling water shall be cooled in the
cooling towers and shall be returned back to the system.
1.07.03 Ash Water System
(a) It is proposed to operate ash water system in a closed circuit. The ash water
from the ash dyke shall be recirculated. During re-circulation mode, the make
up to the ash water system (to compensate for the ash water blow down and
evaporation loss in ash dyke) shall be supplied from plant sea water make-up.
(b) During initial stage when decanted ash water is not available, the ash water
system shall be operated in once through mode and make up water to ash
water system shall be given from CW blowdown.
(c) Considering total ash handling plant water requirement of 3600 Cu.M/hr.
(excluding the water required for cooling of air compressors and vacuum
pumps but inclusive of seal water of ash slurry pumps during re-circulation
mode operation, it is expected that about 2000 M/hr of decanted ash water
shall return to the ash handling system after accounting for evaporation loss.
1.07.04 Other Miscellaneous Water Systems
(a) CW system blow down water shall be used for the stockyard dust
suppression system of coal handling plant, ash slurry pumps sealing, Treated
water after desalination shall meet the other water requirements of the plant.
The service (wash water) water collected from various areas shall be treated
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using oil water separators, tube settlers, coal settling pits etc. as per
requirement and treated water from liquid effluent treatment plant shall be
recycled back to the service water system for re-use. The excess service
water shall be led to central monitoring basin for disposal.
(b) The drinking water requirement of the plant and colony shall be provided from
the treated water storage tank after desalination.
(d) Steam Cycle make-up water, makeup to the primary circuit of ECW (unit
auxiliaries) system, boiler fill water and makeup to the hydrogen generation
plant shall be provided from Demineralising plant.
(e) The quality of cooling water and DM water is enclosed with this sub-section.
(f) The desalinated water from treated water storage tank will have a TDS
ranging from 700 to 1000ppm.
1.08.00 Criteria for Wind Resistant Design of Structures and Equipment
All structures and equipment of the power plant, including plant auxiliary structures
and equipment, shall be designed for wind forces as given in Technical Specification
for Civil and Structural Works.
1. 09.00 Criteria for Earthquake Resistant Design of Structures and Equipment
All power plant structures and equipment, including plant auxiliary structures and
equipment shall be designed for seismic forces as given in Technical Specification
for Civil and Structural Works.

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Annexure-I

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Annexure - II
COOLING WATER ANALYSIS

Constituent as mg per litre

Calcium CaCO
3
2030

Magnesium CaCO
3
6500

Sodium & CaCO
3
43500
Potassium

Cations CaCo3 52030

Bicarbonates CaCO
3
330

Chloride CaCO
3
50000

Sulphate CaCO
3
1700

Anions CaCO
3 52030

Silica SiO2 5

Iron Fe 1

pH Value - 7.5 - 8.0

TSS mg/l 100

Note : The C.W system is expected to operate at about 1.5 Cycles of Concentration.

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Annexure - III
ANALYSIS OF DM WATER TO BE USED FOR
MAKE-UP WATER TO CONDENSER

S.No. Characteristics Value

i) Silica (Max.) - 0.02 ppm as SiO2

ii) Iron as Fe - Nil

iii) Total hardness - Nil

iv) pH value - 6.8 to 7.2

v) Conductivity - Not more than 0.1
excluding the effects
of free CO
2

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TABLE 1

COAL CHARACTERISTICS

Sl. Characteristics Unit Range of 95% Coal Range of
No. supplies Coal (5%)

Design Worst Best
Coal Coal Coal

1 2 3 4 5 6 7

1.0 PROXIMATE ANALYSIS
(As received basis)

1.1 Total Moisture % 14 16 12 11- 17

1.2 Ash % 41 45 32 31 - 46

1.3 Volatile Matter % 21 19 24 24 - 18

1.4 Fixed Carbon % 24 20 32 34 - 19

2.0 ULTIMATE ANALYSIS
(As received basis)

2.1 Carbon % 31.7 27.7 41.9 43.1 - 26.6

2.2 Hydrogen % 3.3 2.6 3.6 3.6 - 2.5

2.3 Nitrogen % 0.83 0.52 1.0 1.39 - 0.40

2.4 Oxygen (by difference)% 8.54 7.26 8.92 9.2 - 6.67

2.5 Sulphur % 0.28 0.5 0.25 0.22 - 0.60

2.6 Carbonates % 0.3 0.38 0.27 0.42 - 0.2

2.7 Phosphorous % 0.05 0.04 0.06 0.07 - 0.03

2.8 Total Moisture % 14 16 12 11 - 17

2.9 Ash % 41 45 32 31 - 46

2.10 Gross Calorific KCal/Kg 3300 2800 4200 4300 - 2700
Value (as received basis)

2.11. Hard Grove Index 55 50 60 65 45

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1 2 3 4 5 6 7

3.0 ASH ANALYSIS

3.1 Silica (SiO
2
) % 58.5 59.54 58.2 58.10 - 59.7

3.2 Alumina (Al
2
O
3
) % 28.63 29.0 28.0 27.8 - 29.2

3.3 Iron Oxide (Fe
2
O
3
) % 6.32 6.42 6.1 5.8 - 6.71

3.4 Titania (TiO
2
) % 1.72 1.6 1.85 1.95 - 1.4

3.5 Phosphoric (P
2
O
5
) % 1.57 0.51 1.91 1.98 - 0.41
Anhydride

3.6 Lime (CaO) % 1.53 1.5 1.7 1.8 - 1.4

3.7 Magnesia (MgO) % 0.57 0.50 0.7 0.8 - 0.4

3.8 Sulphuric (SO
3
) % 0.28 0.25 0.29 0.35 - 0.2
Anhydride

3.9 Sodium Oxide % 0.1 0.08 0.3 0.32-0.08

3.10 Balance Alkalies % 0.78 0.60 0.95 1.1- 0.5
(By Difference)

4.0 ASH FUSION RANGE
(Reducing Atmosphere)

4.1 Initial Deformation
Temperature (IDT) C 1150 1100 1200 1200-1100

4.2 Hemispherical
Temperature C 1350 1300 1400 1400-1300

4.3 Flow Temperature C 1400 1350 1400 1400-1350

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TABLE-2

FUEL OIL CHARACTERISTICS

Sl. Characteristics Heavy Furnace Low Sulphur Heavy Heavy Petroleum
No. Oil Grade HV Stock (LSHS) Stock (HPS)
IS-1593-1982 IS-11489-1985 IS-11489-1985

1. Total sulphur content 4.5% Max. 1.0% Max. 4.5% Max.

2. Gross calorific value of the order of the order of the order
(KCal/kg) of 10,000 of 10,000 of 10,000

3. Flash Point (Min) 66 deg C 66 deg C 72 deg C

4. Water content by 1.0% 1.0% 1.0%
volume (Max)

5. Sediment by weight 0.25% 0.25% 0.25%
(Max)

6. Asphaltene content by 2.5% 2.5% 2.5%
weight (Max.)

7. Kinematic viscosity 370 100 100
in Centistokes at - at 50deg C at 100deg C at 100deg C
(Max)

8. Ash Content by weight 0.1% 0.1% 0.1%
(Max.)

9. Acidity (inorganic) Nil Nil Nil

10. Pour Point (Max.) 57 deg C 66 deg C 72 deg C

11. Sodium content 100 ppm

12. Vanadium content 25 ppm 25 ppm 25 ppm

13. Specific heat below 0.65
pour point (KCal/Kg C)

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TABLE - 3

LIGHT DIESEL OIL CHARACTERISTICS

AS PER IS 1460-2000

Characteristics LDO

1. Pour Point (max) 21 C & 12C for
Summer and Winter respectively

2. Kinematic viscosity in 2.5 to 15.7
centistokes at 40 deg.C

3. Sediment percent by mass (max) 0.10

4. Total sulphur percent by 1.8
mass (max)

5. Ash percentage by mass (max) 0.02

6. Carbon residue (Rans bottom) 1.50
percent by pass (max.)

7. Acidity inorganic Nil

8. Flash point(Min.) - Pensky Martens 66 deg.C

9. Copper strip corrosion for Not worse
3 hours at 100C than No. 2

10. Water content, % by volume (max) 0.25

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Vicinity Map

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-A

PART- A
SUB-SECTI ON-I I A-01
INTENT OF SPECIFICATION

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1.00.00 INTENT OF SPECIFICATION
This specification is intended to cover the following activities and services in respect
of all the equipment of In plant Coal Handling system to be installed for NTPC-
Tamil Nadu Energy Company Limited, 3x500 MW located between Ennore creek &
Kuruvimedu village of Ponneri Taluk of Thiruvallur District in the state of Tamil Nadu,
India.
(a.) (i) Detailed design and engineering of all the equipment and equipment
system(s).
(ii) Complete manufacture including shop testing/ type testing.
(iii) Providing engineering data, drawings, Commissioning procedures and
O & M manuals, etc. for the Employers review, approval and records.
(iv) Packing and transportation from the manufacturers works to site
including transit insurance, customs clearance/ port clearance, if
required.
(v) Receipt, unloading, storage, preservation, conservation and insurance
of equipment at site.
(vi) Fabrication, pre-assembly, (if any), erection, testing and putting into
satisfactory operation of all the equipment including successful
completion of facilities.
(vii) Associated civil, structural, architectural and electrical works.
(viii) Commissioning and completion of facilities and Performance
Guarantee Tests after successful completion of initial operation.
(ix) Furnishing of spares on FOR site basis and handing over to NTPC
stores.
(x) Reconciliation with custom authorities, if applicable.
(xi) Satisfactory completion of the contract.
(b.) The equipment and services to be furnished and installed as required in this
Technical Specification shall also meet all the requirements as stated in
General Conditions of Contract (GCC), Special Conditions of Contract
(SCC) and Bid Form & Procedures which shall be considered as a part of
this technical specification as bound herewith.
(c.) The Contractor shall be responsible for providing all materials, equipment and
services, specified or otherwise (unless specifically excluded) which are
required to fulfill the intent of ensuring operability and the reliability of the
complete system covered under this specification.
(d.) It is not the intent to specify completely herein, all aspects of design and
construction of equipment. Nevertheless, the equipment shall conform in all
respects to high standards of engineering, design and workmanship and shall
be capable of performing in continuous commercial operation.
(e.) Whenever a material or article is specified or described by the name of a
particular brand, manufacturer or trade mark, the specific item shall be
understood as establishing type, function and quality desired. Other
manufacturers products may also be considered provided sufficient
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information is furnished so as to enable the Employer to determine that the
products are equivalent or superior to those named.
(f.) Bidder is requested to carefully examine and understand the specifications
and seek clarifications, if required, to ensure that they have understood the
specifications. Such clarifications should reach Employer at least 15 days
before the scheduled date of the opening of the bids. The Bidders offer
should not carry any sections like clarifications, interpretations and/or
assumptions.
(g.) If the Bidder feels that, in his opinion, certain features brought out in his offer
are superior to what has been specified, those may be highlighted separately.
The Bidder may also make alternative offers provided such offers are superior
in his opinion. In which case, adequate technical information, operating feed
back, etc. shall be enclosed with the offer, to enable the Employer to assess
the superiority and reliability of the alternatives offered. In case of each
alternative offer, its implications on the performance, guaranteed efficiency,
auxiliary power consumption etc. shall be clearly brought out for the Employer
to make an overall assessment. In any case, the base offer shall necessarily
be in line with the bidding documents/ specifications.
Under no circumstances the equipment / system specification in Technical
Specification shall be brought out as alternative offer.
(h.) Any deviation or variation from the scope, requirement and/or intent of this
specification shall be clearly defined by the Bidder in Attachment-6
Deviations of Section-VII of bid documents irrespective of the fact that such
deviations/ variations may be standard practice or a possible interpretation of
the specification by the Bidder. Except for those deviations/ variations
covered under Attachment-6, which are accepted by the Employer before the
award of the Contract, it will be the responsibility of the Bidder to fully meet
the intent and the requirements of the specification within the quoted price.
No other deviation whatsoever from this specification, except for the declared
deviations submitted by the Bidder with his proposal under Attachment-6
Deviations shall be considered. Bids not complying with this requirement
shall be treated as non-responsive and hence liable for rejection. The
interpretation of the Employer in respect of the scope, details and services to
be performed by the Bidder shall be binding unless specifically clarified
otherwise by the Employer in writing before the Award of the Contract.
(i.) Before submitting his bid, the Bidder should inspect and examine the site and
its surroundings and should satisfy himself as to the nature of the ground and
subsoil, the quantities and nature of work, materials necessary for completion
of the work and their availability, means of access to site and in general shall
himself obtain all necessary information as to risks, contingencies and other
circumstances which may influence or affect his offer. No consequent extra
claims on any misunderstanding or otherwise shall be allowed by the
Employer.
(j.) For all the related buildings and facilities in Employers scope and not covered
under the scope of this package, the contractor shall furnish all the related
input data/ details for preparation of Mechanical/ Electrical/ Civil Drawings
within 45 days of award of contract.
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(k.) The sizes of various buildings/conveyor galleries indicated in the tender
drawings and the parameters of equipment indicated in various sections of
technical specifications are the minimum requirements of the employer. Any
increase in these sizes or the parameters, if required to meet the
system/maintenance/operational requirement shall be supplied by the
contractor without any extra cost implication to the employer.
(l.) The works under the scope of this contract are to be executed in an operating
power station. The contractor shall take all necessary precautions to protect
all the existing equipment, structures, facilities and buildings etc. from
damage. In case any damage occurs due to the activities of the contractor on
account of negligence, ignorance, accidental or any other reason whatsoever,
the damage shall be immediately made good by the contractor at his own
cost to the satisfaction of the Employer. The contractor shall also take all
necessary safety measures with specific reference to excavation in rock, at
his own cost, to avoid any harm or injury to his workers and staff from the
equipment and facilities of the power plant.
(m.) After award of work, before finalising his layout especially the layout / levels of
conveyors, cable / pipe routes and other services, the contractor shall carry
out a site survey along with the conveyor alignment & CHP area to identify
the location & details of proposed facilities. The contractor shall suitably
modify his layout / levels to prevent dislocation of existing facilities, if any, and
any cost / time implication arising out of such modifications will be to his
account. Contractor shall also be responsible to determine and obtain the
necessary details at site as required for interfacing and interconnection with
the existing system / facilities.
If during the execution of works it is found that there is interference with the
existing facilities / structures, the contractor shall revise his design / detailed
drawings to clear the interference and shall provide all necessary measures
for the safety of existing structures. No claim in terms of cost or relaxation in
time shall be entertained for any redesign, rework and for safety measures
provided. If at any stage of work, any dismantling or modification or relocation
of any existing facility is required to be done to complete the work in bidders
scope and which has been agreed by the Employer, the same shall be done
by the bidder at no extra cost or time implication to the Employer. All such
changes will be as per drawings and work plan approved by the employer.
1.02.00 Equipment and services covered under IN PLANT COAL HANDLING SYSTEM
package are described in the following sub-sections :
MECHANICAL
III-A-01 : System parameters and Operation & Control Philosophy
III-A-02 : Brakes and Clamps
III-A-03 : Monorails and Hoists
III-A-04 : Chutes and Hoppers
III-A-05 : Belt Conveyor System
III-A-06 : Drive Equipment
III-A-07 : Belt Scales
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III-A-08 : Dust Control & Miscellaneous Systems
III-A-09 : Ventilation System
III-A-10 : CHP Buildings
III-A-11 : Vibrating Screening Feeder
III-A-12 : Ring Granulator & VMS
III-A-13: Travelling Tripper and Bunker Sealing Arrangement
III-A-14 : Inline Magnetic Separator
III-A-15 : Metal Detector
III-A-16 : Coal Sampling Unit
III-A-17 : Elevator
III-A-18 : Stacker and Reclaimer
ELECTRICAL
IIIB-01: Motors
IIIB-02 : LT Switchgear & Bus Duct
IIIB-03 : LT Power Cables
IIIB-04 : Control Cables
IIIB-05 : Instrumentation cables
IIIB-06 : Illumination System
IIIB-07 : Cabling, Earthing & Lightning Protection
IIIB-08 : Transformers
IIIB-09 : Instruments
IIIB-10 : HT Load Break Switch and Junction Box
IIIB-11 : Battery
IIIB-12 : Battery Charger
IIIB-13 : Control Panel
CIVIL
III-D-01 : CHP System Civil Works
III-D-02 : Foundation System and Geotechnical Data
QUALITY ASSURANCE
III-E-01 : Quality Assurance and Inspection
1.03.00 In addition to the specifications of equipment / system indicated in various sections
as above and General Technical Requirement attached at Part-C of the Specification
and Erection Conditions of Contract attached at Part-D of the Specification shall also
form part of this Technical specification.

CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
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1.04.00 TENDER DRAWINGS
The drawings listed in the specification at Part-E, form part of the specification and
shall supplement the requirements specified herein. The scope and terminal points
for the equipment to be furnished under this package shall be as identified in these
drawings and read in conjunction with the text of these specifications. These
drawings are preliminary drawings for bidding purpose only and subject to changes
that may be necessary during the detailed engineering.
1.05.00 In case of any conflicts / contradiction among various volumes / sections / annexures
/ chapters / appendices / tender drawings of bid documents, the same shall be
referred to the Employer for clarifications whose decision shall be final and binding.
No extra claims shall be allowed on this account.
1.06.00 SCOPE

1.06.01 The scope of In-plant Coal Handling system to be furnished, erected and
commissioned under this specification shall be as detailed hereinafter. The
Contractor shall be fully responsible for system and detailed design, engineering,
manufacture, shop fabrication, assembly, testing and inspection at manufacturers
works, packing, dispatch, transportation, transit insurance, custom clearance etc. as
applicable, delivery to site, unloading, handling and storage at site, insurance during
storage, construction, erection, including erection supervision, testing, inspection,
commissioning and handing over to Employer and Guarantee testing including all
associated electrical, civil, structural & architectural works as specified, unless
specifically excluded as per Section-Terminal Points & Exclusions.

1.06.02 The scope of the contractor shall be deemed to include all such items which although
are not specifically mentioned in the bid documents and/or in Contractors proposal
but are needed to make the system complete in all respects for its safe, reliable,
efficient and trouble free operation and the same shall be furnished and erected
unless otherwise specifically excluded as per Section Terminal Points & Exclusions.
The general description of the proposed system and the broad scope of work under
the specification shall include but not be limited to as elaborated below.
2.00.00 DESCRIPTION, SCOPE AND TERMINAL POINTS
2.01.00 BRIEF DESCRIPTION OF PROJECT
2.01.01 NTPC-Tamil Nadu Energy Company Limited proposes to install 3x500MW units. The
proposed In plant Coal Handling System shall meet the daily coal requirements of
3x 500 MW units.
2.01.02 Brief description of proposed in plant Coal handling system:
This shall be read in conjunction with Coal Flow Diagram and the coal handling
system layout enclosed with the specification.
(i) Coal of (-) 100 mm size is unloaded from the ship by two grab unloaders on to
existing conv 40A/40B and this coal is fed either on conv 1A or 1B in existing
JNT-50 of TNEB. Conv 1A & 1B are reversible belt conveyors which shall
feed either the existing TNEB conv 41A/41B or feed the proposed conv 2 at
TP-1. This shall be possible after modifications are carried out in the existing
JNT-50. Conv 1A/1B shall feed the coal to conv 2 at TP-1. From TP-1 the
coal shall be conveyed to cross country conveyor(s) through conv 2, 3 &4.
Two nos. inline magnetic separators (ILMS-I & ILMS-2) shall be provided at
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
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discharge end of conveyor 1A/1B at TP-1 for removal of metallic ferrous
tramp iron from as received coal. One no. Belt scale (BS-1) shall be
provided on conveyor 2 for measurement of coal flow rate. One no. metal
detector (MD-1) shall be provided on conveyor 3 for detection of tramp
present in conveying coal. (cross country conveyor is not in the scope of In-
plant coal handling system package)
(ii) Conv 1A/B, 2, 3 and 4, at the jetty end, are troughed belt conveyors of 4000
TPH rated capacity. These conveyors are in the scope of In-plant coal
handling system package. The cross country conveyor(s) conveys the coal to
the drive house at the power plant end.
(iii) Cross country conveyor(s) shall feed coal on to conveyor 6A/6B at drive
house.
(iv) Coal from each incoming conveyor 6A/6B to Crusher House will pass through
a set of dedicated screen feeders (VSF-1 &2) and Crushers (CR-1 & CR-2).
There shall be a combination of Rod Gate and Rack & Pinion Gate provided
in the inlet chute of each screening feeder. This shall permit maintenance of
equipment, hopper, chutes in one stream without effecting the operation of
other stream. The crusher shall be ring granulator type. Only (+) 20mm size
coal shall be fed to the crusher.
(v) Each vibrating screening feeder shall be of 2000 TPH guaranteed capacity.
Each ring granulator in the CH shall be of 2000 MTPH guaranteed capacity.
Both the screened coal below 20 mm size and crushed coal shall be
discharged on to a dedicated set of reversible belt feeders (RBF-1 and
RBF-2) place below the crusher floor.
(vi) Reversible belt feeder RBF-1 shall discharge coal on to either conveyor
15A/15B for stacking coal in the crushered coal stockyard or on to conveyor
7A/7B for onward conveying to raw coal bunkers.
and
Reversible belt feeder RBF-2 shall discharge coal on to either conveyor
15A/15B for stacking coal in the crushered coal stockyard or on to conveyor
7A/7B for onward conveying to raw coal bunkers.
(vii) Conveyor 7A/7B shall feed coal on to conveyor 8A/8B at TP-5. Conveyor
8A/8B shall feed coal on to conveyor 9A/9B at TP-6. Two number Belt scales
(BS-2 & BS-3) shall be mounted on conveyor 8A/8B for metering as fired
coal. Two nos. metal detectors (MD-2 & MD-3) shall also be provided on
conveyor 8A/8B to detect metal pieces present in theas fired coal.
(viii) Conveyor 9A/9B shall feed coal on to either of the bunker conveyors 12A/12B
at TP-7 and TP-8 respectively or conveyor 10A/10B at TP-8. Conveyor
10A/10B shall feed coal on to either of the bunker conveyors 13A/13B at TP-9
and TP-10 respectively or conveyor 11A/11B at TP-10. Conveyor 11A/11B
shall feed coal on to either of bunker conveyors 14A/14B at TP-11 and TP-12
respectively.
(ix) Two (2) nos Independent rail mounted stackers of 4000TPH rated capacity
shall be provided on yard conveyor 16A and 16B for stacking of coal.
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
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(x) Two nos independent rail mounted, bucket wheel type reclaimers of 2400
TPH rated capacity shall be provided on yard conveyor 16A and 16B to
reclaim the stacked coal from stockyard. .
(xi) The reclaimed coal from yard conveyors 16A and 16B shall be fed on to
conveyor 17A/17B at TP-15 and TP-16 respectively. From conveyor 17A/17B,
the coal can be conveyed to the raw coal bunker through conveyor 8A/8B,
9A/9B, 10A/10B, 11A/11B to the desired row of bunkers.
(xii) Two (2) nos. Inline magnetic separators (ILMS-3 & ILMS-4) shall be mounted
one each at the discharge end of yard conveyors 16A and 16B at transfer
point TP-15 and TP-16 respectively, to remove tramp iron pieces that might
have got introduced during stacking/reclaiming.
(xiii) Two (2) nos. Rack & pinion elevators (EL-1 & 2) shall be installed one each at
crusher house and TP-6 to facilitate movement of men & material in these
buildings.
(xiv) One no. coal sampling unit (CSU-1) for sampling of as-received coal is
placed on conveyor 6A/6B at crusher house, another coal sampling unit
(CSU-2) for sampling as-fired coal is placed on Conveyor 8A/8B at TP-6.
(xv) One (1) number Traveling Tripper is mounted on each of the Bunker
Conveyor 12A/12B/13A/13B/14A/14B (i.e. total six (6) nos. of traveling
trippers) to feed coal into Raw coal bunkers of the boiler units (unit no.
1, 2 & 3).
2.02.00 DETAILED SCOPE
2.02.01 Reversible belt conveyors 1A/1B and belt conveyor 2, 3, 4, 6A/6B, 7A/7B, 8A/8B,
15A/15B, 17A/17B complete with conveyor supporting structures, short supports,
stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units,
pulleys, idlers, gravity take ups including guides, pits etc., internal and external belt
cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic
thruster brakes, all electricals etc. including all civil, structural and architectural works
for conveyor gallery, gallery supporting trestles and their associated foundations.
2.02.02 Conveyor 9A/9B, 10A/10B, 11A/11B and Bunker Conveyors 12A/12B, 13A/13B,
14A/14B in the bunker bay building complete with conveyor supporting structures,
short supports, stringers, short support mounting stools, inserts (if any), deck plate,
etc. drive motors, drive units, pulleys, idlers, gravity take-ups, internal and external
belt cleaners, pull chord switches, belt sway and zero speed switches, electro-
hydraulic thruster brakes, all electricals etc. Structural steel frame work for supporting
takeup arrangement up to ground level and sand pit are excluded from bidders
scope, however, take up maintenance platform at intermediate levels including
platform supporting beams, access ladders between platforms, monorail beams if
any, guide rails etc. shall be in bidders scope.
All civil, structural & architectural works of conveyor gallery, supporting trestles and
their foundations for the portion of conveyor 9A/9B between TP-6 & TP-7 is in the
scope of the Contractor.
2.02.03 Yard conveyors 16A and 16B complete with conveyor supporting structures, short
supports, stringers, deck plates, conveyor foundations, drive motors, drive units,
pulleys, idlers, take-ups, take-up structure, internal and external belt cleaners, pull
chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes,
all electrical, etc. including all civil, structural and architectural works.
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
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2.02.04 One (1) number crusher house (CH) complete with all civil, structural, architectural
and electrical works etc accommodating two (2) nos. crushers, gates etc., goods cum
passenger elevator, conveyors, chute work as per tender drgs, monorails & hoists
and other equipment such as coal sampling unit, dust suppression, dust extraction,
service water system & ventilation system etc. as specified elsewhere.
2.02.05 Two (2) nos. Vibrating screening feeders to feed the coal to crushers in the CH
complete with drives, dust hood, all mechanical, electrical accessories and
supporting structures etc.
2.02.06 Two (2) nos. ring granulators complete with drives, all mechanical, electricals
including civil & structural works, vibration isolation system with springs & viscous
dampers, vibration monitoring system etc.
2.02.07 Two (2) sets of Gates each comprising of one rod gate and one actuator operated
rack & pinion gate at inlet to each of the vibrating screening feeder feeding coal to
crushers complete with drives, all mechanical, electrical, structural works etc.
2.02.08 Transfer points TP-1, TP-2, TP-3, TP-4, TP-5, TP-6, TP-13, TP-14, TP-15, TP-16
complete with all civil, structural, architectural and electrical works including chutes,
monorails, hoists/chain pulley blocks, hoist maintenance platforms, external
staircases, dust & debris chutes upto ground level.
2.02.09 All mechanical, electrical equipment to be housed in Transfer points (TP-7, TP-8, TP-
9, TP-10, TP-11 & TP-12) including coal feeding chutes, maintenance/operating
platforms inside the TPs & maintenance platforms at various levels for take up
including support beams, manual hoists, monorails & electric hoists, dust & debris
chutes upto ground level etc.
2.02.10 Two (2) nos. traveling rail mounted Stackers machines having rated stacking
capacity of 4000 TPH complete with all equipment and conveyors, structural,
electrical, cable reeling drums, all trailing cables and accessories, rails, rail
foundations, boom resting pedestals, boom tie arrangement, lighting towers (with
foundations), fixing and grouting of rails along with all associated civil & structural
works to operate in conjunction with yard conveyors 16A and /16B.
2.02. 11 Two (2) nos. traveling rail mounted bucket wheel reclaimer machines having rated
reclaiming capacity of 2400TPH complete with all equipment and conveyors,
structural, electrical, cable reeling drums, all trailing cables and accessories, rails, rail
foundations, boom resting pedestals, boom tie arrangement, lighting towers (with
foundations), fixing and grouting of rails along with all associated civil & structural
works to operate in conjunction with yard conveyors 16A and 16B.
2.02.12 Complete chute work along with chute block switches and actuator operated flap
gates in all Transfer points and in crusher house as per tender drawings.
2.02.13 Two (2) Nos. passenger cum goods elevators with drives, all mechanical, civil,
structural & associated foundation works, accessories and electrical to serve various
floors of the crusher house (CH) and TP-6.
2.02.14 Six (6) Nos. motorized Traveling Trippers, one (1) each on conveyor 12A, 12B, 13A,
13B, 14A, 14B complete with all mechanical, electrical equipment, rails, chute work,
rail supporting structure (along with structural stools), rail supporting structure fixing
bolts, cables with cable festooning arrangement, brakes, rail clamp, electric hoist,
etc. bunker sealing and Grid/grating over the bunker slot along the entire length of
tripper floor.
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
9 of 21

2.02.15 Adequate number of ventilation equipment for ventilating the bunker bays (housing
tripper conveyors) complete with all mechanical, electrical, civil and structural works.
2.02.16 Pressurized Ventilation system for all Switchgear rooms, MCC rooms complete with
all mechanical, electrical, accessories, civil and structural works.
2.02.17 Air conditioning of Main CHP control room, office room in main CHP control building,
operators cabin & MCC room on Stackers & Reclaimers and in electrical buildings as
specified complete with all electrical, civil & structural works etc.
2.02.18 Exhaust fans to be provided in all battery rooms, all toilets complete with electrical,
civil & structural works etc.
2.02.19 Two (2) Nos. coal sampling units, one for (-) 100 mm size coal in crusher house and
one for (-) 20 mm size coal in TP-6 complete with all accessories, and electrical, civil,
structural works, supporting structures, approach/maintenance platforms, hoists etc.
2.02.20 Four (4) Nos. In-line Magnetic Separators complete with reject chutes, reject trolleys,
and all mechanical, supporting arrangement, electrical, civil, structural works and
accessories. Independent motorized arrangement for hoisting & travel for each ILMS
shall also be provided.
2.02.21 Three (3) Nos. Electronic Belt weighers complete with all mechanical, supporting
arrangement, electrical, and accessories.
2.02.22 Each stacker & reclaimer shall have an electronic Belt weigher complete with all
mechanical, supporting arrangement, electrical, and accessories.
2.02.23 Three (3) Nos. Metal Detectors complete with all mechanical, electrical, civil,
structural works and accessories.
2.02.24 A) Complete dust suppression system for control of fugitive dust in transfer
points, crusher house, coal stock yard complete with pump houses, water
tanks, pumps, drives, hoisting arrangements, piping, valves etc. electrical,
accessories, civil, structural and architectural works as briefly specified below:
a). Sea water dust suppression for stockyard through sprinklers.
b). Complete dry fog type dust suppression system at all Transfer Points,
Crusher House, both at discharge and loading points including all
electrical and accessories.
c). Belt Sealing arrangement in Bunker bays for control of dust coming
out of coal Bunkers.
d). Pump houses & water tanks for dust suppression/ extraction, service
water, cooling water and potable water system.
B) Complete dust extraction system for control of fugitive dust in crusher house
with complete water tanks, pumps, drives, hoisting arrangements, piping,
valves etc. electrical accessories, civil, structural and architectural works.
C) Portable RO (reverse osmosis) machine for drinking water in MCC room at
Jetty area complete with all accessories & mountings.
2.02.25 (i) All inserts, anchor bolts, foundation bolts for Contractors equipment,
platforms etc. in the entire CHP (including the transfer points, bunker
buildings & conveyors galleries in Employers scope).
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
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(ii) All necessary grouting & finishing of the floor after welding at all such pockets
& else where is in Contractors scope.
2.02.26 Cooling water system for scoop couplings, Service water system and potable water
system for complete In-plant coal handling system as specified elsewhere in the
specification.
2.02.27 Monorails and electrically operated hoist blocks as well as hand operated chain
pulley blocks for servicing/installation/easy replacement of drive machinery, different
types of pulleys for all conveyors, GTU and other equipment from ground level to
their locations and vice-versa.
2.02.28 Four (4) Nos. belt vulcanizing machines (2 nos. for 1800mm belt width and 2 nos. for
2200mm belt width) of adequate size complete with all mechanical, electrical,
accessories and consumables for one year consumption. Further, belt jointing
facilities as specified shall be provided.
2.02.29 All buildings in contractors scope shall be complete with all electrical, civil, structural,
architectural works, cable trenches, fire safety walls, foundation / fencing / earthing
for transformers. All cables / duct banks, trenches, cable trestles shall be complete
with associated civil/ structural work and necessary civil foundations.
2.02.30 Drainage of all CHP buildings, conveyor galleries and coal stock yard as described
elsewhere in technical specification including all civil & structural works.
2.02.31 All equipment/fittings, supporting structure, along with insert plates, bolts,
accessories, MS sleeves, base plates, grouting as may be required and proper
alignment etc.
2.02.32 Complete unused set of all special tools and tackles, which are necessary or
convenient for erection, commissioning and overhauling of any equipment, covered
under the scope.
2.02.33 First fill of all consumables e.g.; oils and lubricants for one year toppings
requirements.
2.02.34 Preservative shop coating, final painting of all structures and equipment under the
scope.
2.02.35 Modification & alterations
The following modification/rectification/dismantling works are envisaged under the
scope of the specification:
a) Complete modification of chute work of existing conveyor 40A/40B to enable
feeding of coal on to reversible belt conveyor 1A/1B at JNT-50 including all
associated electrical works. This also includes removal of existing chute
works and installation of new chute. Therefore necessary inserts/ foundations
requirement on this floor for reversible conveyor 1A/1B are to be provided by
the Contractor and finishing work of the same in JNT-50 is also in the scope
of the Bidder. Further, necessary alternations in the structural arrangement of
existing JNT-50 to accommodate conv 1A/1B and the new chute work is also
in the scope of the bidder.
b) Dismantling of existing buildings, railway tracks, structures & other facilities in
the areas identified for CHP plant is in bidders scope. It shall also include
dismantling of existing lighting mast at conveyor 4 near chainage 4500 and
railway track adjacent to TP-3 (as shown in tender drg no: 0260-156A-POM-
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
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A-001 Rev. C). Bidder shall provide one no. lighting mast similar to the
lighting mast specified for coal stockpile area in Cl. No. 2.12.01 of
Subsection-IIIB-06 (Illumination chapter) adjacent to the existing lighting
mast. Power supply of the existing lighting mast (to be dismantled by the
Bidder) shall be used for the power supply to the new lighting mast.
2.02.36 Electrical System / Equipment
Unless specifically excluded in clause no. 2.04.00 contractors scope of work shall
include all electrical works as required for putting into successful operation of the
Coal Handling Plant covered under this specification. The sizing of the various
equipments shall be as defined in the specification.
2.02.36.01 One (1) no. 3.3 KV Load break switch and one (1) no. 3.3 KV junction box for each of
Stacker & Reclaimer machines.
2.02.36.02 LT SWITCHGEAR
415V Switchgear/motor control centers (as shown in electrical single line diagram),
busduct (as applicable), distribution boards, One (1) AC fuse board in each MCC
room, local motor starters as required for plant and equipment. Contractor shall
provide two (2) nos. of 415V, 63A feeders for Employer 24V DC chargers in each
MCC room and control room Contractor shall also provide three (3) nos. of 415V,
63A feeders for UPSs in the control room. Additional feeders shall be provided by
Bidder in different boards for Employers use as indicated in Single line diagram
(Tender Drg. No. 0260-156-POE-A-001).
Outgoing feeders shall be segregated stream wise and equally distributed on each
bus section of the MCC.
2.02.36.03 TRANSFORMERS
One(1) Dry type transformer on each Stacker machine and Reclaimer machine.
2.02.36.04 MOTORS
Motors along with couplings and coupling guards for all rotating auxiliaries covered
under this package. All motors shall be with cable glands & lugs.
2.02.36.05 CABLES
a) LT Power, control & Instrumentation cables, HT & LT trailing cables and any
special cables required for connection between equipment / devices in
Contractors scope.
b) LT Power, control & Instrumentation cables
(i) required for the interconnection of Employers DDCMIS panels,
RI/Os, Control desk & HMI, 24V battery and chargers, UPS,
11/0.433KV & 3.3/0.433KV & 33/3.45KV transformers, 33KV
switchgear, 3.3KV switchgear, 3.3KV busduct.
(ii) required for the connection of the above indicated Employers
equipment with the Contractors equipment.
For termination of cables at employers DDCMIS/RIO panel end, cage clamp (post
mounted) type terminals are envisaged. Bidder to provide suitable lugs for
termination of the cables. The exact arrangements and details of terminal blocks
shall be provided to successful bidder during detail engineering. The shield of
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
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instrumentation cables shall be terminated on a shield of solid bar provided in
employers panel.
In addition to above bidder shall also supply power supply cables for employers 24V
DC chargers (2 nos for each RIO room and 2 nos for CHP control room) and
employers UPS (3 nos for CHP control room). All the power supply shall be 415 V,
50-Hz.
2.02.36.06 CABLING, EARTHING AND LIGHTNING PROTECTION
(a) i) Cable trays with supporting structure, trenches, duct banks etc. as
required for the cables to be supplied by the Contractor for the
complete coal handling system.
ii) Cabling viz., cable laying along with cable accessories for cables
supplied by the contractor.
iii) Employer will provide necessary cable trays in their cable trestle /
structure in the in-plant area as shown in the General Plant Layout
drawing. Contractor shall lay their cables in the trays provided by the
Employer. However, cable routing along with supporting structure and
trays from Employers trestle / structure upto Contractors CHP
equipment are included in Contractors scope.
iv) Cable trestle in Contractors scope is as marked in the General Plant
Layout drawing, however, exact coordinates shall be finalized during
detail engineering. Contractor shall provide necessary cable trays and
supports in their cable trestle and upto the equipment in CHP for all
Contractors cables and Employers HT & Control cables. Employer
shall lay their HT & control cables in the trays provided by the
Contractor.
(b) Earth mat, grounding and lightning protection for the plant and equipment
under Contractors scope along with its interconnection to the nearest
employers earth grid at two points. However, earth mat and lightning
protection in bunker area is in Employers scope.
(c) Underground and over ground earthing of Employers equipment indicated
above.
(d) Eight risers exclusively for employer C&I system in each RIO/control
room connected to earth mat shall be provided. Further earth flats for
panel ground in each RIO/control room shall be provided.
2.02.36.07 ILLUMINATION SYSTEM
i) Illumination system for complete internal and external lighting of associated
plant, equipment, buildings and roads under Contractors scope.
ii) Complete illumination of Employers Bunker TP-7, 8, 9, 10, 11 &12 including
their staircase lighting. However, illumination for Traveling Tripper Floors is in
Employers scope.
2.02.36.08 BATTERY AND BATTERY CHARGER SYSTEM
i) 220V DC System complete with Batteries, chargers and DCDB for the
complete inplant coal handling side including 220V DC emergency lighting
shall be provided by the contractor except for DC requirement at MCC-IC.
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
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Contractors 220V DC requirement is shown in Electrical single line diagram.
Contractors two (2) nos DCFB at MCC-IC shall receive 220V DC from
employers DCDB. Further the contractor shall provide and terminate two (2)
nos. of 220V DC 32A feeders at Employers 3.3 KV CHP Switchgear.
ii) 110V DC System complete with Batteries, chargers and DCDB for the
complete un-loader side coal handling plant including 110V DC emergency
lighting shall be provided by the contractor. Contractors 110V DC
requirement is shown in Electrical single line diagram. Further the contractor
shall provide and terminate two (2) nos. of 110V DC 32A feeders at
Employers 3.3 KV CHP Switchgear.
2.02.36.09 Emergency stop Push Button for all HT and LT motors.
2.02.36.10 CONTROL SYSTEM
a) All drives related to Coal Handling System including Conveyers, Sump
Pumps, Dust Suppression System, except for the systems like Stacker &
Reclaimer machines shall be controlled through microprocessor based
Distributed Digital Control Monitoring and Information System (DDCMIS)
being procured by Employer under separate package (Station C&I Package).
This DDCMIS system shall perform all functions such as auto / manual
operation of gates/ valves/ dampers, pumps, drives, local / remote selection
of operation, status indication, annunciation, interlock and protection of
pumps/drives etc. DDCMIS based control system including its power supply
system for main CHP control is in Employers scope.
b) The above DDCMIS system shall also interface with the systems like Stacker
and reclaimer machines, Mobile trippers over bunkers, Belt weighers, Metal
Detectors, Inline Magnetic separators, Coal sampling Units, Hydraulic scoop
Coupling etc. for which all the required controls , interlocks, protection ,
annunciations etc are to be provided by the Contractor, for remote operation
and monitoring facility. All the alarms shall also be repeated in the employers
DDCMIS and the contractor shall provide all the required contacts, field inputs
etc. for the same. For complete list of such systems, refer corresponding
mechanical chapters.
c) Brief description of capabilities of DDCMIS system being procured by
employer are given below.
(i) Controller loop reaction time (from change of input and the input
module to the corresponding control command output) for closed
loop/modulating control shall be 500 milli seconds.
(ii) Controller reaction time for ON/OFF control shall be one (1) second or
higher. For few specific applications controller reaction time 200 milli
seconds is envisaged. These response timings are from change in
input of digital input module to change of output in digital output
module, with both the modules in the same RIO. In case any
equipment/system being supplied by bidder requires such fast
controller reaction time, bidder shall clearly bring out the same in his
offer along with reasons for the same.
(iii) The maximum permissible cable distance for input/output in the field
from DDCMIS/RIO panel is 400 meters.
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
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(iv) In case any equipment/ system being supplied by the bidder under
this package, has control requirements better than those specified
above, control of such equipments/system shall be through
standalone microprocessor/PLC based system to be supplied by
bidder. Suitable interface to employers control system preferably OPC
compliant (through Ethernet port) to be provided. Bidder shall clearly
bring out in his offer any such equipments/systems, along with
reasons and details of control system offered.
d) For successful implementation of the same, the Contractor shall furnish I/O
list, drive list along with KKS code and all other
details/drawings/data/information like write-ups and detailed logic diagrams
for controls, interlock and protection of Contractors equipment,
recommended control loops, recommended mimics/graphics or any other
data etc as might be required by Employer during detailed Engineering stage
without any cost repercussions. A representative of Contractor shall also be
required to be present during Factory acceptance Testing of Employers
DDCMIS system at the finally selected DDCMIS Vendors work for testing of
the finally implemented control system. The contractor shall furnish
termination details for all I/Os to be connected to Employers RIO/control
system cabinets as per philosophy approved by Employer during detail
engineering stage. The format and exact details by contractor shall be
approved by employer during detail engineering. While preparing I/O list and
drive list during detail engineering the contractor shall obtain details of exact
DDCMIS/RIO configuration from employer and include details of the same in
these lists to be furnished by contractor.
Contractor shall provide all necessary supervision/assistance for proper
commissioning of his equipment to Control System Supplier through
Employer.
e) Contractor shall provide independent PLC based control system consisting of
control Desk, PLC Panels, I/O racks, along with its power supply arrangement
etc. for the control of eachof stacker machines and reclaimer machines.
2.02.37.00 INSTRUMENTS
All the Instruments as indicated in enclosed flow schemes/diagrams and relevant
tender drawings, corresponding Mechanical sections and meeting redundancy and
other requirements specified under technical specifications are to be provided.
Further, all the instruments / equipments including transmitters, transducers
temperature elements, switches which are required to implement the control
philosophy as specified in corresponding mechanical sections shall also be
provided by the contractor.
For temperature elements being supplied by bidder, employer is procuring
temperature transmitters under a separate package. These temperature transmitters
shall be mounted in junction boxes, supplied by employer. The instrumentation
cables/thermocouples extension cables up to temperature transmitters and from the
output of temperature transmitters to employers DCMIS/RIO panel are in scope of
bidder only.
Temperature elements shall be suitably grouped depending on physical locations
and shall be connected to the JBs in which temperature transmitters are mounted.
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
15 of 21

Multi pair instrumentation cable shall be used to connect output of temperature
transmitters to employers DDCMIS.
These temperature transmitters are of 24V DC two wire type which do not require
separate power supply and provide 4-20mA at output.
2.02.38.00 ELECTRICAL BUILDINGS
i) One (1) No. switchgear cum CHP control building near Crusher house to
locate Contractors CHP MCC-IA, 220V DC charger panels, MLDBs &
Welding DBs as required etc. A separate room to accommodate Contractors
220V DC battery shall be provided. Employers 3.3KV CHP Switchgear (27m
x 2m), Employers 33KV Swgr (18m x 2m), UPS battery (2m x 1.5m),
Employers 415V MCC (6m x 2m), Employers VFD Panels (8m x 2m),
Employers 24V DC battery and battery chargers (4m x 1.5m), Employers
MLDBs & Welding DB (for separate package) shall also be accommodated in
the building. The first floor shall consist of Employers CHP Control desk,
processor panels, LVS, R I/O panels, fire alarm panels, EPABX panels, UPS
etc. in the control room (15m x 10m room) and one office room (5m x 5m).
Both rooms shall be air conditioned. Further, Employers Two (2) nos. of
11/3.45KV (12.5MVA), 2 nos. 11/34.5KV (16MVA) and two (2)nos. of
11/0.433 KV (1600KVA) Transformers are to be located by the side of the
building.
ii) One (1) No. Switchgear building near TP-5 to accommodate Contractors
CHP MCC-IB, MLDBs, Welding DB as required, TR panels for ILMS/SM etc.
and Employers 24V DC battery and chargers(4m x 1.5m) in the ground floor.
Further, the ground floor shall have a separate air conditioned room (6m x
6m) to accommodate Employers R I/O panels of DDCMIS. Two (2) Nos. of
Employers 11/0.433KV, 1000KVA transformers are to be located by the side
of this building.
iii) One (1) No. Switchgear room in TP-6 to house Contractors CHP MCC-IC,
MLDBs and Welding DB as required etc. and Employers 24V DC battery &
chargers (4m x 1.5m). One (1) no. air conditioned room of size 8m x 6m for
Employers RI/O panels and its power supply panels shall also be provided.
iv) One (1) No. Switchgear cum CHP control building near TP-4 to accommodate
Contractors CHP MCC-ID, MLDBs, Welding DB, 110V DC charger panels,
TR panels for ILMS/SM etc. as required and Employers 3.3KV CHP
Switchgear (16m x 2m), Employers 2 nos. 33KV Breaker panels (2m x 2m),
Employers 415V MCC ( 6m x 2m), Employers VFD Panels (8m x 2m),
Employers 24V DC battery and chargers(4m x 1.5m) and Employers MLDBs
& welding DB (5m X 2m, for separate package) in the ground floor. Further,
the ground floor shall have a separate air conditioned room (8m x 6m) to
accommodate Employers R I/O panels of DDCMIS and a separate room to
accommodate Contractors 110V DC battery. Employers Two (2) nos. of
33/3.45KV (7.5MVA) and two (2) nos. of 3.3/0.433 KV (1000KVA)
Transformers are to be located by the side of the building. The first floor shall
consist of Employers CHP Control desk, HMI, R I/O panels, fire alarm panels,
EPABX panels, UPS etc. in the control room (10m x 8m room) and one office
room (5m x 5m). Both rooms shall be air conditioned.

CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
16 of 21

v) Civil works shall also include foundation, trenches, slits, support channels,
inserts, fencing, fire walls etc. for Employers Transformers except for 2 nos. of
11/34.5KV 16MVA transformers located near CHP MCC-IA, DDCMIS panels, R
I/O panels, Switchgear & MCCs, 24V DC Battery & Chargers and any other
Employers equipment as indicated elsewhere. Proper covered shed shall be
provided on the transformers to provide cover from the falling coal dust.
2.02.39 CIVIL
2.02.39.01 The work to be performed under this specification consists of providing all labor,
materials, construction equipment, tools and plant, scaffolding, supplies,
transportation, all incidental items not shown or specified, but reasonably implied or
necessary for successful completion of the work including Contractors supervision and
in strict accordance with the drawings and specifications. The nature of work shall
generally involve earthwork in excavation de-watering, shoring and strutting, sheet
piling, back filling around completed structures and plinth protection, area paving ,
disposal of surplus excavated materials, piling, concreting including reinforcement and
form work, brick work, fabrication and erection of structural / miscellaneous steel
works, inserts, architectural items & finishes such as plastering, painting, flooring,
doors, windows & ventilators, glass and glazing, rolling shutters etc., permanently
colour coated profiled steel sheeting, anchor bolts, R. C. C. trenches with covers,
laying and testing of water pipes, sanitation, water supply, drainage, damp proofing,
water proofing and other ancillary items.
2.02.39.02 The work shall have to be carried out both below and above ground level and shall be
involving, equipment foundations including vibration isolation systems, grounding,
slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches,
pits, access roads, culverts, conveyer galleries, trestles, crusher house, transfer
towers, finishes, complete architectural aspects, drainage, sanitation, water supply
(from terminal points to various buildings, conveyor galleries) and all other civil,
structural and architectural works associated with the complete In-Plant Coal
Handling System.
2.02.39.03 Scope of the Contractor shall also include supply and laying earthing mat all around
the periphery of buildings, structures, and outdoor equipments, as per the approved
drawings.
2.02.39.04 The work shall also involve arranging construction water from underground sources,
storage in underground/ overground tanks and taking the water to construction site
through pipelines by pumping or by road tankers etc., including all necessary
accessories, tools & tackles etc.
2.02.39.05 Access roads to all building/ facilities (except TP-1, 2, 3 & 4) will be in employers
scope. However, these access roads would not be available during construction
phase. Bidder shall construct and maintain temporary access roads as required by him
for approach to the building/ facilities in his scope for his construction/ erection
activities.
2.02.39.06 Bituminous access roads (3.75m wide) to TP-1, 2, 3 & 4 will be in bidders scope.
2.03.00 TERMINAL POINTS
Broad terminal points for In-plant coal handling system have been indicated in the
tender drawings. Within these terminal points, all equipment and services, civil,
structural and architectural works, electrical distribution, piping network etc. as
required for in plant coal handling system will be furnished and erected by the
contractor unless specifically excluded as follows:
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
17 of 21

2.03.01 Contractors scope/responsibilities with regard to Employers Transfer points TP-7,
TP-8, TP-9, TP-10, TP-11 & TP-12 and conveyor galleries for Conveyors 9A/9B
(between TP-7 & 8), 10A/10B, 11A/11B, 12A/12B, 13A/13B,14A/14B and tripper floor
of bunker building shall include but not limited to the following :
2.03.01.01 Contractor shall generally support technological structures including Contractors
platforms on foundation/support provided by Employer, through anchor fasteners.
The Contractor shall supply and install all anchor fasteners of requisite capacity to
support his structures. Anchor fasteners shall be used for supporting all such
equipment, where the static and dynamic load due to equipment is within the safe
load carrying capacity of the anchor fasteners.
2.03.01.02 The Employer shall provide the pockets only for those equipment foundations where
the load to be transferred is beyond the safe load carrying of anchor fasteners. For
such equipment, subsequent supply and installation of foundation bolts including
grouting of pockets shall be done by Contractor.
2.03.01.03 In case, fixtures (for supporting of equipment and structure including Contractor
platforms) viz. Foundation/mounting bolts along with templates, inserts and
embedment (including pipe sleeves) along with lugs, etc. are required to be
embedded during the first stage of concreting, then the Contractor shall make such
fixtures available at site (before casting of foundation) for installation by Employer at
the time of the concreting stage itself. During concreting, Contractor shall depute his
engineers to verify that all such fixtures are installed correct to layout and levels as
per their design drawings. Any modification required on these fixtures subsequent to
their placement shall be done by Contractor.
2.03.01.04 All small size Openings having size (within 150 mm x 150 mm area) which are
required on Floors, Walls, Cladding, Roof etc. shall be neatly created and finished by
the Contractor using appropriate tools. The Employer shall however provide larger
size Openings.
2.03.01.05 All grouting of pockets, Underpinning of Base Plates, filling and finishing of Openings
etc. shall be done by the Contractor. Anchor Fasteners shall be fixed in position by
Bidder as recommended by the manufacturer and approved by the Employer.
2.03.01.06 Wherever Contractor is permitted by Employer to take support from any of the
Employers Structures, the Contractor shall ensure that no damage is done to the
Employers Structures including Painting thereof. In case of any damage to the
Employers Structure and/or Painting, then the Contractor shall rectify the same to the
complete satisfaction of the Employer.
2.03.01.07 Details / Data of all openings required by the Contractor in Floors / Walls / Cladding /
Roof to be provided by the Employer shall be given by the Contractor. Basic load
data (i.e. floor loading and major equipment loading) for starting of civil engineering
activity by Employer shall be furnished by Contractor within 45 days of LOA. Final
load data (along with mounting details) shall be submitted by Contractor to Employer
progressively within 6 months of LOA. These submissions by Contractor shall be
listed in Engineering Information Flow Schedule to be furnished by the Contractor. If
any additional tertiary beams are required subsequently after receipt of loading data
due to change of loading or its location by the Contractor, then the same shall be
provided by the Contractor.

CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
18 of 21

If the details / data of all Openings required by the Contractor in Floors / Walls /
Cladding / Roof are not furnished by the Contractor, as per the Engineering
Information Flow Schedule then all such required Openings shall be created by the
Contractor himself, at a later date in Floors / Walls / Cladding / Roof by using special
tools, as required. In this case secondary and tertiary steel members including edge
protection to the openings shall also be provided by the Contractor.
2.03.01.08 Regarding fixing / erection of conveyor short supports and other equipment in
conveyor galleries that are in Employer's scope for Conveyors 9A/9B (between TP-7
& TP-8), 10A/10B, 11A/11B, 12A/12B, 13A/13B, 14A/14B, contractor shall provide
necessary arrangement themselves for fixing / erection of their equipment as
approved by the Employer. Contractor shall provide PTFE bearing /roller at the
location where his conveyor 9A/9B gallery is resting on Employers TP-7 so that no
horizontal load in the longitudinal direction is transferred from his conveyor to TP-7.
Further Contractor shall furnish the vertical load data, from the conveyor, to be
considered in design of TP-7.
2.03.01.09 Conveyor walkways inside TP-7, TP-8, TP-9, TP-10, TP-11 & TP-12 along with
supporting structures shall be in Contractors scope. However walkways for conveyor
galleries of 9A/9B (portion between TP-7 & TP-8), 10A/10B, 11A/11B, 12A/12B,
13A/13B &14A/14B shall be provided by Employer.
2.03.02 All the equipment, conveyors, short supports, stringers, deck and seal plates, head
and tail end frames, operating and maintenance platforms, guides for the VGTU,
intermediate platforms (including support beams) / handrails in the VGTU structure
along with access platforms, complete technological structures, bolts, anchor
fasteners, embedments, inserts, templates, chute work, flap gates and actuators,
ventilation, service water, potable water and dust suppression system, monorails,
electric hosts, manual hoists, chain pulley blocks, internal & external illumination,
cabling, cable trays & cable tray supporting system, equipment earthing and lightning
protection system and all associated electrical works covered under Transfer Points
TP-7, TP-8, TP-9, TP-10, TP-11 & TP-12, along with conveyor galleries for conveyor
9A/9B (portion between TP-7 & TP-8), conveyor 10A/10B, 11A/11B, 12A/12B,
13A/13B & 14A/14B shall be in Contractors scope.
2.03.03 Water supply terminal point shall be provided by the employer are as follows:
i) Jetty area
a) One (1) no. raw water terminal point for service water, DS and cooling
water, drinking water system.
ii) Stockyard area
a) One (1) no. sea water terminal point for stockyard dust suppression
system
b) One (1) no. raw water terminal point for service water, dry fog DS, DE and
cooling water system.
c) One (1) no. potable water terminal point for drinking water system
iii) Main plant area
a) One (1) no. raw water terminal point for service water, dry fog DS and
cooling water system.
b) One (1) no. potable water terminal point for drinking water system
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
19 of 21

Details of these terminal points are given in the tender drawing. Further network of
piping including all pumps, tanks, necessary accessories, supports and fittings etc.
for distribution of potable water, water for dust suppression and service water system
in all TPs, crusher house, control rooms, MCC rooms, Tripper floors, toilets, etc. shall
be under the scope of the contractor.
2.03.04 Cross country conveyor(s) starting from TP-4 & terminating at drive house is not in
the scope of the package. However complete civil, structural & architectural works of
TP-4 is in the scope of the package.
2.03.04 Electrical Terminal Points
(a) HV Terminal box of Contractors equipment.
(b) Incoming 220 V DC supply terminals of contractors two (2) nos. of DCFBs in
MCC-IC room in TP-6.
(c) Employers DDCMIS/RIO panels for instrumentation cables.
2.03.05 Civil
The trunk sewer lines are proposed to be installed by the employer. The sewerage
from all the facilities planned under the contract shall be connected by the Contractor
to this trunk sewer network.
2.04.00 EXCLUSIONS
2.04.01 Civil, structural and architectural works for drive house, transfer points TP-7, TP-8,
TP-9, TP-10, TP-11 & TP-12, along with conveyor gallery for conveyor 9A/9B (portion
between TP-7 & TP-8), 10A/10B, 11A/11B, 12A/12B, 13A/13B & 14A/14B.
2.04.02 Civil, structural and architectural works for bunker buildings including bunkers &
tripper floors are excluded from the Contractors scope.
2.04.03 Site leveling is excluded from the scope of this Contract. However site clearance i.e.
removal of vegetation including bushes and trees etc. shall be the responsibility of
the Contractor.
2.04.04 Supply, laying and termination of the following cables is excluded from Contractors
scope:

(a) 11 kV and 3.3 kV cables (except 3.3KV trailing cables)
(b) Control cables between Employers 11KV switchgear in main Plant area and
Contractors LT switchgears.
(c) Data bus cable between employers R I/Os & DDCMIS.
2.04.05 Supply and erection of the following is excluded from Contractors scope:
(a) DDCMIS based control system including its power supply system.
(b) Telephone and Public address (PA) system.
(c) Close Circuit T.V. system.
(d) Grounding mat and lightning protection in bunker area.

CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
20 of 21

3.00.00 SYSTEM DESIGN BASIS
3.01.00 The rated capacity of the CHP shall be 4000TPH for conveyor 1A/1B, 2, 3, 4,
15A/15B, 16A/16B and 2400 TPH for conveyor 6A/6B, 7A/7B, 8A/8B, 9A/9B,
10A/10B, 11A/11B, 12A/12B, 13A/13B, 14A/14B, 17A/17B. The mechanical and
structural / civil system shall be designed for 4400/2640 TPH capacity (as the case
may be) and round the clock operation with both the streams operating
simultaneously.
3.02.00 Following shall be considered while designing the CHP:
a) The Coal delivered to the power station shall be of size -100 mm & below.
However occasionally 1-2% coal of 150 mm lump size may also be
encountered.
b) HGI of the Coal shall be between 44 to 65. Normally moisture content in coal
will vary between 12% to 15%. However for design purposes, moisture
content of 20% shall be considered.
c) Incoming coal may contain shale and sand stone. Also occasionally metal
pieces like broken shovel teeth, brake shoe, wires, steel channels, pipes etc.,
may also come along with coal.
d) The coal as received shall contain varying percentage of fines. Coal with
such fines may tend to form adhesive lumps, particularly during monsoon
when surface moisture is at its maximum value.
e) The sizing and selection of the vital equipment viz. crushers, vibrating
screening feeders, etc. covered under the system shall be based on the
above characteristic of coal and operating conditions. Contractor shall ensure
that equipment/ system efficiency shall not be affected particularly during
monsoon when surface moisture is at its maximum value.
3.03.00 For the purpose of volumetric computation, the bulk density of the coal shall be taken
as 800 kg/m
3
. Therefore for calculation of belt conveyor capacity, for their drives &
drive motors kW requirement, and sizing (volume calculations) of chute, hoppers etc.
the above bulk density shall be considered. For all other purposes viz. for stresses/
load on structures, torque calculations of bucket wheel of reclaimer, loading on VSF
tables, sizing of actuators for flap gates, R&P gates, calculations of plugged chute/
hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m
3
.
3.04.00 All mechanical and structural / civil system design shall consider simultaneous
running of both the streams at rated load starting of one stream with the other stream
in standstill condition as well as starting of one stream with the other stream in
operation.
3.05.00 Coal Flow paths
3.05.01 For the purpose of conducting guarantee test coal, flow is divided into following coal
flow paths.
i) Flow Path IA (Stacking stream):
Conveyor 1A or 1B taking feed of incoming coal from existing conveyor 40A
or 40B and stacking coal in stockyard using yard conveyor 16A or 16B with
stacker at position farthest from TP-14 or TP-13 and boom conveyor at
CLAUSE NO.

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIA-01
Scope & Supply
Page
21 of 21

highest angle including all intermediate Conveyors and equipment (except
cross country conveyor between TP-4 and DH).
ii) Flow Path IB (Reclaiming stream):
Reclaiming coal from stockyard of CHP using yard conveyor 16A or 16B with
reclaimer at farthest position from TP-15 or TP-16 with the boom conveyor at
its lowest position and feeding last bunker of Unit # 3 through traveling tripper
on conveyor 14B including all intermediate Conveyors and equipment.
iii) Further for the purpose of Guarantee tests conveyor 7A/B, 12A/B, 13A/B, 14A
alongwith all associated equipment shall also be considered.
3.05.02 Performance and Guarantee Tests shall be conducted in such a way that all the
conveyors (including interconnection conveyors) in both the streams are covered. For
this purpose it may be necessary to repeat the Performance & Guarantee tests until
all the conveyors are covered. Combination of conveyors to be tested shall be at the
discretion of the Employer. The maximum liquidated damages calculated as above,
for any one of the paths shall be levied on Contractor.
3.05.03 Contractor shall also demonstrate that all intermediate equipments can perform as
per specification and design requirement. Simultaneous operation of both the paths
in conveyor streams shall also be demonstrated during PG Test.
3.05.04 Performance and Guarantee tests have been elaborated elsewhere in the
specification.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-A

PART- A
SUB-SECTI ON-I I B-01
PG TEST PROCEDURE
CLAUSE NO. GUARANTEE TEST PROCEDURE

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIB-01
PG Test Procedure
Page
1 of 28

1.00.00 STANDARD GUARANTEE AND ACCEPTANCE TESTS AND TESTING
PROCEDURE FOR COAL HANDLING PLANT
1.01.01 SYSTEM FACILITIES
1.01.02 In accordance with Section GTR placed at Part-C after commissioning and before
handing over, the entire plant shall be subjected to System Trial Operations.
1.01.03 The duration of Trial Operations of the complete equipment shall be fourteen (14)
days with minimum twelve hours daily operation. For successful Trial Operation,
the trial shall necessarily include steady operation of the plant at its rated flow path
capacity for at least one hour duration per day on an average.
1.01.04 PERFORMANCE REQUIREMENTS
The Contractor shall guarantee that the equipment offered shall meet the ratings
and performance requirements stipulated for various equipments covered in the
specification.
1.01.05 GUARANTEES
The Contractor shall furnish a declaration in the manner prescribed and included in
the relevant Attachment of Section-VII for the following guaranteed parameters
which shall attract levy of liquidated damages for shortfall in Performance.
Capacity in T/Hr (equivalent to 100% of rated) of conveyor system including the
intermediate equipments for each of the two parallel conveyor streams separately
or any combination thereof to be tested in the following flow path operations.
(i) Flow path 1A (Direct stream):
Conveyor 1A/1B taking feed of incoming coal from existing conveyor
40A/40B and discharging crushed coal into last bunker of unit # 1 through
traveling tripper on conveyor 12B including all intermediate conveyors and
equipment (except cross country conveyor between TP-4 and DH).
(ii) Flow path 1B (Direct stream):
(iii) Flow path 1C (Direct stream):
(iv) Flow Path IIA (Stacking stream):
Conveyor 1A or 1B taking feed of incoming coal from existing conveyor
40A or 40B and stacking coal in stockyard using yard conveyor 16A or 16B
with stacker at position farthest from TP-14 or TP-13 and boom conveyor at
highest angle including all intermediate Conveyors and equipment (except
cross country conveyor between TP-4 and DH).


SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIB-01
PG Test Procedure
Page
2 of 28

(v) Flow Path IIB (Reclaiming stream):
Reclaiming coal from stockyard of CHP using yard conveyor 16A or 16B
with reclaimer at farthest position from TP-15 or TP-16 with the boom
conveyor at its lowest position and feeding last bunker of Unit # 3 through
traveling tripper on conveyor 14B including all intermediate Conveyors and
equipment.
1.01.06 Major Equipment Capacity
Guaranteed capacity in T/Hr of the following:
Crushers
Vibrating Screening Feeders
Stacker
Reclaimer
Note : Guaranteed (rated ) capacities of above equipments are indicated in
section III-A-01.
1.01.07 Power Consumption
Total power consumption for all the equipments including auxiliaries with single
stream operation at its guaranteed flow path capacity except.
- Lighting
- Hoists
- Coal sampling unit
- Elevators
- DS, DE, Ventilation, SW System, Potable water system
1.01.08 Performance Requirements to be Demonstrated
Performance requirements of various individual equipments / systems as
specified, including but not limited to certain minimum requirements as spelt out in
the Guarantee Test procedure shall also be demonstrated during the Guarantee
Tests to the full satisfaction of the Employer.
2.00.00 GUARANTEE TEST PROCEDURE
In accordance with Section GTR placed at Part-C, on successful completion of
System Trial Operation and commissioning, the plant shall be subjected to
guarantee tests. Further, the guarantee tests shall be conducted as per the
procedure specified in the following paragraphs.
2.01.00 Pre-Requisites to the Guarantee Tests
2.01.01 The prerequisites to be ensured by NTPC and the Contractor prior to start of the
tests are placed at Appendix-I and Appendix-II respectively.
2.01.02 After successful completion of trial operation and commissioning the plant shall be
jointly inspected by NTPC and the Contractor & a joint protocol shall be signed that
the plant is fit for guarantee tests.


SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIB-01
PG Test Procedure
Page
3 of 28

2.02.00 Testing for Guarantees
2.02.01 Flow Path Capacity Tests
(a.) For each of the Flow Paths, two conveyor streams shall be formed with
suitable CRISS-CROSS Combinations of A or B Conveyors/ intermediate
equipments. Composition of each stream shall be decided by the Engineer
and shall be recorded as per Appendix-III.
(b.) All above streams formed shall be independently tested for performance &
guarantee. Further, the equipments/ conveyors (except common
equipments) used for performance testing of one stream shall not be used for
performance testing of the other stream.
(c.) In case of direct flow path, guarantee test should include operation of all the
trippers. However, for measurement of guaranteed power consumption
farthest tripper shall be operated.
(d.) Stacking and Reclaiming will be done near the drive house so that the
conveyor is tested under fully loaded conditions.
(e.) While operating the guaranteed capacity of the flow paths, non-spillage of
coal and non-choking of chutes/ equipments shall be demonstrated as
indication of smooth continuous flow through the conveyor system.
2.02.02 Major Equipment Capacity Tests
(a.) Guaranteed capacity of all the major equipments as identified shall be
established separately by operating only one equipment out of the two of a
set at a time. Following equipments shall be considered:
Equipment Capacity Requirement
(1.) Crusher
(2.) Vibrating Screening Feeders
(3.) Stacker
(4.) Reclaimer
(5.) Height and Base Width of Stockpile
2.02.03 Power Consumption Measurement
(a.) The guaranteed power consumption as total sum of all the equipments as
specified shall be measured during capacity test of the identified Flow Paths
for both the streams separately.
The load of the following items shall not be considered during measurement
of Power Consumption for guarantee:
Lighting
Hoists
Coal Sampling Unit
Elevator
DS, DE, Ventilation, SW system, Potable water system


SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIB-01
PG Test Procedure
Page
4 of 28

(b.) Measurement Terminal(s)
The guaranteed power consumption for the entire Flow Path(s) shall be
taken during capacity test as sum of the power measurements at the
following terminals.
(1.) 3.3/6.6/11 kV CHP incoming terminals
(2.) 415 V CHP MCC incoming terminals.
(3.) Switchgear terminal of any load connected to Employers Switchgear.
Further the power consumption for the equipments being fed from CHP board/LT
board but not to be considered for guaranteed power consumption shall be
measured separately at their respective MCC/LT & HT switchgear input terminals
and shall be subtracted from the total power consumption measured. However, if
conditions permit, such equipments may not be operated during power
measurement duration.
For Stacker/ Reclaimer machine, the average power consumption shall be
measured through energy-meter at HT switchgear feeder of Stacker/ Reclaimer.
For Conveyors, the power consumption shall be measured at their respective
switchgear terminals.
Guaranteed power consumption of the yard conveyor(s) and stackers shall be
measured during flow path capacity test in stacking mode whereas for balance
equipments (balance conveyors and Reclaimer machine) the power consumption
shall be measured during capacity test of reclaim flow path with boom of reclaimer
at lowest angle. Lighting, A/C & Ventilation loads on the Stacker or Reclaimer shall
not be considered for guarantee.
(c.) Time Duration
Power Consumption measurement shall be done only for 30 minutes after
the conveyor flow rate stabilizes at the guaranteed capacity. However, for
Reclaimer(s), the average power consumption shall be measured for entire
duration of reclaim flow path capacity test.
(d.) Meters
Ammeter/Voltmeter readings shall be noted from the meters mounted on the
control desk / LT switchgear / HT switchgear or if necessary by means of
clamp type meters.
For power measurement two wattmeter method / one wattmeter method (2 or
3 elements) shall be used. Power measurement shall be taken after stable
condition is achieved. 3 phase clamp type digital wattmeter can also be used.
Wattmeters shall have a min. accuracy class of 1% Energy meter shall be
of min 2%. CTs & VTs shall have accuracy of 1%. All meter readings shall
be recorded. No corrective allowance shall be allowed over the measured
values.
The details of wattmeters and energymeter alongwith their calibration
certificate shall be furnished to NTPC before start of tests. These measuring
instruments shall be calibrated from govt. approved test house.


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BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIB-01
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Page
5 of 28

Calibration certificates of all instruments must not be more than 1 year prior
to test date. Seals of the instruments shall be opened at site in the presence
of Engineer-in- charge. Zero error shall be checked before conducting the
PG Test.
2.02.04 GENERAL
(a.) Test Duration
(1.) Normal duration of the above capacity tests shall be four hours.
However, minimum one (1) hour continuous & steady operation shall be
required to establish the guaranteed capacities.
(2.) In case of any minor interruption due to operation of electrical
protection as well as stoppage due to safety reasons, the duration of
test shall be extended by the time lost in such interruptions. In case of
exceptionally longer interruptions calling for re-mobilization and re-
preparation of plant the implications shall have to be mutually
discussed and agreed upon.
(b.) Weighing scales
(1.) For measurement of flow capacity of a stream and individual
equipments, weighing scales installed in the system shall be used.
(2.) Belt weigher mounted on the luffable boom of Stacker/ reclaimer shall
not be used for this purpose.
(3.) Readings for flow rate capacity test shall be taken at intervals of every
3 minutes.
(4.) Belt weighers accuracy as demonstrated/ observed jointly before the
guarantee testing may be considered for allowing correction factor over
the recorded flow capacity reading.
(c.) The observations of guarantee test for various streams/ equipments shall be
recorded in the formats at Appendix - III, IV & VII.
2.03.00 Testing for Demonstration Requirements
The specified performance parameters of various equipments/ system including
but not limited to the following shall be demonstrated to the full satisfaction of the
Employer.
2.03.01 Conveyors
(a.) Conveyor Profile
(1.) Check against lifting of Conveyor belts over concave curves at the time
of start under empty belt condition.
(2.) Check against wrapping/folding of belt over convex curves/transition
zones.
(3.) There should not be any roll back of coal pieces on moving or stopped
conveyors
(4.) There shall not be build up of coal in chutes, spillage of coal from
skirt/conveyor/hoods while the belt is running.


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Sub-Section IIB-01
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(5.) Smooth non-jerky running of conveyors with no spillage of coal and
centric running of conveyors without vibrations of drives and galleries.
(b.) Coasting Time
Coasting down time of fully loaded conveyors shall be measured and
compared with design values. Check for spillage/blockage of coal from
skirts/in chutes to be made. There shall not be build up of coal in chutes after
stoppage of conveyor so as to cause spillage of coal during next start.
(c.) Belt Alignment
To check against any sway during operation under different loadings and
different conveyor criss-cross combinations.
(d.) Idlers and self aligning idlers
To check for satisfactory performance of idlers and self-aligning idlers
(e.) Control/Sequential Operation
(a) Performance checks for specified controls including sequential starting/
stopping of conveyors and other equipments as per approved control
write-up.
(b) Satisfactory operation of control systems including absence of spurious
trips/communication failures to be demonstrated.
(c) Demonstration for detection of operated pull cord/belt sway switch along
with display in CRT of conveyor number and operated pull cord /belt
sway number.
(f.) Protection Switches
Satisfactory operation of pull chord, belt sway, zero speed, chute blockage
and other safety / protection switches.
(g.) Load Start
Demonstration of the ability of conveyor to start under full designed load
(rated capacity +10% for conveyors and +25% for boom conveyors).
(h.) Simultaneous Operation
Demonstration of simultaneous operation of both the streams under full load
for 30 minutes in order to check healthiness of the system, electrical systems
etc.
Vibrations of crusher house floors and TP floors shall also be measured and
these shall be within allowable limits
(i.) Vibration Level in Conveyors
Both velocity and amplitudes for all the conveyor drives and in each
conveyor gallery under different conditions of conveyor operation as desired
by site. Vibration limits of drive equipments shall be as per VDI 2056 /
equivalent. Observations shall be recorded as per the format at Appendix-V.
Vibration of conveyor galleries at trestles and pt. between trestles shall be
measured and these values shall be within allowable limits.


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BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIB-01
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(j.) GEAR BOXES
Temperature rise not to exceed design values.
No leakages
No abnormal sound.
Satisfactory performance of hold back devices in preventing running back of
conveyor belts in case of conveyor being stopped in fully loaded (at design
load) condition to be demonstrated.
(k.) Fluid Coupling.
No excessive rise of temperature.
Satisfactory and quick operation of scoop in manual/remote modes with no
oil leakages.
(l.) Brakes
Satisfactory and non jerky operation to avoid hold up of Coal in chutes.
(m.) Skirt board and skirt sealing, inspection door, chute joints
Perfect sealing with no spillage/no dust from sealing areas.
2.03.02 Stacker and Reclaimer
(a.) Stacking at maximum boom height.
(b.) Starting of Boom Conveyor at full load (at design load = rated capacity
+25%) at maximum / minimum inclinations.
(c.) Reclaiming at maximum and minimum stockpile heights
(d.) Uniform to and fro travel speed and proper reeling / unreeling of flexible
cables.
(e.) Satisfactory operation of all limit switches, protections and other controls.
(f.) No sway of Boom Conveyor during stacking and reclaiming at different loads
and inclinations.
(g.) Proper hoisting / luffing operation without jerks and operator cabin level
adjustment.
(h.) Check against folding of belt in spaces between horizontal and inclined
troughing idlers at the start of Stackers and Reclaimers.
(i.) No leakage from hydraulic couplings, seals, heat exchangers, instrument
tappings etc
(j.) Demonstration of proper functioning of hydraulic and manual rail clamps and
boom locking.
(k.) Proper functioning of communication system on stackers and reclaimer.
2.03.03 Metal Detector
(a.) Tests for detection of specified smallest size pieces of different metals
including aluminium.
(b.) Operation of tramp markers.
(c.) Demonstration of coast count, total count for multiple tramp metal pieces.

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Sub-Section IIB-01
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2.03.04 In-Line Magnetic Separators
(a.) Demonstration of magnet capacity to separate out specified sizes and
weights of magnetic pieces buried under (rated load) coal:
MS cube of 20mm side
Brake shoe of railway wagon (15 kg)
MS plate of 250x250x10mm size
Shovel teeth and spikes (carbon steel)
MS round bar of 50 kg with L/D ratio not exceeding 5
(b.) Collection of picked up pieces into tramp Iron chutes/ trolley
(c.) Proper discharge of picked up metal pieces into tramp metal chute ( with no
coal pieces going into it)
(d.) Position adjustment
2.03.05 Flap Gates
(a.) Demonstration of remote, local and manual actuation of gates.
Demonstration of successful changeover even while feeding coal.
(b.) Check for stroke and operation of limit switches/ torque switches
2.03.06 Travelling Trippers
(a.) Check for smooth to & fro travel
(b.) Operation of brakes and rail clamps at full load.
(c.) Check against dragging during start up or running (over speed protection)
(d.) Check against blockage of discharge chutes at full load.
(e.) Check against folding of belt in spaces between horizontal and inclined
troughing idlers at the start of Tripper.
(f.) Proper functioning of communication system on trippers.
2.03.07 Dust Suppression System
(a.) Measurement of head of pumps.
(b.) Satisfactory spray atomization and dust suppression effectiveness of all the
DS systems as per appendix-VIII.
(c.) Measurement of SPM before and after DS system operation as per Appendix
- VIII.
(d.) To measure pressure available at inlet to sprinkler in coal yard in running
conditions and this should not be less than 4.5 kg / cm2
(e.) Complete coverage of yard by spray units in stockyard.
(f.) Measurement of noise level and vibration ( velocity and amplitude) at the
bearing of motors and pumps
2.03.08 Ventilation system
(a.) Measurement of rated volumetric capacity of fans of atleast 2 nos. of each
type and rating.

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(b.) Measurement of vibration ( velocity and amplitude) at the bearing of motors
and fans (wherever possible)
2.03.09 Package Air Conditioning (PAC) Unit
(a.) Specified temperature and humidity of conditioned space under worst
ambient conditions.
(b.) Demonstration of rated capacity of PAC unit.
2.03.10 Belt Weighers
(a.) Demonstration of specified weighing accuracy of + 0.25% (+1% in case of
boom conveyor of stackers and reclaimers) between 20% and 120% of rated
capacity
(b.) Satisfactory operation of flow rate indicator and totaliser etc.
2.03.11 Vibrating Screening feeder
(1.) Demonstration of variable capacity adjustment
(2.) Observation of little tendency of choking/ build-up with coal having maximum
moisture of 20%
(3.) Little transmission of vibration to building structure, floor
2.03.12 Coal Sampling Unit
1) Demonstration of bias testing on random basis
2) Demonstration of satisfactory of operation of CSU which shall necessary
include ability to collect samples automatically and continuously for a
minimum period of 7 days of conveyor operation without requiring manual
intervention
2.03.12 Crushers
Output coal size to be sieve analyzed and (-) 20 mm coal to be more than 98% for
ring granulator type crusher.
Vibration measurement (velocity and amplitude) is to be recorded at bearings as
per appendix. Vibration is to be within allowable limits.
No excessive rise of temperature of bearings
One crusher is to be tested for output and size after blocking VSF.
Proper functioning of vibration monitoring system to be checked.
2.03.13 Belt Scrappers
Satisfactory operation of belt scrappers shall be demonstrated even with wet coal
as specified. Scrapping efficiency of belt scrapper shall be minimum 95%.
2.03.14 Noise Levels
2.03.14.01 Noise level measurement, for conformance to specified levels, to be done around
the following equipments/ areas:
(a.) Conveyor Discharge Terminal (including discharge chute, gearbox, coupling
& motor).


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Sub-Section IIB-01
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(b.) Coal discharge chutes on intermediate floors in possible impact zones.
(c.) Ventilation fans
(d.) Water Supply & Dust Suppression Pumps.
(f.) Coal crushers
(g.) Vibrating Screening Feeders
2.03.014.02 Noise level measurement shall be done around the specified equipment location in
the following manner.
(a.) The measurement shall be carried out with a calibrated integrating sound
level meter meeting the requirements of IEC-651 or BS-5969 or IS:9779.
(b.) Sound pressure level shall be measured all around the equipment at a
distance of 1m from the vertical projected plan of the equipment as a whole
(this shall include coupling, gear box, motor etc.) at a height of 1.5 m from
floor level. Microphone positions shall be at horizontal separations of not
more than 1.5m around the equipment.
(c.) The measurement shall be done with slow or impulse response, as the case
may be on the A-weighting scale. The average of the A-weighted sound
pressure level measurements expressed in decibels to a reference of 0.0002
micro bar shall not exceed the guaranteed value indicated in the
specification.
(d.) The tests shall be carried out with the equipments operating at near rated
speed & load Correction for background noise will be considered Inline with
IS:4758. Noise level measurement shall be recorded as per format at
Appendix-VI.
2.03.15 Elevators
a) Check for average speed and load capacity
b) Leveling accuracy
c) Trouble free smooth operation
d) Satisfactory operation of controls and limit switches
e) Unmanned tests of safety devices like brakes etc.
f) Testing as per manufacturers PG Test Procedure given in Annexure-IX


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Sub-Section IIB-01
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Annexure -IX

Elevator

Sl.
No.
NAME OF THE
TEST
PROCEDURE EXPECTED
RESULTS
REMARKS
/RESULT
OBTAINED
1.0 Trial Run Test each landing ( 5
times)

Results of Test
1 2 3 4 5
a) Push the UP,
STOP and DOWN
buttons at every
landing
Cage
should
respond
correctly to
each button

b) Try to operate the
hoist with the UP
and DOWN button
leaving the landing
door open (cage door
closed)
Hoist must
not start.

c) Close the landing
door and also the
cage door, keep the
stop button pressed
while trying to
operate the Elevator
with the "UP &
DOWN buttons five
times.
-do-
d) At each landing floor,
the level deviation
should be within
specified limits.


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Sub-Section IIB-01
PG Test Procedure
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Sl.
No.
NAME OF
THE TEST
PROCEDURE EXPECTED
RESULTS
REMARKS
/RESULT
OBTAINED
Results of Test
1 2 3 4 5
2.0 Check for
operation
from inside
cage
Operate the elevator with
the UP STOP &
DOWN button five
times
Cage should
respond
correctly to
each button

3.0 Check for
interlocking
a) Try to operate the
elevator UP &
DOWN leaving the
cage door open
(landing door closed).
(All the doors are to
be tried separately)
The elevator
must not start
when testing
according to
a,b,c and d.

b) Try to operate the
elevator UP &
DOWN leaving the
trap door open (cage
and landing door
closed).
-do-

c) Try to operate the
elevator UP &
DOWN keeping the
emergency stop
button pressed after
the test.
-do-
d) Check the other
interlocking
equipment in the
same way (each
landing)
-do-
e) Turn the switch
Location /
Operation in the
electric box on the
cage roof to
Erection and test
according to a), b)
and c) from the cage
roof. Reset the switch
to Operation


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Sub-Section IIB-01
PG Test Procedure
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Sl.
No.
NAME OF
THE TEST
PROCEDURE EXPECTED
RESULTS
REMARKS
/RESULT
OBTAINED
4.0 Check for
Automatic
System
Stop Next
Landing
a) Start at the ground
landing and operate
from the push button
box in the Cage,
Push the 0-button as
soon as the elevator
has started.
Cage must stop at
the next landing in
the direction of
travel.

b) Continue upwards
and test all landings
in the same way.

c) Make the test
according to a) & b)
but now in the
opposite direction
Cage must stop at
the next landing in
the direction of
travel.

NOTE : At the top and
bottom landing, no signal
is required from the the
0-button (STOP NEXT
LANDING) to stop the
elevator. The elevator
stops automatically due
to the top and bottom
limit cams.

5.0 Check for
travel speed
Before start of test,
check and record voltage
and frequency of
incoming power supply

a) Start from ground
landing and operate
the UP button

b) Start a Stop Watch
when cage is in line
with first landing


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Sub-Section IIB-01
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Sl.
No.
NAME OF
THE TEST
PROCEDURE EXPECTED
RESULTS
REMARKS
/RESULT
OBTAINED
c) Stop the Stop Watch
with second landing
and note the timing.
Press Emergency
Stop button
The rated travel
speed should
be checked at
415 V, 50 Hz
and should be
as specified

d) Release Emergency
Stop button and
press DOWN button.

e) Start the Stop watch
with second landing

f) Stop the Stop Watch
with first landing and
note the timing.
Continue to ground
landing where cage
will automatically stop.
Calculate travel speed
by the formula :

Speed = Distance (m) / Time (minutes)
N.B. The test may be repeated for longer travel distances
6.0 Checking of
Safety Devices
a) Electro-magnetic
brake and manual
brake release
operation during
power failure.
The Electro-
magnetic brake
and Manual
brake release
shall function as
per their design
and the brake
shall hold
without creep at
all levels.


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Sl.
No.
NAME OF THE
TEST
PROCEDURE EXPECTED
RESULTS
REMARKS
/RESULT
OBTAINED
b) Over travel switch Cage must stop
automatically at
Ground and
Top landings.

c) Reverse phase relay
operation
Lift will not start
in case of
reversal of
phase

d) Alarm at the basement Should operate
when button is
pressed in cage

e) Remote control for
testing the safety
devices as per
Technical
Specifications

7.0 Drop Test Make the test according
to suppliers procedure
Safety Device
should stop
cage in less
than 7 m. of
travel
Ensure that
no person is
present
inside the
cage during
the test.
Note : Remember to reset
the safety device after the
test has been carried out.

8.0 Measurement
of Power
Current and power
measurement by will be
carried out during elevator
movement upwards and
downwards in loaded
condition
Measured
current & power
will be within
the limits as
specified in the
Technical
Specifications.


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Sub-Section IIB-01
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Note : 1. All tests to be conducted with full load
2.Erection platform and erection crane to be removed before conducting
tests.
NTPC /Site Project Manager
--------------------------
Contractor
-----------------
Signature :
Name :
Designation :
Signature :
Name :
Designation :


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APPENDIX-I
GENERAL
PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY NTPC
1. Availability of adequate and uninterrupted supply of coal.
Specifications of coal as per N.I.T and as observed during the test shall be
recorded as per attached format (Appendix-IA).
2. Sufficiently empty bunkers to facilitate continuous tripper dumping of coal
during the test. Sufficient space in stockyard towards drive end of yard
conveyor during stacking. Sufficient heap of Coal towards tail end of yard
conveyor during reclaiming of Coal.
3. Uninterrupted power supply within specified parameters for the duration of
the test.
4. Belt protection switches, local stop push buttons, hooters, brakes/rail
clamps in working order.
5. Adequate and uninterrupted water supply.
6. Plant communication system
7. Proper lubrication and oil level of all equipments.
8. Free rotation of idlers and pulleys.
9. Cleanliness of plant and removal of coal spillage at the start and during
Tests.
10. Power supply voltage and frequency shall be as per technical
specifications.
11. Availability of dry coal during testing of DS system

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APPENDIX-IA
COAL PARAMETERS
Project :
Package :
Date :

As specified, As observed
during the test
1. Size
2. HGI
3. Moisture
4. Shale and sand-stone content

NTPC Contractor


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APPENDIX-II
PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY
CONTRACTOR
1. Deputation of team to site to associate with the Guarantee tests,
2. Calibration of belt weigher scales and accuracy of same to be
demonstrated to NTPC.
3. Arrangement of wattmeters / energymeters calibrated and sealed from
approved Govt. test house or NTPC site laboratory. Arrangement of any
other instrument/ accessory for the test.
4. Proper adjustment of skirt boards and belt cleaners prior to the start of
tests.
5. Arrangement of calibrated equipments for measurement of vibration &
noise levels.
6. Protection Relays of LT/HT switchgears and all motor feeders shall be
checked.
7. Belt protection switches, local push buttons, hooters, brakes/rail clamps to
be in working order.
8. Free rotation of idlers and pulleys.
9. Protection relays of LT/HT switchgears and all motors/transformer feeders
to be checked.
10. Sufficient illumination.


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ANNEXURE IIA
FORMAT FOR SUBMISSION OF GUARANTEE TEST PROCEDURE
Clause No. as per
LOA/ Tech. Specs.
Provision of
LOA / Tech.
Specs.
Name and
Methodology of
Test proposed
by Vendor
NTPC
comments on
the tests
proposed by
vendor


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APPENDIX-III
GUARANTEE TEST PROFORMA
FLOW PATH CAPACITY TEST
Project :
Package :
Date :
1. Composition of Stream
i) Conveyor Nos.
ii) Stacker / Reclaimer
iii) Traveling Tripper Nos.
iv) Dust suppression pumps, service water pumps, Ventilation fan
drives.
v) ..........................
2. Location of Belt Weigher (s) :
3. Plant started (Time) :
4. Material started flowing over belt weigher (Time) :
5. Test period Completed (Time) :
6. Reading taken at three (3) minute intervals :

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Sl.No Time Flow Rate Totaliser

Total plant run time :
Average Flow Rate :

NTPC Contractor


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APPENDIX-IV
POWER MEASUREMENT
Project :
Package :
Date :
1. Equipment/Stream Composition :
2. Motor Description :
3. Sr. No. of meters used :
4. Date of Calibration of instrument and name of test house :
5. Multiplying factor (M.F.) of the wattmeter :
6. Wattmeter Readings (to be taken at 1 minute intervals) :
kw Reading
M.F.
Sl.
No.
Measure-
ment
Terminal
Location
Time Volta-
ge
(Volts)
Curre-
nt
(amps)
W1 W2
Total
(W1+W2)
MF kw

Remarks


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7. Energymeter Readings
Sl.
No.
Equip-
Ment
Time
Duration
Energymeter
Readings kwHr
Equipment kw
(R2-R1)/(t2-t1)
Remarks
Initial
t1 t1
Final t2 Initial
R1 R1
Final
R2

*Reason and duration for system trip/stop may be recorded in remarks column.
NTPC Contractor

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APPENDIX-V
VIBRATION LEVEL MEASUREMENTS
Project :
Package :
Date :
Time :
Details of vibration Level Meter
1. Make
2. Model & Sl.No.
3. Date of calibration with name of Test House
Sl.No Equipme Pick
*Point
Vibration level Amplitude/Velocity
Horizontal
Micron/
mm/ sec.
Vertical
micron/
mm/sec.
Axial
Micron /
mm/sec.

* Reading shall be taken at all the bearings of motor, gear box and driven
equipment. In case of conveyor galleries, vibrations shall be measured at
min. three locations, at midpoint of stringer between two short supports.
NTPC Contractor

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APPENDIX-VI
NOISE LEVEL MEASUREMENT
Project :
Package :
Date :
Details of Sound Level Meter
1. Make
2. Model
3. Date of calibration with name of Test House
Sl.No. Equipment
with location
Equipment
load/capacity
Measurement*
point no.

Sound
level
dBA.
Remarks

NTPC Contractor
* For each equipment location, a Projected Plan Diagram shall be made and the
location of measurement points shall be identified.

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APPENDIX-VII
PROFORMA FOR POWER MEASUREMENT OF STACKER AND RECLAIMER
1. Stream composition
2. Description of following Motors
a) Boom Conveyor
b) Bucket Wheel
c) Long Travel
d) Main Hydraulic Pump
3. Sr. No. of Energy meter used
4. Date of Calibration of instrument and name of test house.
5. Multiplying factor of Energy Meter.
6. Energymeter Readings (to be taken at H. SWGR. FDR of S/R OR In
comer of MCC on S/R)
Sl.
No.
Equipment Time Duration Energymeter
Readings
KWHR
Equipment
KW
Remarks
Intial
T1
Final T2 Intial
R1
Final
R2
(R2-R1) / (T2-T1)

Reason and duration for trip/ stop may be recorded in remarks
Sd/ Sd/
NTPC CONTRACTOR


SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIB-01
PG Test Procedure
Page
28 of 28

APPENDIX - VIII

DUST SUPPRESSION SYSTEM

Fixing of acceptance criteria of ambient air quality

Acceptance criteria of ambient air quality shall be considered with respect to
respirable dust only. Respirable dust is defined as particles having particle size
less than 10 microns meter (Not even equal to 10 microns meter).

The particle size analysis of dust at any one of the DS area shall be carried out
as a sample by placing the High Volume Sampler in the designated test point
(1.5 to 3 M radius of application point) for a period of 4 hours without the DS
system in operation under load.

The sample thus collected will be subjected to the particle size analysis by sieve
Analysis method as a standard test laboratory.

The quantity respirable dust shall thus be determined from particle size Analyser.

Percentage of quartz in respirable dust will be determined by X-ray diffraction.

Acceptable Norms :

i) If the respirable dust fraction contain less than 5% quartz. The
permissible concentration of respirabie dust shall be less than 2 Mg/M
3
.

ii) In case, respirable dust has more than 5% quartz, the permissible
concentration of respirable dust shall be computed as per following
formula.

Threshold limit value for respirable coal dust in work environment (Mg/M
3
)

10
=
(% Quartz in resp. Dust +2)

iii) % Quartz shall be determined by X-ray diffraction.

TEST METHOD (Testing shall not be done during Monsoon)

For determining the ambient respirable dust level average 4 hourly sample
reading shall be taken with high volume sampler at each test point (1.5 to 3
Metre radius of application point) with DS system and material handling system
in operation on load. The average of three such readings shall be taken for each
test point to compute the respirable dust level. Respirable dust level will be
determined by analysis of the sample using sieve analyzer.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-A

PART- A
SUB-SECTI ON-I I C-01
SPARES
CLAUSE NO. SPARES

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIC-01
Spares
Page
1 of 3

SPARES

1.00.00 GENERAL

The Contractor shall include in his scope of supply all the necessary Mandatory
spares, start up and commissioning spares and recommended spares and
indicates these in the relevant schedules of the Bid Form and Price Schedules.
The general requirements pertaining to the supply of these spares have been
described in the following paras.

2.00.00 MANDATORY SPARES

(a.) The list of mandatory spares considered essential by the Employer is
indicated in section VI, part-F. The Bidder shall indicate the prices for each
and every item (except for items not applicable to the Bidders design) in the
Schedule of mandatory Spares whether or not he considers it necessary for
the Employer to have such spares. If the Bidder fails to comply with the
above or fails to quote the price of any spare item, the cost of such spares
shall be deemed to be included in the bid price unless the bidder specifies
"not applicable" for the type of equipment/system offered by him. However
during execution if such spares are found to be applicable, the Contractor
shall supply them without extra cost to the Employer. The Bidder shall
furnish the population per unit of each item in the Bid Forms and Price
Schedules. Whenever the quantity is mentioned in sets the Bidder has to
give the item details and prices of each item.

(b.) Whenever the quantity is indicated as a percentage, it shall mean percentage
of total population of that item in this Project, unless specified otherwise, and
the fraction will be rounded off to the next higher whole number. Wherever
the requirement has been specified as a set it will include the total
requirement of the item for a unit, module or the station or as specified.
Where it is not specified a set it will include the total requirement of the item
for a unit, module or the station or a as specified. Where it is not specified a
set would mean the requirement for the single equipment/system as the
case may be. Also one set for the particular equipment. e.g. set of bearings
for a pump would include the total number of bearings in a pump. Also the
set would include all components required to replace the item; for example,
a set of bearings shall include all hardware normally required while replacing
the bearings.

(c.) The Employer reserves the right to increase/decrease the quantity or delete
any of the mandatory spares parts.

(d.) The prices of mandatory spares indicated by the Bidder in the Price
Schedules shall be used for bid evaluation purposes.

(e.) All mandatory spares shall be delivered at site at least two months before
scheduled date of initial operation of the first unit. However, spares shall not
be dispatched before dispatch of corresponding main equipments.

(f.) Wherever quantity is specified both as a percentage and a value, the
Contractor has to supply the higher quantity until and unless specified
otherwise.
CLAUSE NO. SPARES

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIC-01
Spares
Page
2 of 3

3.00.00 RECOMMENDED SPARES

(a.) In addition to the spare parts mentioned above, the contractor shall also
provide a list of recommended spares for 3 years of normal operation of the
plant and indicate the list and total prices in relevant schedule of the Bid
Form and Price Schedules. This list shall take into consideration the
mandatory spares specified in this Section-VI, part-F and should be
independent of the list of the mandatory spares. The Employer reserves the
right to buy any or all of the recommended spares. The recommended
spares shall be delivered at project site at least two months before the
scheduled date of initial operation of first unit. However, the spares shall not
be dispatched before the dispatch of the main equipment.

(b.) Price of recommended spares will not be used for evaluation of the bids.
The price of these spares will remain valid upto 6 months after placement of
Notification of Award for the main equipment during which the Contractor
shall provide necessary justification for the quoted prices for these spares.
However, if the Contractor fails to provide the aforesaid justification of the
quoted prices, the prices of recommended spare shall remain valid for 3
months from the last date of providing such justification to the satisfaction of
the Employer.

4.00.00 START-UP & COMMISSIONING SPARES

Start-up and commissioning spares are those spares which may be required
during the start-up and commissioning of the equipment/system. All spares used
till the plant is handed over to the Employer shall come under this category. The
Contractor shall provide for an adequate stock of such start up and commissioning
spares to be brought by him to the site for the plant erection and commissioning.
They must be available at site before the equipments are energized. The unused
spares, if any, should be removed from there only after the issue of Taking Over
certificate. All start up spares which remain unused at the time shall remain the
property of the Contractor.

5.00.00 COMMON REQUIREMENTS:

5.01.00 The Contractor shall include in his scope of supply all the necessary Mandatory
spares, start up and commissioning spares and recommended spares and
indicates these in the relevant schedules of the Bid Form and Price Schedules.
The general requirements pertaining to the supply of these spares is given below.

5.02.00 The Contractor shall indicate the service expectancy period for the spares parts
(both mandatory and recommended) under normal operating conditions before
replacement is necessary.

5.03.00 All spares supplied under this contract shall be strictly interchangeable with the
parts for which they are intended for replacements. The spares shall be treated
and packed for long storage under the climatic conditions prevailing at the site e.g.
small items shall be packed in sealed transparent plastic with desecrator packs as
necessary.

CLAUSE NO. SPARES

SECTION VI, PART-A
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIC-01
Spares
Page
3 of 3

5.04.00 All the spares (both recommended and mandatory) shall be manufactured
alongwith the main equipment components as a continuous operation as per same
specification and quality plan.

5.05.00 The contractor will provide Employer with cross-sectional drawings, catalogues,
assembly drawings and other relevant documents so as to enable the Employer to
identify and finalise order for recommended spares.

5.06.00 Each spares part shall be clearly marked or labeled on the outside of the packing
with its description. When more than one spares part is packed in a single case, a
general description of the content shall be shown on the outside of such case and
a detailed list enclosed. All cases, containers and other packages must be
suitably marked and numbered for the purposes of identification.

5.07.00 All cases, containers or other packages are to be opened for such examination as
may be considered necessary by the Employer.

5.08.00 The contractor will provide the Employer with all the addresses and particulars of
his sub suppliers while placing the order on vendors for
items/components/equipments covered under the contract and will further ensure
with his vendors that the Employer, if so desires, will have the right to place order
for spares directly on them on mutually agreed terms based on offers of such
Contractors.

5.09.00 The Contractor shall warrant that all spares supplied will be new and in
accordance with the contract Documents and will be free from defects in design,
material and workmanship.

5.10.00 In addition to the recommended spares listed by the contractor, if the Employer
further identifies certain particular items of spares, the contractor shall submit the
prices and delivery quotation for such spares within 30 days of receipt of such
request with a validity period of 6 months for consideration by the Employer and
placement of order for additional spares if the Employer so desires.

5.11.00 The Contractor shall guarantee the long term availability of spares to the Employer
for the full life of the equipment covered under the contract. The Contractor shall
guarantee that before going out of production of spares parts of the equipment
covered under the Contract, he shall give the Employer atleast 2 years advance
notice so that the latter may order his bulk requirement of spares, if he so desires.
The same provision will also be applicable to sub-contractors. Further, in case of
discontinuance of manufacture of any spares by the Contractor and/or his sub
contractors, Contractor will provide the Employer, two years in advance, with full
manufacturing drawings, material specifications and technical information including
information on alternative equivalent makes required by the Employer for the
purpose of manufacture/procurement of such items.

5.12.00 In case of equipment supplied with grease/lubricants from imported origin, the
supplier shall clearly indicate the indigenous equivalent of the grease/lubricant and
source of supply so as to enable the Employer to procure these items from
indigenous sources.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART B
MECHANI CAL

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B
SUB-SECTI ON-I I I A-01
SYSTEM PARAMETERS AND OPERATION
& CONTROL PHILOSOPHY

CLAUSE NO.
TECHNICAL REQUIREMENTS


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section - IIIA-01
CHP

Page
1 of 20

A-01 : SYSTEM PARAMETERS AND OPERATION &
CONTROL PHILOSOPHY

1.00.00. The specifications as brought out in various Sub-sections for mechanical equipment
shall be applicable to the system of proposed coal handling plant and specifically to
all mechanical including their operation & control philosophy. However, some specific
parameters of the entire system as a whole and the major equipment are brought out
as under.

2.00.00 PARAMETERS

2.01.00 Conveyor System

i. Rated Capacity (Guaranteed)

(a) For conveyor 1A/1B, 2, 3, 4, 15A/15B & 16A/16B : 4000 TPH

(b) For balance conveyors of proposed CHP : 2400 TPH

(c) For conveyor 6A/6B and reversible belt feeder RBF-1 & 2 : 2000 TPH

ii. Design capacity

(a) For conveyor 1A/1B, 2, 3, 4, 15A/15B & 16A/16B : 4400 TPH

(b) For balance conveyors of proposed CHP : 2640 TPH

(c) For boom conveyor of stacker machine : 4400 TPH

(d) For boom conveyor of reclaimer machine : 3000 TPH

(e) For conveyor 6A/6B and reversible belt feeder RBF-1 & 2 : 2200 TPH

iii. Belt width

(a) For 4000 TPH : Minimum 2200 mm

(b) For 2400 TPH & 2000 TPH : Minimum 1800 mm

iv. Maximum Belt speed

(a) For 4000 TPH : 3.4 M/sec.

(b) For 2400 TPH & 2000 TPH : 3.2 M/sec.

2.01.01 Belting and Pulleys

(a.) Belt ratings shall be selected in such a way that there are only three (3) ratings
of belting for each belt width. This however excludes sealing belt (for sealing
slots of tripper floor) and belting of belt feeders.

(b) Minimum number of plies for belting shall be four (4). Other details of belting
shall be as specified else where in the specification.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
2 of 20

(c) For Pulley, following minimum parameters shall be followed:
(1.) Shell thickness : 20 mm (Min.)

(2.) End disc plate thickness : 30 mm (Min.)

(3.) Maximum allowable deflection of shaft at hubs : 5 Minutes

(4.) Diameter :

(i) All drive pulleys : 800 dia (min.)

(ii) All balance pulleys : 630 dia (min)

Further approval from belt manufacturers shall be obtained by the contractor
regarding the adequacy of the pulley diameters.

2.01.02 Coal Crushers & Vibrating Screen Feeders

(a) Nos. required : Two (2) each

(b) Guaranteed (rated) capacity
(considering 100% feed coal
above (+)20 mm size) : 2000 MTPH

(c.) Input size (for sizing of crusher) : (-) 100 mm (occasionally
1-2% 150 mm lump)

(d) Guaranteed size of output from : Min 98% down to (-)20 mm
Ring Granulator type crusher

2.01.03 Travelling Trippers (Mobile)

(a) Nos. required : Six (6)

(b) Type : Motor driven rail mounted,
3-way chute discharge

(a) No. required : Two (2) nos. stackers

: Two (2) nos. reclaimers

(b) Rated Capacity (Guaranteed)

(i) Stackers : 4000 TPH

(ii) Reclaimers : 2400 TPH

(c) Design Capacity (With specified
degree of bucket fill and ring volume

(i) Stacking : 4400 TPH

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
3 of 20

(ii) Reclaiming (Peak) : 3000 TPH

(d) Height of stockpile to be formed : 10 meters

(e) Width of each stockpile at base : 50 meters

(f) Boom length (Center of slew to center
Of bucket wheel) : 41 meters

(g) Lump size to be handled : (-) 20 mm

2.01.05 Dust Control System

The capacity of the dust control system specified hereinafter is for Contractors
guidance only. Contractor shall provide adequately sized and fool proof dust control
system, the performance of which should be guaranteed by the Contractor as
required in the Technical specifications. The performance guarantee test procedure
is to be submitted by the Contractor. However, the capacity of the offered system
shall not be less than the specified values below.

(a ) Dust Suppression System (Dry fog type)

(1) Operation : Water & air sprayed by fogging nozzle

(2) Location of spray : At all Coal discharge & receipt points
all transfer points & crusher house.

(3) Capacity / pressure at : 0.5 Kg/cm
2
for water (min)
Inlet of spray head 5.0 Kg/cm
2
for air (min)

(b) Stockyard Dust Suppression System

(1) Maximum number of nozzles : 1 no. per stock pile
operating simultaneously (2 nos. nozzles per each working stockyard
dust suppression pump)

(2) Capacity & Pressure of each : 500 Lpm / 4.5 kg./ sqcm (g)
spray nozzle

(c) Dust extraction system

Type : Venturi scrubber type

2.01.06 Service Water System

Service water connections are to be provided in conveyor galleries & tunnels at 50
meter interval and one (1) no. on each floor of Transfer Points and minimum two (2)
nos. on each floor of crusher house.

(a.) Flow at each valve : 5 cub.m/hr

(b.) Minimum discharge
Pressure at tap point : 2 kg/sq.cm
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
4 of 20

(c) No. of valves operated : 6 nos. for each working service water pump
simultaneously

2.01.07 Potable Water System : As specified elsewhere in the spec.

2.01.08 Ventilation System

A Mechanical Ventilation System: Minimum 10 supply air changes per hour.

B. Pressurized Ventilation System: Minimum 15 supply air changes per hour

C. Air Conditioning System : Adequate number of air changes to
maintain in uniform temp. & humidity as
specified elsewhere.
2.01.09 Chutes
Minimum clear cross section of chute shall be 1600 mm x 1200 mm and 1800 mm x
1400 mm (inside both ways) for 2400 TPH and 4000 TPH respectively.
2.01.10 Hoists
Suitable hoists as specified elsewhere shall be provided for erection & servicing of all
major equipment. The equipment to be covered shall include (but not limit to) all
conveyor drive units, all pulleys, crushers along with drive units, in line magnetic
separators, sampling units, various DS/service water/potable water pumps, gravity
take up units, lifting of belt drum at all transfer houses/crusher house/bunker floors
etc.
2.01.11 All other equipment under the scope shall be suitable to the system capacities
parameters as specified above.
3.00.00 OPERATION AND CONTROLS
3.01.00 This section is intended to cover control/instrumentation and operational philosophy
as specified hereinafter complete in all respects, required for complete coal handling
plant.
3.02.00 General Requirements
The instruments and controls to be furnished and erected under this specification are
as required for safe and satisfactory operation of the Coal Handling System, as
outlined under mechanical section and as specified elsewhere in the specification.
For the equipment and materials procured by the Contractor from his sub-vendors,
the Contractor shall study the specification, safety requirements, interface drawings
for such equipment and material in detail and shall coordinate his work with his sub
vendors and Employers DDCMIS system and supply instrumentation and control to
suit the actual Coal Handling equipment.
3.02.01 Standards / Codes
All construction, installation, workmanship, design & equipment shall conform to acts,
rules & regulations of the jurisdiction within which the project is to be located, and to
the current edition of the following or equivalent standards or codes, in so far as they
apply :
American Iron & Steel Institute (AISI)

American Society for Mech. Engineers (ASME)
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
5 of 20

American Society for Testing & Materials (ASTM)

American Wire Gauge (AWG)

Institute of Electrical & Electronic Engrs. (IEEE)

Instrument society of America (ISA)

National Electrical Code (NEC)

National Electrical Manufacturers Association (NEMA)

United States of America standards (USAS)

Bureau of Indian Standards (BIS)

Conveyor Equipment Manufacturers Association (CEMA)

3.02.02 This Sub-section shall be read in conjunction with Electrical Sub-sections.
3.03.00 General Construction and Design
3.03.01 General Construction
Control desks/panels and annunciation system shall be as per the requirement of
electrical Section. Annunciations, indications, electrical meters and instrumentation
shall be provided as specified.
3.03.02 Design
The complete coal handling plant except for stacker-reclaimer and wagon tippler
shall be controlled from Employers DDCMIS system as detailed elsewhere.
The Contractor shall provide a comprehensive control indication and annunciation
scheme. Contractor shall furnish block diagram and write-up on the scheme
proposed. The final scheme will be approved by the Employer. In general,
interlocking shall be achieved through feed-back signals from field equipment.
Comprehensive Annunciation and Indication scheme shall be provided such that, it
will be possible for the operator to locate and identify the fault from the face of
DDCMIS/LVS/Control-Panel/ CRT itself. The scheme shall include the basic remote
control instrumentation, indication and annunciation requirements as per various
technical specification requirements. Analogue ammeters shall be provided for
conveyors, crushers, belt feeders, VSF on the control desk in CHP control room.
However, the Contractor may offer any alternative proposal which he considers to be
equal, superior to the scheme as described in subsequent clauses below for
achieving reliable and trouble free operation of the plant, for consideration of the
employer.
4.00.00 OPERATION AND CONTROL PHILOSOPHY

The coal handling system shall be controlled from the following control points.

4.01.00 Coal Handling Plant Main Control Room

Overall, operation of the following equipment of Coal Handling Plant shall be
controlled from the main CHP control room.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
6 of 20

(a.) Conveyors, feeders, flap gates, R & P gates, crushers, hydraulic scoop
couplings.

(b.) Complete Dust Suppression system & service water system.

(c.) Ventilation system (group/individual control as required).

(d.) In line Magnetic separators (ON/OFF control with indication).

(e.) Metal Detectors (ON/OFF control with indication).

(f.) Coal Sampling Units.

(g.) Belt weigher (ON/OFF control with indication)

(h.) Stackers and Reclaimers (ON/OFF status with stop facilities).

(i.) Mobile trippers over bunkers (tripper position indications).

4.02.00 Local Control Panels

Local control stations for following equipments shall be provided

(a) Mobile trippers over bunkers

(b) Belt Weighers

(c) Metal detectors

(d) Electric hoist - wall mounted control box with pendent push button controls.

(e) In line magnetic separators

(f) Coal Sampling Units

(g) Hydraulic scoop coupling.

All the above local control panels shall be accessible and located near their
respective equipment and shall be complete with all the required controls, interlocks,
annunciations etc. However, for items (i.), (j) and (k) above, controls shall be through
Employers DCS as applicable. Further, necessary controls, indications and
annunciations for all the above equipment shall also be provided at main CHP
Control Room as described under relevant clause.

In addition to the remote control of various equipments, local stop push button
stations shall be provided for all equipment.

4.02.01 Stacker / Reclaimer Control Room

The entire control & operation of each Stacker and each Reclaimer machines shall
be from the operators cabin on the machine itself. LCD screens shall be provided at
the Control desk of the operators cabin.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
7 of 20

4.03.00 In addition to the remote control of various equipment, local stop push button stations
shall be provided for all equipment.

4.04.00 System Operation

4.04.01 Operation philosophy of the plant, in general, shall be as elaborated below:

(a.) Coal flow path selection shall be done from LCD screen/Keyboard to select
any one of the following conveying paths.

(1.) Conveyor 1A/1B to boiler bunker
(2.) Conveyor 1A/1B to stock yard
(3.) Stock yard to boiler bunkers
(4) Combination of above

The coal handling system operator will select any one of the above paths from OWS
located on the main control desk. The flow stream path is then selected by
positioning different flap gates/ movable discharge pulley at desired positions by
means of keyboard available at the central control desk. Once the system is in the
operation, the gates/ movable discharge pulley can not be moved from their positions
and path. Flap gates which do not come in the stream in which coal flow is taking
place, can be operated at any time. However, for the flap gates in bunker area
conveyors, it shall be possible to change flap gate position while the conveyor is in
operation and feeding coal using interlock bypass facility, provided that sequential
permissive are available.

The Control system will be designed for Auto & Manual operation of the conveyors
in the selected path. Auto/Manual Selection shall be done from keyboard.

Auto Mode : In the Auto mode, the conveyors and related equipment will start
sequentially when the System Start is activated. During stopping, when the System
Stop is activated, all conveyors will also stop sequentially (in the reverse sequence)
allowing time delays for clearing the belts.

Manual Mode : In Manual Mode, the operator will start the conveyor system, in the
same sequence as in Auto mode from keyboard. The operator will also stop the
conveyor system, by pressing "System stop" or individual Stop push
buttons/command from keyboard in the reverse sequence.

During Sequence Start in both Auto and Manual modes, first the required number of
hooters (3 phase induction motor type) will be energized simultaneously for a preset
time of 1 minute or so (adjustable at site) as per the program. After the preset time,
the hooters will stop and a preset time of two minutes (adjustable at site) as per
program will be allowed for the movement of the personnel and for the permissive of
the conveyor system operation. This condition will be indicated on the panel by
glowing of lamp Coal Handling Sequence Start. The starting permissive will be
available for a period of 5 minutes (Pre-programmed and adjustable in the field). In
the event the last conveyor / equipment is not started within this preset time of 5
minutes, the start command for equipment not started will be withdrawn. The system
cannot be started again unless the Sequence Start push button is again pressed
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
8 of 20

and the hooters sound again, as described before. Those conveyors and equipment,
which have already started, will continue to run.

The status indication in the graphic display against all conveyors and equipment in
the selected path/stream will start slow flickering. However, all status indications
against all flap gates / movable discharge pulley in the selected path will glow
steadily. Therefore, from the selected flow stream path of the flap gates / movable
discharge pulley, the operator will come to know the conveyors and equipment to be
started for the selected path/stream. After a conveyor/equipment is started, the
status indications against that conveyor / equipment will change to steady glow
indicating that it is running.

Graphic display status indicators associated with a particular motor/equipment shall
flicker fast in case of fault / trip.

In addition, emergency stop push button on the control desk for immediate shut down
of complete plant shall be available.

For changeover of feed from one row of Bunkers to another row of Bunkers without
stopping of the CHP, provision shall be made for interlock bypass on the control desk
for flap gates of all conveyors in Boiler area for a preset period. If the changeover, in
above specified time, is not completed then the entire CHP shall stop.

4.05.00 Conveyor System

(a) Each conveyor shall be protected against damage to the edge of the belt due
to excessive sideways movement by providing an adequate number of belt
sway switches. In addition, each conveyor shall be provided with one (1) No.
speed detection device (zero speed switch). The zero speed switches shall
be designed to sense belt speed. In case of speed of belt goes below 85% of
rated speed, it shall trip the conveyor.

(b) All the conveyors shall be protected from reverse running due to power failure
by providing mechanical or electrical locking system.

(c) The starting sequence of the conveyors shall follow a direction opposite to
that of flow of material i.e. :

(1.) In case of direct conveying of coal to boiler bunkers, start from bunker
conveyor and end up with reclaim conveyors

(2.) In case of stacking of coal in stock yard, start from yard conveyor and
end up with reclaim conveyors. However, for yard conveyor to start,
the stacker or reclaimer shall be in operation.

(3.) In case of reclamation of coal from stock yard, start from bunker
conveyors and end up with yard conveyor alongwith Reclaimer.

(4.) The starting of mobile trippers shall be interlocked with operation of
the bunker bay conveyors.

(d) Inter locking of yard conveyor with stacker and reclaimer boom conveyor shall
be provided.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
9 of 20

(e) Any individual equipment (belt conveyor etc.) should not be allowed to start
unless the equipment immediately following the same in the direction of flow of
material is already in operation.

(f) Stop/tripping of any equipment from running condition shall trip all preceding
equipment in the system, except crushers but shall not effect succeeding ones
which shall continue to operate.

(g) Adequate number of pull-cord switches shall be provided at suitable intervals
along the length of each belt conveyor, which shall enable the respective
conveyor to be stopped immediately. Each pull chord switch shall be identified
by a specific number on HMI in the main control room. Each belt sway switch
shall also be identified by a specific number on HMI in main control room.

(h) Means shall be provided to pre-warn personnel working nearby when starting
any conveyor, stacker, reclaimer and mobile tripper.

(i) Interlocking of various conveyors shall be achieved with Flap Gate, discharge
pulleys, Rack & Pinion gate, limit switches and zero speed switches.

(j) Motors shall start only when the brake/rail clamp if-provided, is in not
appliedcondition. This signal shall be obtained from limit switch provided for
that purpose.

(k) Ring granulators shall be provided with speed and vibration monitoring
instruments. Ring granulators shall trip in case speed/ vibration is going
beyond tolerable limits of design. Temperature sensing devices shall be
installed on all bearings of each of the ring granulator to trip the ring granulator
in case of temperature goes beyond limit. Audio-visual annunciation shall be
provided in main control room and locally also.

(l) Once a conveyor trips, flap gate directing coal from this conveyor shall change
over its position with a time delay and shall come back to the original position
again. This is to prevent jamming of gate.

(m) Tripping of the respective conveyor shall be provided in case any of mobile
trippers starts running along with conveyor belt at speed higher than their rated
speed by providing an over speed sensing device on the equipment.

(n) It shall be possible to trip bunker conveyor and yard conveyor from mobile
tripper and stackers / reclaimers respectively.

(o) Where ever scoop type coupling provided for HT motors, the coasting time of
respective conveyor, thrustor brake, actuator selection and the chute size shall
be so selected such that there is no spillage of coal from any down stream
conveyors during next start. If required necessary fly wheel may also be
provided in the down stream Conveyor to restrict the speed.

(p) Wherever the conveyor/belt feeder is provided with the movable discharge
pulleys in place of flap gates, the starting of the conveyor/belt feeder will be
interlocked with the position of the movable discharge pulley.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
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(q) Control system shall envisage blending of coal. For this blending can be
considered by suitably mixing of coal reclaimed by two reclaimers. Suitable
block logic shall be furnished by the bidder for incorporation in Employers
control system.

4.06.00 Interlocking

(a.) The following conveyors / equipment will come under interlock scheme :-

(1.) All conveyors
(2.) All flap gates
(3) Rack & Pinion Gates

(4) Metal detectors

(5) Magnetic Separators

(6) Crushers

(7) Belt scale

(8) Mobile Trippers

(9) Stackers and Reclaimers

(b.) The following equipment will not come under interlock of the conveyor
scheme.
(1.) All dust suppression systems & service water system.
(2.) Ventilation systems
(c.) All conveyors and equipment will have local push button stations each
consisting of :
(1.) Pos - I, Pos - II & stop button for flap gate and R & P gate
(2.) Emergency stop push button (Red) for other equipment
(d.) Belt scale shall be started when relevant conveyors are started.
(e.) The dust suppression systems will be energized as soon as the conveyors
are energized.
(f.) Coal handling plant shall be tripped in case of detection of fire.
(g.) Interlock for H.T. Motor :

H.T. motors used will continue to run on no load by disengaging the fluid
coupling in case of failure of any process interlock. The H.T. motors will
however be tripped in case of any motor fault like O/L, high motor winding
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
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temperature etc. In addition, in case of normal stop command, after running of
the system, motors will stop.

(h.) The following are the various safety interlocks for the conveyors and other
equipment. This list is indicative only and the Contractor shall develop a
comprehensive interlocking scheme.

Conveyors
a). Pull - Chord switch - not operated
b). Belt sway switch - not operated
c). Under speed switch - closed at 90% speed of the conveyor within designed
accelerating time.
d). Motor protection - not tripped
e). Local stop PB reset
f). Chute Block switch - not operated.
g). Brakes for conveyor not operated.
h). Trip circuits healthy.
i). Temp. of fluid coupling oil - not high
Travelling Tripper:
a). Stop PB in Local control station - reset
b). Motor O/L not tripped.
c). Over Travel Limit switches - not tripped.
Magnetic Separators / Metal Detectors
a). O/L / fault relay - not tripped.
b). Stop PB (Local & Remote) reset.
c). Metal detector reset
d). Oil temperature - not high
Flap Gates/ R & P Gates:
a). End of travel limit switches - reset.
b). Torque limit switches - reset.
c). Local stop - reset.
Ring Granulator
a). Zero speed - not operated
b). Temp. of fluid coupling oil - not high.
c). Local stop push button reset.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
12 of 20

d). Temperature of bearings not high.

e). Cooling water flow switch - reset

4.06.01 The lists of indications and audio-visual annunciation given in subsequent clauses
are indicative only and the same shall be finalised during detail engineering.
4.06.02 Status indications in Large Video Screen

Following individual status indications shall be provided in LVS with individual
ON/OFF/TRIP indications on CRT.

(a.) Conveyor 'ON'

(b.) Flap Gate/Rack and Pinion.

(c.) Belt scale flow rate indication and totalizer.

(d.) Belt sway switch operated for each conveyor (individual switch indication on
CRT).

(e.) Pull cord switch operated for each conveyor (Individual switches indication on
CRT).

(f.) Zero speed switch operated for each conveyor

(g.) Travelling tripper position.

(h.) Crusher ON

(i.) MD/ ILMS/ CSU ON

(j.) DS/ SW/ Vent ON (System wise)

(k.) Stackers and reclaimers ON (any travel position)/stacking/reclaiming

(l.) Unit wise MW indication, total coalflow & Bunker level.

Further Mimic lamps for HT and LT SLDs shall be provided on the control desk.

4.07.00 Annunciation System:

Following annunciations shall be provided on OWS.

(a) 33 KV & 3.3 kV Breaker Trip (Group wise for each board)

(b) 415 V MCC Breaker Trip (MCC wise)

(c) Bus under voltage for each LT MCC & HT switchgear buses.

(d) Following group wise annunciation shall be provided for transformers :

(1.) Buchholz alarm
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
13 of 20

(2.) Winding/oil temperature high alarm

(3.) Oil level low alarm

(4.) Buchholz trip

(5.) Winding/oil temperature high trip

(e) A.C Control Supply failure.

(f) D.C. Control Supply failure.

(g) Annunciation supply failure.

(h) Both CPU fail

(i) Stand by CPU in service

(j) H.T. motor overload alarm (individual)

(k) HT motor bearing/ winding temp. high alarm (for each) and trip (for each)

(l) HT motor trip on electrical fault (for each)

(m) LT motor overload tripped (for each).

(n) Crusher vibration monitor alarm (for each).

(o) Belt sway switch operated (for each)

(p) Pull cord switch operated (for each)

(q) Zero speed switch operated. (for each)

(r) Chute plugged (for each)

(s) Tripper over speed tripped (for each)

(t) Stacker/ reclaimer tripped (for each)

(u) Magnetic separator fault and cleaning belt trip.

(v) (i) Metal Detector fault (for each)

(ii) Metal detected / MD not reset (for each)

(w) Belt Scale fault (for each)
(x) Sampling system faults and trips (for each)
(ab) Dust suppression/service water system faults and trips (system wise)
(ac) Water level low in tanks (for each)
(ad) Oil temperature of fluid coupling high
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
14 of 20

(ae) Crusher low speed & crusher bearing temperature high.
For identification of the fault for a particular conveyor or equipment, status indication
against that conveyor / equipment in the mimic will start fast flickering and the
annunciation window will be blinking against that particular fault. In addition, a buzzer
(alarm) will start sounding. After acknowledgement of the fault, the buzzer will stop,
but the fast flickering on the mimic and the steady glow on the annunciation window
will continue until the fault is cleared and the Reset push button is pressed. When the
fault is cleared and the Reset push button is pressed, the status indication of that
conveyor / equipment on the mimic will start slow blinking if it is on selected path
otherwise it will go off and the steady glow in the annunciation window will go off.
However, pressing of the Reset push button before clearance of the fault, will have
no effect on the lamps.

At the time of a fault, the faulty conveyor / equipment, as well as the preceding
conveyors / equipment in the interlock sequence, will stop except H.T. motors for
which only scoop coupling will be disengaged and motor will continue to run for
process fault. In case of motor fault, H.T. motor will trip but the succeeding conveyors
/ equipment will continue to run. The status indication against the preceding
conveyors / equipment will start slow blinking while the faulty conveyor / equipment
will be fast blinking.

Start command shall not be initiated unless reset button in pressed after clearance of
fault.

The sequence of operation of the annunciation system shall be as follows :-

Condition Status
Normal : Ann. Window : Off.
Status indication : Steady glow
Buzzer : Off.
Fault : Ann. Window : Blinking.
Status indication : Fast blinking
Buzzer : Sounding.
Press
Accept. PB.
Ann. Window : Steady glow.
Status indication : Fast blinking
Buzzer : Off.
Press Reset
PB (When
Ann. Window : Off.
fault is
cleared):
Status indication : i) Steady blinking (if on
selected path)
ii) Off (if not on selected path)
Buzzer. : Off.


(a.) Conveyors / Equipment

(1.) It shall be possible to operate the dry fog system on to coal stream only
when corresponding conveyors/equipment are running with material at
spray application points.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
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(2.) If a running pump trips stand-by pump shall start automatically. It shall be
possible to select any of the pumps as auto standby from main CHP
control room.

(3.) Pump/pumps shall trip with a time delay, if discharge valves fail to open.
Suitable pressure/flow switch shall be provided to sense this condition.

(4.) Pumps shall trip in case of low level of water in tank.

(5.) All feeding pumps to tank shall trip in case of high pressure & no flow by
pressure switch.

(6.) Motorized inlet valve to dust suppression tanks shall close in case of
High-High level & open in case of low level.

(7.) All the controls shall be through DDCMIS.

(b.) Stock yard Dust suppression system

(1.) Water supply pumps shall be started in Manual mode from Main CHP
control room. Controls shall be through DDCMIS.

(2.) If any of the running pump/ pumps trip, standby pump/ pumps shall start
automatically (pressure switch signal shall not be used for this purpose).

(3.) Pumps shall trip in case of low level of water in tank.

(4.) All feeding pumps to tank shall trip in case of high level in tank

4.09.00 Metal detectors

(a) It shall be possible to start the conveyors only after energizing the metal
detector and Metal detector reset condition. Once the metal is detected, the
corresponding conveyor shall trip.

It shall be possible to restart the conveyors, after local resetting of metal
detector and putting back the marker bag in position. Metal detector ON/OFF
push buttons shall be provided in main control room also.

(b) In case of tripping of conveyor system, metal-detector shall get de-energized
after a time lag.

(c) Following individual indications shall be provided on local control panel.
(1) Metal detector ON
(2) Metal detected
(3) Metal detector 'reset'.
(4) Metal detector faulty.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
16 of 20

4.10.00 Coal Sampling system

(a) Coal Sampling Unit shall be controlled through main coal handling plant
DDCMIS. Controls and interlocks for proper material flow shall be provided
similar to conveyor system. Mimic shall be provided in the Operator Work
Station (OWS) at main CHP control room.

(b) Only one start/stop push button along with selector switches for various modes
of operation of coal sampling system shall be provided for automatic operation
of complete coal sampling system. This control facility shall be provided at main
CHP control desk as well as locally. In any case, local push button stations
shall be provided for all individual equipment of coal sampling system near the
equipment.

(c) All necessary automatic controls shall be provided for meeting the requirements
of ASTM-D-2234.

(d) Following indications shall be provided on local control panel

(1.) System ON/OFF/TRIP

(2.) Primary cutter stuck up between parking positions.

(e) In case of primary cutter getting stuck between parking positions, preceding
conveyor shall trip and annunciation shall appear at Main CHP Control room.

(f) There shall be protection in the primary coal sampler to trip the conveyor belt in
case primary sampler falls on running conveyor due to coupling failure etc.

Individual motor ON/OFF/TRIP indications shall be provided at main CHP
control room.

4.11.00 Mobile Trippers

(a) Mobile tripper unit shall be locally controlled from the operating platform suitably
located with the unit as per instructions given from main CHP control room.

(b) End travel limit switches shall also be provided.

(c) Travel drive motor shall start only when brake and rail clamps are in
disengaged condition.

(d) It shall be possible to trip the bunker Conveyors from tripper.

(e) When the last bunker is full, it shall not be possible to change over the tripper
flap gate from bunker feeding position to last bunker feeding position.

(f) As soon as the bunker conveyor trips, tripper flap gate shall change over its
position after a time lag.

(g) Two nos. emergency stop button one on each side shall be provided on tripper
to stop the machine at any position. The control unit on tripper shall be provided
with start / stop push button and indication lamp for travel / gate. The tripper
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
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brakes and rail clamps shall be energised (and released) when the tripper
motors are ON and the brakes will be applied when the travel motors are OFF.
Two travel limit switches shall be provided at either end of tripper carriage for
limiting the travel drive between two ends of the track. The first one shall be
normal limit and the second one for over travel limit. In addition to above,
position indication for bunker position of tripper will be provided in Main control
room. Necessary position encoders/ limit switches shall be provided. Over
speed protection for protection against dragging shall be provided.

(h) Following individual indications shall be provided on local control panel

(1.) Motor ON/OFF/TRIP
(2.) Brakes applied
(3.) Rail clamps applied
(4.) Flap gate position

(i) Indication of tripper flap gate positions shall be given in the main CHP control
room.

(j) It shall be possible for operator to manually trip the coal feeding eqpt. viz.
stacker / reclaimers from the tripper.

(k) Chute blockage switch shall be provided at each leg of chute and shall trip the
tripper conveyor in case of blockage.

4.12.00 Flap Gates/ R&P Gates
All Flap Gates/ R&P Gates shall be motorised with actuators and remote controlled
from the main control desk. Their position shall be indicated on the mimic of main
control room.

4.13.00 Belt Weighers

Each belt scale shall give output to Employers DCS for display of flow rate indicator
and totalizer on CRT and print out at main CHP control room. Each belt scale shall
also have rate flow indicator and totaliser mounted near the unit. Belt weighers shall
also be provided on Stackers and Reclaimers as described elsewhere in the
specification.

4.14.00 Magnetic separator

It shall be possible to start the conveyor only after energising the magnet of ILMS.
Further, if conveyor system trips magnetic separators shall get de-energised after a
time lag. Also if drive motor of cleated belt of ILMS trips, magnetic separator shall not
get de-energised, but conveyor system shall trip and audio-visual annunciation shall
appear at main CHP control room.

Following individual indications shall be provided on local control panel

(a.) Magnetic separator ON.
(b.) Incoming supply ON
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
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(c.) Under current relay operated
(d.) Cleated belt motor ON/OFF/TRIP
(e.) Oil temperature high
4.15.00 Service water, Cooling Water and potable water pumps

(a) These pumps shall be started from main CHP control room

(b) Pump shall trip in case of low water level in tank.

(c) Following individual inputs shall also be provided to DDCMIS system for
alarms/indications :

(1.) Motor ON/OFF/TRIP
(2.) Discharge water pressure low
(3.) Water level low in tank
(4.) Water level high in tank
4.16.00 Stacker and Reclaimer machines

(a) The Stacker and reclaimer shall be controlled from the operators cabin in their
machines through PLC system.

(b) Slew speed shall be controlled through Power transducers on Bucket wheel
drive motor for uniform feeding. Setting of Power transducer shall be done from
operators cabin.

(c) Slew reversal shall be automatic through

(1.) Power transducer on Bucket wheel and/or

(2.) Extreme end limit switches and/or

(3.) Manual command.

(d) At the end of Slew Pass Reclaimer drive shall advance automatically to
required depth of cut. Depth of cut shall be controlled through the setting of
power transducer on Bucket wheel. It shall also be possible to set the depth of
cut through a separate setting knob in operator cabin.
(e) All controls shall be based on feed back signals from field equipment.

(f) All electronic circuitry shall have self-diagnostic features.

(g) Operators cabin shall maintain horizontal level automatically as per Boom
Conveyor position.

(h) For all drives, zero speed shall be ensured before affecting reversal, by
providing suitable speed sensing device.

(i) Motors shall start on when the Brake and/or rail clamp, is in Not Applied
condition. This signal shall be obtained from limit switch provided for that
purpose.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
19 of 20

(j) If wind velocity is high, it shall cut off power supply to stackers and reclaimers
with a time delay, after giving sufficient time to operator to bring the Boom in
minimum wind pressure direction/ position.

(k) All sequential interlocks for proper material flow shall be provided.

(l) It shall be possible to operate the lubrication system from operators cabin.

(m) Manual - Local.

With the selector switch in this position all drive functions on the stackers and
reclaimers can be operated by push buttons local to the drives. All other
operation initiating devices shall be locked out.

(n) Manual Remote

Manual controls facility shall also be provided in control desk and keyboard
(operators cabin) as below :

(1.) Individual controls shall be provided for each equipment.

(2.) Manual slew speed variation and depth of cut setting facilities shall be
provided.

(o) Following minimum audio-visual annunciation shall be provided through integral
type annunciation system in operators cabin in stackers and reclaimers.
Annunciation system shall meet the requirements specified in the relevant
electrical sections.

(1.) Wind velocity high

(2.) Lubrication system trouble for slew drive

(3.) Lubrication system trouble for bucket wheel drive.

(4.) Hoisting system trouble.

(5.) Chute plugged

(6.) Coal flow rate high

(7.) Belt sway switch operated

(8.) Zero speed switch operated

(9.) Pull chord switch operated

(10.) Motor electrical protection operated (Individual)

(11.) For L.T. transformer Wind temp. high alarm and trip.

(12.) LT breaker tripped
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP

Page
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(13.) HT switch tripped

(14.) 20% spare windows.

(15.) Rail clamps of stackers and reclaimers not engaged.

(p) Following individual indications shall be provided in operators cabin and CRT

(1.) Motor ON / OFF / TRIP

(2.) Control supply healthy

(3.) All necessary position/motion/level indications

(q) Ammeters shall be provided in control desk for all the motors.

(r) Wind velocity indication shall be provided in operator's cabin.

(s) Contractor shall provide a comprehensive interlock and protection scheme and
include a block logic diagram and write up on the scheme proposed. The final
scheme shall be subject to approval of Employer. Sequential interlocking as
applicable shall be provided. This shall be a part of main interlock scheme
/writeup for the entire Coal Handling Plant.

(t) Boom conveyor shall be interlocked in such a way that it cannot start in
reclaiming mode unless yard conveyor is running. In addition, yard conveyor
would not start unless boom conveyor is running in stacking mode (with CHP in
stacking mode). Following indications shall also be provided in operators cabin.

(1.) Boom conveyor stacking

(2.) Boom conveyor reclaiming

For indications/interlocks indicated above, and for communication system
between stacker/ reclaimer and main control room, contractor shall provide all
necessary control cables.

(u) It shall be possible to trip stacker/ reclaimer from main CHP control room also.

(v) A push button shall be provided in operators cabin to trip the yard conveyor.

4.17.00 Logic diagram

The contractor shall furnish comprehensive logic diagram showing all interlock,
protection, sequence and alarm requirements of complete system to the employer
during detail engineering stage. In this logic diagram tag number corresponding to
I/O list and drive list shall be clearly indicated. The format of this logic diagram shall
be informed by employer during detail engineering. The recommended write-up and
logic diagram shall match fully.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
BRAKES & CLAMPS

CLAUSE NO. TECHNICAL REQUIREMENTS

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
Brakes and Clamps

Page 1 of 3

A-02: BRAKES AND CLAMPS

1.01.00 GENERAL

Brakes shall be provided for decelerating of driven equipment/conveyors as per
requirement.

Rail clamps shall be provided for various mobile machines traveling on rails.

1.01.01 STANDARDS

The design, manufacture, inspection and testing of Brakes & Clamps shall comply
with all the currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. The Brakes & Clamps shall conform
to the latest edition of the standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance, shall also be
accepted. Nothing in this specification shall be construed to relieve the contractor
of the required statutory responsibility. In case of any conflict in the standard and
this specification, the decision of the Employer shall be final and binding.

1.02.00 DESIGN REQUIREMENT

1.02.01 Electro Hydraulic Thruster Brakes/Disc Brakes

The necessary Electro Hydraulic Thruster (AC) brakes/disc brakes, totally
enclosed and fail safe, shall be provided as required for various equipments.
Braking torque shall be adjustable from 0 to 100% of rated braking torque. The
thruster brake shall be actuated by compression springs.

1.02.02 Clamps

1.02.03 Electro-hydraulic thruster and manual rail clamp shall be designed for holding the
machine stationary.

1.02.04 Electro-hydraulic thruster and manual rail clamp shall be actuated by compression
springs, the spring shall apply the clamping force directly on the Rail clamp
mechanism once power supply is cut-off. The force transmission mechanism from
spring to rail clamp faces shall be very simple with minimum linkages.

1.03.00 CONSTRUCTION REQUIREMENT

1.03.01 Thruster Brakes

1.03.02 The electro hydraulic thruster shall be fitted with the brake. Limit switches shall be
provided for brake applied/released positions. The windings shall be provided with
class-B insulation suitable for 415V 10% at 50 Hz 5% and combined variation
of 10%. Brake lining shall be asbestos with inter woven brass wires capable of
withstanding 200C temperature.

1.03.03 Clamps

1.03.04 Electro Hydraulic thruster shall be fitted directly above spring.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
Brakes and Clamps

Page 2 of 3

1.03.05 Rail clamp shall be provided between the two travel wheels. Further, limit switches
shall be provided for Rail clamp ENGAGED and DISENGAGED signals.

1.03.06 Minimum clearance between the Rail clamp face and rail surface shall be 50mm.
However, this clearance may not be uniform for both the faces of Rail clamp
throughout the length of rails. Rail clamp shall operate satisfactorily under this
condition without the need for any adjustments.

1.03.07 In addition to electro hydraulic thruster clamps, separate manual clamps for
stacker, reclaimer and traveling tripper shall also be provided.

SECTION VI, PART-B
BID DOC. NO: CS-0260-156-2(R)
Brakes and Clamps

Page
3 of 3

DATA SHEET: BRAKES AND CLAMPS

1.0.0 GENERAL

1.1.0 Brakes (i) For decelerating of conveyors
& rotating equipments.

(ii) Brakes are mandatory for H.T.
drives involving scoop type
coupling except crusher motor.

1.2.0 Rail Clamps For various mobile equipment
travelling on rails.

2.0.0 DESIGN & CONSTRUCTION REQUIREMENT

2.1.0 Brakes

2.1.1 Type Electro Hydraulic Thruster brakes A.C.
operated or Disc brakes.

2.1.2 Braking Torque Adjustable from 0 to 100% of rated
braking torque.

2.1.3 Brake Shoes Operated directly by spring

2.1.4 Shoe lining Asbestos with interwoven brass wires.

2.1.5 Max. Temperature for shoe lining 200 degree C.

2.1.6 Thrustor Class-B insulation, IP-65 protection.

2.2.0 Clamps

2.2.1 Rail Clamp support Independent from the rails.

2.2.2 Limit Switches ENGAGED & "DISENGAGED
signals.

2.2.3 Clearance between Rail clamp face
& Rail surface

Minimum 50 mm
2.2.4 Material for Rail clamp Mechanism Forged steel

2.2.5 Thruster Class-B insulation, IP-65 Protection

2.2.6 Type Electro hydraulic thruster and manual

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
MONORAILS AND HOISTS


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Monorails and Hoists

Page
1 of 6

A-03: MONORAILS AND HOISTS

1.01.00 GENERAL

Suitable handling arrangements shall be provided for all equipments included in
Contractors scope to transfer the equipment to maintenance area within the
building and/or to transfer the equipment outside the building upto ground level for
further transportation by the Employer. For this purpose Contractor shall provide
monorails and hoist blocks with cross travel facility.

1.01.01 CODES AND STANDARDS

The design, manufacture, inspection and testing of Monorails and Hoists shall
comply with all the currently applicable statutes, regulations and safety codes in
the locality where the equipment is to be installed. The Monorails & Hoists shall
conform to the latest edition of the following standards & codes. Other
internationally acceptable standards/codes, which ensure equal or higher
performance than those specified, shall also be accepted. Nothing in this
specification shall be construed to relieve the contractor of the required statutory
responsibility. In case of any conflict in the standard and this specification, the
decision of the Employer shall be final and binding.

IS:3938 : Specification for Electric Wire Rope Hoist

IS:3832 : Chain pulley blocks

IS:2429 : Round steel short link chain

IS:6216 :Short link chain grade 80

IS:15560:Points hooks with shank upto 160 tonne

IS:210 : Cast Iron Castings

1.02.00 DESIGN REQUIREMENTS

1.02.01 For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift,
with the exception of hoists for GTU and bend pulleys motor operated hoist blocks
for both long travel and lift shall be provided. Other hoist blocks shall be of hand
operated type for both travel and lift. For hoists for GTUs and bend pulleys clause
no. 1.02.18 shall be referred to. All monorails coming out of the buildings shall be
provided with electric hoist blocks, irrespective of load and lift. Minimum 3 meter
length of Cantilever from the edge of the building / cladding shall be provided in
monorails coming out of the building to lower the equipment to ground level
clearing the building sidewalls/cladding and any other facilities beneath the floor
upto ground level.

1.02.02 The exact lift/travel and the number of the hoisting mechanisms and the mode of
lifting equipments to various floors of the buildings shall be as decided by the
employer at the time of detailed engineering. Clear height shall be maintained
when handling one equipment over other, in such case dismantling of any
equipment shall not be permitted. The center line of monorail shall not deviate by
more than 500 mm from the center of gravity of any equipment that is to be lifted.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
2 of 6

Contractor shall take clear note of the fact that the number and monorail hoisting
systems shall also be decided considering the movement of the equipment being
lifted over/by the side of other equipments without removing the later. The
necessary levels of floors in various buildings shall be decided considering the
above requirement.

1.02.03 Monorails shall be extended outside the building to handle the equipment to
ground level. For monorail/hoist routed inside the buildings, suitable machinery
well and removable handrailing and grating shall be provided on various floors of
buildings, as necessary, to handle the equipment.

1.02.04 Electrically operated monogirder type hoists shall consist of following major
components.

(a.) Electrically operated trolley complete with drive motor (Trolley travel speed
maximum 15 m/min.).

(b.) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting
speed maximum 6m/min.).

(c.) Limit switch to prevent overhoisting, over lowering and over travel.

(d.) Festoon arrangement of feeding power to trolley assembly.

(e.) Erection hardware.

(f.) Pendent control station suspended from hoist.

(g.) Control panel mounted on wall.

1.02.05 The electric hoist shall be designed and constructed in accordance with the latest
revision of IS:3938 and shall be suitable for duty class 2.

1.02.06 For electric hoists, trolley movement and hoisting shall be effected by using two
separate motors. Motors shall be as per technical requirements discussed
elsewhere. However the motors shall be suitable for 150 starts per hour at 40%
CDF.

1.02.07 Trolley for motorized / manual cross travel shall be designed to accommodate a
wide range of I beams and shall be capable of travelling on straight as well as
curved monorails with the design being such to maintain uniform distribution of
pressure on the flanges.

1.02.08 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which
shall be driven through motor.

1.02.09 Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36 construction
with a breaking strength of 160 -175 kgf/ sq. mm. Reverse bend of ropes is not
acceptable. Minimum number of falls of rope shall be four (4).

1.02.10 All gears and pinions shall be of hardened and tempered steel with machine cut
teeth in metric modules. Surface hardening of steel is not acceptable.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
3 of 6

1.02.11 All running shafts and wheels shall be fitted with ball / roller bearings with a rated
life not less than 20 years based on equivalent running time as per IS:3938.

1.02.12 An electromechanical brake shall be provided for hoisting as well as cross travel.
Brake lining shall be of asbestos.

1.02.13 Cast iron parts, wherever used, shall be of minimum grade 30, IS:210.

1.02.14 All chain pulley blocks shall be designed to IS:3832, the operating hand chain shall
conform to IS:2429 grade 30 pitched and polished and the load chain to IS:6216
grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be
as per IS: 15560 & with antifriction bearing for bottom hook.

1.02.15 All hoists/chain pulley blocks shall be selected to have minimum headroom and
shall be selected to lift heaviest piece of equipment. Further, it shall be possible to
handle any equipment without disturbing other equipment.

1.02.16 The hand chain wheels shall be of cast steel, the wheels shall be with flanges and
designed to ensure effective operation of hand chain. Further, suitable local brake
shall be provided as per IS:3832 to arrest and sustain loads in all working
positions.

1.02.17 The velocity rates, effort on chain required to raise the safe working load and travel
and speed shall be within the limit specified in IS:3832. Proof load test shall be
carried out as per IS:3832. Balance requirements shall be as discussed in earlier
clauses pertaining to electric hoists.
1.02.18 Hoist for Gravity Take up arrangement and bend pulley.

For handling bend pulley, take-up pulley and counter weights following hoisting
arrangement shall be provided:

(1) For handling bend pulleys, hooks of adequate capacity shall be provided at
the top of gallery. Further minimum four (4) nos. manually operated chain
pulley blocks of adequate capacity shall also be provided for the entire coal
handling plant for handling bend pulleys.

(2) For handling take-up pulleys, manual hoist along with mono rail beam of
adequate capacity having cross travel, arrangement shall be provided at
bottom of gallery to handle take-up pulley only of conveyors.

(3) For handling take-up weight, a separate manual hoist with mono rail beam
of adequate capacity shall be provided to hold complete counter weight
(inclusive of all counter weight blocks). This hoist shall be provided for
holding the counter weight and shall be located in the zone of counter
weight travel.


1.03.01 The hoist mechanism shall consist of a grooved rope drum driven by electric motor
through gears. Each end of the rope shall be anchored to the drum in such a way
as the anchorage is readily available for maintenance. Each rope shall have not
more than two (2) full turns of the drum when the hook is at its lowest position and

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
4 of 6

one (1) spare groove when the hook is at its highest position. The leading rope
taken by the drum should not slope sideways when slack and it should not be
caught between the gear wheel.

1.03.02 Rope drum, gear box, block etc. should be fabricated out of weldable quality steel.

1.03.03 Trolley wheels shall be of single flange type in the taper treads. The wheels shall
be mounted on antifriction bearings and shall be easily removable for
repair/replacement.
1.03.04 The load hook shall be swiveling type forged circular shank section and shall
confirm to IS:15560.

1.03.05 All gears and bearings shall be lubricated by grease. All lubricating points shall be
grouped together in easily accessible position.

1.03.06 The bottom block shall be of enclosed type and shall have guard against rope
jamming in normal use. It shall have standard forged swivel shank hook fitted on
antifriction thrust bearing. Lock to prevent hook from rotation and locking
arrangement to prevent accidental unlocking shall be provided. Pulley of the
bottom block shall be provided with antifriction bearings.

1.03.07 All parts requiring replacement/inspection/lubrication shall be accessible without
need for dismantling of other parts/structures.

1.03.08 All components of hoists of identical capacity and duty shall be interchangeable.

1.03.09 Hoists shall have permanent inscription in English on each side readily
recognizable from floor level stating safe working load.

1.03.10 Pendant shall be provided with fluorescent up/down/forward/reverse travel push
buttons and indicating lamps. Its power supply shall be limited to 24V AC.

1.03.11 The control panel shall be wall mounted type & easily approachable from the floor
by a standing man.

1.03.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x
1.5m) with ladder shall be provided for each electrical hoist.

1.03.13 Each inline magnetic separator shall have independent motorised hoist for
handling / maintenance purpose.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
5 of 6

DATA SHEET : MONORAILS AND HOISTS

1.0.0 GENERAL

1.1.0 Functional Requirement : To transfer equipments to
maintenance area or outside the
building.


2.1.0 Hoists

2.1.1 Drive

(i) More than 2.0 tonne or more than
10.0 m lift or hoists coming out-side
the buildings

Motor driven for both travel & lift.
(ii) Other hoists including the hoists for
handling takeup pulley and takeup
weight

Manual for both travel & lift.

2.1.2 Maximum trolley travel speed for electric
hoists

15m/min
2.1.3 Maximum Hoisting speed for electric
hoists

6 m/min
2.1.4 Drive Motors SQIM, Separate for travel & lift

2.1.5 No. of starts for drive motor 150 starts/hr at 40% CDF

2.1.6 Wire Rope

(i) Type/Construction Pre-formed type, hemp cored,
regular lay 6/36 construction

(ii) Breaking Strength 160-175 kgf/sq. mm

2.1.7 Bearing

(i) Type Ball/Roller bearing

(ii) Life 20 years

2.1.8 Brake Electro Mechanical type with
asbestos lining.

2.1.9 Load Hook Swiveling type forged circular
shank section.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
6 of 6

2.1.10 Duty Class 2

2.2.0 Monorail location/layout

2.2.1 Cross section I beam

2.2.2 Distance between C/L of monorail &
C.G. of equipment to be lifted

Maximum 500 mm
2.2.3 Power Cables Support Festoon type arrangement

2.3.0 Manual Hoists

2.3.1 Maximum manual effort for operation. 30 Kg

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
CHUTES & HOPPERS


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Chutes and Hoppers
Page 1 of 7

A-04: CHUTES AND HOPPERS
1.00.00 GENERAL
Chutes & Hoppers, flap gates and rack & pinion gates shall be furnished integral
with coal handling system being supplied. All necessary accessories, electricals
etc. shall be provided to ensure proper flow/storage/bifurcation of coal as per
system requirements.
The design, manufacture, inspection and testing of Chutes & Hoppers shall comply
with all the currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. The chutes, hoppers shall conform
to the latest edition of the following standards and codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance than
those specified, shall also be accepted. Nothing in this specification shall be
construed to relieve the contractor of the required statutory responsibility. In case
of any conflict in the standard and this specification, the decision of the Employer
shall be final and binding.
IS:4682 :Code of practice for lining of vessels and equipment for chemical
processes.
IS:226 : Structural Steel (Standard Quality)
IS:11592 : Code of practice for selection and design of Belt Conveyors.
1.02.00 DESIGN AND CONSTRUCTION
1.02.01 Chutes, Hoppers
1.02.02 The minimum valley angle of chutes shall be 60 degrees from horizontal.
1.02.03 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of
coal without any accumulation anywhere.
1.02.04 Complete chute work above the drive floor for conveyors provided with In-line belt
magnetic separators shall be of 10 mm thick SS - 304 in the zone of magnetic
field.
1.02.05 Direct impact of material on conveyor belt shall be avoided by providing an inclined
surface at 60 degrees valley angle at the feeding point to guide the material in the
direction of belt travel. Further, chute construction below flap gate shaft shall be
such that there will not be any accumulation of coal dust between chute and flap
gate in that zone.
1.02.06 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL or
equivalent material. (SAILHARD of M/s. SAIL & LSLAS07 of M/s. Lloyd steel are
equivalent to TISCRAL (in material composition)). Long chutes guiding flow from
considerable height shall be provided with impact plates wherever change in
direction of flow takes place. Hinged inspection doors of leak proof construction
shall be provided for access/ maintenance purpose, at approachable heights for
chutes and flap gates. All chutes should have one inspection door at every floor
and for the ones in between the floors (more then 1.5 meter above the operating
floor level) suitable access for trouble free maintenance shall be provided. For
sealing of inspection doors labyrinth type arrangement to be provided. In addition

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Chutes and Hoppers
Page 2 of 7

to positive locking arrangement, mounting bolts, to tighten the door further against
rubber shall also be provided.
1.02.07 Bottom side of the chutes on which the coal slides shall be welded to the side
plates to form a trough. Bottom sides along with its adjacent sides shall be flanged
and made from TISCRAL or equivalent material of 20 mm thickness. The non-
striking surface i.e. the covers of the trough shall be of 10 mm thick mild steel and
bolted to the flange provided on the trough. Inside welding shall be provided in the
corners for permanent sealing. Further, the chute boxes not more than 1.5 m in
length shall be joined through bolted flange connection to form the chute legs.
Adequate care shall be taken to locate the flange joint away from floor level for
easy maintenance.
Bolted flange joints shall be of dust tight construction and necessary sealing
material shall be provided in all the flange connections for adequate sealing.
Complete chute work in the region of flap gates shall be fabricated from 20 thk
TISCRAL or equivalent. In case of vertical chute (valley angle more than 80
degree) complete chute, work shall be of 20 mm thick TISCRAL or equivalent
material. While finalising the chute work inside the building, arrangement for
shifting and replacing chute legs, proper handling arrangement/wall openings,
trolleys, hoists shall also be provided.
1.02.08 Hoods over the conveyor head pulleys shall be made of suitably stiffened
minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed
inspection doors with suitable access to them. Further, serrated rubber seal shall
also be provided at the very inlet of head chute to minimize dust nuisance.
1.02.09 Separate maintenance sealed door shall be provided for access to belt cleaners in
head pulley hood, flap gates for maintenance and inspection doors shall be of
hinged with positive locking facility.
1.02.10 (a) There should be sufficient clear space to install, remove and maintain
scrappers without cutting structures.

(b) Slope of plates below scrappers to direct coal scrapped by these to the
main stream shall be 60 min.
1.03.00 Skirt Boards
1.03.01 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage.
Suitable Skirt Plates shall be provided for entire feeding chute and shall be
extended minimum 3m ahead of front edge of chute and 500 mm beyond rear
edge of chute. The width of the Skirt Boards shall be two-third the conveyor belt
width. In the belts before Crusher House the gap between the bottom of the skirt
board and the belt shall be made to increase uniformly in the direction of belt
travel. The height of the skirt boards shall be sufficient to contain the material
volume as it is loaded on the belt and shall not be less than 750 mm. The skirt
plates shall be fitted with modular segmented and replaceable rubber skirting pads
having facility of adjusting the pressure on the belt conveyor and shall have
provision of on line removal for the purpose of easy maintenance. Such
segmented rubber pads with its holding down adjustment arrangements shall be of

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Chutes and Hoppers
Page 3 of 7

proven design. The edges of segmented pads shall be installed at an angle for
providing a better seal. All care shall be taken while designing, to combine good
sealing with minimum belt wear.
1.04.00 Flap Gates
1.04.01 The motor operated 2 position flap gates shall be provided in transfer chutes as
specified and shall be complete with electrically operated actuators. The gates
shall be of robust construction and suitable for trouble free operation. The face of
the flap gate shall be made out of 20 mm thick TISCRAL or equivalent material.
1.04.02 The equipment shall be capable of being operated for at least 15 switchings per
hour at rated load and thrust and shall be suitable for 10 Nos. consecutive
switchings at rated load and thrust.
1.04.03 The motor rating for the actuator shall be so selected as to provide sufficient thrust
for operation of the flap gates against the moving weight of coal and/or flap gate.
The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be
completely dust tight.
1.04.04 Lever arm shall be provided between actuator and flap gate shaft for obtaining
required thrust.
1.04.05 The actuators shall be capable of preventing any over travel. Suitable travel
dependent limit switches controlling the travel of the flap gates on either direction
shall be furnished. These shall be placed internal to the drive unit and shall be
completely dust-proof. The limit switches shall be capable of adjustments to vary
the total length of travel of the gates.
1.04.06 Suitable thrust dependent limit switches shall be provided in the actuator, which
shall trip off the actuator motor in case of excessive thrust due to jamming of the
gates during its travel in either direction. The same shall also be integral to the
drive unit and shall be dust proof.
1.04.07 Provision for alternative manual operation shall also be made using declutchable
hand wheel. The diameter of hand wheel shall be selected considering convenient
force to be applied by a single operator. However, minimum diameter of hand
wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel
shall be provided. Manual effort required to operate the flap gate shall not exceed
25 kg.
1.04.08 All the two way chutes, one way of which is leading towards the future conveyor
shall be provided with blind flange and flap gate with a provision to mount an
actuator in future.
1.04.09 The Contractor shall furnish calculations for selection of actuator for approval of
Employer. However, all the actuators in the plant should be selected based on
heaviest loading, but the rating shall not be less than 3500 kg with a lever arm of
1.0 m in any case.
1.04.10 Suitable stiffening arrangement shall be provided between the two faces of the
gate plate. At the end of the travel the total length of edge of the flap gate shall
rest on a suitable projected surface from chute to prevent leakage of coal dust
through the available clearance between chute and flap gate.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Chutes and Hoppers
Page 4 of 7

1.04.11 Maximum feasible counterweights shall be provided for better utilisation of system.
However, for calculation of thrust required, the benefit of counterweight shall not
be taken into considerations.
1.04.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the
gate shaft. Suitable provision for regreasing shall be provided.
1.04.13 For standardization purposes, only one standard type of actuator for flap gates
shall be provided. The standard type actuator shall be selected for maximum thrust
as calculated for various locations. Flap gate actuator as a whole and individual
component wise shall be completely interchangeable for all locations.
1.04.14 The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall
be suitable for motor stalled condition and associated twisting.
1.04.15 Approach/maintenance platforms complete with the chequered plate floor, hand
rails, ladders etc. shall be provided for all flap gates. The platforms shall be
extended for access to dust & debris chute inside buildings.
1.04.16 Shaft & flap gate shall be tightly fitted to each other.
1.05.00 Rack & Pinion Gates
1.05.01 Rotary actuator operated rack and pinion gates shall be provided at various
locations as specified. The gate shall be mounted such that coal load does not act
vertically on gate.
1.05.02 Suitable manually operated rod gates shall be provided over rack and pinion gates
for their easy operation and maintenance.
1.05.03 The rack and pinion gate shall be guided properly and suitable rollers with
bearings sealed for life and dust proof shall be provided.
1.05.04 The rack and pinion gates shall be of mild steel construction with liner plate of 10
mm thick TISCRAL or equivalent material. The gates shall be operated by means
of double rack and pinion. The material for rack & pinion wheel shall be cast steel
and shaft shall be EN.-8.
1.05.05 Provision for alternative manual operation of motorized rack and pinion gates shall
also be made. Limit switch for safety of person operating the hand wheel shall be
provided.
1.05.06 Manual effort required to operate the rack and pinion gate shall not exceed 25 kg.
1.05.07 Approach/maintenance platforms complete with chequered plate floor, hand
railings, ladder etc. shall be provided for all gates.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Chutes and Hoppers

Page
5 of 7

DATA SHEET : CHUTES AND HOPPERS
1.0.0 GENERAL
1.0.1 Coal Parameters As specified elsewhere
2.0.0 DESIGN & CONSTRUCTION
2.1.0 Chutes & Hoppers
2.1.1 Minimum Valley Angle 60 degrees
2.1.2 Material :
(a) Chute work
Sliding zones & adjacent sides 20 mm thk. TISCRAL / equivalent
No striking/ Non sliding zones 10 mm thk MS
Chute with valley angle 80
degree and above
All four sides of 20 mm thk.
TISCRAL/equivalent material
In the zone of magnetic field of
ILMS (chute above floor over
which ILMS is suspended)
SS-304 10 mm thk.
In the zone of flap gates 20 thk TISCRAL/ equivalent material
Discharge Hoods over head
pulleys
4 mm thk M.S. with rubber curtain
2.1.3 a) Size of Chutes for 2400 TPH.

Minimum 1600mm X 1200mm (inside
both ways)
for 4000 TPH Minimum 1800mm X 1400mm (inside
both ways)
2.1.4 Inspection Doors Hinged & labyrinth type leak proof
construction (min. size 350 x 450
mm)
2.1.5 Chute Construction
(a) Corners One face of removable bolted flange
connection
(b) Joints Bolted Flange joints of dust tight
construction
(c) Bolt size Min. M-16
(d) Bolts spacing Not more than 125 mm C/C
(e) Fixing Arrangement Bolts with plain spring washers

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Chutes and Hoppers

Page
6 of 7

2.2.0 Skirt Boards
2.2.1 Length Entire feeding chute shall be
extended minimum 3m ahead of front
edge of chute & 500 mm beyond rear
edge of chute.
2.2.2 Height Not less than 750 mm
2.2.3 Width 2/3 of belt width
Side plate Min. 10 thk TISCRAL/equivalent
Top cover 6 mm thk M.S.
2.3.0 Flap Gate
2.3.1 Type Linear actuator operated, 2 position
2.3.2 Travel 60 to 70 deg. (with limit switches on
both sides).
2.3.3 Automatic operation
(i) Drive Dust tight motor driven with suitable
linkages
(ii) Minimum Actuator Rating 3500 kg with 1 m lever arm
(iii) No. of Operation / Hr 15 (with 10 consecutive switchings)
(iv) Protection
Travel and Thrust dependent limit
Switches.
2.4.4 Manual Operation
(a) Maximum effort Convenient for single operator by
declutchable hand wheel regardless
of electrical power.
(b) Minimum Handwheel
Diameter
500 mm
2.4.5 Flap gate shaft
(i) Diameter minimum 150 mm
(ii) Material EN-8
2.5.0 Rack & Pinion Gate Rotary actuator operated with
provision of manual operation
2.5.1 Material Mild Steel

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Chutes and Hoppers

Page
7 of 7

2.5.2 Liner 10 mm thick TISCRAL/equivalent
2.5.3 Rack & Pinion Cast Steel
2.5.4 Shaft EN-8
2.5.5 Max. time for closing/ opening 50 sec.(Approx)
2.5.6 Maximum manual effort Convenient for a single operator
2.5.7 Limit switches Both travel & thrust dependent
2.5.8 Main shaft dia. Min. 150 mm
2.5.9 No. of Operations /hr. 15 (with 10 consecutive)
2.5.10 Diameter of rod for Rod Gate 40 mm (Min.)

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
BELT CONVEYOR SYSTEM


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Belt Conveyor System

Page
1 of 15

A-05: BELT CONVEYOR SYSTEM
1.00.00 GENERAL
All Belt Conveyors shall be furnished and erected along with necessary supporting
structures, platforms, on ground or overhead galleries, trestle structure with
foundation footings, carrying and return idlers, automatic take-ups, pulleys, drive
motors with suitable reduction units and couplings, belting, transfer chutes, flap
gates, hydraulic couplings and other necessary accessories as per scope specified
elsewhere.
a) The belt conveyor system design for the works under the scope of the contract
shall be carried out by design agency who has designed at least one
installation of belt conveyor system of 2000 TPH capacity for any material and
the same is working satisfactorily as on date of bid opening. The system
design of the reference installation shall include design calculations for belt
tension and selection of drive rating.
b) The bidder is required to furnish in the bid documents, details regarding his
design experience or the design agency proposed to be engaged by him,
meeting the above requirements.

The design, manufacture, inspection and testing of the Belt Conveyor System shall
comply with all the currently applicable statues, regulations and safety codes in the
locality where the equipment is to be installed. The belt conveyor system shall
confirm to the latest edition of the following standards & codes. Other
Belt Conveyors for Bulk Materials published by Conveyor Equipment
Manufacturers Association.
IS:7155 : Codes of Practice for Conveyor Safety.
IS:1891 (Part-I) : General Purpose Belting
IS:8598 : Idlers and Idler Sets for Belt Conveyors
IS:4009 (Part-II) : Conical Head Grease Nipples
IS:8531: Pulleys for Belt Conveyors.
IS:226 : Structural Steel (Standard Quality)
IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical
Processes.
IS:11592 :Code of practice for selection and design of Belt Conveyors.
CAN / CASA - M422 M87 : Canadian standard association.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
2 of 15

1.02.01 Design of belt conveyor system shall be suitable for coal parameters specified
elsewhere.
1.02.02 Slopes of conveyors, wherever applicable, shall not exceed 16 deg. depending on
the lump size, and other governing factors.
1.02.03 The guaranteed capacity of all conveyors shall be the rated capacity.
1.02.04 All conveyors (except boom conveyor of Reclaimer) shall be designed for 110% of
rated capacity. The boom conveyor of Reclaimer shall be designed for 125% of
rated capacity. Design capacity of the conveyor system shall be considered for the
selection of belt width, belt speed and the continuous motor rating at 50 deg C
Ambient.
1.02.05 The drive chain equipments for various belt conveyor systems shall consist of
drive motors, fluid couplings, gear reduction units, low speed flexible couplings and
pulleys. For the ratings of various equipments as mentioned above in the drive
chain of conveyor systems relevant sections of this specification shall be referred
to.
1.02.06 Conveyors and belt feeders shall be provided with electro hydraulic thrustor brakes
or fly wheels to adjust the coasting time of conveyors such that there will not be
any build up of material in the chutes. Further conveyor shall come to halt as early
as possible. All conveyors with HT drives (except bunker conveyors) shall be
provided with brakes.
1.02.07 Belt conveyor system shall be designed as per the latest edition of Belt Conveyors
for Bulk Materials published by Conveyor Equipment Manufacturers Association
or equivalent International Standard. Ai value for idler shall be considered 2.8lb
(min.) for the purpose of conveyor design calculation only.
1.04.00 Belting
1.04.01 The belting shall be of synthetic fabric such as Nylon-Nylon, Polyster / Polymide,
EP/ Steel cord etc. with rubber covers of adequate flexibility to give a troughing
angle of 35 deg. For all the conveyors the number of plies, cover thickness, factor
of safety etc. shall be as per the recommendation of belt manufacturer, but not
inferior to the figures as tabulated in data sheet.
1.05.00 Idlers
1.05.01 Carrying idlers shall be provided with three equal rolls with troughing angle of 35
deg. and 2 deg. forward tilt (except in case of reversible conveyors).
1.05.02 In no case, shall the diameter of the idler roll be less than 152 mm for both
carrying side and return side. However, for impact idlers the steel roll diameter
shall not be less than 139 mm and rubber ring thickness shall be minimum 25 mm.
1.05.03 Roller used in idlers shall be made from ERW steel tube. Wall thickness shall be
minimum 4.0 mm without any negative tolerance. The rollers shall be mounted on
EN-8 or equivalent material spindles by means of ball bearings of either deep
groove type or seize resistant type (SKF/Equivalent), of minimum 35 mm size for
carrying idlers and minimum 25 mm size for return idlers. The bearings shall be
adequately sealed and lubricated for life. The rolls shall be supported from
fabricated steel brackets. Fixing arrangement of rollers with brackets shall be drop-
in type. For adjusting the alignment of the idlers, slotted holes shall be provided in

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
3 of 15

idler supporting base plates. Direction of belt travel shall be clearly marked on the
brackets of carrying idlers by embossing / punching.
1.05.04 Idler rollers shall be waterproof, dust proof and weather proof against a high
velocity water jet. All idlers shall be provided with minimum double labyrinth dust
seal.
1.05.05 Impact idlers used at the loading and transfer point shall be so designed as to
avoid direct loading impact, belt damage and excessive punishment to the carrier.
The material used in construction of this type of idlers shall be of resilient type.
1.05.06 The return idlers for all conveyors shall be single roll type. For conveyors longer
than 400m, two roll return idlers with 10 deg. troughing angle shall be provided.
1.05.07 The self-aligning idlers shall be direct acting type, complete with actuating rollers
fitted with the ball bearings and mounted inclined towards the belt. The idler frame
shall be suitably cradled about a vertical pivot, supported in bearing over a fixed
plate. Adequate sealing arrangement shall be provided to prevent contamination
of the lubricant by dirt and moisture.
1.05.08 Transition type troughing idlers shall be used adjacent to all pulleys to permit
proper support of the loaded belt near the pulleys without excessive stretch of the
belt edges. The transition idlers shall be provided with preferably adjustable
concentrator (end) rolls and long center rolls to suit the troughed belt contour
between the last regular troughing idler and the adjacent pulleys. The transition
length and the number of the transition idlers shall be selected depending upon the
tensions, type and size of belt, number of plies and other necessary governing
factors.
1.05.09 All the conveyors shall be provided with one self cleaning type rubber disc return
idler located near the head pulley for cleaning the return belt.
1.05.10 Proper arrangement shall be provided in the brackets of all types of idlers for
preventing the rollers from coming out of the brackets during normal / abnormal
conditions.
1.06.00 Belt Cleaners
1.06.01 External Belt Cleaner
Spring loaded scraper type cleaner with modular segmented and replaceable
polyurethane scrapers blades complete with main cleaner, pre-cleaner (mounted
separately) along with accessories and necessary fines (reject of scrapper) chutes
shall be provided for all discharge pulleys. The modular units shall be easily
replaceable. The scraper assembly shall be easily maintainable from outside
without any interference with the chute arrangement and assembly.
1.06.02 Internal Belt Cleaner
V-plough type belt cleaner made of mild steel flats and hard rubber strips with
automatic wear adjustment and necessary accessories shall be furnished for
cleaning internal surface of the conveyor belt.
1.07.00 Belt Take-up Arrangement
1.07.01 Automatic take-up of gravity type shall be generally provided with necessary take-
up arrangements complete with bend pulleys, take-up pulley, with its supporting /
sliding assembly, wire ropes with turn buckle arrangement (to adjust the level) for
suspending the separate take - up weight sliding assembly close to the ground,
counter weights and other accessories. Suitable guards marked up scale attached

SECTION VI, PART-B
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to the frame to monitor belt stretch and access/maintenance platforms with
handrails all around etc. shall be provided. Adequate access from conveyor
gallery/transfer house/ground etc., as the case may be shall be provided to
inspect, repair and maintain the gravity take-up arrangement. Suitable
arrangements shall be provided for clearing accumulated coal from various
platforms to ground level. Guides of take up pulley/counter weights shall be
sufficiently strong so that they do not bend during belt snapping.
1.07.02 The prime consideration should be to locate the automatic take-ups at a place
where these will work best, in relation to the drive, to keep belt tension at a
minimum. Other considerations such as available space, maintenance
considerations and the economics of the location should also be taken into
account while designing. Take up shall not be located over buildings unless
indicated in tender drawings. Height of take-up guide structure shall be sufficient to
allow the take-up weight movement up and down for all operating conditions of
conveyor and to allow minimum two (2) vulcanizing lengths margin in the belt or
percentage of conveyor length (2.5% for synthetic belting, 0.5% for steel cord
belting) whichever is larger. Suitable guides shall be provided both for take up
pulley and take up weight.
1.07.03 Two (2) meter safety fencing along with suitable gate and locking arrangement
shall be provided around gravity take-up at the base level / ground level.
1.07.04 Irrespective of take-up location, the travel zone of take-up weight shall start from a
suitable height above ground level.
1.07.05 Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley in
order to avoid damage of the pulley assembly in case of belt snapping. Similar
buffer arrangement shall be provided for take-up weight also, in case of, take-up
weight travel zone terminating above a building floor. Sandpits of 600 mm deep
shall be provided at ground below the take-up weights.
1.07.06 In case of double stream conveyors, a partition of 3 mm steel plate shall be
provided between the two take-up pulleys along entire travel zone of take-up
pulleys. Intermediate platforms shall be provided in the take-up zone for
maintenance of take - up pulleys / counter weight.
1.07.07 Take-up weight shall consist of multi-blocks and not of single block to facilitate
adjustment in weight if required during operation. Single heaviest piece shall be
suitable for easy handling. Take-up weight block shall be provided with edge
protection angle to take care of any damage. Take up weights shall be kept inside
a take up weight box and shall be properly anchored / bolted with the main frame,
so that the none of the weight shall be loose/free inside the box. The box shall be
painted with counter weight and conveyor number and shall have good aesthetic
look.
1.08.00 Hold Back Devices
1.08.01 Suitable hold back devices for preventing running back of the conveyor belt in
case of conveyor being stopped in loaded conditions due to power failure or during
normal operational delays shall be provided to give positive protection. The hold
back shall instantaneously engage without shock and be capable of protecting
equipment and personnel. It shall be released instantly when power resumes or
the delay is removed. The holdback devices shall be integral with gearbox.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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1.09.00 Pulleys
1.09.01 Pulleys shall be provided as required for various conveyors. In determination of
pulley diameter, no account shall be taken of the pulley lagging. The nominal
diameter and face width of the pulleys shall be as stated in IS:8531.
1.09.02 The snub pulleys on each conveyor shall be located to provide a belt wrap on the
drive pulleys of not less than 210 deg. wrap is envisaged for single snub drive
only.
1.09.03 All drive pulley surfaces shall be hot lagged with vulcanised natural rubber lagging
grooved in diamond pattern.
1.09.04 All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with plain
lagging.
1.09.05 The rubber to be used for lagging of pulleys shall confirm to specifications listed in
data sheet of this section.
1.09.06 The rubber lagging of pulleys and method of lagging and testing the same shall
conform to IS:4682.
1.09.07 The pulleys shall be made from mild steel conforming to IS:2062 (Tested Quality).
However, for conveyors with in line magnetic separators, at head end pulleys shall
have shell and end disc made of non-magnetic stainless steel material. Suitable
stiffening shall be provided at all weld location in the shell on all pulleys. Stainless
steel pulley shall have only shell & end discs of SS.
1.09.08 All the pulleys shall be mounted on the forged steel shafts of EN-8 or equivalent
material of adequate proportion by taper lock arrangement, running in heavy duty
roller bearings with proper greasing arrangement. The plummer blocks for pulleys
shall be of horizontally split type construction with minimum (4) nos. bolts holding
the two split halves and with min (4) nos. foundation bolts. The plummer blocks
shall be dust tight with double labyrinth seals. Conical head shape nipples
conforming to IS:4009, suitable drain plug and eye bolt shall be provided. Side
covers of plummer blocks shall be heavy duty metallic sheets. No plastic
components shall be used.
1.09.09 Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall
be provided for all tail pulleys and bend pulleys for safety of operating personnel.
1.09.10 Suitable stiffening arrangements shall be provided in all pulleys. For selection of
pulley shaft dia of all the pulleys, a margin of atleast 20% shall be considered on
the maximum tension at designed Conveyor capacity. Selection of pulley
diameter, shell thickness, stiffening and shaft diameter shall be subject to approval
of Employer during detailed engineering.
1.09.11 Maximum type of pulleys permitted based on pulley diameter and shaft diameter
shall be limited to five (5) for each belt width. These shall comprise of two (2) nos.
drive pulleys and three (3) nos. non drive pulleys for each belt width. SS pulleys
and tripper pulleys and pulleys for stacker and reclaimer will not come under the
above categories.
1.10.00 Belt Protection Equipment
1.10.01 Pull chord Switch
Pull chord type (manually reset type) emergency stop switches shall be located on
both sides of belt conveyors along the walkways for the entire length of conveyors
for emergency stopping of conveyor. The enclosure shall be of cast aluminum with

SECTION VI, PART-B
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degree of protection IP-65. It shall have a separate terminal box with a separate
hinged cover which shall be totally sealed from main box containing actuating
mechanism / limit switch etc. Local pull chord actuation shall be provided by
means of mechanical flap. Each switch shall have two NO and two NC contacts,
which shall be wired out to the terminal block. The terminal block shall have
facilities of cable looping. The Contact rating of the switches shall be rated for
atleast 5 Amps, breaking at 240 VAC at 0.3 p.f. lagging. Adequate length of rope
and all accessories shall be furnished. Pull chord in stone picking area shall be
routed inside G.I. pipe of 1 size.
1.10.02 Belt Sway Switches
Belt sway switches of self resetting type shall be furnished at periodic intervals to
limit belt sway to permissible extent. The enclosure shall be of cast aluminum
having degree of protection of IP-65. It shall have a separate terminal box with a
separate hinged cover totally sealed from the main box containing actuating
mechanism/ limit switch etc. Each switch shall have two NO and two NC contacts
one for alarm and one for trip, which shall be wired upto terminal block. The
terminal block shall have facilities for cable looping. The contacts of the switches
shall be rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The
roller length of the switch shall be at least 150 mm. Belt Sway Switch shall also be
provided at the HGTU & VGTU to detect excessive belt Sway.
1.10.03 Zero Speed Switch
Zero speed switch shall be non-contact (proximity) type electronic switch.
Mounting arrangement/ location shall be such that operation, effective sensing
distance, sensitivity etc. shall not be effected by accumulation of dust on rotating
part or surface of probe. Adequate mechanical protection by means of non-metallic
shields shall be provided on top of the switch to prevent any damage due to falling
coal / metallic pieces etc. In built initial start up delay and nuisance, tripping delay
through timers shall be provided. Each switch shall have two NO and two NC
contacts wired out to the terminal blocks. The contact of the switches shall be
rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The monitoring
unit shall have cast aluminum body having IP-65 degree of protection. A separate
terminal box with a separate cover, which shall be totally sealed from main box,
shall be provided. Terminal blocks shall be suitable for terminating 1.5 mm sq.
standard copper cable.
1.10.04 Chute Blockage Switches
One no. chute blockage switch of proven type (subject to approval of the
employer) shall be provided at a suitable height on each leg of the conveyors
discharge chute, vibrating screening feeders by pass chutes, crusher feeding
chutes, tripper discharge and feeding chutes nearest to the skirt boards. Chute
blockage switch shall trip the feeding conveyor in case of Chute blockage and
protect the feeding conveyor equipment. Chute blockage switch shall also be
provided at each leg of mobile tripper and shall trip the tripper conveyor.
The switch and its operating arrangement shall be suitable for working in dusty
areas. The minimum degree of protection of switch shall be IP-65. Local
indication of chute blockage switch actuation shall also be provided. Location of
chute block switch shall be such that washing does not affect it.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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1.10.05 Sensing arrangement shall be provided in the DDCMIS based control system for
detecting the presence of material on the belt which shall in turn be used for
operating solenoid valves of dust suppression/extraction system elaborated
elsewhere. The arrangement shall detect three events simultaneously as follows:
(a.) Belt loaded
(b.) Belt running at more than preset speed.
(c.) Preset initial start delay.
1.10.06 The terminal boxes of all the belt protection equipments / switches shall be such
that all the components / terminals inside are easily accessible for inspection and
maintenance without removing the cables / connections / components.
1.10.07 Each pull cord and belt sway switch shall have necessary chip for using in circuit
for the identification of the operated switch in main control room. The scheme for
switch identification shall be fail safe and shall have all diagnostic features. The
scheme shall have facility to by pass one or more switches, if required.
1.11.00 Drive Motors
1.11.01 Rating of all drive motors of conveyors shall not be less than 120% of the power
required at drive motor output shaft at specified design capacity. The motor rating
shall be at 50 deg Cent. ambient.
1.11.02 Single LT drive motors shall be used for conveyor drive ratings up to 160 KW. For
conveyor drive rating beyond 160 KW, single HT drive shall be used for conveyors.
However for boom conveyor drive on stacker/reclaimer, single LT motor may be
used above 160 KW also.
1.12.00 Conveyor Bridges
1.12.01 All overground and overhead conveyors shall be located in suitably enclosed
bridge structure. Structural steel bridges of adequate width and depth (2700 mm
clear head room) shall be provided complete with conveyor bottom deck plates,
seal plates, walkways of chequered plates with anti-skid arrangement(s), hand
rails (on both sides of each conveyor belt except where equipment (like stacker/
reclaimer, trippers etc.) traverse over conveyor supports.
1.12.02 The conveyor bridge shall have permanently colour coated steel sheeting covers
on roof and both sides, properly screwed or locked to steel structure as required.
Adequate provision of windows shall be kept. A continuous slot opening of 500
mm shall be provided on both sides just below the roof sheeting.
1.12.03 The floors of outdoor conveyor galleries shall be designed and constructed as
follows:
Side and central walkways for double streams conveyors shall be 800mm and
1100mm wide respectively. The side walkways for single conveyors shall be 800
mm on one side and 1100mm on the other side. However, if the centre to centre of
conveyors or the width of the gallery is decided by some other criteria, maximum
walkway widths consistent with gallery sizes shall be provided. In the complete
length of conveyor gallery minimum walkway clearance as indicated above is to be
maintained inclusive of all equipments and clearances.
All conveyors shall be provided with 12 G steel seal plates throughout the length
and width of the conveyor gallery in such a way that complete gallery bottom
surface area forms a single water proof floor and no water / coal falls down from
conveyor gallery incase of cleaning / washing. It is envisaged to clean the

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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conveyor gallery with water periodically. All the water / coal slurry shall be suitably
guided to down comers provided at every trestle. Each downcomer shall lead the
coal slurry into a 2 cub meter brick wall tank at ground level having 2 Nos.
decanting taps at suitable elevations. Decanted water shall be led to the nearest
drain in the Contractors scope. Necessary arrangement shall be provided to
avoid choking of downcomers by bigger coal lumps and for cleaning of choked
downcomers.
1.12.04 The conveyors shall be provided with continuous decking plate of minimum 3 mm
thickness plain steel sheet.
1.12.05 Structures and floors shall be so designed as to provide suitable space for routing
of 200 NB fire fighting pipe with water, cables and conduits.
1.12.06 Steel trestles to support the conveyor bridge shall rest upon concrete foundations
to be provided by the Contractor. Complete trestle structures shall also be
supplied by the Contractor. Suitable approach/access platforms with hand railings
shall be provided to approach the conveyor gallery (like in case of fire) through
monkey ladders on the trestles. Suitable wire mesh doors on steel frame
construction lockable from outside only shall be provided in the conveyor galleries
at these locations. All monkey ladders shall have cage for safety of personnel
using them.
1.12.07 Independent supports for walkways, conveyor structures shall be provided. The
width of conveyor galleries shall be decided by the Contractors depending on the
equipments size and the walkway width as specified. However, in no case the
width of gallery shall be less than the width specified in tender drawings.
1.12.08 Provision shall be kept with platforms and ladders for crossing over the conveyors
at approximately every 100m intervals of route length and minimum one per
conveyor.
1.13.00 Special Cleaning, Protection and Painting
All equipments of Coal Handling Plant inclusive of belt conveyor system and
technological structures shall be kept clean. Painting of conveyor structure,
platforms, deck plates, technological structures, outdoor CHP equipment/ CHP
machines shall be in line with clause No.19.00.00, Sub section-IIID -01 of Section-
VI. However for indoor equipments only, following painting procedure shall be
followed:
a) Surface Preparation : Commercial Blast Clean
b) Primer : Epoxy based Zinc Phosphate
Nominal coating thickness : 70 microns
c) Intermediate : Epoxy based TiO2 Pigmented Paint
Nominal coating thickness : 70 to 80 microns
d) Finish Coats : Epoxy based finished coat
Nominal Coating thickness : 50 to 80 microns
f) Dry film thickness of system : 190 to 240 microns

For all water/air piping, pipe clamps/hangers etc. the following shall be applicable.

a) Surface Preparation : Power Tool Clean
b) Primer : Epoxy based Zinc Phosphate
Nominal thickness coating : 70 microns
c) Under Coats : Epoxy basedTiO2 Pigmented coat
Nominal Coating thickness : 25 to 40 microns

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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d) Finish Coats : Epoxy based finish coat
e) Dry film thickness of system : 120 to 150 microns
The painting colour code shall be provided to the Contractor during detailed
engineering.
1.14.00 Belt Vulcanizing Machine
1.14.01 Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice and
shall be of easy-to-handle type.
1.14.02 Equipment should be suitable for vulcanizing of entire splice width in single setting.
1.14.03 Equipment should be capable of applying uniform pressure over the splice by
pneumatic or hydraulic means.
1.14.04 Heating element should be preferably of flexible type.
1.15.00 Belt Jointing Facilities
For the purpose of jointing the belting or replacement of belting, following belt
facilities shall be provided:
1.15.01 5M X 5M paved area near take up to make joints.
1.15.02 Hooks shall be provided on TPs, Conv. Gallery to pull the old belt while replacing
the same with new belt.
1.16.00 Fixed idler pulleys are to be provided on return side of each conveyor gallery at
suitable location to facilitate laying of new belt.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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DATA SHEET : BELT CONVEYOR

1.0.0 GENERAL

1.1.0 Design Capacity 110% of rated (guaranteed) capacity
for all conveyors except boom
conveyor of reclaimer. For boom
conveyor of reclaimer, the design
capacity shall be 125% of rated
(guaranteed) capacity.
1.2.0 Maximum slope 16 deg

1.3.0 Max. belt Sag between idlers 2%

1.4.0 Minimum Radius

(i) Concave curve 250 m (In case of travelling trippers,
the requirement of minimum radius
shall be decided based on the space
availability)

(ii) Convex Curve 50 m

1.5.0 Coal Parameters As specified elsewhere


2.1.0 Belting

2.1.1 Type Synthetic Fabric of Nylon / Nylon,
Polyester / Polyamide/ Steel cord,
etc.

2.1.2 Cover Grade a) Flame test : Conforming to
ISO:340

b) Drum Friction and Electrical
Surface Resistance Test:
Conforming to Canadian
standard association CAN / CSA
M-422- M87 Grade - C.
2.1.3 Cover Thickness (without -ve
tolerances).

Synthetic belting

Steel cord belting
(a) Face 5.0 mm (min.) 5.0 mm (min.)
(b) Bottom

2.0 mm (min.) 5.0 mm (min.)
2.1.4 No. of plies Minimum 4

2.1.5 Drive Arrangement Snub drive

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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2.1.6 Factor of Safety
- for Synthetic belting
- for Steel cord belting

10 (Minimum)
7 (Minimum)
2.1.7 Normal Working tension at design
capacity
Less than 80% of max. allowable
working tension

2.2.0

Idlers

2.2.1 Type

(a) Carrying Three roll, 35 degree troughing,
2 degree forward tilt

(b) Return

Single Roll, For conveyors upto
400 m c/c length. Two roll with 10
degree angle for conveyors more
than 400 m c/c length

(c) Loading point Impact type

2.2.2 Spacing

(a) Carrying idlers 1.2 m (0.6 m for convex curves).

(b) Return idlers 3.0 m (for convex curves not more
than 1.5 m.)

(c) Loading point Minimum six (6) with 400 mm
spacing.

(d) Self-aligning troughing
idlers
At 10 m distance from head & Tail
pulleys with intermediate spacing
15m

(e) Self - aligning return idlers At 10 m distance from Head & Tail
pulleys with intermediate spacing
20m. (Not required for conveyors
more than 400m c/c long where 2
roll return idlers are provided).

2.2.3 Bearings

(a) Carrying Ball Bearings of deep groove type or
seize resistance type of min. 35 mm
size, lubricated for life.

(b) Return Ball Bearings of deep groove type or
seize resistance type of min. 25 mm
size, lubricated for life.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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2.2.4

Material

(a) Roller ERW Steel tube min. wall thickness
4.0 mm

(b) Spindle E.N. 8 or equivalent.

2.3.0 Belt Cleaners

2.3.1 External Spring loaded scraper type cleaner
with modular, segmented and
replaceable PU blades with
separate main-cleaner & pre-cleaner
etc.

2.3.2

Internal V-Plough type, mild steel flats with
hard rubber strips.

2.4.0 Belt Take up

2.4.1 Type Automatic Gravity Type.

2.4.2 Location In relation to the drive to keep belt
tension at minimum.

2.4.3 Take-up travel To suit all operating conditions or
(2.5% for synthetic belt and 0.5% for
steel cord belt) of conveyor center to
center length whichever is larger.
Further the initial location of take-up
shall be decided in such a way that
it is possible to carryout min. two (2)
nos. Vulcanizing Joints without
adding any external belt.

2.5.0 Hold Back Device

Integral with gear Box

2.6.0 Pulleys

2.6.1 General (for all types of Pulleys)

(i) Minimum shell thickness 20 mm

(ii) Minimum end disc thickness 30 mm

(iii) Maximum allowable
deflection of shaft at the
hubs
5 minutes

(iv) Pulley shaft diameter Margin of minimum 20% shall be
considered on maximum tension at
design capacity for arriving at the
shaft dia.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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2.6.2 Drive Pulleys

(1) Minimum shell thickness 20 mm

(2) Lagging Hot lagged with vulcanised natural
rubber

(3) Lagging thickness 12 mm thick grooved in diamond
pattern with grooves 6 mm wide x 6
mm deep

(4) Minimum angle of wrap 210 degrees

(5) Maximum Out of roundness 0.5% of nominal diameter

2.6.3 Other pulleys

(1) Minimum shell thickness 20 mm

(2) Lagging Hot lagged with vulcanised natural
rubber

(3) Lagging thickness 12 mm thick plain

2.6.4 Rubber for lagging

(1) Type Natural rubber blended with styrene
Butadiene rubber.

(2) Hardness 55 to 65 durometer (Shore A)

(3) Elongation Over 300%

(4) Strength 160-245 kg/cm
2

(5) Abrasion loss 250 mm3 as per DIN 53516

(6) Specific Gravity Max. 1.5

(7) Adhesion Strength 10 kg/cm (minimum)

2.6.5 Bearings for Pulleys

(1) Type Heavy duty roller type

(2) Casing Horizontal Split Type

(3) Sealing Dust tight with double labyrinth
seals.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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(4) Lubrication Greasing arrangement with conical
head shape nipples.

2.6.6 Pulley Material Mild steel conforming IS:226 / IS :
2062

2.6.7 Shaft Material Forged Steel shaft EN-8 or
equivalent material.

2.7.0 Belt Protection Equipment

2.7.1 Emergency Stop Switch System

(1) Type Pull chord type (manually reset)

(2) Location Both sides of conveyor for entire
length

(3) Spacing Approx 30 m

2.7.2 Belt Sway Switches

(1) Type Limit switches snap action.

(2) Spacing One pair at 50m interval (Minimum
two (2) pairs)

2.7.3 Zero Speed Switches

(1) Type, Location Proximity switch, mounted on Bend
pulley of GTU.

2.8.0 Drive Motors

2.8.1 Type Three Phase Squirrel Cage
Induction Motors

2.8.2 Mounting (for conveyors) Base mounted

2.8.3 Continuous motor rating (Name
plate rating) at 50
o
C
120% of actual power requirement
at motor output shaft at design
capacity.

2.9.0 Conveyor Bridges

2.9.1 Walkways

(a) Construction Chequered plate with antiskid
arrangement.
Chequered plate steps shall be
provided where conveyor slope
exceeds 10 degrees. (Totally sealed

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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so that no water falls down while
washing.)

(b) Central walkway width 1100 mm

(c) Side walkway width 800 mm (for single conveyors, the
width of side walkways shall be 800
mm on one side and 1100 mm on
the other)
2.9.2 Side Windows

(a) Spacing (Center to center) 25.0 m on each side (in staggered
fashion)

(b) Size 1.2 m x 1.5 m

(c) Window material Refer Civil Section

2.10.0 Trestles

2.10.1 Spacing of monkey ladders on
trestles

(a) Where height of conveyor
gallery (walkway level) is 10
m or more.

: On every trestle
(b) Where height of conveyor
gallery (Walkway level) is less
than 10m.
: On alternate trestle

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
DRIVE EQUIPMENT



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Drive Equipment
Page 1 of 4

A-06: DRIVE EQUIPMENT

1.00.00 GENERAL
Suitable Drive Chain Equipments like electric motors, gearboxes (where applicable),
fluid couplings (where applicable), flexible couplings and other accessories shall be
provided for all the belt conveyor systems, paddle feeders, crushers, mobile trippers,
various pumps of dust suppression/extraction system, fans for ventilation system,
monorail electrical hoists and other equipments specified in this specifications.
Various requirements as spelt out in the Technical Specifications for individual
equipments shall be taken into consideration while designing the associated drive
chain equipments.
The design, manufacture, inspection and testing of Drive Equipment shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment in to be installed. The Drive Equipments shall conform to the
latest edition of the following standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those specified,
shall also be accepted. Nothing in this specification shall be construed to relieve the
contractor of the required statutory responsibility. In case of any conflict in the
standard and this specification, the decision of the Employer shall be final and
binding.
IS:3688 : Dimensions for shaft ends
IS:3681: General plan for spur & helical gears
IS:7403 : Code of practice for selection of standard worm and helical gear boxes
1.02.00 DESIGN AND CONSTRUCTION REQUIREMENTS
1.02.01 GEAR BOXES
1.02.02 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces.
1.02.03 The gearboxes shall be designed for 24 hours continuous duty. For thermal and
mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with
cooling coils are not acceptable.
1.02.04 The gears used shall be helical conforming to IS:3681 (latest revision) or worm
reduction units or spiral bevel speed reduction units conforming to suitable Indian
Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest
revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical
type only.
1.02.05 Recommended oil grade shall be compatible with gear internals like material of
bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick,
drain plug etc.
1.02.06 Couplings
1.02.07 Flexible / Rigid Couplings
Couplings shall be used for power transmission depending upon duty requirements.
The design of the coupling shall be such that it can take shock and misalignment
without sacrificing its efficiency. Flexible couplings shall be used for low speed


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Drive Equipment
Page 2 of 4

application only. Geared type flexible coupling shall be used on low speed side for all
conveyors and other drive chains where gear box is provided. Other couplings in the
drive chains shall be either rigid or flexible type, depending upon the requirement of
equipment design and shall be finalised during detailed engineering.
1.02.08 Fluid Couplings
Fluid couplings shall be provided in all the drive machinery for belt conveyor systems
and coal crushers if the actual power requirement at motor output shaft is more than
40 kW. The fluid coupling for LT motors shall be of traction type. Cooling water coils
for traction type fluid coupling shall not be accepted. Scoop tube type fluid coupling
shall be provided for conveyors with HT motors and ring granulator type coal
crushers. Suitable electrically operated actuators shall be provided for scoop tube
operation from local as well as remote. Suitable provision for alternate manual
operation shall also be kept. Separate pump with motor or integral shaft driven oil
pump shall be provided for circulating the fluid coupling oil through oil cooler.
Arrangement for forced cooling water supply to oil cooler shall be provided by
Contractor. Suitable interlock using flow switches shall be provided in both oil as well
as water lines to trip the drive motor in the event of flow in either lines falling below
acceptable levels. Suitable pressure indicators and flow indicators shall be provided
in the cooling water lines along with all-relevant valves, and accessories. Necessary
isolation valves shall be provided in the oil / water line for maintenance of any
equipment in the line. Necessary interlock shall also be provided so that the HT
motor cannot be started from remote / local unless position of scoop tube permits no
load start of the motor. Tripping of downstream equipment while the system is under
normal operation shall result in scoop tube re-positioning to permit no load run of the
concerned HT motor. Temperature switch shall be provided in the oil circuit and shall
trip the system in case of high oil temperature.
Selection of rating & speed of actuator for scoop type fluid coupling shall be made
taking into consideration the coasting time of down stream and up stream conveyors
and the engagement/disengagement time achievable. The scoop tube operation
must be such so to ensure draining of oil from the operating circuit by providing a
double speed motor. The speed (for draining) shall be selected to match the coasting
time of down stream equipment/ conveyor. In case of crusher scoop coupling,
complete draining of oil from the operating circuit is to be ensured so that the crusher
rotor comes to a standstill when the drive is disengaged from the crusher.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Drive Equipment
Page 3 of 4

DATA SHEET : DRIVE EQUIPMENT
1.0.0 GENERAL

1.1.0 Continuous Motor Rating (Name Plate Rating) at
50 Degree Centigrade Ambient temp. for Electric
Motors

a) For conveyors of belt conveyor systems and
belt for In line magnetic separator
*120% of actual power at
drive motor output shaft at
specified design capacity

b) Crushers, Mobile trippers travel drive, mono-
rail hoists (travel and hoisting), elevators rack
and pinion gates, all the drives in coal
sampling units, various pumps of DS/DE
systems, service water systems, cooling
water system, potable water system and
Ventilation Fans
*110% of actual power
requirement at drive motor
output shaft at guaranteed
(rated) capacity.

*The actual power at drive motor output shaft shall be calculated after considering
all the losses of down the line equipments of the drive train.

2.1.0 Gear Box

2.1.1 Type

(a) Below 40 KW Helical, worm, bevel as per
requirement without cooling
coil

(b) Equal to and above 40 KW Helical / bevel helical without
cooling coil

2.1.2 Service Factor As per accepted engineering
practice / manufacturer's
recommendations

2.1.3 Ambient temperature for Thermal rating 50
o
C Minimum

2.1.4 Mounting On Machined/ Ground
surfaces
2.1.5 Output Rating
a) For belt conveyor systems
@ Service factor X {1.2 times
the actual power requirement
at drive pulley shaft at design
capacity}

b) For other equipment
@ Service factor X {1.2 times
the actual power requirement
of the driven equipment }
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Drive Equipment
Page 4 of 4

@ Service factor shall include all the components considered by the supplier and
should be clearly indicated in manufacturers gear box selection catalogues.

2.1.6 Duty 24 Hrs. Continuous

2.1.7 Rating Not less than motor name
plate rating
2.2.0 Flexible Couplings

2.2.1 Type Geared coupling.

2.2.2 Rating Not less than motor rating.

2.3.0 Fluid Couplings For all motors having rating
more than 40 KW.
2.3.1 Type

(a) L.T. Motors Traction type

(b) H.T. motors Scoop tube type.

2.3.2 Rating Not less than motor
nameplate rating

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
BELT SCALE



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Belt Scale
Page 1 of 3

A-07: BELT SCALE
1.00.00 GENERAL
Belt weigh scale for measurement of coal flow rate and quantity shall be provided at
specified locations. System shall be complete with flow rate indicator, totaliser,
control panel etc.
1.01.00 Codes & Standards
The design, manufacture, inspection and testing of Belt Scales shall comply with all
the currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The Belt Scales shall conform to the latest edition of
the following standards and codes. Other internationally acceptable standards/codes,
which ensure equal or higher performance than those specified, shall also be
accepted. Nothing in this specification shall be construed to relieve the contractor of
the required statutory responsibility. In case of any conflict in the standard and this
specification, the decision of the Employer shall be final and binding.
NEMA
NEC For electronic circuit enclosures.
IS:11547 Electronic weighing in motion system.
1.02.00 Design & Construction Requirements
1.02.01 The weigh scale shall be automatic and electronic type. It should be designed for
continuous automatic weighing, metering and printing of coal flow.
1.02.02 Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4
nos. weighing idlers. It shall have unitised construction for ease of installation and
shall be fully floating type (without pivot points). Minimum 4 nos. hermetically sealed
load cells of precision strain gauge type shall be applied in tension to support the
weigh bridge. The load cells shall have 100% overload protection and shall be
structurally safe upto to 250% of rated belt scale capacity.
1.02.03 Belt scale shall be electronic microprocessor based with its program stored in non-
volatile memory.
1.02.04 It shall be provided with self diagnostic features for trouble shooting of the entire belt
scale system.
1.02.05 Fully automatic zero and span calibration facility shall be provided.
1.02.06 The electronic systems offered by the Contractor shall include all signal conditioning,
power amplifiers and printed circuits etc. The printed circuits shall be encapsulated
against dust and moisture.
1.02.07 Belt scale shall be provided with flow rate, total quantity etc.
1.02.08 The flow rate indicator shall have minimum 4 digits. The flow totalizer should have 8
digits display scale with reset facility.
1.02.09 Complete belt scale system shall be suitable for 50C ambient temperature and
100% relative humidity. It shall be suitable for out door installation in a dusty area.
The electronic circuit enclosure, sensors housing shall be dust and watertight. The


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Belt Scale
Page 2 of 3

electronic printed circuits shall be encapsulated with epoxy or other suitable material
for protection against dust and moisture.
1.02.10 Minimum three years battery back up power failure protection shall be provided.
1.02.11 Belt scale shall be designed for a range of 20% to 120% of rated capacity with an
accuracy of atleast (+) 0.25 percent throughout its range. Belt scale provided on
Stacker Reclaimer Boom Conveyor shall have an accuracy (in the horizontal position
of Boom) of (+) 1 percent for the range of 20% to 120% of boom conveyor rated
capacity.
1.02.12 Per two (2) belt weighers, the contractor shall furnish one (1) necessary test load
chain sets required for calibration and periodic testing of the equipment. The test
load chain shall be two idler spaces longer than the weighing length of the weighers
and shall be complete with chain reset equipment with weight adding reels of
adequate size. The calibrated weight parameter length of the test chain shall be
stamped at a suitable location on the body of the equipment. The test chain shall be
installed near belt weigher with suitable arrangement for easy mounting/dismounting
of chain onto/from conveyor belt. Alternatively, supply of test weights for calibration of
belt scales is also acceptable.
1.02.13 Local panel for belt scale shall be of sheet metal.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Belt Scale
Page 3 of 3

DATA SHEET : BELT SCALE

1.0.0 GENERAL

1.1.0 Ambient Temperature 50C

1.2.0 Relative Humidity

100%

2.1.0 Type Electronic load cell type

2.2.0 Operation Microprocessor based fully automatic

2.3.0 No. of floating idlers Minimum four (4)

2.4.0 Load Cells

2.4.1 Type Strain gauge type hermetically sealed

2.4.2 Minimum Nos. Four (4)

2.4.3 Overload protection 100% of rated belt scale capacity

2.4.4

Structural capacity 250% of rated belt scale capacity

2.5.0 Flow Rate Indicator Electronic Digital Display Minimum 4
digits

2.6.0 Flow totalizer 8 digit display with reset facility.

2.7.0 Accuracy

For boom conveyor belt scale
For others
For entire range of 20% to 120% of
rated capacity

: Minimum + 1%
: Minimum + 0.25%

2.8.0 Calibration

2.8.1 Automatic

Zero & span calibration
2.8.2 Manual

With test load chain
(a) Test load chain length Two idler spaces more than weighing
lengths

(b) Chain reel equipment Complete with weight adding facility.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
DUST CONTROL
AND
MISCELLANEOUS SYSTEM


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Dust Suppression & Misc.
Page
1 of 15

A-08: DUST CONTROL AND MISCELLANEOUS SYSTEM

1.00.00 GENERAL
1.01.01 General Information/Description
1.01.02 Dust Control System
The dust control system to be furnished under this specification is required for control
of fugitive dust emissions from dust generation points such as transfer points,
screening feeders, crushers etc. Dust control is achieved by dust suppression/
extraction system.
Contractor shall guarantee and offer dust control system which shall not allow a dust
concentration in the ambient air inside the buildings more than acceptable limits as
per Employer approved guidelines or any internationally recognized hygienic
Standards/Codes.
The Capacity of dust control system specified elsewhere is for Contractors guidance
only. Contractor shall provide adequately sized fool proof dust control systems the
performance of which should be guaranteed by the Contractor. However, the
capacity of the offered system shall not be less than the specified values. Further,
for computation of design capacity of the pumps, permanent recirculation lines as
shown in tender drawings shall al
so be considered.
Water scheme for dust suppression shall be provided as indicated in tender
drawings. Dry fog type dust suppression system shall be used for all receipt and
discharge points in Transfer Houses & Crusher House. Sea water dust suppression
system shall be used for stockyard dust suppression.
Adequately sized dust extraction system shall be provided for all vibrating screening
feeders at screening feeders floor and all belt feeders at belt feeders floors of crusher
house.
1.01.03 Miscellaneous Systems
Service water system, potable water system & cooling water system shall be
provided as specified elsewhere in this specification and as indicated in tender
drawings.
1.02.00 Scope
1.02.01 a) Plain Water Dust Suppression System
Complete with water supply system, piping, spray heads, pumps, drive
motors with canopy (wherever required), couplings with enclosure, electricals,
supporting structures, approach/maintenance platforms, handling for
equipment, civil and structural works and necessary accessories shall be
provided for coal stock yard etc.
b) Dry fog dust suppression system
Complete with water supply system, compressed air system, pressure
regulating units, flow activation system, necessary instrumentation for auto &
manual operation, drives, pumps, maintenance platforms, alongwith

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Page
2 of 15

associated Civil / Structural & electrical works for dust suppression system at
coal dust generating points in all Transfer point & Crusher house.

Service water distribution system complete with water supply system, valves, quick
couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy,
couplings with enclosure, electricals, including supporting structures, handling for
equipments, civil and structural works and necessary accessories shall be provided
throughout the coal handling plant area in Contractors scope.
1.02.03 Pipings, Fittings, Valves and Specialities
The material to be supplied for completing the pipe work shall include but not be
limited to the following:
(1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing
unions, couplings, caps, blank flanges, saddles etc. necessary for making
reliable piping system.
(2) Gaskets, ring joints, jointing material etc. as required.
(3) Instrument tapping connections, stubs.
(4) Gate / plug, globe and check valves to start/stop, regulate and to prevent
back flow.
(5) Duplex Strainers.
(6) Anchors, hangers and supports as required including secondary steel
embedment etc.
(7) Bolts, nuts, fasteners as required for interconnection piping, valves and
fittings as well as for terminal points.
(8) The entire water piping of DS/SW/PW/CW / DE system (except for stockyard
DS) shall be routed/supported on concrete pedestal and conveyor galleries.
Wherever the layout does not permit the pipes to be routed over ground, the
same shall be buried in conformity to the relevant standards & shall be
provided with necessary protective coating as per relevant standards.
(9) Painting, anti-corrosive coatings etc. outside pipes as necessary.
(10) Welding electrodes and welding rods.
(11) The area around storage tanks strainers, valves etc. (located out side pump
house) shall be paved.
1.03.00 Codes and Standards
The design, manufacture, inspection and testing of Dust Control & Miscellaneous
Systems shall comply with all the currently applicable statutes, regulations and safety
codes in the locality where the equipment is to be installed. The Dust Control &
Miscellaneous Systems shall conform to the latest edition of the following standards
and codes. Other internationally acceptable standards/codes, which ensure equal or
higher performance than those specified, shall also be accepted. Nothing in this
IS:778 : Gun Metal gate, globe & check valves for general purpose.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Page
3 of 15

BS:5150 :Cast Iron Gate Valve for water works purposes
BS:5152 :Cast Iron Globe Valve for water works purposes
BS:5312 :Cast Iron Check Valve for water works purposes
IS:1239 : Mild Steel tubes & fittings.
IS:2379 :Colour for the identification of pipe line.
IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm)
IS:5312 : Swing check type reflux (non return) valves.
IS:1520 : Horizontal centrifugal pump for clean, cold fresh water.
IS:5120 :Centrifugal pump for clean, cold & fresh water.
BS: 5169 & BS:1123 : Air Receivers.
ANSI B 31.1:Code for pressure piping.
Hydraulic institute Standards of U.S.A.
1.04.01 Dry fog Dust Suppression
At specified locations dry fog dust suppression system shall be provided which
comprises spray nozzles discharging plain water & air in a fine spray to form dry fog
to capture air borne dust particles and direct them into the main coal flow. This dry
fog shall be discharged through spray heads at the dust suppression zones.
The dry fog dust suppression system shall consist of the following:
(a) Fogging system & controls consisting of:
(i) Spray bar assemblies.
(ii) Pressure regulating units
(iii) Flow activation system
(iv) Instrumentation for auto spray
(b) Compressed air system consisting of:
(i) Two (2) nos. (one no. working and one (1) no. standby) air
compressors (screw type) for each group of dry fog dust suppression
system, alongwith air receivers as specified elsewhere.
(ii) Various instrumentation & valves.

1.04.02 Each spray head in the CHP shall have a provision for installing a pressure gauge
whenever required. Further, pressure gauges shall be provided at least at two
locations.

1.04.03 Coal Yard Dust Suppression System
Sea water shall be drawn from the sea water storage tank by electric motor driven
pumps and discharged via a pipe work system through spray heads. Spray heads
shall comprise of swiveling type spray units spaced at an interval of approximately 40
meters around each coal pile as shown in tender drawings. Manually operated globe
valve shall be provided to control water supply to each spray unit. Pressure at inlet to
spray unit shall not be less than 4.5 kg/cm2 (g). HDPE pipes from pump house
onwards shall be laid in pipe trenches filled with sand.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Page
4 of 15

1.04.04 Service Water (SW) System
Service water connections are to be provided in conveyor galleries and tunnels at 50
meter intervals. Adequate number of these connections shall be provided in all
transfer houses with minimum one no. at each floor and with minimum two (2) nos. at
each floor in crusher house. Each connection shall be provided with one (1) no. 32
NB globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be
provided in each building.
Service water distribution system shall be designed considering the water scheme
and water requirement indicated in tender drawings.
1.04.05 Potable water (PW) system
Potable water connections are to be provided in all transfer points, crusher house, all
tripper floors and all control rooms/MCC rooms and toilets etc.
Water shall be drawn from the water storage tank by electric motor driven pumps and
discharged via a pipe work system to the overhead drinking water storage PVC tanks
of 2500 litres capacities. The drinking water storage tanks shall have provision for
maintenance & drain.
A portable RO (reverse osmosis) machine of reputed make is to be provided in the
MCC building at jetty area. This machine shall use raw water and convert the same
to drinking water. The RO machine shall have minimum capacity of 15 liters per hour.
The drinking water produced by the RO machine shall confirm to relevant IS.
1.04.06 Hoists with monorail of adequate capacity shall be provided in the service water/dust
suppression/potable water pump houses.
1.04.07 Wet Type Dust Extraction System
Bidder shall provide wet type dust extraction system for Vibrating Screening feeder
and Belt Feeders after crusher in crusher house. The dust extraction system shall be
of Venturi scrubber system. One independent dust extraction system for each stream
shall be provided (Total 2 nos. system to be provided). Bidder may provide multiple
Units in each of the independent dust extraction system as per his design.
1.04.07.01 Venturi Scrubber System
Venturi scrubber type wet dust collection system shall be provided at crusher house
for extracting the dust from vibrating screening feeders & belt feeders after crushers.
The system shall operate on the principle of mixing of dust laden air with water by
collision in the venturi throat forming a mass of larger particles for successful
collection in the cyclones. The scrubber unit shall have a design for built in collection
of the damp dust in a sedimentation tank which shall be discharged automatically at
periodic intervals (time setting variable) into an additional ground based settlement
pit from which only clear water shall be led by drain line (by bidder) upto coal slurry
pond.
The scrubber unit shall be of minimum maintenance type design. The system shall
be complete with venturi unit, water pockets, risers, circulating water pumps,
throttling valve, pressure gauges, all associated valves/accessories, baffles, reducing
discs, partition plates, cyclones, discharge pipe, inlet, deflectors, inspection doors of
dust light/air tight construction, sedimentation tank, float control valve, overflow trap,

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Page
5 of 15

quick filling/discharge connection, duplex structures, automatic sludge disposal
arrangement.
Further, the dust sedimentation tank with the scrubber shall have water level
maintained inside if by means of float valves. Also water overflow with trap shall be
provided. Requisite water shall be circulated in the unit by means of circulating pump
located outside this scrubber.
All items of scrubber exposed to water shall be galvanized / spray galvanised. Min.
6mm thick M.S. plate shall be used for tanks.
Pressure drop through the scrubber unit shall not exceed the range of 180 mm w.c.
An external monometer drop during operation. The system shall be designed with
min. consumption of slurry water. The dust collection efficiency shall be 95% down to
10 micron size.
1.04.07.02 Arrangement shall be provided in the slurry discharge system for separating dust and
water and discharging only clear water to the coal slurry pond. The dust shall be
removed manually for subsequent transportation to yard. Technical details of the
offered system shall be furnished in the bid. All materials including piping, valves,
trenches etc. required for the satisfactory operation of aforesaid removal system shall
be included in bidders scope.
1.04.07.03 Dust Collection Hood:
(i) The hood connections shall be designed for collection of dusty air from
vibrating screening feeders, Belts Feeders (after crusher).
(ii) Centre line of the hoods shall be located at the point of generation of
maximum dust.
(iii) The hoods shall be adequately sized to collect all dusty air generated at the
point. Velocity in the hood must not be so high as to draw larger size particles
unnecessarily.
(iv) At all suction hoods (except for bunker dust extraction units) damper shall be
provided.
(v) The hoods shall be made of MS plate of adequate thickness.
1.04.07.04 Ducting
(i) The ducts for conveying dusty air shall be of round shape and of streamline
appearance.
(ii) The velocity of air in the duct shall be high enough (in the range of 18 to 21
metres/sec.) to transport in the suspended dust in the air.
(iii) Flexible connections shall be provided at the duct connections to inlet and
discharge of the fans. All flexible connections shall be non-collapsible type
and their length shall be kept to a minimum.
(iv) Duct supports shall be provided as per stipulations here under:
Diameter of duct Spacing of support
Less than 200 mm Maximum 3.00 metre
More than 200 mm Maximum 2.50 metre
(v) The ducting shall be made of MS Sheet with thickness not less than 14
gauge.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Page
6 of 15

1.04.07.05 Suitable platform and ladders shall be provided for carrying out maintenance of dust
separator / collection tower.
1.05.01 Water Supply Pumps

1.05.01.01 Water supply pumps shall be provided as required.

1.05.01.02 The pumps shall be complete with drive motors, baseplate and other accessories.
The constructional features of the pump shall be as follows:
a). Pump casing may be axially or radially split. The casing shall be of robust
construction. Casing drain and vent connections shall be provided.
b). Impeller shall be made in one piece and securely keyed to the shaft. Locking
device shall be provided to prevent its loosening during all conditions of
operation.
c). Wearing rings shall be of renewable type. Opposed wearing surface shall be
of hardened material and shall have a hardness difference of at least 50 BHN.
d). Replaceable shaft sleeves shall be provided to protect the shaft where it
passes through bearings and stuffing boxes. The end of the shaft sleeve
assembly shall extend through the packing gland. Shaft sleeve shall be
securely locked or keyed to the shaft to prevent loosening or rotation. Shaft
and shaft sleeves shall be machined and assembled for concentric rotation.
e). The design of the shaft shall take into consideration the critical speed, which
shall be at least 20% away from operating speed.
f). Pump bearings shall be of antifriction type. Bearings shall be readily
accessible without disturbing the alignment of pump.
g). Packed stuffing boxes shall be of sufficient length to prevent leakage along
the shaft and shall be complete with all packing and lantern rings required.
h). Pumps shall be furnished complete with an approved type of flexible -
coupling.
i). Couplings guards made of expanded metal and bolted to the base plate shall
be furnished.
j). The common base plate for pumps and motor shall be in one piece and shall
be made of fabricated steel.
k). Pump speed shall be less than 1500 rpm for pumps of capacity more than 10
m3/hr.
1.05.01.03 The power, head and flow characteristics of each pump shall be suitable for parallel
operation. The Power characteristics of the pumps shall be of non overloading type.
1.05.01.04 All rotating parts of the pumps shall be statically and dynamically balanced.
1.05.01.05 The motor shall be rated for continuous operation and confirm to companion
electrical specification. However, motor rating shall not be less than the max. power
demand throughout the entire range of operation of pump.
1.05.01.06 Design duty point of pump shall match with the average value of maximum and
minimum flow rates of the pump in the stable operation zone.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Page
7 of 15

1.05.01.07 Materials of construction of pump components shall be as stated in data-sheet to this
section.

1.05.02 Piping, Fittings, Valves and Specialties

1.05.02.01 Piping & Fittings
(a) Material of construction of piping and fittings shall not be inferior to those
given in data sheet of this section.
(b) All piping shall be capable of withstanding the maximum pressure in the
corresponding line at the relevant temperature.
(c) In general pipe sizes 65 mm NB and larger are to be joined by butt welding
and pipe work of size 50 mm NB and below by socket welding/screwed
connections. Joints at valves or specialities shall be flanged for sizes 65 mm
NB or large and screwed for sizes 50 mm NB and below. All galvanised
piping shall be joined by screwed connections. Minimum pipe diameter
selected for DS/SW/PW/Cooling Water System (along with branch pipes)
shall be 32 NB (except for dry fog system). However, for Dry fog dust
suppression system minimum pipe size shall be 20NB.
(d) End preparation for butt welding shall be done by machine/flame cutting.
Socket weld and preparation shall be saw/machine cut.
(e) Hangers and supports shall be capable of carrying the sum of all concurrently
acting loads. They shall be designed to provide the required supporting
effects and allow pipe line movements as necessary. All guides, anchors,
braces, dampers, expansion joints and structural steel to be attached to the
building/structure, trenches etc. shall be provided. The type of hangers and
components for all piping shall be selected and approval obtained from the
Employer.
(f) All piping shall be routed on ground on concrete pedestals and at road
crossings, these shall be buried through hume pipes.
1.05.02.02 Valves and Specialities
(a) Valves & Specialities shall be used to start, stop or regulate the flow. All
valves/specialities below 50 mm size in service water/dust suppression/
potable water lines should be plug type of proven make.
(b) All valves shall be suitable for most stringent service conditions i.e. flow,
temperature and pressure under which they may be required to operate.
(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above 50NB
and Globe valves shall be used for regulating the flow.
(d) Valves shall be provided with back seating bush to facilitate gland renewal
during full open operation.
(e) All gate and globe valves of size 65 NB and large shall be bolted bonnet,
outside screw, rising type with flanged ends. Valves of size 50 NB and
smaller shall be with screwed ends.
(f) Valves shall be provided with the following as necessary :
(1) Hand wheel
(2) Position indicator

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Page
8 of 15

(3) Draining arrangement.

(g) Material of construction of valves shall not be inferior to those given in data
sheet of this section.
(h) Globe valves shall be provided with contoured plug to have well controllability.
(i) Non-return valves shall be swing check type. These valves will have a
permanent arrow inscription on its body to indicate direction of motion of the
fluid.
(j) All valves shall be provided with hand wheel, chain operated, extension
spindle and floor stand wherever required so that they can be easily operated
either at a lower or higher elevation as the case may be.
(k) Strainer shall be of duplex type designed with 3 way valves so that one filter
can be cleaned while the other is in operation. Suitable vent and drain valves
shall also be provided. Screen opening area shall be at least four times the
pipe cross sectional area. Pressure drop in clean conditions shall not exceed
1.5 MWC at full flow.
(l) Bib cocks provided for potable water system shall be made of copper alloy/
Cast Iron.
1.05.03 Special cleaning, protection and painting
1.05.03.01 Piping & Fittings

(a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust
etc. by wire brushing.

(b) For painting of overground exposed steel pipes refer Sub-section-IIIA-05.

(c) For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall
be applied on the cleaned surface. Finally, it should be wrapped with
minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt
shall be generally touched with heavy duty bitumastic paint.

1.06.00 Pumps for DS/SW/CW/PW/DE systems shall be selected with minimum 10% margin
on capacity and 20% margin on computed head.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
9 of 15

DATA SHEET: DUST CONTROL & MISCELLANEOUS SYSTEM

1.0.0 GENERAL

1.1.0 Dust Control Dust suppression/ extraction system.

1.2.0 Miscellaneous systems Service water system, Potable water
system, Cooling water system.


Operation (a) Sea water sprayed through
nozzles for stockyard.

(b) Water & air sprayed to form dry
fog through nozzles at coal
transfer points.
2.1.1 Dry fog dust suppression system
(i) Compressor Screw Type
(ii) No. of Compressors to be provided One working & one Standby, per
group
(iii) Air receivers One no. of min. 2 cu.m capacity
located near compressors & 200
litres capacity at various location
(iv) Nozzles Dry fog type
2.1.2 Coal Yard Dust Suppression

a) Pump As per tender drawing.
b) Spray heads
(i) Type Swiveling type spray unit
(ii) Spacing 40 m.
(iii) Minimum Pressure at inlet 4.5 Kg/sq.cm
(iv) Flow from each sprinkler 500 LPM
(v) Throw of sprinkler spray Suitable to cover entire stockpile
surface as per tender drawing

(vi) Material of construction:

a) Nozzle SS-316L


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
10 of 15

2.2.1 Water connections
(a) Conveyor Galleries every 50 m
(b) Transfer points & Drive house Min. 1 no. at every floor
(c) Crusher House Min. 2 nos. at every floor
(d) Pump House Min. 1 no.
2.2.2 Connection details 32 NB plug valve
2.2.3 Hose pipes with hose reel One in each building of 25 mtr.
Length with nozzle
2.3.0 Potable Water System
2.3.1 Pumps 2 X 100% electric motor driven
2.3.2 Water connections
(a) Transfer points Minimum one (1) no. at each floor
(b) Crusher house Minimum two (2) no. at each floor
(c) Tripper floor Minimum one (1) no. at every tripper
bay.
(d) Control room Minimum one (1) no. at each floor
(e) MCC rooms and toilets Minimum one (1) no.
(f) Pump house Minimum one (1) no.
3.0.0 CONSTRUCTION REQUIREMENTS

3.1.0 Water Supply Pumps for
DS/SW/PW/CW

3.1.1 Casing Axial or radially split with drain & vent
connection

3.1.2 Impeller One piece, keyed to shaft along with
locking device

3.1.3 Shaft Critical speed atleast 20% away from
operating speed

3.1.4 Shaft sleeves at bearings & stuffing boxes.

3.1.5 Bearings Antifriction type

3.1.6 Wearing rings Renewable type (preferable)


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
11 of 15

3.1.7 Pump speed Below 1500 rpm for capacity more
than 10 cub. m/hr.

3.1.8 Head flow characteristics Suitable for parallel operation.

3.1.9 Materials (except stockyard DS)

(a) Casing Cast Iron to IS:210, FG 260

(b) Impeller Bronze conforming to Gr.I of IS:318

(c) Impeller Wearing ring Bronze conforming to Gr.I of IS:318

(d) Casing Wearing ring Bronze conforming to Gr.I of IS:318

(e) Shaft Medium carbon steel

(f) Shaft sleeve Stainless steel conforming to AISI-
416 hardened.

(g) Gland packing Impregnated teflon

Material for Sea Water Supply Pumps
for stockyard DS

a) Casing 18% Ni-cast Iron D-2 Type
b) Impeller ASTMA 351 CF 8 M
c) Wear Plates/ Liners/ Wear rings,
Shaft & Shaft sleeve
SS 316 L
The other parameters for the Stockyard Dust Suppression pumps shall remain
as applicable for other water pumps.

3.2.0 Piping & Fittings (except stockyard
DS)

3.2.1 Joints

(i) Pipe to pipe

Pipe size < 50 NB
Pipe size > 65 NB

Socket welding/screwed
Butt welding
(ii) Pipe to valves

Pipe size < 50 NB
Pipe size > 65 NB

Screwed
Flanged

3.2.2 Isolation of flow Plug / Gate / Sluice valves

3.2.3 Regulation of flow

Globe Valve


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
12 of 15

3.2.4 Valves

(i) Size > 65 NB Bolted bonnet outside screw rising
type, flanged end.

(iii) Size < 50 NB

screwed ends (only plug valve)

3.2.5 Materials for Pipework

(a) For sizes 200 NB and Larger ERW carbon steel pipes to API-5L-
Gr.B/IS:3589 with minimum
thickness 6.35 mm

(b) For sizes 150 NB to 65 NB ERW carbon steel black pipes to
IS:1239 (Part-I, Heavy class).

(c) For sizes 50 NB & below

ERW carbon steel galvanized pipes
to IS:1239 (Part-I) Heavy class.

3.2.6 Materials for Valves & Specialities

(a) Cast Iron Valves (65 NB & above)

(i) Body and bonnet Cast Iron to IS:210, Gr.FG-200

(ii) Disc for non- return Cast Iron to IS:210, Gr.FG-200
valves

(iii) Seating surfaces and rings 13% chromium steel

(iv) Hinge pin for non return valves Stainless steel type AISI-316

(v) Stem for gate and globe valves 13% chromium steel

(vi) Back seat bush 13% chromium steel

(b) Gun metal valves (50 NB &
below and upto a working
pressure of 10 kg/cm2)

(i) Body Gun metal to IS:318, Gr-2.

(ii) Trim Gun metal to IS:318, Gr-2.

(c) Duplex Strainer

(i) Body MS fabricated

(ii) Strainer Stainless steel type element AISI-
316


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
13 of 15

(d) Pressure Gauge/Switch (to be
provided with isolating valves,
gauge cock, snubber and
siphon)

(i) Dial size 150 mm

(ii) Accuracy (+/-) 1% of range span

(iii) Bourdon AISI 316 SS

(iv) Block AISI 316 SS

(v) Movement AISI 316 SS

(vi) Case and Bezel Die cast Alum. Weather proof case
stove enameled block with screwed
type inner bezel of ABS plastic and
glycerin filled.

(vii) No. of contacts 2NO + 2 NC

(viii) Type of contact Adjustable throughout the range.

(ix) Degree of protection IP- 65

(e) Solenoid valve (to be provided
with isolating valve)

(i) Type 2/2 way Diaphragm type pilot
operated

(ii) Diaphragm molded synthetic rubber

(iii) Body Forged brass / SS

(iv) Pressure 0.5 to 10 kg/cm2

(v) Protection Class IP 65

(f) Flow Switch (to be provided
with isolating valves)

(i) Body Forged steel

(ii) Extension Rod/wire SS-304

(iii) Sleeve and Sleeve pipe SS-304

(iv) Cover Die cast aluminum


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
14 of 15

(v) Max. working pressure 10 kg/sq.cm

(vi) Repeatability 0.5%

(vii) No. of contacts 2NO + 2 NC

(viii) Type of contact Adjustable throughout the range.

(ix) Protection class IP 65
(g) Level Switch

(i) Type Displacer operated magnetic type

(ii) Displacer SS 316

(iii) Wire rope SS 316
(iv) Spring Housing Spring and
sleeve pipe

SS 316

(iv) Cover Cast Aluminum

(v) No. of Contacts 2 NO + 2 NC

(vi) Type of Contact Adjustable throughout the range.

(viii) Protection class IP 65

(h) Level gauges

(i) Type Float type mechanical gauge with
arrow scale

(ii) Accuracy (+/-)1% of full scale range

(iii) Material of construction

(aa) Float & Guide wire 316 SS

(bb) Elbows Suitable grade of SS

(cc) Housing Mild Steel

(dd) Cable fastener SS 304

(i) Dust suppression Nozzles (for
dry fog DS)

(i) Type Fogging, non-clogging type

(ii) Material Stainless Steel


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
15 of 15

(iii) Nozzle housing To ensure protection of nozzle
against damage.

(j) Y Strainer

(i) Body SS 304

(ii) Plug SS 304

(ii) Filter Element SS 316, 60 mesh

3.3.0 Piping & fitting (for sea water DS for
stockyard)

3.3.1 Material for pipe work HDPE Heavy duty

3.3.2 Material for Valves & Specialities

a) Valves

i) Body/wedge/Disc 18% Ni cast iron D-2 type

ii) Tram /stem / shaft SS-316 L.

b) Duplex strainer

i) Body SS-316L

ii) Strainer SS-316 L

c) Level switch/Level gauge

i) Displacer/wire rope/float/grid SS 316 L

ii) Elbow SS 316 L

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
VENTILATION SYSTEM


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page 1 of 8

A-09: VENTILATION SYSTEMS
1.00.00 GENERAL
1.01.01 Mechanical Ventilation system
The air quantity for mechanical ventilation system shall be estimated based on
equipment and solar heat loads and the temperature rise inside the building.
Necessary air filters shall be provided to supply only clean air into building. Exhaust
air shall be discharged at a suitable height above building. Exhaust fans shall be
provided for tripper floor, Toilets, Battery rooms.
Fans for toilets and battery rooms shall be propeller type. Fans for tripper floor shall
be axial flow fans complete with rain protection cowl and bird screen.
1.01.02 Pressurised Ventilation System
The pressurised ventilation system having adequate nos. of supply air fans with
washable metallic pre filters, HDPE fine filters and self closing flaps (gravity louver
shutter), ducting along with 3 phase AC motor drives, electricals, supporting
structures, access / maintenance platforms shall be provided in all MCC/switchgear
room areas of coal handling plant to be furnished under this specification. The
pressurized ventilation system shall be designed considering 15 air changes per hour
to maintain these areas pressurised slightly above atmospheric pressure to prevent
ingress of dust from outside.
1.01.03 Air Conditioning System
Air conditioning system shall be furnished for control room area of main CHP control
building, MCC rooms on stackers & Reclaimers, operators cabins in Stackers &
Reclaimers, office room in main CHP control room, and other electrical buildings as
specified elsewhere. It shall be designed considering the equipment heat loads, solar
heat loads, heat gain into the room, adequate no. of air changes etc. to maintain a
uniform temperature and relative humidity within the air conditioned areas.
2x100% capacity air conditioning packaged units (PAC) with air cooled condensers
shall be provided for Main Control Room, office room of Main Control Room &
various MCC Rooms as specified elsewhere in spec. complete with supply and return
air ducting.
Window ACs shall be provided for MCC room of Stacker & Reclaimer, operator's
cabin of Stacker & Reclaimer and RIO room.
Area around centrifugal fans, filters, motor foundation shall be paved to have a clear
surrounding.
The design, manufacture, inspection and testing of Ventilation & A/C System shall
comply with all the currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. The Ventilation & A/C System shall
conform to the latest edition of the following standards and codes. Other

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page 2 of 8

IS:3588 : Specification for electrical axial flow fans.
IS:2312 :Propeller type AC Ventilation fans
IS:3963 :Specification for roof-extractor units
IS:4894 :Centrifugal Fans
IS:655 :Specification for Metal Air Duct
ARI:210 :Standard for Unitary air conditioning equipment.
ARI:270 :Standard for application, installation and servicing of unitary equipment.
IS:8183 :Specification for bonded mineral wool.
IS:661 :Thermal insulation for cold surfaces.
IS:4671:Expanded polystyrene for thermal insulation purpose.
IS:8148 :Packaged Air conditioners.
1.03.01 Axial Fans
1.03.01.01 Design duty point of the fan shall match with the average value of maximum and
minimum flow rates of the fan in the stable operation zone. The speed of the fan
shall not exceed 960 rpm for fan with impeller diameter above 450 mm and 1440 rpm
for fan with impeller diameter 450 mm and less. The first critical speed of rotating
assembly shall be at least 25% above operating speed.
1.03.01.02 Impellers shall be axial flow type single piece.
1.03.02 Centrifugal Fans
1.03.02.01 The fan units shall be centrifugal type with radial bladed impeller. For design,
purpose out door ambient temperature shall be taken as 50 deg.C.
1.03.02.02 Fans shall be manufactured vibration free in operation and shall be designed to limit
noise level within limits specified in Data Sheet.
1.03.02.03 The motor shall be rated for continuous operation and conform to companion
electrical specification. However, motor rating shall not be less than the max. power
demand throughout the entire range of operation of fan.
1.03.02.04 All fan mountings shall have adequate arrangement for vibration isolation.
1.03.02.05 The reverse flow through non-working fan shall be prevented by dampers. The
dampers shall be made out of 18 SWG MS sheets.
1.03.02.06 Design duty point of the fans shall match with the average value of maximum and
minimum flow rate of the fan in the stable operation zone.
1.03.03 Filters
1.03.03.01 Metallic Filters
Metallic cleanable filters shall be provided as required. Max. air velocity considered
shall be 2 m/sec.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page 3 of 8

1.03.03.02 HDPE Filters
HDPE filters should have an efficiency of 90% down to 5 microns. Velocity across
the filter shall be limited to 2.5 m/sec.
High efficiency filter (for A/C purpose). Filtration efficiency shall be 99% down to 5
microns. Pressure drop across the filter under clean condition shall not be more than
10 mm w.c.
1.03.04 Packaged Air-Conditioning Unit
PAC units shall be provided as required.
1.03.04.01 PAC units shall be factory tested and assembled self contained units complete with
refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units
wherever required shall be insulated with expanded polyethylene conforming to
IS:4671.
1.03.04.02 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air
cooled condenser (outdoor air) section. Heavy gauge steel cabinet finished with
paint of approved colour or powder coating, shall be used to house components of
PAC.
1.03.04.03 The evaporator and condenser coils shall be arranged for direct expansion cooling
and shall be formed of aluminum fins mechanically bonded to seamless copper tubes
and electrically tinned. The inter-connecting refrigerant circuits shall comprise of
hermetically sealed scroll compressor and motor with all necessary isolation valves,
with adjustable set point, sight glass, copper tubing and pipeline ancillaries. The
condenser coils shall be air cooled by propeller type fans complete with safety
guards. The condensing coils shall be suitably arranged to avoid radiant heat pick-
up from solar sources.
1.03.04.04 The evaporator air blower(s) shall be centrifugal forward curved type belt driven by
individual motor(s) and suitable for the external static pressure. The fan assembly
shall be isolated from the casing by anti-vibration mounts. The fan/motor drive shall
be capable of capacity adjustment by pulley changes within +15% of design duty.
1.03.04.05 High efficiency filters shall be provided in the main supply air duct and in the fresh air
connection to return air duct.
1.03.04.06 Supply and return air distribution ducting complete with insulation, of resin bonded
mineral wool equivalent of density at least 24 Kg/m and thermal conductivity of max.
0.49 mw/cmC conforming to IS:8183 including supporting structures, approach/
maintenance platforms, civil and structural works and necessary accessories shall be
provided.
1.04.00 Construction Requirements
General construction details of various equipment under Contractors scope shall be
as elaborated in subsequent clauses below.
1.04.01 Axial Flow Fans
Axial flow fans shall be provided as required.
1.04.01.02 Impellers shall be axial flow type and single piece cast aluminum with aerofoil blades
construction. It shall be finished all over and balanced dynamically. Impeller shall be
mounted directly on the motor shaft.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page 4 of 8

1.04.01.03 Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall
be provided with suitable supports. Access door shall be provided in the casing for
easy access to motor and impeller. Suitable arrangement for mounting of motor shall
be provided.
1.04.01.04 Rain protection cowls will be designed to suit wall exhausters/supply fans for
protecting fans/motors from rain. It will be provided with bird screen.
1.04.01.05 Inlet cone or bell and outlet cone shall be provided as required. It should be made of
G.I. or M.S.
1.04.01.06 Motor shall be of totally enclosed type complying with the companion electrical
specification. Suitable rain/sun shade for motors shall also be provided.
1.04.02 Centrifugal Fan
Centrifugal fans shall be provided as required.
1.04.02.01 The casing shall be of welded construction fabricated with heavy gauge material. It
shall be rigidly reinforced and supported by structural angles. The seams shall be
permanently sealed airtight. Split casing shall be provided on larger sizes of fans.
Casing drain with valves shall be provided wherever required.
1.04.02.02 The impeller shall have die formed curved blades fabricated out of MS heavy gauge
welded to the rim and back plate to have a non overloading characteristics of the fan.
Rim shall be spun to have a smooth contour. If required intermediate stiffening rings
shall be required. The impeller, pulley and shaft sleeves shall be secured to the shaft
by key and/or nuts. The impeller along with driven pulley shall be dynamically
balanced. Fan shaft shall be of EN-8 equivalent.
1.04.02.03 The bearings shall be self-aligning heavy-duty ball or roller bearings. They shall be
adequately supported. They shall be easily accessible and lubricated properly from
outside.
1.04.03 Filters
1.04.03.01 Metallic Filters
Metallic cleanable filters shall consist of V-fold galvanised wire mesh inter spaced
with a flat layer of galvanised wire mesh. The density of the filter medium shall
increase in the direction of airflow. Wire mesh edges shall be suitably hemmed to
eliminate the danger of abrasion during handling. Filter medium shall be supported
on either side by galvanised expanded metal casing. Filter frame shall be constructed
from galvanised sheet of thickness not less than 18 gauge.
1.04.03.02 HDPE Filters
HDPE filters shall be provided as required. To facilitage periodic cleaning of filters by
water washing, tap or service water connection near the filters shall be provided.
1.04.03.03 High efficiency filter (for A/C purpose)
The media of the filter shall be made from either special synthetic non-woven bond
fiber design or made from micro fiber glass media. It shall be supported with GI wire
mesh or aluminum mesh and shall be housed in an aluminum sheet frame. It shall
be of washable type several times.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page 5 of 8

1.04.04 Package A/C Unit
1.04.04.01 A separate cubicle shall be provided within the overall casing to house the
thermostatic controls, which shall be electric/electronic solid state, prewired and
tested. The refrigerant system shall be protected by pressure limiting devices,
electric and thermal overloads and unloading facilities to provide the required control
range tolerances. A low voltage room thermostat or RTD based temperature sensing
device shall be provided for wall mounting. The casing shall be fitted with all
necessary coil drains and service connections/ entries.
1.04.04.02 PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The
units shall be fully packaged and incorporate integral room air temperature sensor
and manufacturers work fitted safety interlocks. All controls shall be prewired to unit
mounted control/power terminal boxes.
1.04.05 Ventilation and Air Conditioning system ducting
1.04.05.01 All GI sheet metal ductwork required for ventilation and air conditioning system shall
be furnished by the supplier. All ducts and plenums unless otherwise noted shall be
constructed out of standard quality galvanised steel sheet. All sheet metal ducts
shall be fabricated and installed in conformity to the requirements of IS:655. Steel
supports for the ductwork shall be furnished as required. The thickness of ducting
steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be
1.25 mm. The flexible connection between fan and ducting shall be on teflon
impregnated canvas. The zinc coating on GI sheet shall be 275 gm/m
2
.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page
6 of 8

DATA SHEET: VENTILATION SYSTEM

1.0.0 GENERAL

1.1.0 Mech. Ventilation System To provide ventilation using
fans for specified areas.

1.1.1 No. of air changes per hour for overground
buildings

Not less than 10 air changes
1.1.2 Equipment

Axial fans
1.2.0 Pressurised ventilation system To provide clean air to all
MCC / Switchgear buildings

1.2.1 No. of air changes per hour Not less than 15

1.2.2 Equipment Centrifugal fans/Axial Fans
and exhaust air fan

1.3.0 Air-conditioning system

1.3.1 Temperature to be maintained 24 1 deg. C

1.3.2 Humidity to be maintained 60 5% relative humidity

1.3.3 Fresh Air intake Minimum 1.5 air changes per
hour.

1.3.4 Equipment 2 x 100 % roof mounted
package AC units along with
ducting etc. and 2X100%
window AC

1.4.0 Outside Ambient Conditions

As per weather data given in
project synopsis


2.1.0 Axial Fans

2.1.1 Capacity 10% more of actual
requirement

2.1.2 Head 20% more of actual
requirement

2.1.3 Speed

(a) Impeller dia above 450 mm Max. 960 rpm


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page
7 of 8

(b) Impeller dia less than or equal to 450 mm Max. 1440 rpm

(c) Critical speed 25% above operating speed.

2.2.0 Centrifugal Fans

2.2.1 Capacity 10% more of actual
requirement

2.2.2 Head 20% more than actual
requirement

2.2.3 Speed Max. 1500 rpm

2.2.4 Outdoor temperature 50 deg.C.

2.2.5 Rating Continuous

2.3.0 Packaged Air-Conditioning Unit

2.3.1 Mounting Outdoor

2.3.2 Service/application

Continuous, round the clock.
2.3.3 Capacity

(i) TR Suitable

(ii) CFM Suitable

2.3.4 Type of compressor Hermetically sealed scroll
compressor

2.3.5 Condenser Air cooled type

2.3.6 Fan Forward curved centrifugal
fan

2.3.7 Filter High efficiency filter

2.3.8 Cooling Coil

(a) Type Direct Expansion

(b) Material Copper

(c) Fins Aluminum mechanically
bonded.

2.3.9 Refrigerant Piping Copper

2.3.10 Insulation for PAC parts Expanded polyethylene of
density at least 15 kg/cub.m.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Ventilation System

Page
8 of 8

2.4.0 Filters
2.4.1. Metallic Filters
(1) Max. air velocity 2m/sec.
2.4.2 HDPE filters

(1) Efficiency 90% down to 5 microns

(2) Max. velocity 2.5 m/sec.

(3) Testing As per BS 2831 / Sqv.
2.4.3 High Efficiency Filter

(1) Efficiency 99% down to 5 microns.

(2) Pr. drop across 10 mm W.C.

(3) Testing As per BS 2831 / Sqv.

2.5.0 Insulation for A/C Ducting Resin Bonded
Mineral wool as per IS:8183

2.5.1 Density 24 kg/cub.m

2.5.2 Thermal conductivity 0.49 mw/cm deg.C

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
CHP BUILDING


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP BUILDINGS

Page
1 of 5

A 10: CHP BUILDINGS

1.00.00 GENERAL
Various buildings in coal handling plant like transfer houses, crusher house, control
rooms, MCC rooms complete with all associated civil foundations and other civil,
structural and architectural works shall be provided by the Contractor as per the
specification.
Construction/fabrication/erection and designing aspects of various buildings shall be
as per the Civil/Structural specifications.
The design and construction of CHP Buildings shall comply with all the currently
applicable statutes, regulations and safety codes in the locality where the equipment
is to be installed. The CHP Buildings shall conform to the latest edition of the Indian
standards and codes. Other internationally acceptable standards/ codes, which
ensure equal or higher performance than those specified, shall also be accepted.
Nothing in this specification shall be construed to relieve the contractor of the
required statutory responsibility. In case of any conflict in the standards and this
1.02.00 Design Requirements
1.02.01 All CHP buildings shall have sufficient space to accommodate the entire equipment
like head end, drive unit and tail end of various conveyors, crushers, hoppers,
chutes, control equipments, MCCs, batteries, supports for conveyor bridges,
tensioning arrangements, approach/maintenance platforms with ladders, external /
internal stairs, handrails, RCC floors, foundations etc. Moreover, ample space shall
be provided for maintenance purposes. Outside stairs to transfer points and crusher
house shall be open type. However, a weather canopy shall be provided at the top.
1.02.02 Mechanical Handling arrangements with adequate monorails etc. shall be furnished
for servicing and installation of various housed equipment as described elsewhere.
1.02.03 Building floors shall be washed periodically with water for which necessary slope &
drains shall be provided from each floor leading to minimum 4 nos down comers of
minimum 273mm OD each building. However for MCC, control buildings and pump
houses, minimum 150 mm dia, 4 nos galvanized MS pipes conforming to IS :1239
shall be provided. The system shall be designed considering water mixed with coal.
A drain pit shall be provided near each building to collect water/coal mixture.
Overflow from this pit shall be connected to nearest drain. 1 mtr x 1 mtr size
dust/debris MS chutes from all the floors to ground floor shall be provided at all
buildings/transfer houses (including the TPs in Employers scope) and crusher
house. The plate thickness shall not be less than 6mm.
1.02.04 Various dimensions and relative elevations shown in tender drgs. for various
buildings/structures are minimum acceptable to the Employer. However, final
dimensions for various buildings/structures and relative elevations shall be decided
based on actual details/maintenance requirements of contractors equipment to meet
technical specification requirements without any implication to the Employer. The
sizes of these houses shall be approved by the Employer at the stage of detailed
employer.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP BUILDINGS

Page
2 of 5

Openings in the floors of CHP buildings (i.e. TPs/CH etc.) shall be provided with curb
of 100mm high to avoid water falling down to lower floors.
1.02.05 Vertical bracings in transfer points and crusher house shall be provided only along
four sides. No bracing system projecting outside the building shall be allowed.
1.02.06 Floor at ground shall be provided in all transfer points, crusher house, ground
conveyors etc. Level of floor at ground shall be 500 mm above ground/grade level
unless noted otherwise. For enclosed ground conveyor 750mm wide plinth protection
along with drainage arrangement shall be provided along the conveyor on both sides.
Suitable opening at every 50mtr interval shall be provided on either side in a
staggered manner for exit / entry of personals. Necessary drains must be provided all
along the floors of ground conveyor.
1.02.07 The accessories for dust control & miscellaneous system like water pumps etc. shall
be housed in separate pump houses.
1.02.08 For areas where ground floor is located less than 500 mm above ground level/grade
level, outside face of the brickwalls shall be plastered with rich cement-sand mortar
(1:4) with neat cement finishing over it for a height of 500 mm above ground
level/grade level.
1.02.09 Toilet with potable water facilities shall be provided in all MCC Control Rooms,
crusher houses and potable water shall also be provided at all transfer houses,
crusher house and all tripper floors in bunker bay.
1.02.10 All associated civil & structural work for the elevator, elevator stairs, platforms at
various landings shall be carriedout for crusher house and Transfer Point, where
elevator is provided.
1.02.11 Necessary facilities for ventilation of control/MCC rooms and Bunker bay shall be
provided as specified elsewhere.
1.02.12 External fire escape stair case alongwith internal staircase (wherever applicable)
shall be provided for all MCC/ control rooms & Crusher house.
1.02.13 5 mtr wide paving beyond the surface drains shall be done around all transfer points,
Crusher house for movement of trucks.
1.02.14 All building shall have the fire protection provisions to meet TAC and IS 3034
regulations. The approach for trucks should be provided around transfer point,
crusher house and upto hoist lifting area.
1.03.00 Construction Requirements
1.03.01 Transfer Houses
1.03.02 All overground buildings shall be of steel frame construction.
1.03.03 All underground & partially underground structures shall be entirely in RCC.
1.03.04 External staircases shall be provided for all transfer points.
1.03.05 The transfer houses shall have permanently colour coated steel sheet enclosure with
steel framed doors and louvered windows.
1.04.00 Crusher House
The crusher house shall have permanently colour coated steel sheet enclosure with
steel framed doors and louvered windows.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP BUILDINGS

Page
3 of 5

1.05.00 MCC/ Control Rooms
1.05.01 Control rooms, MCC rooms shall be of RCC construction with Brick enclosure. Fire
safety wall in/around transformer yards shall be as per detailed engineering.
1.05.02 Air-conditioned areas of CHP buildings shall have double glass windows.
Roofs/sidewalls shall be provided with insulation to minimise the heat load. All frames
of doors and windows shall be of extruded aluminum and shall be capable of
isolating the conditioned space. All AC Control rooms & MCC rooms shall have two
independent entry points through doors.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP BUILDINGS

Page
4 of 5

DATA SHEET : CHP BUILDING

1.0.0 GENERAL

1.1.0 Transfer Houses, Crusher House

Steel Construction
1.2.0 Control/MCC rooms RCC construction

REQUIREMENT

2.1.0 Transfer Houses & Crusher House

2.1.1 Space requirement To accommodate all equipments drive
units, head/ tail ends of conveyors
transfer chutes etc. and to provide
adequate space for maintenance.

2.1.2 Roofs & Floors RCC construction with facility to wash
the floors. Min. slope of 1:100 for roof
and 1:80 for floors in TPs and 1:100 for
floors in crusher house shall be
provided towards drain pipes.

2.1.3 Walls/Enclosure Permanently colour coated cladding

2.1.4 Stairs Steel construction with minimum 1000
mm width.

2.1.5 Doors & Windows Steel construction

2.1.6 Monorails Capacity as per equipment installed

2.1.7 Drainage From each floor to drain pit suitable to
handle coal slurry.

2.1.8 Elevators Necessary space, platforms /
interconnections with the respective
buildings, machine room etc. wherever
applicable.

2.1.9 Vertical bracing Only along four sides.

2.1.10 Maintenance platform with handrails. Chequered plate floors Min.1500 mm
wide

2.1.11 Flooring 50 mm thick metallic hardener like
ironite floor finish.

2.1.12 Level of ground floor 500 mm above ground level.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP BUILDINGS

Page
5 of 5

2.2.0 Control/MCC Rooms

2.2.1 Construction RCC construction with Brick Enclosure

2.2.2 MCC Rooms Pressurised with dust free air

2.2.3 Control Rooms Air conditioned Environment

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
VIBRATING SCREENING FEEDER



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Vibrating Screening Feeder

Page
1 of 3

A-11: VIBRATING SCREENING FEEDER

1.00.00 GENERAL
a) Vibrating screening feeder shall be provided before each crusher to ensure
uniform feeding of coal to the crusher and separation of (-) 20 mm coal from feed
to the crusher.
b) Bidder shall source vibrating screening feeders from a manufacturer / supplier
who has supplied minimum two (2) nos. of vibrating screening feeders of at least
1600 TPH capacity for handling coal which should be in successful operation for
a minimum period of two (2) years as on date of bid opening.
1.01.00 CODE & STANDARD
The design, manufacture, inspection and testing of Vibrating screening Feeder shall
locality where the equipment is to be installed. The Vibrating screening Feeder shall
conform to the latest edition of standards and codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance than those
specified, shall also be accepted. Nothing in this specification shall be construed to
relieve the contractor of the required statutory responsibility. In case of any conflict in
the standard and this specification, the decision of the Employer shall be final and
binding.
IS:8723 - Dimensions for vibrating conveyors and feeders
1.02.01 The vibrating screening feeder shall be of mechanical type.
1.02.02 The screening feeder shall be capable to segregate the (-) 20 mm size of coal
alongwith coal dust, any muck & muddy coal (which is likely to be encountered during
rainy season) etc. The segregated material shall be directly fed onto the
corresponding belt conveyors/feeders through separate hoppers/chutes provided
under each screening feeder. The width of vibrating screening feeder shall match to
feed the material uniformly over the entire length of crusher rotor without any
deflectors in the feeding chute.
1.02.03 The screening area excluding solid deck area shall be minimum 0.75 m
2
per 100
tonnes/hr of incoming feed. Inclination of the screening pan shall be so selected so
as to ensuing proper flow ability of Coal on the deck without any hindrance.
1.02.04 The equipment shall be designed in such a manner that choking does not occur
during operation, particularly during rainy season when the coal gets sticky.
1.03.01 The deck of vibrating screening feeder shall have continuous solid deck section in
the impact zone under direct coal fall and remaining deck shall be fitted with
perforated deck assembly. The solid deck section shall be provided with replaceable
tiscral or eqvt. liner plate of adequate thickness. The perforated deck shall be wear
resistant and shall be rigidly fixed with main frame along the length of grizzly deck.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)


Page
2 of 3

1.03.02 The vibrating screening feeders shall be mounted on the floor with the help of helical
springs made of alloy steel. No rubber/synthetic material for the support shall be
acceptable.
1.03.03 Vibrator bearings shall be grease lubricated, double spherical roller type suitable for
vibrating equipment. The bearings shall be sized for minimum 8,000 hours of
operation.
1.03.04 Suitable sealing arrangement shall be provided between the vibrating structure and
chute work to avoid dust nuisance in the surrounding area.
1.03.05 Proper arrangement to avoid dust ingress into lubricant of eccentric shafts shall be
provided.
1.03.06 Necessary arrangements shall be provided for maintaining / replacing the complete
vibrator assembly.
1.03.07 Marker plate to indicate stroke length and stroke angle shall be mounted.
1.03.08 In case of V- belt drive, suitable arrangement like taper bush or dobicon coupling
shall be provided, to avoid loosening of sheave mounted on eccentric shaft.

1.03.09 Dust hood shall be provided over the deck of screening feeder to avoid dust
nuisance.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
3 of 3

DATA SHEET : VIBRATING SCREENING FEEDER

1.0.0 GENERAL

1.1.0 Functional Requirement Uniform feeding of (+) 20 mm coal
to crushers.


2.1.0 Type Mechanical vibrator

2.2.0 Inclination Suitably selected to ensure proper
flow ability of Coal without any
hindrance.

2.3.0 Pan Size

(a) Screen area Min. 0.75 sq.m per 100 TPH feed

(b) Pan width To match with crusher rotor length
without deflector plates

2.4.0 Performance size on deck Suitable to pass (-) 20 mm coal.

2.5.0 Liners on solid deck

- Type, Material Replaceable, Tiscral or eqvt.

- Thickness 16 mm minimum.

2.6.0 Perforated Deck Assembly

- Material

TISCRAL or equivalent
- Construction

Perforated deck plate

2.7.0 Support Helical springs only

2.8.0 Bearings

(a) Type Double spherical roller suitable for
vibrating screens.

(b) Lubrication Grease

(c) Life 8,000 hours Min.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
RING GRANULATOR AND VMS


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
RING GRANULATOR
AND VMS

Page
1 of 6

A12: RING GRANULATOR AND VMS
1.00.00 GENERAL
a) Ring granulator type crusher shall be provided for sizing the input coal to (-) 20
mm size. Crusher shall be supplied complete with accessories and subsystems.
b) Bidder shall source ring granulators from a manufacturer / supplier who has
supplied minimum two (2) nos. of ring granulator type crushers of at least 1600
TPH capacity for crushing coal which should be in successful operation for a
minimum period of two (2) years as on date of bid opening.
The design, manufacture, inspection and testing of Coal Crushers shall comply with
all the currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The Coal Crushers shall conform to the latest edition
of standards and codes. Other internationally acceptable standards/codes, which
required statutory responsibility. In case of any conflict in the standard and this
1.02.01 The crusher shall be of ring granulator type and shall be designed based on following
clauses and the data sheet enclosed.
1.02.02 The crusher design should be such that the crushing action is accompanied by the
minimum of attrition.
1.02.03 Uniform crushing impact shall be assured.
1.02.04 Maximum crushing efficiency shall be obtained, i.e., thermo dynamically, the ratio of
surface energy produced to the kinetic energy expended should be maximum.
Accordingly, the number of central discs along the rotor shaft shall be maximum with
minimum spacing in between.
1.02.05 The crusher shall be capable of delivering the normal rated output even when
handling damp sticky coal having maximum moisture content. No clogging or building
up of material on the crushing element shall develop.
1.02.06 Temperature sensing devices shall be installed on both bearings of each of the
crusher to trip the crusher incase temperature goes beyond limit.
1.03.01 The gap between cage bars/cage screen and the hammers shall be adjustable to
compensate for the normal wear and tear and the mechanism shall be made simpler
for easy operation and maintenance, having separate cage actuating shaft, gear train
and suitable hinge connection.
1.03.02 The drive chain equipment for crusher shall consist of drive motors scoop type fluid
couplings and other couplings. The crushers with its drive chain equipments shall be
mounted on a base plate with necessary accessories, e.g., anchor bolts, coupling
guards etc. The specification of the fluid coupling shall be as discussed elsewhere.
Gear box shall not be used in the drive chain of crushers.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
RING GRANULATOR
AND VMS

Page
2 of 6

1.03.03 The entire inside surface of crusher coming in contact with coal shall be provided
with abrasion resistant steel liners.
1.03.04 The plummer block shall be of Split Type design and shall be fixed with minimum
four numbers of high tensile steel bolt studs of adequate size complete with adequate
locking device and locating arrangement. In addition, the jacking screw shall be
provided for easy lifting of top part of the plummer block. The same shall be of solid
base with flat machined bottom surface all around having maximum contact on the
foundation plate.
1.03.05 Additional support shall be provided to plummer block across the longitudinal axis of
crusher rotor to take care of misalignment against certain jerk, regular vibration etc.,
with simple readjustment facilities. Further, plummer blocks shall be provided with
provisions for installing vibration monitoring equipment.
1.03.06 Necessary locking arrangements shall be provided for suspension bars at both the
ends of rotor assembly to arrest any relative movement of the same. In addition, the
design shall be such that these locking arrangements do not undergo any damage
during normal operation as well as under hammer replacement operation. Two
suspension bars shall be provided in each row to facilitate replacement of broken
hammers without requiring withdrawal of other hammers.
1.03.07 The general arrangement of crusher and the drive equipment shall permit atleast
50% extraction of suspension bars towards the drive end also, besides full extraction
towards non-drive end.
1.03.08 For safety, necessary tramp iron pocket of sturdy design with adequate cover shall
be provided inside the crusher. The bottom of tramp iron pockets shall be of grizzly
or screen type.
1.03.09 Maximum accessibility shall be provided for routine inspection and replacement of
parts. For these purposes, the doors shall be of hinge connection with effective dust
sealing arrangement. Hydraulically operated top cover of crushers shall be provided
for quick inspection and replacement of hammers.
1.03.10 The material for major components of crusher shall not be inferior to the quality and
standards as mentioned in data sheet.
1.04.00 VIBRATION MONITORING SYSTEM FOR COAL CRUSHER
1.04.01 Vibration monitoring system should be offered for crushers as indicative below :
Sl.
No
Equipment Type No. * No. of
location
per equip.
Equipment bearing
type
1. Coal Crusher Radial ring 4 2
one at DE
one at
NDE
As per manufacturer's
design
Vibration shall be measured at each location in Horizontal as well as vertical
direction.
1.04.02 Specification of the Vibration Monitoring System

a) Number & type of
vibration
One (1), Microprocessor based, monitoring system
able to distinguish between high frequency
vibration caused by bearing trouble and low
frequency vibration caused by imbalance.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
RING GRANULATOR
AND VMS

Page
3 of 6

b) Number of channels 16 (Rack mounted in cabinet)

c) Transducer a) Velocity pick-up or a peizo-electric
accelerometer. Type shall be decided during
detail engineering based on the details of
equipment to be monitored.

b) Light weight stud mounting.

c) Frequency response 1 Hz -10 kHz.

d) Connecting cable Low noise fire proof coaxial cable to be laid in
flexible conduit.

e) Monitors (to be
located in CHP control
room)
Dual channel monitor for each location alongwith :

a) Buffered signal output and software for
vibration analysis through CHP control desk
HMI.

b) Recorder signal output

f) Display Analogue and digital
g) Alarm 0-100% full scale adjustable.

h) Trip 0-100% full scale adjustable.

i) Test Functional checking from front inhibiting alarm &
trip

j) Relays 0.25 A at 220 Volts DC or 5 Amp at 240V AC.
Independent potential free contacts for alarm & trip
purpose.

k) Signal Conditioner Individual 4-20 mA DC analogue output.

l) Power Supply 240 V 10% AC, 50 Hz + 3%, -5%


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION - IIIA-12
RING GRANULATOR
AND VMS

Page
4 of 6

DATA SHEET: CRUSHER

1.0.0 GENERAL

1.1.0 Type Ring granulator

1.2.0 Input Coal Parameters As specified elsewhere.

Input coal lump size (-) 100 mm

1.2.1 Extent of oversized lumps (occasional) in feed
coal

(a) Maximum percentage 1 to 2%

(b) Maximum lump size 150 mm

1.3.0 Coal Feeding Arrangement Through vibrating screening
feeder (However, the crusher
shall be designed/sized
considering zero passage of
coal through screen).

2.0.0 DESIGN AND CONSTRUCTION

2.1.0 Number of rows of hammers 4 rows placed at 90deg

2.2.0 Hammer profile Toothed and plain alternately
or only toothed

2.3.0 Weight of each ring hammer Not to exceed 40 Kg.

2.4.0 No. of suspension bars passing through each row
of ring hammers

Max. of Two (2) number
2.5.0 No. of holes in each segment of central and end
discs for suspension bars (for each row of
hammers)

Max. of Three (3) number
2.6.0 Drive arrangement

2.6.1 Motor rating at 50oC Refer technical specification
elsewhere

2.6.2 Fluid coupling

Type Scoop tube type

2.7.0 Rotor Balancing

2.7.1 Type of balancing reqd. Both static and dynamic


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
RING GRANULATOR
AND VMS

Page
5 of 6

2.7.2 Grade of balancing Q-16 as per VDI-2060 1966
(However, for purpose of
calculating the unbalanced
force for the design of
machine supporting
structure, balance grade as
given in the relevant section
for foundation design shall be
followed).

2.8.0 Plummer Block

2.8.1 Type of plummer block Split type

2.8.2 Type of sealing Labyrinth, dust tight
arrangement

2.8.3 Type of bearings Spherical roller

2.8.4 Lubrication Manual through grease gun

OR
with recommended grade of
oil in which case the plummer
block shall be designed with
oil filling, oil draining and
visual oil checking facilities

2.9.0 Tramp iron rejection Required for unbreakable
material facility

2.10.0 Output size adjustment facility Desirable

2.11.0

Top cover of crushers Hydraulically operated
3.0.0 MATERIAL OF CONSTRUCTION

3.1.0 Ring Hammers Manganese steel to IS - 276
Gr. III or made of low alloy
(sillico manganese) steel in
forged condition as per
ASTM A 322 grade 9260

3.2.0 Rotor Shaft ASTM-A668, Class E / C-
45(IS 2004) / E8D, BS
970/1955

3.3.0 Suspension bars ASTM-A322, Grade AISI
4140 / EN-24, Bright bar


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
RING GRANULATOR
AND VMS

Page
6 of 6

3.4.0 Cage bars/cage screens and side screen plates Manganese Steel (IS:276) /

3.5.0 Rotor Discs ASTM-A108, AISI 1045

3.6.0 Breaker plate Manganese steel IS-276 Gr.
III min. 40mm thick

3.7.0 Liners

(a) Material Material composition shall be
as that of breaker plate
above

(b) Thickness 20 mm minimum.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
TRAVELLING TRIPPER & BUNKER
SEALING ARRAGEMENT


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
TRAVELLING TRIPPER

Page
1 of 4

A13: TRAVELLING TRIPPER AND BUNKER SEALING ARRANGEMENT

1.00.00 GENERAL
Mobile Trippers on bunker conveyors along with belt sealing arrangement shall be
furnished and erected complete with rails, including necessary supporting structures,
approach/ maintenance platforms with ladders and hand railings, trailing cables, all
electricals including machine mounted local control panel & control panel on one end
of Bunker, location of which shall be decided during detail engineering.
Complete Bunker Sealing arrangement shall be provided over the bunkers to prevent
dust emission into tripper bay.
The design, manufacture, inspection and testing of Mobile Tripper & Bunker Sealing
Arrangement shall comply with all the currently applicable statutes, regulations and
safety codes in the locality where the equipment is to be installed. The Mobile
Tripper & Bunker Sealing Arrangement shall conform to the latest edition of
standards and codes. Other internationally acceptable standards/codes, which
1.02.01 Mobile Tripper
1.02.02 The Mobile tripper on bunker conveyors shall be motor driven type. It shall consist of
structures, supports, walkways, rails, belt scrapper with adjustable rubber strip,
rubber lagged head and bend pulleys complete with shaft bearings, chutes, stops,
limit switches, brakes etc. The tripper shall have provision for dropping coal from
conveyor onto both sides of tripper to the bunker or back to the conveyor for the
purpose of skipping intermediate bunkers. The rating of tripper travel motor shall be
adequate to move the tripper smoothly either in same or opposite direction to belt
direction under fully loaded conditions. Adhesive weight requirement and tractive
effort calculations shall be subject to approval of Employer. Coefficient of adhesion
shall be considered as maximum 0.15. Minimum two drive axles shall be provided
for tripper travel. Arrangement shall be provided at the starting point of the tripper to
avoid folding of belt.
In case of tripper running at a speed more than its rated speed due to chute jamming
or other reason, conveyor shall trip and annunciation shall appear.
1.02.03 Supply of adequate length of rails to cover the runway length for the motor driven
tripper shall be included. The supporting structures for the rails with necessary end
stops shall also be supplied under this specification. Suitable belt hold down guide
pulley shall be provided over the concave curve of belt over tripper.
1.02.04 The Contractor shall include in his proposal necessary electricals for traveling
trippers. Adequate length of trailing cables (power & control) with festoon
arrangement shall be supplied for each of the traveling tipplers. Alternatively, drag
chain arrangement may be provided for trailing cables (power & control) for each

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
TRAVELLING TRIPPER

Page
2 of 4

traveling tripper. 3 pairs of control cable shall be provided in the control trailing cable
of each machine for connecting employers telephone and P.A. equipment to be
provided on each machine. Isolating switch to isolate the power supply to the
machines shall be provided in each power JBs to be located GT the Centre of travel
length..
1.02.05 The travelling trippers shall be provided with fail safe A.C. thruster operated brake of
totally enclosed type which shall engage as soon as tripper travel motor stops. A.C.
thruster operated rail clamps alongwith manual Rail clamps on both sides of the
tripper shall also be provided. The specifications of brakes and clamps are as
discussed elsewhere.
1.02.06 For selection and specification of drive motor, gearboxes, pulleys, belt cleaners and
all other equipment associated with tripper & Bunker sealing arrangement relevant
sections of this specification shall be referred to. Independent motorized linear
actuator shall be provided to operate each flap gate of the tripper chute.
1.02.07 All drive equipment shall be selected based on 110% of actual power requirement at
specified guaranteed capacity. Further complete drive equipment shall be suitable for
minimum 60 starts/hours.
1.02.08 Monorail & electric hoist shall be provided for lifting one complete belt drum to bunker
floors. Monorail all along the bunker conveyor to facilitate maintenance of tripper
shall be provided.
1.02.09 Bunker sealing arrangement
1.02.10 The sealing belt shall be of suitable grade (minimum 2 plies) with 5 mm x 5 mm
covers (fire resistant) in line with other conveyor belting. The belt shall rest on 16 x
50 mm MS plates spaced at 200 mm placed 50 mm below floor level, provided over
the bunker slot on tripper floor for tripper conveyor as shown in the tender drawing for
tripper conveyor. Necessary guide rollers, bearings, brackets, safety guards etc.
shall be provided by the Contractor. The bunker sealing arrangement shall keep the
bunkers sealed and prevent dust emission into tripper floor. The width of the bunker
seal belt shall be at least 100 mm more than the bunker slot opening.
1.03.02 Suitable dust cover shall be provided over tripper head pulley. Serrated rubber seal
shall be provided at open side to prevent dust nuisance. Suitable dust tight access
doors shall be provided. Modular segmented type spring loaded external belt cleaner
shall be provided below the tripper head pulley for cleaning the carrying side of the
belt.
1.03.03 The tripper shall run on rails (90 lbs/yard) with double flanged wheels. Rails for
tripper travel shall be mounted on supporting structure of respective conveyors.
1.03.04 Suitable system having encoders for monitoring position of tripper in DCS shall be
provided. In addition, travel end limit switches and end stops shall also be provided.
1.03.05 Suitable access platform of chequered plate with ladders, handrailing and walkways
on both sides shall be provided for access/maintenance of equipment on tripper. In
addition, crossover platform shall be provided with tripper so that operator can cross

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
TRAVELLING TRIPPER

Page
3 of 4

the belt through the same. Walkway with handrailing shall be provided on both sides
of the tripper.
1.03.06 Suitable rail cleaners shall be provided on leading and trailing edge of tripper for
either track.
1.03.07 3mm deck plate continuous shall be provided below carrying idlers on the trippers.
1.03.08 For specification of flap gates/actuator on trippers relevant clauses of this
specification shall be referred to.
1.03.09 Tripper shall be operated as elaborated elsewhere.
1.03.10 Provision shall be kept for automatic tripping of bunker bay conveyor in the event of
travelling tripper getting dragged (i.e. travel speed in excess of rated speed)
1.03.11 The operating controls of the tripper shall be mounted at an height, easily accessible
from bunker floor.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
TRAVELLING TRIPPER

Page
4 of 4

DATA SHEET ; TRAVELLING TRIPPER
1.0.0 GENERAL

1.1.0 Mobile Tripper Motor driven type rail mounted.

1.2.0 Bunker Sealing Arrangement Sealing belt type.



2.1.1 Mounting Rail mounted on rails (90 lbs/yard) with
double flanged wheels.

2.1.2 Drive Motor driven with suitable gearbox.
Suitable for minimum 60 starts/hours.

2.1.3 Pulleys

(a) Head & Bend Pulleys

As specified elsewhere
2.1.4 Brakes AC operated electro hydraulic thrustor
type on either side of tripper.

2.1.5 Clamps A.C. operated electro hydraulic thrustor
type on either side of tripper.

2.1.6 Walkways Both sides of tripper, 800 mm wide
each

2.2.0 Bunker Sealing Arrangement

2.2.1 Sealing Belt

(a) No. of plies Minimum two

(b) Top/Bottom cover Thickness 5 mm/5 mm (Fire Resistant)

(c) Width Atleast 100 mm more than bunker slot.

2.2.2 Guide Rollers As per requirements.

2.2.3 Bunker Slot

(a) Width As per tender drawing

(b) Cross bars over the slot opening

16 mm x 50mm MS plates

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
INLINE MAGNETIC SEPARATOR AND
SUSPENDED MAGNET


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ILMS

Page
1 of 4

A14: IN-LINE MAGNETIC SEPARATOR

1.00.00 GENERAL
Inline Magnetic Separators shall be provided for continuous and automatic extraction
and discharge of tramp magnetic pieces from coal being discharged from conveyors
as specified. The sets shall be complete in all respects with drives, magnets, inline
belts, hoppers, chutes, tramp-iron boxes and all electrical ancillaries like control
panels etc.
1.01.00 CODES & STANDARD
The design, manufacture, inspection and testing of In line Magnetic Separators shall
comply with all the currently applicable statutes, regulations and safety codes in The
Magnetic Separators shall conform to the latest edition of standards and codes.
Other internationally acceptable standards/codes, which ensure equal or higher
decision of the Engineer shall be final and binding.
1.02.01 Inline Magnetic Separator
1.02.02 Magnet core material shall be pure annealed iron or equivalent high permeability
magnetic material. The coil shall be of aluminum wire with class H insulation, to
limit the absolute temperature of the winding to 140 deg. centigrade. The oil used for
cooling the ILMS shall be silicon based.
1.02.03 The Force Index i.e. the product of flux density in gauss and rate of change of flux
density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000
(gauss x gauss/inch) minimum in hot condition for mounting height of 400 mm.
However, the strength of the magnet shall not be less than 1000 gauss in hot running
condition at 400 mm distance. The minimum strength of the magnet shall be 1000
gauss at the specified mounting height at the centre of Belt width. Contractor shall
select magnet width to suit above.
Mounting height of 400 mm shall be taken between top of conveyor belt or bottom of
falling material trajectory and the surface of magnetic separator belt. Characteristic
curve of magnet with the value of flux density varying between 50 mm to face of
conveyor belt shall be provided. The cross section of magnet shall be suitably
designed to provide sufficient area for magnetising the coil effectively covering full
cross section of the discharge material. The magnetic separator shall be located
such that it picks-up tramp iron from coal trajectory after it has been discharged from
head pulley.
1.02.04 The tramp magnetic pieces buried under coal picked up by the magnetic separator
shall be discharged suitably to ensure that it falls into the tramp iron chute, which
shall be provided upto ground level. All conveyors with magnetic separator at head
end shall have non-magnetic SS pulleys. Head pulleys of all conveyors with in line
magnetic separator at head end shall be provided with SS shell and end disc.
However, hub and shaft shall be of same materials as in other pulleys. (EN-8 or
equivalent).

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ILMS

Page
2 of 4

1.02.05 The motor and the gear reduction unit for driving the in-line belt shall be adequately
sized with minimum 20% margin to avoid any over loading during operation. Suitable
zero speed switch shall be provided. No Chain/belt drives shall be accepted.
1.02.06 The belt shall be designed to withstand high temperature at the bottom of the magnet
and any serious damage due to the impact of the sharp edges of the tramp iron. The
belt shall be provided with rubber cleats spaced suitably. The belt shall be of fire
resistant grade. For other details of belt, refer belt specification as specified else
where. Side rollers shall be provided to keep the belt aligned.
1.02.07 The idlers and the pulleys supporting the belt shall be manufactured to the best
engineering practices and shall conform to relevant Indian Standards. For details of
idlers & pulleys, refer specification as specified else where.
1.03.01 In-line Magnetic separator
1.03.02 The magnetic separator units shall be supported by suitable structural member from
the top by taking support from the operating floor beams with turn buckle
arrangement to facilitate the necessary adjustments during operation. Further,
electric Hoists operated cross travel arrangement shall be provided to move
individual each of the magnetic separator away to facilitate maintenance of the
conveyor discharge pulley/Belt.
1.03.03 ON/OFF control push buttons with indicating lamps shall be provided at the local
station. The materials of chutes and hoppers associated with magnetic separators
above the drive floor shall be SS-304 in the magnetic zone. Tramp chutes shall be of
1 mtr. sq. dimension and shall be made of MS. chutes shall have poking doors at all
floors to clear jammed material.
1.03.04 Suitable arrangements shall be provided in the magnet for keeping the coil of the
magnet dry from atmospheric condensation when the magnetic separator is not in
use.
1.03.05 Protection against high oil temperature in magnet shall be provided.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ILMS

Page 3 of 4

DATA SHEET : ILMS

1.0.0 GENERAL

1.1.0 Type In line magnetic separator
type as specified.


2.1.0 In-line Magnetic Separator

2.1.1 (a) Location of ILMS Over discharge pulley.

2.1.2

Force index (As defined earlier) Minimum 100,000
2.1.3 Strength of magnet at the specified mounting
height

1000 gauss.
2.1.4 Mounting height Mounting height of In Line
Magnetic Separator shall be
400 mm (between top of
conveyor belt & surface of
magnetic separator)

2.1.5 Magnetic Separator Belt

(i) Drive Unit Adequately sized with 20%
margin.

(ii) Belting Suitable to withstand high
temp. & impact of tramp iron.
(FR Grade)

(iii) Discharge Into Tramp iron chute.

2.2.0 Tramp Iron Items

(i) MS cube of 20 mm size

(ii) Brake shoe of Railway Wagon (Cast Iron
15 Kg.)

(iii) MS plate of 250 x 250 x 100 mm size.

(iv) Shovel Teeth and spikes.

Material Carbon Steel

Size Typical

(v) MS round bar of 50 Kg with L/D ratio not
exceeding 5.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ILMS

Page 4 of 4

2.3.0 Control

Inline Magnetic Separator Local and remote

2.4.0 Electric Supply 415V, 3 phase, 50 Hz input Silicon Rectifier units

2.5.0 Location of silicon rectifier unit Nearby control/MCC room

2.6.0 Handling Arrangement for inline Magnetic
separator

(a) Height adjustment With turn buckle arrangement

(b) Cross-travel Electric Hoist operated cross
travel facility.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
METAL DETECTOR


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
METAL DETECTOR

Page
1 of 3

A15: METAL DETECTOR

1.00.00 GENERAL
Metal detectors shall be provided at specified location to detect metallic objects in the
coal stream.
The design, manufacture, inspection and testing of Metal Detectors shall comply with
all the currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The Metal Detectors shall conform to the latest
edition of standards and codes. Other internationally acceptable standards/codes,
which ensure equal or higher performance than those specified, shall also be
accepted. Nothing in this specification shall be construed to relieve the contractor of
the required statutory responsibility. In case of any conflict in the standard and this
1.02.01 Metal detectors shall have high reliability with enough sensitivity to detect 25mm
aluminum sphere below the burden of coal in case of synthetic belting. However for
steel cord belting the sensitivity shall be 35 mm. It shall also detect other metals, like
brass, copper, stainless steel, manganese steel, bars, scraps etc.
1.02.02 The equipment shall have provision for automatic static calibration with adjustable
sensitivity.
1.02.03 Metal detectors shall be completely solid state using latest state of art technology. It
shall be suitable for 50C ambient and RH of 100%. The search sensor shall be
protected from rain and direct sunlight by means of a non metallic covering other
than wood. Control unit shall have adjustable controls for sensitivity, ON/OFF push
buttons, resettable operation counter, audio-visual alarms local remote selector
switch and all other necessary controls for trouble free operation of metal detector. It
shall be suitable for mounting on wall, column, structure etc. with IP-65 Degree of
protection. It shall be constructed from FRP of thickness not less than 2mm.
1.02.04 The metal detectors shall also have the following features :
(a.) The coils shall be protected against being struck by an oversized
material/coal. The coils should have adjustment for magnetite/iron in incoming
coal. It should ignore magnetite/iron and shall distinguish between metal
pieces and magnetite/iron.
(b.) In order to counteract interference from external sources such as motors,
lightning and radio-transmitters, and to nullify the effect of climate
changes/aging, dual receiver coils are to be used.
(c.) In order to allow passing of steel cord belt and metal belt fasteners without
giving alarm and at the same time detecting tramps, suitable arrangements
shall be provided.
(d.) In case a few non-magnetic idlers or non magnetic deck plates are required,
the Contractor shall provide these. However, these shall be metallic. Wood is
not to be used.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
METAL DETECTOR

Page
2 of 3

(e.) LED display of COAST COUNT to indicate the number of pieces of tramp iron
detected since last reset shall be provided so that the operator is alerted for
the pieces of tramps, if any, between tramp marker and coil before restoring
conveyor.
(f.) TOTAL COUNT, which is not resettable, shall also be provided on the same
LED display on demand.
(g.) The location of tramp metal pieces shall be indicated by sand bag marker.
1.03.00 CONSTRUCTION REQURIEMENT
1.03.01 Fiber glass enclosure (with IP 65 degree of protection) shall be provided for all type
of coils.
1.03.02 Sand bag markers shall be provided.
1.03.03 Local control panel shall be provided with IP:65 degree of protection.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
METAL DETECTOR

Page
3 of 3

DATA SHEET : METAL DETECTOR

1.0.0 GENERAL

1.1.0 Type Coil type


2.1.0 Sensitivity 25 mm aluminium sphere
below coal for synthetic
belting.

35 mm aluminium sphere
below coal for steel cord
belting.

2.2.0 Enclosure Fiber glass

2.3.0 Control Through local control panel.

2.4.0 Calibration Provision for automatic static
calibration with adjustable
sensitivity.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
COAL SAMPLING UNIT


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
COAL SAMPLING UNIT

Page
1 of 3

A16: COAL SAMPLING UNIT

1.00.00 GENERAL
a) Coal Sampling Unit shall be complete with necessary samplers, crushers, flap
valves, chutes, hoppers, belt feeders and sample collectors etc. to give samples
from any of the two streams running at guaranteed capacity.
b) Bidder shall source coal sampling system from a manufacturer / supplier who has
engineered and supplied two (2) numbers of coal sampling systems for sampling
coal/ other bulk mineral from conveyor of 1200 MTPH and above and working
successfully for two years as on date of bid opening.
The design, manufacture, inspection and testing of Coal Sampling Unit shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Coal Sampling Unit shall conform to the
latest edition of standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those specified,
shall also be accepted. Nothing in this specification shall be construed to relieve the
contractor of the required statutory responsibility. In case of any conflict in the
standard and this specification, the decision of the Project Manager shall be final and
binding.
ASTM-D-2234 :Standard Methods for collection of a Gross Sample of Coal.
ASTM-D-2013 :Standard Method of Preparing Coal Samples for Analysis.
1.02.01 Coal sampling unit shall be automatic & provided at place specified elsewhere.
1.02.02 The coal sampling units suitable to give Samples conforming to ASTM-D-2234 shall
be selected by the Contractor for taking samples from any of the two streams running
at guaranteed capacity. The different Equipment selected for coal sampling unit shall
be such that there shall be no loss of fines and moisture from the samples. The
capacity, make and model of all equipments of coal sampling unit shall be subject to
approval of Project Manager.
1.02.03 The normal input feed size shall be considered as (-) 100 mm for coal sampling unit
before coal crusher. However occasionally (-) 150 mm lumps may also arrive. Coal
lump size after crusher (as fired coal) shall be (-) 20mm. However occasionally (-) 50
mm lumps may also arrive in as fired coal.
1.02.04 Primary samplers (separate for each conveyor) shall be rugged, able to withstand
severe shock loads and operate trouble free.
1.02.05 Belt feeders shall be provided for entire sampling path upto sample collector. The
feeders shall meter the flow accurately, produce a non-plugging condition and resist
sticky and wet coal.
For rejects path also, belt feeders shall be preferred. Screw conveyors for the same
shall be accepted only where space constraints do not permit distribution of coal
rejects to receiving conveyors below.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
COAL SAMPLING UNIT

Page
2 of 3

1.02.06 Sample crushers (make subject to Employers approval) shall be provided for
reducing the main input feed coal to 95% minus 8 mesh size and 100% minus 4
mesh size. Single stage crushing shall be provided. There should be no re-circulation
of fines in the crushers.
1.02.07 Lot size shall be equivalent coal quantity handled in 8 hours operation assuming
average conveyor loading at 75% of rated conveyor capacity. However sampling
system shall also be suitable for taking one gross sample for each lot of 3500 Te
coal.
1.03.01 The traversing mechanism and all electric parts shall have dust tight protection.
1.03.02 Belt feeders shall be positively self cleaning and have dust tight construction. It shall
be provided with flanged belt, rubber lagged head pulleys and inspection doors. No
chain/belt drives shall be accepted.
1.03.03 The crushers base should be built of reinforced concrete and be sufficiently large in
mass.
1.03.04 The primary / secondary samplers shall be of dust tight construction and self
contained type.
1.03.05 The sample chutes shall have minimum valley angle of 60 degrees to horizontal and
shall be of stainless steel plates. The chutes shall be suitable to handle wet sticky
coal as specified elsewhere. The welding of chutes shall be done externally only.
The inside surface of the material near welds shall be smooth. Radius at corners not
less than 1" shall be provided in chute work. All solid connected members shall be by
means of bolting flanges with atleast 6 mm thick standard grade neoprene gasket
material between the metal flanges. No control gates to regulate the flow of material
shall be incorporated in the chute work.
1.03.06 Bias connections shall be provided at suitable locations. The materials rejected from
samplers shall be returned to main conveyor stream.
1.03.07 Minimum 4 nos. sample collecting bins shall be provided with auto indexing. The
bins shall be provided with air tight connection.
1.03.08 The system shall be suitable for operation through employers DCS/DDCMIS.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
COAL SAMPLING UNIT

Page 3 of 3

DATA SHEET : COAL SAMPLING UNIT

1.0.0 GENERAL

1.1.0 Type Automatic


2.1.0 Codes & Standard ASTM D-2234

2.2.0 Uncrushed feed coal size (-) 100 mm

2.3.0 Crushed feed coal size (-) 20 mm

3.0.0 CHUTES

3.3.1 Min. angle 60 deg

3.3.2 Cross section Square/rectangular with
rounded corners.

3.3.3 Joints Bolted flanges with 6 mm
thick standard grade
neoprene gasket.

4.0.0 CRUSHER

4.4.1 Uncrushed (as received) feed coal size (-) 100 mm

4.4.2 Crushed (as fired) feed coal size (-) 20 mm

4.4.3 Output size ASTM D-2234

4.4.3 Stages of size reduction Single stage crushing

5.0.0 BELT FEEDER

5.5.1 Belt Flanged type, FR grade

5.5.2 Pulleys Rubber lagged head pulley

5.5.3 Drive Electric Motor

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
ELEVATOR


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ELEVATOR

Page
1 of 6

A17: ELEVATOR
1.00.00 GENERAL
This specification is intended to cover design, engineering, supply, erection, testing
and commissioning of the complete Rack & Pinion type Elevators as specified
hereinafter complete in all respects and adequate for safe, efficient and trouble free
operation of the elevator.
1.01.00 CODES AND STANDARD
The design, manufacture, inspection and testing of Elevator shall comply with all the
currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The Elevator shall conform to the latest edition of
standards and codes. Other internationally acceptable standards/ codes, which
1.02.00 DESIGN AND CONSTRUCTION REQUIREMENTS
1.02.01 GENERAL
1.02.02 This section covers the design, engineering, fabrication, installation, commissioning
and testing of the rack and pinion type vertical lift elevator including required
enclosures, hoist, mast and guide rail, cab drive unit machinery buffers, power cable,
control cable, mechanical and electrical equipment. The design of the elevator shall
be in such a way that the elevator operation will be safe at all times.
1.02.03 Elevator shall be located as indicated in the relevant tender drawings and shall be
capable of operating from the ground floor to the top interior platform with
intermediate stops at all interior platforms.
1.02.04 All mechanical and electrical operating devices and Trailing cable shall be designed
for outdoor operation with dusty and high humidity conditions and shall operate
equally well in any ambient temperature as per project synopsis. Additionally, all
mechanical and electrical components of the elevator shall be designed to withstand
a temperature of 50C ambient.
1.02.05 ENCLOSURES
A three-sided enclosure with one access door shall be provided for ground landing.
At each platform landing above ground level, a one sided enclosure with access door
shall be provided. Enclosures shall be fabricated from tubular steel and/or other
structural shapes expanded metal or wire mesh of suitable height and primer coated
with one coat of the manufacturers standard primer and finish paint. The ground
landing shall be provided at a suitable height above the foundation slab to ensure a
safety space underneath the cage. The space under the landing shall be surrounded
by foundation enclosure. The staircase shall be provided for access to the cage.
Enclosure access doors shall be electrically and mechanically interlocked so that
they remain closed and locked except when the cab is at a landing. Doors shall be
bi-parting and swinging type.
Base of the three-sided enclosure shall be securely anchored to the ground level
floor slab using expansion type anchors.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ELEVATOR

Page
2 of 6

1.02.06 Mast
Mast shall be provided in sections of suitable length, consisting of tubular sections
and/or structural shapes welded together to form a framework to which the rack is
bolted. Mast shall be securely anchored to the building structure.
1.02.07 Cab
1.02.08 Cab frame shall be fabricated from tubular steel and/or other structural shapes
enclosed with expanded metal or wire mesh.
1.02.09 Cab floor shall be of 6 mm thick Aluminum chequered plate or approved equivalent.
Cab shall be attached to a framed structure and form an integral part with the drive
mechanism located atop the cab.
1.02.10 Framed structure shall include guide rollers and safety hooks to ensure positive
engagement of the rack and pinion to prevent cab disengagement in case of roller
failure.
1.02.11 Cab roof shall be provided with an escape hatch electrically interlocked with the hoist
control system. Tubular steel handrail shall enclose the cab roof for maintenance
operations.
1.02.12 Cab door and landing level enclosure doors shall be electrically and mechanically
interlocked to prevent the cab from being operated unless the cab door and landing
level enclosure doors are fully closed and to prevent the doors from being opened
while the cab is in motion.
1.02.13 One cabin fan and two recessed fluorescent lamps along with the fittings to be
provided with one no. emergency light with battery & battery charger.
1.03.00 Drive Unit & Safety Device
1.03.01 Drive unit located on the cab shall be complete with AC squirrel cage induction
motor, reduction gear, drive pinion and an over-speed governor. Drive unit shall
incorporate an electric disc brake and an external manual brake release. The brake
on the electric motor will be self adjusting type. In case of the power failure, the brake
will be automatically applied & will stop the cab. A hand lever, which can be
operated from the cage, is to be provided to enable the occupants to ease the brake
and lower the cage to the bottom level. Motor shall be connected to a reduction
gear, which drives the pinion.
1.03.02 An over-speed governor must be incorporated to protect the cab against over speed
during the cab downward motion. At a predetermined speed higher than normal, the
brake, mechanism shall be actuated and stop the downward motion of the cab
gradually. The brake should remain locked on following this action and has to be
manually reset before normal elevator operation can be resumed.
1.03.03 A remote control shall be provided for testing the safety device. The Contractor shall
ensure that no individual is in cab during the test.
1.03.04 The drive system shall be designed so that it will be capable to operate smoothly
without any tendency to rock or judder with all vertical, horizontal forces as well as
the moments through the rack.
1.03.05 Suitable arrangement shall be provided to bring the cage safely to the ground by
gravity in the event of power failure.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ELEVATOR

Page
3 of 6

1.04.00 Buffers
Sufficient no. of buffers of spring loaded/hydraulic type shall be fitted below the cab.
The buffer shall be capable of stopping the cab without permanent damage or
deformation to themselves or any other part of the equipment. The no. of buffers
shall be fixed as to ensure proper sharing of impact loads by all of them.
1.05.00 Power supply
Two incomers (One from Bus-A and One from Bus -B of the MCC) for the supply to
each elevator shall be provided with castle key interlocks.
1.06.00 Power and Control Cabinets
All electrical components furnished with the elevator shall be completely wired,
energised and checked.
All electrical control devices shall be in enclosures. Equipment furnished shall also
include the following:
(a.) Momentary contact push button for raise/lower control.
(b.) Reversing combination motor starter with a three phase thermal overload relay
for motor protection. However, the control circuit in the elevator will have
miniature circuit breakers.
(c.) Electric and mechanical interlocks on cab access door and landing level
enclosure doors.
(d.) An ultimate three phase over travel limit switch which cuts off power and control
supply in case of over travel. The switch can also be manually turned to off
position.
(e.) Safety device as mentioned elsewhere in this specification.
(f.) An alarm push button shall be provided in the cage. Alarm signal will be
transferred to the auxiliary panel at elevator base.
The auxiliary panel at the base will have battery and battery charger for the
alarm horn. Potential free contracts for remote alarm shall also be provided.
(g.) Reverse phase relay connected to prevent operation of the cab with improper
phase rotation or failure in any phase in the power supply.
(h.) The cable shall be supported by brackets on the cage and guide rails. A cable
trolley will keep it in tension and will be guided on the same rail as the cage.
The trailing cable shall run through cable guides.
(i.) One auxiliary panel shall be furnished and mounted on the ground level
enclosure. Panel shall be in enclosure equipped with a main ON-OFF switch,
main Contractor, relays, control transformer and MCBs, terminal blocks, and all
other accessories required for normal operation of the elevator.
(j.) One main control panel shall be furnished and mounted on the top of cab.
Panel shall be in enclosure equipped with necessary equipment like rectifier,
battery, battery charger, contactors, breakers, control transformer and MCBs,
thermal overload relays and all other equipment and accessories required for
normal operation of the elevator.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ELEVATOR

Page
4 of 6

(k.) Cab shall be controlled by a semiautomatic control system with push buttons for
UP Down and Stop next landing. The cab shall be controlled from inside and
shall have painted placard located above the door. Cab shall be furnished with
emergency alarm push button, limit switches, and all other necessary control
devices required to ensure safe and continuous cab operation, One trailing
cable shall connect the cab main control panel to the auxiliary panel at ground
level to supply the cab with all power requirements. An extra core of equal size
shall be provided for earthing of cab. Cable guides shall be installed every 6
meters to avoid entanglement of this cable.
(l.) Each landing assembly shall include a limit switch and push button control
station installed and wired to a landing junction box.
(m.) All enclosures containing electrical, devices shall be provided with 240 Volts,
single phase space heaters with adjustable thermostat control.
(n.) Cab shall be equipped with a 220 Volts, 20W fluorescent lights, fan, 5A, 220V,
3 pin receptacle, emergency light, battery & battery charger.
(o.) Control cabinets shall be sheet steel enclosed dust, weather and vermin proof.
Sheet steel used shall be cold rolled and at least 2.0 mm thick. Degree of
protection of control cabinet shall be as per relevant electrical section. Control
cabinet shall be provided with hinged doors (s) with pad locking arrangements.
All doors, removable covers and plates shall be gasketted all round with
neoprene gaskets.
(p.) Each motor to be controlled from the control cabinet shall be provided with 3-
pole isolating switch. HRC fuses, contactors shall be of AC4 duty class with
thermal overload relays with single phase preventer. The isolating switch and
contactor shall be rated at least 20% more than the connected motor full load
current. The controller and resistor for motor shall confirm to relevant IS and
shall be continuously rated for 150% full load current of the motor.
(q.) All fuses shall be of the HRC cartridge type mounted on plug in type of fuse
base having a prospective current rating of not less than 80 kA.
(r.) All push buttons shall have 2NO and 2NC self reset contacts.
1.07.00 Electric Motor
Elevator drive motor shall be squirrel-cage induction type designed and
manufactured to conform to the requirements of this specification.
Motor shall be designed for operation at the required speed, 415Volts, 3 phase, 50
hertz, and shall be suitable for full voltage starting, frequent starting S3 duty class as
per IS:4722 with CDF of 25% and maximum number of starts 120/hour at 50C
ambient temperature.
Motor nameplate kW ratings shall not exceed when the equipment is operating within
the limits of the maximum load requirements. Motor shall have class F non-
hygroscopic insulation with temp. rise limited to Class B (IS:325),
Motor shall be totally enclosed and furnished with cast iron or Al alloy frame,
brackets, gaskets conduit box & fan cover. Motor shall be furnished with grease pre
lubricated, double-shielded, anti-friction bearing having life rating of not less than
42,500 hours under coupled service requirements. All exposed metal surfaces shall
be protected with a polyester paint or coating which is moisture & corrosion resistant.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ELEVATOR

Page
5 of 6

Motor shall be provided with internal 220 Volt AC single-phase space heaters or an
alternate heating system to prevent condensation within the motor during extended
periods of idleness.
Motor and driven equipment shall be direct coupled and mounted on a common base
plate.
1.08.00 CABLES
Insulated armoured power /control cable shall be FRLS - HR insulated, stranded
copper / aluminum conductors and shall be provided in accordance with IS:1753
(latest edition) and IS:1554 (Part-I) (latest edition).
Trailing cables in the elevator shaft should be specially designed for the specific
service and shall conform to IS. Trailing cables shall be EPR insulated for 1.1 kV and
shall be neoprene jacketed flexible cord.
Conductor accessories including terminal materials like glands, lugs etc. markers,
tying materials, and cable supports shall be furnished and installed.
1.09.00 Earthing
(a.) GENERAL
Complete earthing system shall be furnished for all equipments and
accessories of the elevator as per relevant IS.
(b.) MATERIALS
The earthing of all electrical items being supplied by the Contractor shall be in
his scope. For earthing the various equipment, conductor sizes shall be as
listed below:
(1.) Motor above 5 kW upto 30 kW 25x6 mm
2
GI flat
(2.) Motors upto 5 KW and misc. small item like conduits,
junction boxes etc. 8 SWG GI wire
(3.) Cab earthing Additional core of trailing cable
The earthing strip/wire shall be connected to the earthing mat by the Contractor.
Clamps and other hardware of iron or steel used with the grounding system shall be
hot-dip galvanised. Bolts, washers, and nuts shall be hot-dip galvanised steel.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
ELEVATOR

Page
6 of 6

DATA SHEET : ELEVATOR

1.0.0 GENERAL

1.1.0 Type of Service Passenger-Cum-Goods


2.1.0 Carrying capacity 1000 Kg

2.2.0 Rated speed Approx 25 - 40 mtrs / min.

2.3.0 Total Travel Shall be as per actual
dimension of the Building

2.4.0 No. of floors to be served As per requirement

2.5.0 Entrance As per requirement

2.6.0 Min. cab Floor size (inside) WxLxH 1.3m x 2.0m x 2.1 m

2.7.0 Various heights of landing floors to be served Suitable for working floors as
indicated in the tender
drawing.

2.8.0 Drive Motors (AC) One (1) No.

2.9.0 Cab Flooring 6 mm thk. Al. Chequered
plate.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART- B
STACKER CUM RECLAIMER



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
STACKER AND RECLAIMER

Page
1 of 10

A-18: STACKER AND RECLAIMER
1.00.00 GENERAL
1.01.00 Travelling Stacker and Reclaimer machines
1.01.01 Travelling stackers and reclaimers with yard conveyor shall be provided as specified.
Stackers and Reclaimers shall be capable of stacking and reclaiming respectively.
The stacker shall be complete with cantilever boom conveyor, boom hoist, control
panel, operators cabin, electrical power distribution system, motorised cable reeling
drum along with adequate length of trailing cables etc. The reclaimers shall be
complete with cantilever boom conveyor, boom hoist, bucket wheel, control panel,
operators cabin, electrical power distribution system, motorised cable reeling drum,
adequate length of trailing cables etc.
2.00.00 CODES & STANDARDS
The design, manufacture, inspection and testing of Stacker and Reclaimer shall
locality where the equipment is to be installed. The Stacker and Relaimer shall
conform to the latest edition of the following standards and codes. Other
decision of the Engineer-in-Charge shall be final and binding.
ISO 5049/1 : Mobile Continuous Bulk Handling Equipment.
FEM : Federation Europeanne De La Manutention Section-I-Rules for
Design of Hoisting Appliances.
3.00.00 DESIGN REQUIREMENTS
3.01.00 Stacker and Reclaimer shall be capable of operating at high wind velocities upto 65
km/hr. It shall also be able to withstand maximum wind velocity as indicated in
Project Synopsis, when it is not operating. A suitable anemometer shall be provided
which shall indicate the wind velocity in the control cabin of each machine.
Electro-hydraulic thruster operated rail clamp and manual rail clamp shall be
provided for holding the stacker and reclaimer. Suitable arrangement shall be
provided for keeping the stacker and reclaimer in fixed stable position when the
weather is stormy.
3.02.00 Stacker and reclaimer shall operate on rail track running for adequate length to cover
the entire coal stockyard. The wheel load of stacker and reclaimer shall not exceed
27.0 tonnes. The ratio of boom length (as specified) to the rail track gauge shall not
exceed 5. Top of rail level shall be maintained at 0.7 m above the ground level, i.e.,
coal pile base level unless specified otherwise. Suitable number of rail scrappers
shall be provided.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
2 of 10

3.03.00 The machine shall be mounted on traverse carriage provided with driven and non-
drive wheels of cast or forged steel and double flange design. The track wheels shall
be combined in pairs in the track wheel bogies. The wheels shall rotate on self-
aligning roller bearings. Between the motor and the gearing, electro-hydraulic
thrustor brake shall be provided.
3.04.00 The reclaimer shall be capable of travelling at any desired speed within its speed
range. During stacking/reclaiming operation, the equipment travel shall be limited to
its travel zone and shall automatically stop when the machine reaches the extreme
ends of such travel zone.
3.05.00 The lower works of the under-carriage of the machine shall be designed to transmit
load on the wheel sets of the travel carriage in such a manner that the equipment is
stable during normal operating condition as well as during hazardous weather
condition with maximum permissible variation in centre distance of rails and rail top
levels. The rail mounting for under-carriage shall be four legged system with
hydraulic/mechanical equalising arrangement to make it three point suspension
system for the best stability during operation. The traverse carriage and the under-
carriage shall be interconnected in a manner which will permit uniform distribution of
overloads even if the rails are not level.
3.06.00 The upper frame of the machine shall be designed in such a manner that minimum
number of angular movement points affect the luffing operation. Also the variation of
moment/torque on slew bearing shall be minimum. The ring bearings shall be
dimensioned in such a way that all forces can be safely transmitted to the structures
of the wheels.
3.07.00 The roller bearing slewing ring shall be sealed against penetration of water and dust.
3.08.00 Angular movement points (hinge points) namely between equalising beam and base
frame, luff pivots and hydraulic cylinder hinge points shall be provided with
maintenance free bearings requiring no periodic lubrication during entire life span of
bearings. Minimum life span of self lubricating type bearings shall be 25 years with
average 10 hrs. daily operation.
3.09.00 The luffing motion shall be through hydraulic pumps and cylinders. In case of more
than one cylinder being used for boom luffing operation, necessary provisions shall
be provided such that the differential oil pressure between two cylinders are always
maintained within permissible limits, during luffing operation and as well as when the
boom is fixed at any position. In case of any undue increase in differential pressure,
the hydraulic circuit shall trip and suitable alarm indication shall be provided before
tripping. The hydraulic system of luffing shall be such that in case of failure of
hydraulic system due to leakage or any other reason the boom could be held in
position.
3.10.00 The boom shall revolve by atleast 180 deg. about the centre of the receiving hopper
and discharge/reclaim material on/from both sides of track anywhere within specified
radius of the boom.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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3.11.00 The boom conveyor of reclaimer shall be of adequate capacity to match with the rate
of peak reclaiming by the bucket wheel. For other details, the relevant clauses on
belt conveyor system of this specification shall be referred to.
Boom conveyor shall be provided with a Belt Weighing Scale with weighing accuracy
(in the horizontal position of the boom) of 1% for a range of 20% to 120% of boom
conveyor rated capacity. The belt scale shall provide only flow rate indication in the
Operator's Cabin on the Stacker and Reclaimer. Rest of the features shall be as
specified in the relevant section of Belt Scale specification.
3.12.00 The bucket wheel assembly shall consist of 8 numbers of buckets of cell-less design
and stationary annular chute. The bucket shall be of suitable shape and design
which will enable to empty out the material fully from the bucket, and to prevent
spilling of the scooped material during transfer to boom conveyor. The buckets shall
be readily removable.
Bucket size shall be selected for peak reclaim capacity based on maximum 80%
degree of fill with respect to water fill capacity of the bucket. Further, not more than
50% of annular ring volume shall be considered as effective volume. Rate of bucket
discharges shall not exceed 55 per minute.
The teeth of the bucket shall be hard faced.
3.13.00 The bucket wheel drive shall be complete either with hydraulic drive (with or without
gear box) or with electric motor, reduction gear unit moving in oil bath and suitable
coupling between motor and the gear unit. Bucket wheel drive system, structural
members, mast, hydraulic system etc shall be designed considering completely wet
coal with max. surface moisture. Adequate safety devices shall be provided to
prevent overloading of the bucket wheel drive, particularly when wheel will get stuck-
up in the stockpile. In such an event the power supply of the drive shall get
automatically cut-off. Suitable electro hydraulic thruster brake (in case of electric
drive) shall be provided to avoid backward movement of the bucket wheel after the
power supply is cut-off and during maintenance work.
3.14.00 The boom conveyor with bucket wheel assembly, the mast and counter weight
mounted on the upper structure shall rotate on the bearing ring. The drive
mechanism shall consist of the gear rim and drive unit shall comprise of motor, safety
coupling, gear box and pinion. Protective devices against overloads shall also be
provided. The slew speed shall be variable. The boom conveyor shall be provided
with self training arrangement of latest design to avoid belt sway in Boom Conveyor.
Manual locking of boom shall be provided.
3.15.00 One tripper shall be furnished for stacker unit for working in conjunction with the yard
conveyor. The tripper shall be complete with supporting structure, walkways,
platforms, railing, belt scrapper, head pulleys, bend pulleys, hold-down pulley, chute
and support with adequate number of wheels in bogie construction travelling on the
same rails as those of the stacker.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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3.16.00 Group-wise lubrication system shall be provided combining different zones of
lubrication points under different groups depending upon location and number of
lubrication points. Each group lubrication unit shall be independently functional
through separate pump (motorized), grease container, valves, metering devices,
pipes and other accessories etc. Preferably, the grease entry into various lubrication
points shall be vertically downwards. The grease container shall have adequate
capacity for supply of lubricants to all points and grease quantity for the points to be
greased shall be adjustable. Further, all the lubrication points shall be easily
accessible.
3.17.00 The stacker and reclaimer shall receive power through trailing cables. Separate
motorized cable reeling drums for power and control cable shall be provided with
arrangements for winding and rewinding of the cables. The trailing cables shall run in
a cable tray which shall be subject to approval of Engineer-in-Charge. Further, the
trailing cable arrangement shall be such that the cables run in-between the track
rails. Cushion shall be provided in the cable reeling drums for about 15 m extra
cabling length.
3.18.00 3 pairs of control cable cores shall be provided in the control trailing cable of each
machine for connecting employers telephone and P.A. equipment to be provided on
each machine.
3.19.00 Stacker and reclaimer shall be operated as elaborated in Sub-Section -IIIA-01.
Further, limit switches shall be provided to prevent traverse movement, slew and
hoisting etc. beyond the respective safe extremities. Interlocking shall also be
provided for S/R rail clamps and travel motors.
Yard conveyor can be stopped from control panel of stacker / reclaimer. Provision
also be given to trip the stacker/ reclaimer from CHP control room.
3.20.00 Travel drive equipment and slew drive equipment shall be suitable for 150 starts/hr.
with continuous reversals.
3.21.00 Speed control of long travel and slew drive motor (in case of electric drive) shall be
through Variable Voltage Variable Frequency System (VVVF) with minimum 6 (six)
pulse design. Necessary input & output devices to be provided to reduce harmonics
as per IEE519. All necessary protections e.g. Input Phase Loss, Earth Fault, Over
Voltage, Output Short Circuit, Load Loss, Input Transient Protection, Overload etc to
be provided. VVVF system shall be capable of generating suitable starting torque
with / without encoder. Squirrel cage induction motor with VPI insulation shall
provided With VVVF system.
3.22.00 Hydraulic control shall be provided for
(a) Hoisting/luffing
(b) Operator cabin level adjustment



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
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(c) Equalising arrangement for travel carriage (in case of hydraulic equalising)
Axial piston pumps shall be provided for pressurising hydraulic control fluid.
3.23.00 All drive equipments shall be selected based on 110% of actual power requirement at
specified design capacity. Further for selection and specification of various individual
equipments, relevant clauses of specification shall be referred to.
In addition to the requirements elaborated above, the structural design of the stacker-
reclaimer shall be supplemented by following standards :-
ISO 5049/1 : Mobile Continuous Bulk Handling Equipment.
FEM : Federation Europeanne De La Manutention Section-I - Rules for
Design of Hoisting Appliances.
The supplier shall furnish the detailed basis of design (BOD) used for design of the
structural components of the stacker reclaimer. The BOD shall be comprehensive
and shall account for the various technical requirements of the specification and
should include all parameters, assumptions, structural codes adopted, loading
conditions and design software used. The supplier shall also furnish the basis and
computer printout of input & output data of calculations of foundation loads.
Manufacture of the stacker reclaimer shall be taken up by the supplier, only after
approval of the BOD by NTPC.
Should the stacker and reclaimer under go any structural distress/ failure during
operation or in the anchored condition during the plant life of 30 years, apart from
meeting the other contractual requirements specified elsewhere, the supplier shall
have to furnish, to NTPC, the complete structural design document / calculations,
pertaining to the equipment.
4.01.00 Continuous R.C. C. Stacker / Reclaimer rail foundation to be provided throughout
the length of travel zone and suitable RCC platform to be provided at one end of
travel of the stacker-and-reclaimer to rest the head end of the boom while either
under maintenance or out of operation.
4.02.00 The under-carriage shall be fabricated of steel plates and section.
4.03.00 The wheel mounting arrangement shall be such that the wheels can be dismantled
easily from their supports.
4.04.00 Walkways with hand railings shall be provided on both sides of boom conveyor.
4.05.00 The upper structure shall consist of rigid box type steel plate construction on which
the super-structure supporting mast, boom with bucket wheel and counterweight
boom with ballast are erected. The upper works shall be mounted on under-carriage
by means of large diameter ring bearing of double roll roller type.
4.06.00 The boom shall be fabricated from rolled steel plates and sections and shall be of
luffing type.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
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4.07.00 The counterweight boom with ballast which balances the boom conveyor shall be
mounted on the upper structure and shall be suitably dimensioned. The
counterweight boom shall be fabricated with rolled steel plates and sections.
Suitable boxes shall be provided for placing the counter weights.
4.08.00 Each stacker and reclaimer shall be provided with one enclosed dust proof & air
conditioned operator's cabin and so located as to enable the operator to get clear
vision of both sides of the track and the cutting of coal by buckets. The cabin shall
be suitable for operation in monsoon and tropical conditions and the inside ambient
temperature shall be maintained at 27
0
C. The cabin shall be provided with toughened
glasses with wipers and the arrangement shall be such that glasses can be cleaned
from outside without any scaffolding, Cabin door shall be provided with hydraulic
door closers. The cabin shall be kept in horizontal position through hydraulic
cylinders irrespective of the angle of inclination of the boom conveyor. All controls for
operation of all parts of the stacker-reclaim unit shall be provided in the cabin within
easy reach of the operator. Lights and fan for operator's cabin and adequate number
of flood lights for all necessary illumination for working at night shall also be provided.
Coal cutting by bucket wheel shall be clearly visible from operators cabin.
4.09.00 Electrical/MCC room shall be fabricated of sheet steel with suitable floor matting.
The room shall be dust tight and air conditioned. Fire proof insulation shall be
provided under the roof of MCC room. Further, the door shall be provided with
hydraulic door closer.
4.10.00 Adequate number of impact idlers shall be provided integral with stacker and
reclaimer at the region where the boom conveyor feeds material through transfer
chutes onto the yard conveyor for the protection of the yard conveyor.
4.11.0 Suitable arrangement shall be provided at the starting point (belt take off point) of the
tripper to avoid folding of belt while the tripper is in tension.
4.12.0 Dry type transformers PCRD, CCRD & all drives shall be suitably protected by
providing canopy from accumulation of coal dust falling from the tripper section of
machine.
4.13.0 Suitable anti-collision device (infrared and mechanically operated limit switch type)
shall be provided.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
7 of 10

DATA SHEET
1.0.0 GENERAL
1.1.0 Type : Travelling boom stacker and bucket
wheel reclaimer.
1.2.0 Quantity : 2 Nos.
1.3.0 Input Coal Parameters : As specified elsewhere
1.4.0 Wind Velocity
1.4.1 Maximum under operating
condition
: 65 kmph
1.4.2 Maximum under non-operating
condition
: As indicated in weather data in Project
Synopsis
1.5.0 Height of Stockpile : 10 m
1.6.0 Design Capacity : 110% of rated (guaranteed) capacity
1.7.0 Peak Reclaim Capacity : 125% of rated capacity, (For bucket size
calculations)
1.8.0 Width of stock pile at base : min 50 m.
2.1.0 Stacker and Reclaimer Travel
Mechanism

2.1.1 Type of Rail : 52 kg/ mtr.
2.1.2 Rail Track Gauge : Not Less than 20% of boom length.
2.1.3 Wheel Load : Not to exceed 27.0 Te.
2.1.4 Wheel Bearings : Self aligning roller bearings.
2.1.5 Top of Rail Level : 0.7 m above ground level unless specified
otherwise.



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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2.1.6 Drive Equipment : Electric motor (squirrel cage Induction
motor) with suitable coupling & electro
hydraulic Thruster brakes.
2.1.7
Anti Collision Device : Mechanical and Infra red type
2.2.0 Bucket Wheel Mechanism
2.2.1 No. of Buckets : Eight (8)
2.2.2 Type of Buckets : Cell-less
2.2.3 Max. degree of fill for Buckets to
be considered.
: 80%
2.2.4 Effective Ring volume to be
considered
: Max. 50% of annular ring Volume.
2.2.5 Bucket discharge rate : Not to exceed 55 per min.
2.2.6 Drive : Hydraulic drive (with or without gear box)
or
Electric motor with gearbox & suitable
coupling.
2.2.7 Brake : Electro hydraulic thruster operated (if
applicable) (for electric drive only)
For hydraulic motor the brake shall be
integral to the system.
2.2.8 Overload Protection : Suitable safety device with power supply
tripping.
2.3.0 Boom Conveyor
2.3.1 Design average capacity : a) 125% of rated reclaiming capacity
b) 110% of rated stacking capacity
2.3.2 Belt speed : About 3m/sec.
2.3.3 Boom Length & Width of Belt 41 mtr., Suitable for above capacity
2.3.4 Carrying Idlers : 35
0
troughing three equal rolls
2.3.5 Return Idlers : Single piece rollers


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

Page
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2.3.6 Drive : Electric motor with suitable coupling.
2.3.7 Gear Unit : Helical / bevel helical
2.3.8 Brake : Electro Hydraulic Thruster (if applicable)
2.3.9 Skirt Board Liftable at head/tail end.
2.3.10 Type of Take up arrangement : Screw
2.4.0 Slewing Mechanism
2.4.1 Drive : Pinion driven by hydraulic drive (with or
without gear box) or
Pinion driven by squirrel cage Induction
motor with gear unit & suitable coupling.
2.4.2 Drive Mechanism Gear rim mounted with under frame
2.4.3 Bearing : Ring type roller bearing
2.4.4 Brakes : Electro hydraulic thrustor operated (for
electric drive only).
For hydraulic motor the brake shall be
integral to the system.
2.5.0 Luffing Mechanism
2.5.1 Drive : Hydraulic pumps & cylinders.
2.5.2 Protection : Against undue differential pressure
2.5.3 Hinge point bearings : Life lubricated antifriction bearings.
2.5.4 Bearing life to be considered : 25 years with 10 hrs/day operation.
2.6.0 Operators Cabin
2.6.1 Construction : Dustproof & Air conditioned
2.6.2 Inside Temperature : 27
0
C
2.6.3 Doors : Hydraulic door closers
2.6.4 Level Maintaining Mechanism. : Hydraulic type.



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)

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2.7.0 Material for chutes and hoppers : 10 mm thk S.S. liner for cylindrical portion
of central hopper/chute. For other
locations, as specified in the relevant
section for chutes & hoppers.
2.8.0 Walkways on the tripper : Both sides, 800 mm wide each

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B

ELECTRI CAL

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B

SUB-SECTI ON-I I I B-01

MOTORS



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION - IIIB-01
MOTORS

Page
1 of 8

MOTORS

1.00.00 GENERAL REQUIREMENTS

1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50 deg.
centigrade and relative humidity of 95% shall be considered. The equipment shall
operate in a highly polluted environment.

1.02.00 All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3%
& -5%, and 10% combined variation of voltage and frequency unless specifically
brought out in the specification.

1.03.00 Contractor shall provide fully compatible electrical system, equipments, accessories
and services.

1.04.00 All the equipment, material and systems shall, in general, conform to the latest
edition of relevant National and international Codes & Standards, especially the
Indian Statutory Regulations.

1.05.00 The auxiliary AC voltage supply arrangement shall have 11kV, 3.3 kV and 415V
systems. It shall be designed to limit voltage variations as given below under worst
operating condition:

(a) 11kV, 3.3 kV +/- 6%

(b) 415/240V +/- 10%

1.06.00 The voltage level for motors shall be as follows :-

a) Upto 0.2KW : 240V, Single Phase AC/
415V Three phase AC

b) Above 0.2KW and upto 200KW : 415V, Three Phase AC

c) Above 200KW and upto 1500KW : 3.3 kV, Three Phase AC

d) Above 1500KW : 11KV, Three Phase AC

For CHP conveyors motor above 160 kW rating 3.3 KV, three phase AC supply is to
be used. However all the motors on the S/R machine shall be on 415 AC only.

1.07.00 Fault level shall be limited to 40kA RMS for 1 second for 11kV & 3.3kV system and
45 kA RMS 1 second for 415V system. 415V system shall be solidly grounded and
220 VDC system shall be isolated type.

1.08.00 Paint shade shall be as per RAL 5012 (Blue) for indoor and outdoor motors.

1.09.00 The responsibility of coordination with electrical agencies and obtaining all necessary
clearances shall be of the contractor.



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
MOTORS

Page
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1.10.00 Degree of Protection

Degree of protection for various enclosures as per IS:4691, IEC60034-05 shall be as
follows :-

i) Indoor motors - IP 54

ii) Outdoor motors - IP 55

iii) CW motors (in case of - IP 23
screen prot. Drip proof)

iv) Cable box - indoor area - IP 54

v) Cable box - outdoor area - IP 55


1) Three phase induction motors : IS:325, IEC:60034

2) Single phase AC motors : IS:996, IEC:60034

3) Crane duty motors :IS:3177, IEC:60034

4) DC motors/generators : IS:4722

5) Energy Efficient motors : IS 12615

3.00.00 TYPE

3.01.00 AC Motors:

(a) Squirrel cage induction motor suitable for direct-on-line starting.

(b) Continuous duty LT motors upto 160 KW Output rating (at 50 deg. C ambient
temperature), shall be Energy Efficient motors, Efficiency class-Efficiency 1,
conforming to IS 12615.

(c) Crane duty motors shall be slip ring/ squirrel cage Induction motor as per the
requirement.

3.02.00 DC Motors: Shunt wound.

4.00.00 RATING

(a) Continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor.

(b) Whenever the basis for motor ratings are not specified in the corresponding
mechanical specification sub-sections, maximum continuous motor ratings
shall be at least 10% above the maximum load demand of the driven


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
MOTORS

Page
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equipment under entire operating range including voltage and frequency
variations.

5.00.00 TEMPERATURE RISE

Air cooled motors

70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation.

Water cooled

80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance
method for both thermal class 130(B) & 155(F) insulation .

6.00.00 OPERATIONAL REQUIREMENTS

6.01.00 Starting Time

6.01.01 For motors with starting time upto 20 sec. at minimum permissible voltage during
starting, the locked rotor withstand time under hot condition at highest voltage limit
shall be at least 2.5 sec. more than starting time.

6.01.02 For motors with starting time more than 20 sec. and upto 45 sec. at minimum
permissible voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 5 sec. more than starting time.

6.01.03 For motors with starting time more than 45 sec. at minimum permissible voltage
during starting, the locked rotor withstand time under hot condition at highest voltage
limit shall be more than starting time by at least 10% of the starting time.

6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above
requirements are not met.

6.02.00 Torque Requirements

6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall be
at least 10% motor full load torque.

6.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall
be 275% for crane duty motors.

6.03.00 Starting voltage requirement

(a) 85% upto 1500KW

(b) 80% from 1501 KW to 4000KW

(c) 75% > 4000KW



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
MOTORS

Page
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7.00.00 DESIGN AND CONSTRUCTIONAL FEATURES

7.01.00 Suitable single phase space heaters shall be provided on motors rated 30KW and
above to maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided. However for flame proof
motors, space heater terminals inside the main terminal box may be acceptable.

7.02.00 All motors shall be either Totally enclosed fan cooled (TEFC) or totally enclosed tube
ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors
rated 3000KW or above can be Closed air circuit water cooled (CACW). CW motors
can be screen protected drip proof (SPDP) type. Motors located in hazardous areas
shall have flame proof enclosures conforming to IS:2148 as detailed below

(a) Fuel oil area : Group - IIB

(b) Hydrogen generation : Group - IIC (or Group-I, Div-II as per NEC)
plant area

7.03.00 Winding and Insulation

(a) Type : Non-hygroscopic, oil resistant, flame resistant
(b) Starting duty : Two hot starts in succession, with motor
initially at normal running temperature.
However, conveyor motors shall be
suitable for three consecutive hot starts.
(c) 11kV, 3.3 kV AC motors : Thermal Class 155(F) insulation with winding
temperature rise limited to thermal class
130(B). The winding insulation process shall
be total Vacuum Pressure Impregnated i.e.
resin poor method. The lightning impulse &
Inter-turn insulation surge withstand level
shall be as per IEC-60034 Part-15.
(d) 415V AC & 220V DC
motors
: Thermal Class130(B) or better
(e) Short circuit rings of conveyor motors shall be either joint less or welded type.
Brazed joint is not acceptable.

7.04.00 Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft
currents.

7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable alarm
contacts to indicate inlet and outlet primary air temperature.

7.06.00 Noise level for all the motors shall be limited to 85dB(A). Bearing housing vibration
shall be limited within the limits prescribed in IEC 60034-14/IS:12075 . Motors shall
withstand vibrations produced by driven equipment. HT motor bearing housings shall
have flat surfaces, in both X and Y directions, suitable for mounting 80mmX80mm
vibration pads.



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
MOTORS

Page
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7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum
resistance type temperature detectors shall be provided in each phase stator
winding. Each bearing of HT motor shall be provided with dial type thermometer with
adjustable alarm contact and minimum 1(one) number duplex platinum resistance
type temperature detectors.

7.08.00 Motor body shall have two earthing points on opposite sides.

7.09.00 HT motors can be offered with either elastimold termination or dust tight phase
separated double walled (metallic as well as insulated barrier) cable boxes. In case
elastimold terminations are offered, then protective cover and trifurcating sleeves
shall also be provided. In case cable box is offered, then Employer shall provide
termination kit. Removable gland plates of thickness 3 mm (hot/cold rolled sheet
steel for three core cables) or 4 mm (non magnetic material for single core cables)
shall be provided in case of cable boxes.

7.10.00 The spacing between gland plate & centre of terminal stud shall be as per Table-I.

7.11.00 All motors shall be so designed that maximum inrush currents and locked rotor and
pullout torque developed by them at extreme voltage and frequency variations do not
endanger the motor and driven equipment.

7.12.00 The motors shall be suitable for bus transfer schemes provided on the 11kV, 3.3
kV/415V systems without any injurious effect on its life.

7.13.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall be
provided on each phase in a separate neutral terminal box.

7.14.00 11KV and 3.3KV motors Terminal Box shall be suitable for fault level of 750MVA for
0.12 sec and 250MVA for 0.12 sec respectively.

7.15.00 The size and number of cables (for HT motors) to be intimated to the successful
bidder during detailed engineering and the contractor shall provide terminal box,
cable glands & lugs suitable for the same.

7.16.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the
following (without any further tolerance).

(a) Upto 110KW : 11.0

(b) Above 110KW & upto 1500KW : 10.0

(c) Above 1500KW & upto 4000KW : 9.0

(d) Above 4000KW : 6 to 6.5

7.17.00 CW motors shall be designed with minimum power factor of 0.8 at design duty point.



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
MOTORS

Page
6 of 8

8.00.00 TYPE TEST

8.01.00 HT MOTORS

8.01.01 The contractor shall carry out the type tests as indicated in the "LIST OF TYPE
TESTS TO BE CONDUCTED on the equipment mentioned there in. The Bidder
shall indicate the charges for each of these type tests separately in the relevant
schedule of BPS and the same shall be considered for the evaluation of the Bids.
The type test charges shall be paid only for the test(s) actually conducted
successfully under this contract and upon certification by the Owner's Engineer.

8.01.02 The type tests shall be carried out in presence of the Owner's representative, for
which minimum 15 days notice shall be given by the Contractor. The Contractor shall
obtain the Owner's approval for the type test procedure before conducting the type
test. The type test procedure shall clearly specify the test set-up, instruments to be
used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.

8.01.03 In case the contractor has conducted such specified type test(s) within last ten years
as on the date of bid opening, he may submit the reports of the type tests indicated in
the "LIST OF TYPE TESTS TO BE CONDUCTED " to the owner for waival of
conductance of such type test(s).These reports should be for the tests conducted on
the equipment similar to those proposed to be supplied under this contract and the
test(s) should have been either conducted at an independent laboratory or should
have been witnessed by a client. The Owner reserves the right to waive conducting
of any or all of the specified type test(s) under this contract. In case type tests are
waived, the type test charges shall not be payable to the contractor.

8.01.04 Further the Contractor shall only submit the reports of the type tests as listed in "LIST
OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED" and carried out
within last ten years from the date of bid opening. These reports should be for the
tests conducted on the equipment similar to those proposed to be supplied under this
contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client. In case the Contractor is not
able to submit report of the type test(s) conducted within last ten years from the date
of bid opening, or in case the type test report(s) are not found to be meeting the
specification requirements, the Contractor shall conduct all such tests under this
contract free of cost to the Owner and submit the reports for approval.

8.01.05 LIST OF TESTS TO BE CONDUCTED

The following type tests shall be conducted on each type and rating of HT
motor

(a) No load saturation and loss curves upto approximately 115% of rated voltage

(b) Measurement of noise at no load.

(c) Momentary overload test (subject to test bed constraint).

(d) Full load test (subject to test bed constraint).



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
MOTORS

Page
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(e) Temperature rise test at rated conditions. During heat run test, bearing temp.,
winding temp., coolant flow and its temp. shall also be measured. In case the
temperature rise test is carried at load other than rated load, specific approval
for the test method and procedure is required to be obtained. Wherever ETD's
are provided, the temperature shall be measured by ETD's also for the record
purpose.

8.01.06 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED

The following type test reports shall be submitted for each type and rating of
HT motor

(a) Degree of protection test for the enclosure followed by IR, HV and no load run
test.

(b) Terminal box-fault level withstand test for each type of terminal box of HT
motors only.

(c) Lightning Impulse withstand test on the sample coil shall be as per clause
5.1.3.2, IEC-60034,Part-15.

(d) Surge withstand voltage test on inter-turn insulation as per IEC 60034-15

8.02.00 LT Motors

8.02.01 LT motors shall be of type tested design. For each type & rating of LT motors rated
above 50 KW, the contractor shall submit for Owner's approval the reports of all the
type tests as per relevant standards and carried out within last ten years from the
date of bid opening. These reports should be for the tests conducted on the
equipment similar to those proposed to be supplied under this contract and the
have been witnessed by a client.

8.02.02 In case the Contractor is not able to submit report of the type test(s) conducted within
last ten years from the date of bid opening, or in case the type test report(s) are not
found to be meeting the specification requirements, the Contractor shall conduct all
such tests under this contract at no additional cost to the Owner either at third party
lab or in presence of client/owners representative and submit the reports for
approval.

8.03.00 All acceptance and routine tests as per the specification and relevant standards shall
be carried out. Charges for these shall be deemed to be included in the equipment
price.

8.04.00 The type test reports once approved for any projects shall be treated as reference.
For subsequent projects of NTPC, an endorsement sheet will be furnished by the
manufacturer conforming similarity and No design change. Minor changes if any
shall be highlighted on the endorsement sheet.



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
MOTORS

Page
8 of 8

TABLE - I

DIMENSIONS OF TERMINAL BOXES

FOR LV MOTORS:

Motor MCR in KW Minimum distance between
centre of stud and gland
plate in mm

UP to 3 KW As per manufacturer's practice.

Above 3 KW - upto 7 KW 85







Above 125 KW-upto 200 KW 203

FOR HT MOTORS:

The distance between gland plate and the terminal studs shall not be less than 500
mm.

PHASE TO PHASE/ PHASE TO EARTH AIR CLEARANCE:

NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with lugs
installed shall be as follows:

Motor MCR in KW Clearance

UP to 110 KW 10mm

Above 110 KW and upto 150 KW 12.5mm

Above 150 KW 19mm

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


LT SWITCHGEAR & BUS DUCT



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
1 of 10

LT SWITCHGEAR & BUSDUCT

1.00.00 CODES AND STANDARDS IEC: 60947, IS : 13947, IEC: 60439,IS:8623,IEC:61850
2.00.00 TYPE
Circuit Breakers Shall be air break, three pole, spring charged,
horizontal drawout type, suitable for electrical
operation.

Switchgear Fully drawout type single front

MCC Fully drawout type single front/Double front.

ACDB/DCDB Fixed type single front

3.00.00 SYSTEM PARAMETERS
415VAC +/- 10 %(SOLIDLY GROUNDED)

50 Hz +3%/-5%

45KA RMS(105 KA PEAK) / 1SEC (FAULT LEVEL)

220V/110V DC NOMINAL ISOLATED TYPE FOR CHP SYSTEM

The temperature rise of the horizontal and vertical busbars and main bus link
including all power draw out contacts when carrying 90% of the rated current along
the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C
with all other types of joints over an ambient of 50 deg C. The temperature rise of
the accessible parts/external enclosures expected to be touched in normal
operation shall not exceed 20 deg.C. The temperature rise of manual operating
means shall not exceed 10 deg. C for metallic & 15 deg. C for insulating material.
The above temperature rise limits are applicable for busducts also without any
current derating.
5.00.00 OPERATIONAL REQUIREMENTS
5.01.00 Breakers
5.01.01 Breakers shall have anti-pumping feature.
5.01.02 The incomer and bus coupler breakers for switchgear shall be electrically operated
with Numerical communicable relays.
5.01.03 Breakers shall have inherent fault making and breaking capacities. They shall have
shunt trip coils. All breakers shall have built in interlocks for equipment and personnel
safety.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
2 of 10

5.01.04 Paralleling of two supplies shall be avoided by interlocking except for switchgear
where auto-changeover is provided. Breaker contact multiplication, if required, shall
be through latch relay.
5.01.05 Mechanical tripping shall be through red Trip push button outside the panels for
breakers, and through control switches for other circuits.
5.01.06 Provision of mechanical closing of breaker only in Test and Withdrawn position
shall be made. Alternatively, mechanical closing facility should be normally
inaccessible, accessibility rendered only after deliberate removal of shrouds. It shall
be possible to close the door with breaker in test position.
5.01.07 Clear status indication for each circuit shall be provided through lamps, switch
positions or other mechanical means.
5.02.00 Switches, Contactors and Fuses
5.02.01 Incomers for MCCs and DBs rated below 250A could be load break isolators. The
250A & above feeders up to 630A shall have MCCB. MCCB shall be provided with
Microprocessor based inbuilt front adjustable releases (overload & short circuit) and
shall have adjustable earth fault protection unit also. MCCB shall have current
limiting feature. ON and OFF position of the operating handle of MCCB shall be
displayed and the rotary operating handle shall be mounted on the door of the
compartment housing MCCB.
5.02.02 Motor starter contactors shall be of air break, electromagnetic type suitable for DOL
starting of motor, and shall be of utilisation category AC-3 for ordinary and AC-4 for
reversing starters. For conveyor motors, minimum rating of power contactors shall be
200% of the full load current of the motors. For other motors minimum rating of power
contactors shall be 160% of full load current of motor. DC contactor shall be of DC-3
utilisation category.
5.02.03 Fuses shall be HRC type with operation indicator. Isolating switches shall be of AC
23A category when used in motor circuit, and AC 22A category for other applications.
Fuse switch combination shall be provided wherever possible.
5.02.04 The compartment door shall be interlocked mechanically with the MCCB/isolating
switches, such that the door can not be opened unless the MCCB/isolating switch is
in OFF position. Means shall be provided for defeating this interlock at any time by
making use of special tools/tackles. MCCB/isolating switches shall be provided with
padlocking facility to enable the operating mechanism to be padlocked.
5.03.00 Panels
5.03.01 All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall
have prominent engraved indentification plates.
5.03.02 Local push button stations shall have metal enclosure of die cast aluminium or rolled
sheet steel of 1.6mm thickness & shall be of DOP IP55. The DOP shall be IP-65 in
case the same are located in dusty areas. Push buttons shall be of latch type with
mushroom knobs.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
3 of 10

5.03.03 Where breaker/starter module front serves as compartment cover, suitable blanking
covers, one for each size of modules per switchboard shall be supplied for use when
carriage is withdrawn.
5.03.04 All non-current carrying metal work of boards/panels shall be effectively bonded to
earth bus of galavanised steel, extending throughout the switchboard/MCC/DB.
Positive earthing shall be maintained for all positions of chassis and breaker frame.
5.03.05 Suitable trolley arrangement shall be provided for breaker/starter modules. Two
trolleys per switchgear room shall be provided so that top most breaker module of all
types, sizes and rating can be withdrawn on trolley and lowered for maintenance
purpose.
5.03.06 The incoming connection to transformer of more than 1000KVA and inter-connecting
sections between switchboards shall preferably be of bus ducts. The bus duct
enclosure shall be made of minimum 3mm thick aluminium alloy. The section of the
bus duct should have adequate strength to withstand internal and external forces
resulting from the various operating conditions. Aluminium sheet hood shall be
provided for outdoor bus duct enclosure joints to provide additional protection against
water ingress. The bus duct top shall be sloped to prevent retention of water. The
bus duct enclosure shall have DOP of IP55 and paint shade RAL 5012.
5.03.07 It should be possible to carryout maintenance on a feeder with adjacent feeders
alive.
5.03.08 DC fuse board shall consist of:
-1 no.63A switch as incomer with meters, lamps and auxiliary contactors.
-8 nos. outgoing feeders with 16A HRC fuses.
5.03.09 AC fuse board shall consist of:
-1 no 63A TPN SFU as incomer with lamps and meters.
-9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing.
5.03.10 Main lighting distribution board(MLDB) to be located in MCC room shall consist
of:-
a) Two (2) nos. x 100% rated, lighting transformers (415V/433V, delta/star,
epoxy insulated, air cooled, dry type). Transformer shall be 50KVA \
100KVA rating for 10/15 nos. outgoing feeder.
b) TPN SFU on primary and secondary side of the transformer
c) 63A TPN SFU as outgoing feeders including 20% spare.
d) Voltmeter, ammeter with selector switches, indicating lamps.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
4 of 10

e) The two incomers (One from Bus-A and One from Bus-B of the MCC) and
one bus-coupler for the power supply to each MLDB shall be provided
with castle key networks.
5.03.11 Welding distribution board (WBD) to be located in MCC room shall consist of:
a) One (1) no. welding transformer (415/433 V, delta/star, epoxy insulated,
air cooled, dry type). Transformer shall be 50 KVA/100 KVA for upto 10/15
nos outgoing feeders.
b) TPN SFU on primary and secondary side of the transformer
c) 63 A TPN SFU as outgoing feeders including 20 % spare.
d) Voltmeter, ammeter with selector switches, indicating lamps.
5.03.12 MCCs located on the Stacker reclaimer, paddle feeders, travelling trippers shall be
fixed type, compartmentalized, single front and suitable for the system fault level.No
spare feeders are to be provided on these MCCs. Degree of protection for the MCCs
mounted on paddle feeders and travelling trippers shall be IP-65.
5.04.00 Control, Protection & Metering Requirements
5.04.01 Control circuits shall operate at suitable voltage of 110V AC or 220V DC/110V DC.
Necessary control supply transformers having primary and secondary fuses shall be
provided for each MCC, 2 x 100% per bus section. However the breakers shall
operate on 220V DC The auxiliary bus bars for control supply shall be segregated
from main bus bars. The control supplies shall be monitored.
5.04.02 Contractor shall fully co-ordinate overload and short circuit tripping of breaker with
upstream and down stream breakers/fuses/MCCBs motor starters. Various
equipments shall meet requirement of Type-II class of coordination as per IEC.
5.04.03 The protective relays shall be communicable numerical relays These numerical
relays shall be of types as proven for the application and shall be subject to
Employers approval Numerical relays shall have appropriate setting ranges,
accuracy, resetting ratio and other characteristics to provide required sensitivity. All
equipments shall have necessary protections as detailed in the standard scheme
drawings.
5.04.04 All equipments shall have necessary protections. However, following minimum
protections shall be provided:
1)

Contactor controlled motor feeders (Motors up to 160KW)
a) Instantaneous short circuit protection on all phases through HRC
cartridge type fuses rated for 80 kA rms (prospective breaking
capacity at 415V).

b) Thermal overload protection

c) Single phasing protection for motors protected by fuses

2) Incomers / buscoupler / outgoing breaker feeders other than motor feeders.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
5 of 10

a) Three phase over current protection (50)

b) Three phase earth fault protection (50N3)

c) Restricted earth fault protection for transformer incomers (64R)

d) Sync Check
1.01.00 General requirements of Numerical Relays
1.01.01 All relays and timers shall be rated for control supply voltage as mentioned
elsewhere under parameters and shall be capable of satisfactory continuous
operation between 80-120% of the rated voltage. Making, carrying and breaking
current ratings of their contacts shall be adequate for the circuits in which they are
used. Interrogation voltage for the binary inputs shall be suitably selected to ensure
avoidance of mal operation due to stray voltages.
1.01.02 All Numerical relays shall have communications on two ports, local front port for
communication to laptop and a second port on IEC 61850 to communicate with
owners data concentrator through LAN.
1.01.03 All Numerical Relays shall have features for electrical measurement including
voltage, current, power (active / reactive) and energy parameters.
1.01.04 All Numerical Relay shall have key pad / keys to allow relay settings from relay front.
All hand reset relays shall have reset button on the relay front. Relay to be self or
hand reset shall be software selectable. Manual resetting shall be possible from
remote.
5.05.05 The protective relays shall have at least 10 Nos. programmable potential free
contacts. Programmable Auxiliary relays shall have contacts as required.
5.05.06 For control from DDCMIS, 24V DC signal shall be provided from DDCMIS to the
numerical relays. Preferably, no separate coupling relays shall be provided.
5.05.07 Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker
trip circuit both in pre trip and post trip conditions.
5.05.08 Schematics requiring auxiliary relays / timers for protection function shall be a part of
Numerical Relay. The number of auxiliary relay and timer function for protection
function shall be as required by the scheme. Auxiliary relays for interlocking purpose
shall be of self reset type.
5.05.09 The numerical processor shall be capable of measuring and storing values of a wide
range of quantities, all events, faults and disturbance recordings with a time
stamping using the internal real time clock. Battery back up for real time clock in the
event of power supply failure shall be provided.
5.05.10 Sequence of events shall have 1ms resolution at device level.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
6 of 10

5.05.11 Ethernet switches shall be substation hardened and shall comply to IEC61850-3
for communications and environment requirements. The Ethernet switches shall be
of managed type with required number of ports to achieve the owners LAN
configuration. One(1) no. Ethernet switch per switch board shall be provided &
these switches shall be mounted inside the switchgear Panels.
5.05.12 In case of remote controlled breaker panels, following shall be ensured.
The circuit breaker will normally be controlled from remote control panels (employers
DDCMIS) through closing and shunt trip coils. The Local control console of the relay
flush mounted on the switchgear would normally be used only for testing of circuit
breaker in isolated position, and for tripping it in an emergency. Provision for closing
& tripping of the circuit breaker locally from laptop through serial port shall be
possible to facilitate commissioning activities. The basic control scheme of breaker
feeders shall be developed as per the schematic logics in the relay. The schematics
shall be developed in soft inside the relay. Numerical relays shall be interfaced with
employers DDCMIS through 24V DC signal for closing / opening operations.
5.05.13 Hardwired contacts from the relay shall be wired to PLC / DCS system as per
requirements. The numerical relay shall be capable of measuring and storing values
of a wide range of quantities, events, faults and disturbance recordings.
5.05.14 The alarm / status of each of protection function and trip operation shall be
communicated to PLC/DCS. The numerical relays shall have built in feature /
hardware interface to provide such inputs to PLC / DCS for analog / digital values..
5.05.15 It shall be possible to carryout open / close operation of breakers from a laptop by
interfacing from the relay front port (RS232) during initial commissioning.
5.06.00 Meters / instruments
All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size
with 90 degree linear scales and accuracy class of 2.0.
5.06.01 All motors of 30kW and above upto 100 kw shall have an Ammeter & current
transducer. Each bus-section shall have bus VT, voltmeter with selector switch, and
other relay and timers required for protection. Adequate control and selector
switches, push buttons and indicating lamps shall be provided. Thermostatically
controlled space heaters with switches shall be provided to prevent condensation.
5.06.02 For all motor feeders related to dust suppression system and for all other motor
feeders having 100KW & above rating, contractor shall provide multifunction Digital
Energy Meter with communication facility to display the current, voltage, power
factor, power, energy related data locally and shall communicate these for remote
metering /audit/analysis purposes. The technical specification for Digital indicating
energy meter shall be as follow:
a) Input Voltage: 110 V AC/220 V DC
b) Input Current:1A
c) Size: 96X96 SQ.MM


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
7 of 10

d) Accuracy:1.0% for power & energy
e) Mounting: Flush mounting
f) Type:True RMS 3-PHASE V, I,KW,PF & KWHr indication
g) 4 Digit, seven segment LED display/LCD display, with floating decimal
h) Communication: In built RS 485 serial bus port
i) Operating Frequency: 45 HZ-65HZ
j) Dielectric Test: 2KV RMS for 1 minute
k) Over current: 10 times for 3 sec.
l) Aux. supply: 90V-300V AC/DC
m) Compliance: EMC/EMI
n) Field programmable CT ratio
5.07.00 Control from Remote
Necessary hardware shall be provided in the switchgear panel like coupling relays (if
required ) of 24V DC, with max. burden of 2.5VA, auxiliary relays, current/voltage
transducers (4-20 mA, dual output) etc. to effect interlocks, exchange information /
status and exercise control from remote.
6.01.00 All 415V switch gear motor control centers (MCCs), AC & DC distribution boards (DB
s), etc shall have following features :
1) Shall be of metal enclosed, indoor, floor mounted and free standing
type.

2) All frames and load bearing members shall be fabricated using mild
steel structural sections or pressed and shaped cold rolled sheet steel
of thickness not less than 2mm.

3) Frame shall be enclosed in cold rolled sheet steel of thickness not
less than 1.6mm.Doors and covers shall also be of cold rolled sheet
steel of thickness not less than 1.6 mm. Stiffeners shall be provided
wherever necessary. Removable gland plates of thickness 3mm
(hot/cold rolled sheet steel) or 4 mm (non-magnetic material) shall be
provided for all panels.

4) All switchboards/panels shall be of dust and vermin proof. All cutouts
shall have EPDM/Neoprene gaskets.

5) All switchboards, MCCs and DB s shall have following distinct vertical
sections.

a) Completely enclosed bus bar compartment for horizontal and
vertical bus bars.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
8 of 10

b) Completely enclosed switchgear compartments (one for each
circuit housing circuit breakers, motor starter or switch-fuse
feeder).

c) Compartment for cable alley or cable box for power and
control cables.

In case of cable box, they shall be segregated with complete
shrouding for individual feeders at the rear for direct
termination of cables.

d) For cable connection to circuit breaker, a separately enclosed
cable compartment shall also be acceptable.

e) Compartment for relays and other control devices associated
with a circuit breaker, wherever necessary.

f) The switchboards/MCC/DBs of 1600A & above rating shall be
of DOP IP42 & of IP52 for less than 1600A rating.

g) All 415V switchgears, MCCs, AC & DC distribution boards etc.
shall be painted by powder coating process. Paint shade for
complete panels excluding end covers shall be RAL9002 &
RAL5012 for extreme end covers of all boards.

h) All draw out modules shall have distinct service, test and
isolated positions with provision of external pad locking facility
in each position. Power contacts shall get disconnected in
both test and isolated positions whereas the control contacts
shall get disconnected in isolated position only.

6) Busbars shall be of high conductivity aluminium alloy or copper.

7) The cross section of the horizontal bus bars shall be uniform through
out the length of the switchboard and both horizontal as well as
vertical bus bars shall be adequately supported and braced to
withstand the stresses due to the specified short circuit currents.
Neutral bus bar short circuit strength shall be same as the main bus
bars.

8) Minimum air clearance in air between phases and phase-earth shall
be 25 mm for busbars and cable terminations. For all other
components, the Clearances shall be at least 10mm. Wherever
above is not possible except for horizontal and vertical busbars,
insulation shall be provided by anti tracking sleeving or barriers.
However for horizontal and vertical busbars, clearances specified
above shall be maintained even when busbars are insulated/sleeved.
In case of DC DBs/ fuse boards, the busbar system shall be insulated
or physically segregated with barriers to prevent interpole short circuit.



SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
9 of 10

9) Busbar insulators shall be of track-resistant high strength non-hygro-
scopic, non-combustible type and suitable to withstand stresses due
to over-voltages and short circuit current. Insulators and barrier of
inflammable material such as Hylam shall not be accepted.

10) All types of relays and timer shall be subject to Employers approval.
They shall be flush mounted with connections from inside, and shall
have transparent & dust tight cover, removable from front, drawout
construction for easy replacemernt and testing facility. The auxiliary
relays and timer may be provided in fixed cases.

11) Terminal Blocks
Terminal blocks shall be 650V grade, 10Amps rated, made up of
unbreakable polyamide 6.6 grade. The terminals shall be either screw
type or screw-less (spring loaded) / cage clamp type with lugs.
Marking on terminal strips shall correspond to the terminal numbering
in wiring diagrams. All metal parts shall be of non-ferrous material. In
case of screw type terminals the screw shall be captive, preferably
with screw locking design. Maxi terminal / cage clamp type terminal
blocks shall be provided for signals to be interfaced with DDCMIS /
PLC.

12) The switchgears/MCC shall be designed to offer adequate level of
safety to operating/ maintenance personnel. Means shall be provided
to prevent access to the live part to avoid accidents during service as
well as maintenance period. Bidder shall bring out the safety means
provided to achieve above. A detailed instruction plate suitable for wall
mounting shall be provided for each switchgear/MCC room describing
various safe operating procedure/safety precautions for safe operation
and maintenance of switchgear/MCC.

13) All current and voltage transformers as required for metering &
protection specified shall be completely encapsulated cast resin
insulated type. Incomers from transformers shall have CTs for
transformer REF protection. The accuracy shall be as follows:

CTs PTs
Protection 5P20,5VA 3P
Metering 1.0 0.5
REF PS
6.02.00 Indicating lamps shall be cluster LED type.All overload relays shall have overload
reset push button.
6.03.00 Switchgear/MCC shall have bottom cable entry.
6.04.00 Contractor shall provide 20% spare feeder (minimum one spare feeder) for each type
and rating of the out going feeders on each MCC.
6.05.00 Outgoing feeders shall be segregated streamwise and equally distributed on each
bus section of the MCC.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
LT SWITCHGEAR &
BUSDUCT

Page
10 of 10

7.00.00 TYPE TESTS
7.01.00 GENERAL
(a.) All equipments to be supplied shall be of type tested design. The Contractor
shall submit for Owners approval the reports of all the type tests as listed in
this specification and carried out within last ten years from the date of bid
opening. These reports should be for the tests conducted on the equipment
similar to those proposed to be supplied under this contract and the test(s)
should have been either conducted at an independent laboratory or should
(b.) In case the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the
type test report(s) are not found to be meeting the specification requirements,
the Contractor shall conduct all such tests under this contract at no additional
cost either at third party lab or in presence of client/ownerss representative
and submit the reports for approval.
(c.) All acceptance and routine tests as per the specification and relevant
standards shall be carried out. Charges for these shall be deemed to be
included in the equipment price.
(d.) The type test reports once approved for any projects shall be treated as
reference. For subsequent projects of NTPC, an endorsement sheet will be
furnished by the manufacturer confirming similarity and No design Change.
Minor changes if any shall be highlighted on the endorsement sheet.
7.02.00 L. T. SWITCHGEAR
The following type test certificates on each type & rating of L.T. Switchgear and MCC
panel shall be submitted.
(a.) Short time withstand test.
(b.) Temperature rise test.
(c.) Class II - Protection co-ordination test for any three ratings of MCC module as
selected by employer
(d.) Test sequence 1 & combined test sequence on each rating of circuit breaker
mounted inside the panel.
(e.) Degree of protection tests
(f.) Type test certificates for Numerical relays.
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BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


LT POWER CABLES


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
Sub-Section - IIIB-03
LT power Cables

Page
1 of 7

LT POWER CABLES

1.01.00 All standards, specifications and codes of practice referred to herein shall be
the latest editions including all applicable official amendments and revisions as
on date of opening of bid. In case of conflict between this specification and
those (IS : codes, standards, etc.) referred to herein, the former shall prevail.
All the cables shall conform to the requirements of the following standards and
codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working
voltages upto and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wires and tapes
for armouring of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for
working voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning
or decomposition of plastics.
ASTM-D-2863 Standard method for measuring the minimum oxygen
concentration to support candle like combustion of plastics.
IEC-754 (Part-I) Test on gases evolved during combustion of electric cables.
IEEE-383 Standard for type test of Class IE Electric Cables.
IEC -332 Tests on Electric cables under fire conditions.
Part-3 : Tests on bunched wires or cables (category -B)


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
LT power Cables

Page
2 of 7

2.00.00 TECHNICAL REQUIREMENTS
2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground burried installation with chances of flooding by water.
2.02.00 Cables shall be armoured, flame retardant, low smoke (FRLS), armoured type
designed to withstand all mechanical, electrical and thermal stresses develop
under steady state and transient operating conditions as specified elsewhere in
this specification.
2.03.00 Aluminium conductor used in power cables shall have tensile strength of more
than 100 N/ sq.mm. Conductors shall be multi stranded.
2.04.00 XLPE insulation shall be suitable for a continuous conductor temperature of 90
deg. C and short circuit conductor temperature of 250 deg.C. PVC insulation
shall be suitable for continuous conductor temperature of 70 deg C and short
circuit conductor temperature of 160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever
necessary. It shall not stick to insulation and inner sheath. All the cables, other
than single core unarmoured cables, shall have distinct extruded PVC inner
sheath of black colour as per IS : 5831.
2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For
multicore armoured cables armouring shall be of galvanised steel as follows : -
Calculated nominal dia
of cable under armour
Size and Type of armour
i) Upto 13 mm

1.4mm dia GS wire
ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia
GS wire

iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia
GS wire

iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia
GS wire

v) Above 55 & upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia
GS wire

vi) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia
GS wire
2.06.01 The aluminium used for armouring shall be of H4 grade as per IS:8130 with
maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of
aluminium wires/formed wires for armouring shall be same as indicated above in
clause 2.06.00 for galvanised steel.
2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /

SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
LT power Cables

Page
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formed wire. Zinc rich paint shall be applied on armour joint surface of G.S.
wire/formed wire.
2.07.00 Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to
meeting all the requirements of Indian standards referred to, outer sheath of all
the cables shall have the following FRLS properties.
(a.) Oxygen index of min. 29 (As per ASTMD 2863)
(b.) Acid gas emission of max. 20% (As per IEC-754-I).
(c.) Smoke density rating shall not be more than 60% during Smoke Density
Test as per ASTMD-2843.
2.08.00 Cores of the cables shall be identified by colouring of insulation. Following colour
scheme shall be adopted:
1 core - Red, Black, Yellow, Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
2.09.00 For reduced neutral conductors the core shall be black.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking
shall also be provided over outer sheath.
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Sequential marking of length of the cable in metres at every one metre-To
be embossed / printed
The embossing shall be progressive, automatic, in line and marking shall be
legible and indelible.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC
332 Part -3.
2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum over the declared value in the technical data sheets.
2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes
etc.are not acceptable.
2.14.00 Cable selection & sizing
2.14.01 Cables shall be sized based on the following considerations:
(a) Rated current of the equipment
(b)
The voltage drop in the cable, during motor starting condition, shall be
limited to 10% and during full load running condition, shall be limited to
3% of the rated voltage

SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
LT power Cables

Page
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(c) Short circuit withstand capability

This will depend on the feeder type. For a fuse protected circuit, cable
should be sized to withstand the let out energy of the fuse. For breaker
controlled feeder, cable shall be capable of withstanding the system
fault current level for total breaker tripping time inclusive of relay pickup
time.
2.14.02 Derating Factors
Derating factors for various conditions of installations including the following shall
be considered while selecting the cable sizes:
a) Variation in ambient temperature for cables laid in air
b) Grouping of cables
c) Variation in ground temperature and soil resistivity for buried cables.
2.14.03 Cable lengths shall be considered in such a way that straight through cable joints
are avoided.
2.14.04 All LT power cables of sizes more than 120 sq.mm. shall be XLPE insulated
upto 120 sq.mm size shall be PVC insulated and preferable sizes are 1Cx150,
1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm.

3.00.00 CONSTRUCTIONAL FEATURES
3.01.00 1.1 KV Grade Power Cables
(a.) 1.1 KV grade XLPE power cables shall have compacted aluminium
conductor, XLPE insulated, PVC inner-sheathed (as applicable), armoured/
unarmoured, PVC outer-sheathed conforming to IS:7098. (Part-I).
(b.) 1.1KV grade PVC power cables shall have aluminium conductor
(compacted type for sizes above 10 sq.mm), PVC Insulated, PVC inner
sheathed (as applicable) armoured/ unarmoured, PVC outer-sheathed
conforming to IS:1554 (Part-I).
(c.) 1.1 KV grade Trailing cables shall have tinned copper (class 5) conductor,
insulated with heat resistant elastomeric compound based on Ethylene
Propyline Rubber (EPR) suitable for withstanding 90 deg.C continuous
conductor temperature and 250deg C during short circuit, inner-sheathed
with heat resistant elastomeric compound, nylon cord reinforced, outer-
sheathed with heat resistant, oil resistant and flame retardant heavy duty
elastomeric compound conforming to IS 9968.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
LT power Cables

Page
5 of 7

4.00.00 CABLE DRUMS
(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall
be covered with water proof layer. Both the ends of the cables shall be
properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails
so as to eliminate ingress of water during transportation, storage and
erection. Wood preservative anti-termite treatment shall be applied to the
entire drum. Wooden drums shall comply with IS : 10418.
(b.) Each drum shall carry manufacturer's name, purchasers name, address
and contract number, item number and type, size and length of cable and
net gross weight stenciled on both sides of the drum. A tag containing same
information shall be attached to the leading end of the cable. An arrow and
suitable accompanying wording shall be marked on one end of the reel
indicating the direction in which it should be rolled.
5.00.00 TESTS
(b.) However if the Contractor is not able to submit report of the type test(s)
type test report(s) are not found to be meeting the specification
requirements, the Contractor shall conduct all such tests under this
contract, at no additional cost to the Owner either at third party lab or in
presence of client/owners representative and submit the reports for
approval.
(c.) All acceptance and routine tests as specified below and in relevant
(d) The type test reports once approved for any projects shall be treated as
furnished by the manufacturer conforming similarity and No design
change. Minor changes if any shall be highlighted on the endorsement
sheet.
5.01.01 TYPE TESTS
The reports for the following type tests shall be submitted on one size each of
XLPE/PVC LT Power cables:
S.No. Type Test Remarks
For Conductor
1. Annealing test For copper conductor only.
2. Tensile test For aluminium conductor only.

SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
LT power Cables

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3. Wrapping test For aluminium conductor only.
4. Resistance test
For Armour Wires/ Formed Wires
5. Measurement of Dimensions
6. Tensile Test
7. Elongation test
8. Torsion test For round wires only
9. Wrapping test For aluminium wires/formed wires only
10. Resistance test
11.(a) Mass of Zinc Coating test For G.S. Formed wires /wires only.
11.(b) Uniformity of zinc coating For G.S. Formed wires /wires only.
12. Adhesion test For G.S. Formed wires /wires only.
For PVC/XLPE insulation & PVC Sheath
13. Test for thickness
14. Tensile strength & elongation tests before ageing and after ageing
15. Ageing in air oven
16. Loss of mass test For PVC insulation and sheath only
17. Hot deformation test For PVC insulation and sheath only
18. Heat shock test For PVC insulation and sheath only
19. Shrinkage test

SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
LT power Cables

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20. Thermal stability test For PVC insulation and sheath only
21. Hot set test For XLPE insulation only
22. Water absorption test For XLPE insulation only
23. Oxygen index test For outer sheath only
24. Smoke density test For outer sheath only
25. Acid gas generation test For outer sheath only

For completed cables

26. Insulation resistance test
(Volume resistivity method)
27.
High voltage test
28. Flammability test as per IEC - 332 Part-3 (Category -B)

5.01.02 Indicative list of tests / checks, routine and acceptance tests shall be as per
quality assurance and inspection table of LT power cables.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


CONTROL CABLES

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-04
CONTROL CABLES

Page
1 of 6

CONTROL CABLES

1.01.00 All standards, specifications and codes of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions as on
date of opening of bid. In case of conflict between this specification and those
(IS: codes, standards, etc.) referred to herein, the former shall prevail. All the
cables shall conform to the requirements of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working
voltages upto and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wire and tapes
for armouring of cables.
IS : 4905 Methods for random sampling.
IS : 5831 PVC insulation and sheath of electrical cables.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D 2843 Standard test method for density of smoke from the burning
or decomposition of plastics.
ASTM-D-2863 Standard method for measuring the minimum oxygen
concentration to support candle like combustion of plastics.
IEC-754 (Part-I) Test on gases evolved during combustion of electric cables.
IEEE-383 Standard for type test of Class IE Electric Cables.
IEC 332 Tests on Electric cables under fire conditions
. Part-3 : Tests on bunched wires or cables (category -B)

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-04
CONTROL CABLES

Page
2 of 6

2.00.00 TECHNICAL REQUIREMENTS
2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground burried installation with chances of flooding by water.
2.02.00 Cables shall be armoured. flame retardant, low smoke (FRLS), type designed to
withstand all mechanical, electrical and thermal stresses develop under steady
state and transient operating conditions as specified elsewhere in this
specification.
2.03.00 Conductor of control cables shall be made of multi stranded, plain annealed
copper.
2.04.00 PVC insulation shall be suitable for continuous conductor temperature of 70 deg
C and short circuit conductor temperature of 160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever
necessary. It shall not stick to insulation and inner sheath. All the cables, other
than single core unarmoured cables, shall have distinct extruded PVC inner
sheath of black colour as per IS : 5831.
2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as
follows: -
Calculated nominal dia.
of cable under armour
Size and Type of armour
1) Upto 13 mm

1.4mm dia GS wire
2) Above 13 upto 25 mm

0.8 mm thick GS formed wire / 1.6 mm dia
GS wire


0.8mm thick GS formed wire / 2.0mm dia
GS wire

4) Above 40 upto 55mm

1.4 mm thick GS formed wire/2.5mm dia GS
wire


1.4mm thick GS formed wire / 3.15mm dia
GS wire

6) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia
GS wire
The gap between armour wire / formed wire shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /
formed wire. Zinc rich paint shall be applied on armour joint surface.
2.07.00 Outer sheath shall be of PVC (grade as applicable) and grey in colour . In
addition to meeting all the requirements of Indian standards referred to, outer
sheath of all the cables shall have the following FRLS properties.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-04
CONTROL CABLES

Page
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(a.) Oxygen index of min. 29 (As per ASTMD 2863)
(b.) Acid gas emission of max. 20% (As per IEC-754-I).
(c.) Smoke density rating shall not be more than 60% during Smoke Density
Test as per ASTMD-2843.
2.08.00 Cores of the cables of upto 5 cores shall be identified by colouring of insulation.
Following colour scheme shall be adopted.
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
5 core - Red, Yellow, Blue, Black and Grey
2.09.00 For cables having more than 5 cores, core identification shall be done by
numbering the insulation of cores sequentially, starting by number 1 in the inner
layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). The
number shall be printed in Hindu-Arabic numerals on the outer surfaces of the
cores. All the numbers shall be of the same colour, which shall contrast with the
colour of insulation. The colour of insulation for all the cores shall be grey only.
The numerals shall be legible and indelible. The numbers shall be repeated at
regular intervals along the core, consecutive numbers being inverted in relation
to each other. When the number is a single numeral, a dash shall be placed
underneath it. If the number consists of two numerals, these shall be disposed
one below the other and a dash placed below the lower numeral. The spacing
between consecutive numbers shall not exceed 50 mm.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking
shall also be provided over outer sheath:
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Sequential marking of length of the cable in metres at every one metre.
- To be embossed / printed.
The embossing / printing shall be progressive, automatic, in line and marking
shall be legible and indelible.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC
332 Part -3.
2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum over the declared value in the technical data sheets.
2.13.00 Inplant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes
etc. are not acceptable.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-04
CONTROL CABLES

Page
4 of 6

2.14.00 Cable selection & sizing
Control cables shall be sized based on the following considerations:
(a) The minimum conductor cross-section shall be 1.5 sq.mm.
(b)
The minimum number of spare cores in control cables shall be
as follows:
No. of cores in cable Min. No. of spare cores
2C, 3C NIL
5C 1
7C-12C 2
14C & above 3
2.14.01 Cable lengths shall be considered in such a way that straight through cable
joints are avoided.

3.00.00 CONSTRUCTIONAL FEATURES
3.01.00 1.1 KV Grade Control Cables shall have stranded copper conductor multicore
PVC insulated, PVC inner-sheathed ,armoured / unarmoured, PVC outer-
sheathed conforming to IS:1554. (Part-I).
3.02.00 1.1KV grade trailing cables shall have tinned copper (class-5) conductor,
insulated with heat resistant elastomeric compound based on Ethylene Propyline
Rubber (EPR) suitable for withstanding 90 deg C continuous conductor
temperature and 250 deg C during short Ckt., inner sheathed with heat resistant,
oil resistant and flame retardant heavy duty elastomeric compound conforming to
IS 9968. Minimum conductor size shall be 2.5sqmm.
4.00.00 CABLE DRUMS
(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall
be covered with water proof layer. Both the ends of the cables shall be
properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails
so as to eliminate ingress of water during transportation, storage and
erection. Wood preservative anti-termite treatment shall be applied to the
entire drum. Wooden drums shall comply with IS : 10418.
(b.) Each drum shall carry manufacturer's name, purchasers name, address
and contract number, item number and type, size and length of cable and
net gross weight stenciled on both the sides of the drum. A tag containing
same information shall be attached to the leading end of the cable. An
arrow and suitable accompanying wording shall be marked on one end of
the reel indicating the direction in which it should be rolled.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-04
CONTROL CABLES

Page
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5.00.00 TESTS
type test report(s) are not found to be meeting the specification
approval.
furnished by the manufacturer conforming similarity and No design
sheet.
5.01.00 TYPE TESTS
5.01.01 The reports for the following type tests shall be submitted for one size of control
cables :
S. No. Type Test Remarks
For Conductor
1. Annealing test For copper conductor only.
2. Resistance test
For Armour Wires / Formed Wires
3. Measurement of Dimensions
4. Tensile Test
5. Elongation test
6. Torsion test For round wire only
7. Wrapping test
8. Resistance test
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-04
CONTROL CABLES

Page
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9(a). Mass of zinc Coating test For GS wires/formed wires only
9(b). Uniformity of zinc coating For GS wires/formed wires only
10. Adhesion test For GS wires/formed wires only
For PVC insulation & PVC Sheath
11. Test for thickness
12. Tensile strength and elongation
test
before ageing and after ageing
13. Ageing in air oven
14. Loss of mass test For PVC insulation and sheath only
15. Hot deformation test For PVC insulation and sheath only
16. Heat shock test For PVC insulation and sheath only
17. Shrinkage test
18. Thermal stability test For PVC insulation and sheath only
19. Oxygen index test For outer sheath only
20. Smoke density test For outer sheath only
21. Acid gas generation test For outer sheath only

For completed cables
22. Insulation resistance test(Volume resistivity method)
23. High voltage test
24. Flammability test as per IEC - 332 Part-3 (Category-B)
5.01.02 Indicative list of tests / checks, routine and acceptance tests shall be as per
quality assurance and inspection table of LT power cables.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


INSTRUMENTATION CABLES

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-05

Page
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1.00.00 INSTRUMENTATION CABLES
1.01.00 GENERAL
1.01.01 The Contractor shall supply, erect, terminate and test all instrumentation cables
for control and instrumentation equipment/devices/systems included under
Contractor's scope.
1.01.02 Any other application where it is felt that instrumentation cables are required due
to system/operating condition requirements, are also to be provided by
Contractor.
1.01.03 Other type of cables like fiber optic/co-axial cables for system bus, cables for
connection of peripherals etc. (under Contractor's scope) are also to be furnished
by the Contractor.
1.01.04 Contractor shall supply all cable erection and laying hardware trays, supports,
flexible conduits, cable glands, lugs, pull boxes etc. on as required basis for all
the systems covered under this specification.
1.02.00 Instrumentation Cable Specifications
1.02.01 All the instrumentation cables shall be Armoured, twisted, shielded multipair, pre
fabricated, flame retardant low smoke (FRLS) type. The Cables shall be provided
in non-returnable drums. The drum length shall be 1000m (+/-5%) up to &
including 12 pairs and 500 m (+/- 5%) above 12 pairs.
1.02.02 Voltage grade of the instrumentation cables shall be 225V (peak value).
1.02.03 All instrumentation cables covered in this specification shall comply with VDE
0815, VDE 0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN 4241475,
ANSI MC 96.1, IS-8784, IS-10810 (latest editions) and its amendments read
along with this specification.
1.02.04 The conductor shall be of minimum 0.5-sq.mm size, high conductivity, multi-
stranded copper for all types of instrumentation cables where as the same shall
be min. 1.5sqmm when used in the trailing cables.
1.02.05 The insulation of individual conductor shall be extruded PVC meeting the
requirements of VDE 0207 Part 4 compound Y I3. The outer sheath of
instrumentation cables shall be extruded PVC (compound YM1) as per VDE
0207 Part 5 and shall be of flame-retardant low smoke (FRLS) type. The cable
shall be provided with marking including manufacturer's name, insulation
material, and conductor sizes, no of pairs, voltage ratings, type of cable etc. at
intervals not exceeding 625mm. Progressive sequential marking of the length of
the cable at every one meter & progressive markings to read 'FRLS' at every 5
meters shall be provided on the outer sheath of all instrumentation cables. The
colour of outer sheath shall be sky blue.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-05

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Fillers in multiple conductor cables shall be flame retardant and moisture
resistant. Cable accessories such as harnessing components, markers, bedding,
cable jointer, binding tape etc. shall also have flame retardant quality.
1.02.06 All instrumentation cables shall be provided with overall shielding. However,
multipair cables carrying analog signals shall be provided with individual pair
shielding in addition to overall shielding. Shielding shall be of Aluminium-Mylar
tape with 100% coverage and with atleast 20% overlapping. The thickness of
individual pair shield shall be 28 micron (minimum) and that of overall shield shall
be 55 microns (minimum). Separate drain wires for individual pair shield
(wherever applicable) as well as overall shield shall be provided. Drain wire shall
be of seven (7) strand 20 AWG (0.51 Sq.mm) tin coated copper conductor.
Maximum lay of individual twisted pair shall be 50 mm. Bidder to ensure that
individual core diameter shall be suitable for maxi-termi connection. Insulation
thickness of individual core shall be between 0.28 and 0.35 mm for 0.5 mm2
cables.
1.02.07 The outer sheath of the instrumentation cables shall meet the following minimum
requirements:
(i) An Oxygen index of not less than 29% and a Temperature index of not
less than 250 deg.C as per ASTMD-2863.

(ii) Maximum acid gas generation by weight as per IEC-754-I shall not be
more than 20%.

(iii) Smoke Density Rating shall not be more than 60% during Smoke Density
Test as per ASTMD-2843. The results of smoke density test shall be
plotted on a curve indicating light absorption vs. time as per ASTMD2843.
The average area under the curve (smoke density rating) shall not be
more than 60%.

(iv) Complete cable assembly shall pass Swedish Chimney test as per SEN-
4241475 and flammability test as per IEEE-383.

The thickness of outer sheath shall be as per the guidelines given in VDE 0816.
Thickness of outer sheath shall not be less than 1.8 mm in any case. Allowable
tolerance of overall diameter of the cables shall be +/-2 mm max. over the
declared value in technical data sheets. The variation in diameter and the ovality
at any cross section shall not be more than 1.0 mm.
1.02.08 All instrumentation cables shall be suitable for continuous operation at 70 deg.C,
except for high temperature resistant teflon insulated cables which shall be
suitable for continuous operation at 205 deg.C. The cables shall be suitable for
laying in wet or dry locations in trays, conduits, ducts, trenches and under ground
buried installations.
1.02.09 The thermocouple extension cables shall be of single/multi pair, twisted &
shielded, PVC insulated, FRLS PVC sheathed and compatible for the type of
thermocouples employed. The material of conductor shall be as per ANSI MC-
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-05

Page
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96.1. The material and requirements of conductor insulation, shielding and outer
sheath shall be as per the above clauses.
1.02.10 Cable parameters such as mutual capacitance between conductors, conductor
resistance, insulation resistance, characteristic impedance, cross talk and
attenuation figures at 20 deg.C ( 3 deg.C) for various types of cables as
applicable shall be as specified under Table A.
1.02.11 Identification of the cores & pairs shall be done with suitable colour coding &
band marking as well as by numbering of cores/pairs as per VDE: 0815. The
details of colour coding etc. shall be as approved by Employer during detailed
stage. Also refer Table B for description of various type of cables.
1.02.12 The Contractor shall furnish all documentary evidence including cross-sectional
drgs, test certificates to substantiate the suitability of cables offered for different
applications. The contractor shall also clearly bring out the application wise
details for each type of cable offered.
1.02.13 All prefabricated cables shall have 10% spare cores which will not be connected
to pin connectors.
1.02.14 CABLE PARAMETER
Table A : CABLE PARAMETER
Conductor Size 0.5 Sq.mm.
Parameter/
Type of Cable
Individual and
overall shielded
(Type F)
Overall
Shielded(Type-G)
Compensating
cables
(with/without
Teflon coating)
(Type A,B,C)
Mutual
capacitance at
0.8 kHz (max.)
120 nF/Km. 100 nF/Km. 200 nF/Km
Conductor
Resistance
(max.)
73.4 ohm/km
(loop)For Type F
73.4 ohm/km
(loop)

Insulation
resistance
100 M ohm/ Km 100 M ohm/ Km 100 M ohm/ Km
Cross-Talk
figure at 0.8
kHz (min.)
60 dB 60 dB 60 dB
Characteristic
impedance
(max.)
320 ohm 340 ohm
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
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Attenuation at 1
kHz (max.)
1.2 dB/Km 1.2 dB/Km

1.02.15 DESCRIPTION OF VARIOUS TYPE OF CABLES
TABLE B
Type Conductor
Size
Description
A
0.5 mm
2

Two pair shielded and twisted pair T/C extension cable,
ANSI type KX, stranded conductor.
B
0.5 mm
2

Two pair shielded & twisted T/C extension cable ANSI
type SX, stranded conductor.
C
0.5 mm
2

Two pair shielded & twisted heat resistant teflon
insulation & Outer sheath T/C extension cable ANSI
type KX, stranded conductor.
F
0.5 mm
2

Multi pair individual pair & overall shielded twisted pair
instrumentation cable (4/8/12/24 pair) for analog
signals with stranded copper conductor.
G
0.5 mm
2

Multi pair overall shielded & twisted pair
instrumentation cable (2/4/8/12/24/48 pair) for binary
signals with stranded copper conductor.
I
0.5 mm
2

Type F cable/type G cable with heat resistant teflon
insulation & outer-sheath for high temperature
application.
S As per
specific
Standard/
Requirement
for each
application
Multi core/ Multi pair shielded cable for system specific
cables. Like conductivity type level switches, Vibration
monitoring system cable , System Bus cable, Bus
communications cable etc. as applicable.

1.03.00 INSTRUMENTATION CABLE INTERCONNECTION AND TERMINATION
PHILOSOPHY

1.03.01 The cable interconnection philosophy to be adopted shall be such that extensive
grouping of signals by large scale use of field mounted Group JBs at strategic
locations (where large concentration of signals are available, e.g. switchgear) is
done and consequently cable with higher number of pairs are extensively used.
The details of termination to be followed are mentioned in the given table C.

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TABLE C:- CABLE TERMINATION TO BE FOLLOWED
Application Type Of Termination Type Of
Cable
FROM (A) TO (B) END A END B
Valves/dampers
drives (Integral
Junction box)
Marshalling
ubicle/local group
JB/Ter-
mination/Control
Cabinets/System
Cabinets
Plug in
connector
Post moun
ted Maxi
termi/cage
clamp type.
G
RTD heads Local junction box Plug in
connector
Maxitermi/
cage clamp
(Rail moun
ted) type.
F
Thermocouples CJC box Plug in
connector
Screwed/
Cage clamp
Type
A,B,C*
RTD
thermocouple
Temperature
transmitter
Plug in
connector
Screwed/
Cage clamp
Type

Local Junction
box, CJC box,
Group JB/
MCC/SWGR
Marshalling
Cubicle/local
group
JB/Termination/
Control
Cabinets/System
Cabinets
Maxitermi/
cage clamp
(Rail moun
ted) type.
Post moun
ted Maxi
termi/cage
clamp type.
F,G
Local Junction
box,
MCC/SWGR
Group JB Maxitermi/
cage clamp
(Rail moun
ted) type.
Maxitermi/
cage clamp
(Rail moun
ted) type.
F,G
Field mounted
Instrument
Group JB Maxitermi/
cage clamp
(Rail moun
ted) type.
Maxitermi/c
age clamp
(Rail moun
ted) type.
F,G
Marshalling
cubicle/
Termination
Cabinet
Electronic system
cabinet
Post
mounted
Maxi
termi/cage
clamp type.
Post
mounted
Maxi
termi/cage
clamp type.
F,G
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Marshalling /
Termination
system cabinets
UCP mounted
equipments
Post moun
ted Maxi
termi/cage
clamp type.
Plug in
connector/
Cage clamp
type (rail
mounted).
F,G (with
plug-in
connector at
one end)
DDCMIS/PLC
cabinets
PC, Printers etc. Plug in
connector
Plug in
connector
Mfr.s
Standard
Notes 1 Normally 10% spare core shall be provided when the
number of pairs of cables are more than four pairs.
2 For analog signals individual pair shielding & overall
shielding & for Binary signals only overall shielding of
instrumentation cables shall be provided.
3 * For high temperature application only.
2.00.00 TERMINAL BLOCKS
2.01.00 All terminal blocks shall be rail mounted/post mounted, cage clamp type/maxi-
termi type (MTP) with high quality non-flammable insulating material of melamine
suitable for working temperature of 105 deg. C. The terminal blocks in field
mounted junction boxes, CJC boxes, etc., shall be suitable for cage clamp/ MTP
connections. The terminal blocks in Control Equipment Room
logic/termination/marshalling cubicles shall be suitable for post mounted maxi-
termi/cage clamp connection at the field input end. The terminal blocks for
DDCMIS input/output connections from/to SWGR/MCC, Actuators with Integral
Starter (for coupling relays and check back signals of 11 kV and 3.3 kV
auxiliaries, LT drives/valves & dampers/solenoids, CT & VT, etc.) shall be
provided with built in test and disconnect facilities complete with plug, slide
clamp, test socket, etc. The exact type of terminal blocks to be provided by the
Contractor and the technical details of the same including width etc. shall be
subject to Employer's approval.
2.02.00 All the terminal blocks shall be provided complete with all required accessories
including assembly rail, locking pin and section, end brackets, partitions, small
partitions, test plug bolts and test plug (as specified above for SWGR
connections) transparent covers, support brackets, distance sleeves, warning
label, marking, etc.
2.03.00 The marking on terminal strips shall correspond to the terminal numbering on
wiring diagrams. At least 20% spare unused terminals shall be provided
everywhere including local junction boxes, instrument racks/enclosures,
termination/marshalling cabinets, etc. All terminal blocks shall be numbered for
identification and grouped according to the function. Engraved labels shall be
provided on the terminal blocks.
2.04.00 The terminal blocks shall be arranged with atleast 100 mm clearance between
two sets of terminal blocks and between terminal blocks and junction box walls.
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2.05.00 For ensuring proper connections, Contractor shall provide suitable accessories,
along with insulation sleeves. The exact connecting accessory shall be finalised
as per application during detail engineering stage subject to Employer's approval
without any cost repercussions.
2.06.00 Internal wiring in factory prewired electronic equipment cabinets may be installed
according to the Contractor's standard as to wire size and method of termination
or internal equipment. Terminal blocks for connection of external circuits into
factory prewired electronic equipment cabinets shall meet all the requirements as
specified above.
3.00.00 INTERNAL PANELS/CABINETS/SYSTEM CABINETS WIRING
3.01.00 Internal panel/cabinet wiring shall be of multistranded copper conductor with
FRLS PVC insulation without shield and outer sheath meeting the requirements
of VDE 0815.
3.02.00 Wiring to door mounted devices shall be done by 19 strand copper wire provided
with adequate loop lengths of hinge wire so that multiple door opening shall not
cause fatigue breaking of the conductor.
3.03.00 All internal wires shall be provided with tag and identification nos. etched on
tightly fitted ferules at both ends in Employer's approved format. All wires directly
connected to trip devices shall be distinguished by one additional red colour
ferrule.
3.04.00 All external connection shall be made with one wire per termination point. Wires
shall not be tapped or spliced between terminal points.
3.05.00 All floor slots of desk/panels/cabinets used for cable entrance shall be provided
with removable gasketed gland plates and sealing material. Split type grommets
shall be used for prefabricated cables.
3.06.00 All the special tools as may be required for solderless connections shall be
provided by Bidder.
3.07.00 Wire sizes to be utilised for internal wiring.
(i) Current (4-20 mA), low voltage signals (48V) 0.5 Sq.mm.
(ii) Power supply and internal illumination. 2.5Sq.mm. minimum (shall be
as per load requirement.)
4.00.00 CABLE INSTALLATION AND ROUTING
4.01.00 All cables assigned to a particular duct/conduit shall be grouped and pulled in
simultaneously using cable grips and suitable lubricants. Cables removed from
one duct/conduit shall not be reused without approval of Employer.
Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the
higher voltage cable shall be in higher position and instrumentation cable shall be
in bottom tier of the tray stack.
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4.02.00 Cables shall terminate in the enclosure through cable glands. All cable glands
shall be properly gasketed.
4.03.00 All cables shall be identified by tag. Nos. provided in Employer's approved format
at both the ends as well as at an interval of 5 meters.
4.04.00 Line voltage drop due to high resistance splices, terminal contacts, insulation
resistance at terminal block, very long transmission line etc. shall be reduced as
far as practicable.
4.05.00 The cables emanating from redundant equipment/devices shall be routed
through different routes.
5.00.00 CABLE LAYING AND ACCESSORIES
5.01.00 CABLE LAYING
1 Cables shall be laid strictly in line with cable schedule.
2 Identification tags for cables.
Indelible tags to be provided at all terminations, on both sides of wall or
floor crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in
cable trench/tray.
3 Cable tray numbering and marking.
To be provided at every 10m and at each end of cable way & branch
connection.
4 Joints for less than 250 Meters run of cable shall not be permitted.
5 Buried cable protection
With concrete slabs; Route markers at every 20 Meters along the route
& at every bend.
6 Road Crossings
Cables to pass through burried high density PE pipes encased in PCC.
At least 300 mm clearance shall be provided between
- HT power & LT power cables,
- LT power & LT control/instrumentation cables,
Spacing between cables of same voltage grade shall be in accordance
with the derating criteria adopted for cable sizing.

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7 Segregation (physical isolation to prevent fire jumping)
a All cable associated with the unit shall be segregated from cables of
other Units.
b Interplant cables of station auxiliaries and unit critical drives shall be
segregated in such a way that not more than half of the drives are
lost in case of single incident of fire.
8 Cable clamping
All cables laid on trays shall be neatly dressed up & suitably
clamped/tied to the tray. For cables in trefoil formation, trefoil clamps
shall be provided.
6.00.00 FIELD MOUNTED LOCAL JUNCTION BOXES
(i) No. of ways 12/24/36/48/64/72/96/128 with 20% spare terminals.
(ii) Material and
Thickness
4mm thick fiberglass reinforced polyester.
(iii) Type Screwed at all four corners for door. Door handle shall be
self locking with common key. Door gasket shall be of
synthetic rubber.
(iv) Mounting
clamps and
accessories
Suitable for mounting on walls, columns, structures etc.
The brackets, bolts, nuts, screws, glands and lugs
required for erection shall be of corrosion resistant
material, included in Bidders scope of supply.
(v) Type of
terminal blocks
Rail mounted maxitermi or cage-clamp type suitable for
conductor size upto 2.5 mm
2
. A M6 earthing stud shall
be provided.
(vi) Protection
Class
IP:55 minimum for Indoor & IP-65 Outdoor applications
(vii) Colour To be decided during detailed engineering & subject to
Employers approval.
7.00.00 CONDUITS
7.01.00 All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild
steel in accordance with IS:9357 Part-I (1980) and Part-II (1981). The conduit
interior and exterior surfaces shall have continuous zinc coating with an overcoat
of transparent enamel lacker or zinc chromate. Flexible conduit shall be heat
resistant lead coated steel, water leak, fire and rust proof. The temperature rating
of flexible conduit shall be suitable for actual application.

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8.00.00 TESTS
8.01.00 GENERAL
(a.) All equipments to be supplied shall be of type tested design. The
Contractor shall submit for Owners approval the reports of all the type
tests as listed in this specification and carried out within last ten years
from the date of bid opening. These reports should be for the tests
conducted on the equipment similar to those proposed to be supplied
under this contract and the test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client.
conducted within last ten years from the date of bid opening, or in case
the type test report(s) are not found to be meeting the specification
approval.
reference. For subsequent projects of NTPC, an endorsement sheet will
be furnished by the manufacturer conforming similarity and No design
sheet.
8.02.00 TYPE TEST
8.02.01 Following type tests reports shall be submitted for one size of each type of
instrumentation cables:
8.02.02 For Conductor (including Drain Wire)
Sl.
No.

Test Reference Standard Remarks
1. Resistance Test VDE:0815

2. Diameter IS:10810

3. Tin coating test*
(Persulphate Test)
As per relevant
standard
*Applicable for drain
wire only

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8.02.03 For PVC Insulation And PVC Sheath
Sl.
No.
Test Reference
Standard
Remarks
1. Test for thickness** IS:10810

2. Tensile strength and elongation test
before and after ageing**

VDE:0472
3. Ageing in air ovens** - do-
4. Loss of Mass Test -do-

5. Hot deformation test -do-

6. Heat shock test -do-

7. Shrinkage test** -do-

8. Cold bend/ cold impact test -do-

9. Colour fastness to water -do-

10. Thermal stability test -do-

11. Bleeding and blooming -do-

12. Oxygen index test (for sheath & fillers) ASTMD-2863

13. Smoke density test (for sheath & fillers) ASTMD-2843

14. Acid gas generation test (for sheath &
fillers)
IEC-754-1

8.02.04 For Al-Mylar Shield

Sl.No. Test Reference Standard Remarks

1. Continuity test As per relevant standard

2. Shield thickness test -do-

3. Overlap test -do

4. Noise interference
test
IEEE-Transaction
March'67

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


ILLUMINATION SYSTEM

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ILLUMINATION

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ILLUMINATION
1.00.00 GENERAL
1.01.00 This specification covers the general description of design, manufacture and
construction features, testing, supply, installation and commissioning of the
illumination system equipment required to be provided by the bidder.
1.03.00 All standards and codes of practice referred to herein shall be the latest edition
including all applicable official amendments & revisions as on date of bid
opening. In case of conflict between this specification and those (IS codes,
standards etc.) referred to herein, the former shall prevail. All work shall be
carried out as per the following standards & codes.
1.04.00 Lighting Fixtures and Accessories
IS:1913 General and safety requirements for luminaries.
IS:2148
Flame proof enclosures of electrical apparatus.
IS:418 Tungsten filament general service electric lamps.
IS:1258 Bayonet lamp holders.
IS:1534 Ballast for fluorescent lamps.
IS:1569
Capacitors for use in tubular fluorescent, high pressure
mercury vapour and low pressure sodium vapour discharge
lamp circuit.

IS:1777 Industrial luminaire with metal reflectors.
IS:2149 Luminaire for Street lighting.
IS:2215 Starters for fluorescent lamps.
IS:2418
Tubular fluorescent lamps for general lighting services.
IS:3323 Bi-pin lamp holders for tubular fluorescent lamps.
IS:3324 Holders for starters for tubular fluorescent lamps.
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IS:4013 Dust-tight electric lighting fittings.
IS:6616 Ballasts for high pressure mercury vapour lamps.
IS:8224 Electric Lighting fittings for Division 2 areas.
IS:9900 High-pressure mercury vapour lamps.
IS:9974 High pressure Sodium vapour lamps.
IS:10276 Edison screw lamp holders.
IS:10322 Luminaires.
IS:13021
AC Supplied Electronic Ballasts for tubular fluorescent
lamps.
1.05.00 Lighting Panels, Switch-boxes, Receptacles and Junction Boxes
IS:2147
Degree of protection provided by enclosures for low-voltage
switchgear and control gear.
IS:1293
Plugs & socket outlets of rated voltage upto and Including
250volts & rated current upto and including 16 Amps.
IS:2551 Danger notice plates.
IS:13947 Low voltage switchgear and controlgear
IS:3854 Switches for domestic and similar purposes.
IS:6875
Control switches (switching devices for control and auxiliary
circuits including contactor relays) for voltages upto and
including 1000 V AC and 1200 V DC.
IS:13703
Low voltage fuses for voltages not exceeding 1000V AC or
1500 V DC.
1.06.00 Conduits, Pipes and Accessories
IS:2667 Fittings for rigid steel conduit for electrical wiring.
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IS:3837 Accessories for rigid steel conduits for electrical wiring.
IS:9537 Conduits for electrical installations.
1.07.00 Lighting Wires/Cables
IS:694
PVC insulated cables for working voltages upto and
including 1100 V
IS:3961
Recommended current ratings for cables.(PVC Insulated and
PVC sheathed heavy duty cables and light duty cables).
IS:8130
Conductors for insulated electric cables and flexible cords.
IS:10810 Methods of tests for cables.
1.08.00 Electrical Installation Practices & Miscellaneous
IS:1944 Code of practice for lighting of public thorough fare
IS:3646 Code of practice for interior illumination.
IS:5572 Classification of Hazardous areas (other than Mines)having
flammable gases and Vapours for electrical installation
IS:6665 Code of practice for industrial lighting.

.
.
National Electrical Code
Indian Electricity Rules.
Indian Electricity Act
IS:5 Colour for ready mixed paints & enamels.
IS:280 Mild steel wires for general engineering purposes.
IS:374 Electric ceiling type fans & regulators.
IS:732 Code of practice for electrical wiring installations.
IS:1255
Code of practice for installation and maintenance of power
cables Upto and including 33KV rating.
IS:2062
Steel for general structural purposes
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IS:2629
Recommended practice for hot-dip galvanizing of iron and
steel.
IS:2633
Methods for testing uniformity of coating of zinc coated
articles.
IS:2713 Tubular steel poles for overhead power lines.
IS:3043 Code of practice for earthing
IS:5216
Guide for safety procedures and practices in electrical work.
IS:5571
Guide for selection of electrical equipments for hazardous
areas.
BS:6121 Mechanical cable glands

2.00.00 LIGHTING SYSTEM DESCRIPTION
2.01.00 Normal AC Lighting System
Normal AC lighting system 415V, 3Phase, 4wire, will be fed from lighting panels
(LPs) which will be fed from the lighting distribution boards (LDBs) which in turn
will be fed from LT MCCs.
2.02.00 Emergency Lighting System
2.02.01 100W, 220V DC/110 V DC Lighting fixture shall be provided as follows:
- One (1) no. in each local control area
- Three (3) nos. in each MCC/ Switchgear room and control room
- One (1) no in each office room and each pump house
- Two (2) nos in each underground portion of TPs
- One (1) no at every 5.0m height interval in the staircases of various TPs
and buildings under contractors scope
- One (1) no in each drive floor in each TP under contractors scope
The above fixtures shall be mounted suitably on wall/columns at strategic
locations for safe movement of operating personnel and access to important
control points during an emergency, when the normal AC lighting system fails.
These lighting fixtures shall be fed from bidder's 220 V DC//110 V DC LDBs
through DC lighting panels.
The supply to the DC lighting panels shall be automatically switched on in case
of loss of AC supply .The DC supply will be automatically switched off after about
3 minutes following the restoration of AC lighting system.
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Four (4) nos. 240V AC lighting fixtures fed from UPS shall be provided on each
stacker reclaimer machine.
2.03.00 DESIGN PHILOSOPHY
1. A comprehensive illumination system shall be provided.
2. All lighting system shall be automatically controlled by synchronous timer.
Provision to bypass the timer shall be provided in the panel for manual
control.
3. The system shall include distribution boards, lighting panels, lighting
fixtures, junction boxes, receptacles, switch boards, lighting pole/masts,
conduits, cables and wires, etc. The system shall cover all interior and
exterior lighting such as area lighting, including Transformer yard etc.
The constructional features of lighting distribution boards shall be similar
to AC/DC distribution boards described in chapter of LT Switchgear.
Outgoing circuits in LPs shall be provided with MCBs of adequate ratings.
4. The illumination system shall be designed on the basis of best
engineering practice and shall ensure uniform, reliable, aesthetically
pleasing and glare free illumination. The lighting fixtures shall be
designed for minimum glare. The design shall prevent glare/luminous
patch seen on VDU/ Large video screens, when viewed from an angle.
The finish of the fixtures shall be such that no bright spots are produced
either by direct light source or by reflection. The diffusers/ louvers used in
fluorescent fixtures shall be made of impact resistant polystyrene sheet
and shall have no yellowing property over a prolonged period. The Lux
levels to be adopted for various area are indicated at Annexure A.
5. Apart from maintenance factor as given below, Temperature correction
factor shall be considered in the lighting design for fluorescent fixtures
located in non air conditioned area.
(a) Air conditioned area : 0.8
(b.) Non Air conditioned and other indoor area : 0.7
(c.) Dust prone indoor areas and outdoor areas : 0.6
6. All outdoor fixtures shall be weather proof.
7. All lighting fixtures & control gears shall be powder coated.
8. Wires of different phase shall normally run in separate conduit. For areas
illuminated by more than one circuit, the adjacent circuits shall be from
different phases.
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9. Lighting in each critical area like control room etc. shall be distributed
between different MLDBs.
10. Power supply shall be fed from suitable number of conveniently located
lighting distribution boards (LDB) and lighting panels (LP). AC lighting
supply shall be isolated from main supply by isolation transformers
(415/433V, delta / star, epoxy insulated, air cooled, dry type) of max.
rating of 100KVA and fault level restricted to 3 to 5 KA at Lighting Panels.
Minimum 2 ways shall be kept as spare feeders in the lighting panels.
11. Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel.
The door shall be hinged and the panel shall be gasketted to achieve
specified degree of protection. The panel shall be provided with terminal
bocks for incoming and outgoing circuits, earthing terminals, removable
gland plates at bottom and canopy shall be provided with slope towards
the rear side of the panel. Wiring inside the panel shall be carried out
with 1100 V grade PVC insulated stranded copper wires of adequate
size. Terminal blocks shall be 750 V grade, clip-on stud type, moulded in
melamine and shrouded.
All MCBs/ Isolators/ Switches/ Contactors etc. shall be mounted inside
the panel and a fibre glass sheet shall be provided inside the main door
such that the operating knobs of MCBs etc., shall project out of it for safe
operation against accidental contact. MCBs shall be current limiting type
with magnetic and thermal release suitable for manual closing and
automatic tripping under fault condition with short circuit interrupting
capacity of 9 KA rms. Isolators of AC lighting panels shall be of TPN,
continuous duty, load make-break type and fuses shall be of HRC plug in
type.
Synchronous timers shall be quartz controlled electronic type, complete
with rechargeable nickel cadmium cell, 24 hours range day dial, NO/NC
contacts etc. and suitable for operation on 240V AC supply. The exterior
side of panel, shall be powder coated with smoke grey, shade RAL9002
and the interior side of panel, shall be white.
Lighting panels shall have IP55 degree of protection in general. However
LP located in dusty areas shall have IP65 degree of protection.
Ladder approaches shall be provided for maintaining the fixtures
wherever applicable.

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12.
20A, 240V AC industrial type receptacles shall be provided in the
following areas :
- Two in each switchgear / MCC room, Pump house and on
stacker-reclaimer.
- One on each floor of TPs and crusher house building
- At 30m interval on both sides of the conveyor gallery. At 50m
interval on one side of yard conveyor
- These receptacles shall be energized from lighting
panel.Maximum three receptacles shall be connected in one
circuit.
10A, 24V AC receptacles with IP55 DOP shall be provided in the
following areas.
- One in each switchgear / MCC room, Pump house and on
stacker-reclaimer.
- One on each floor of TPs and crusher house building
- It shall not be possible to insert 24V plug into 240V receptacle
- These receptacles shall be energized from lighting panel.
Maximum three receptacles shall be connected in one circuit.
13. All fluorescent fixtures shall have energy efficient T5 type fluorescent
lamps except those in div 2 hazardous area. The louvers of these
fixtures shall be designed for T5 type fluorescent lamps. All
fluorescent lamps shall have cool day light colour designation. The
mirror optics type fluorescent fixtures shall have no iridescence
effect.
2.03.00 Ballasts
2.03.01 All HPSV and HPMV lamp fixtures shall be provided with wire-wound ballasts.
All fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings
(Div-II/Hazardous Area) shall be provided with electronic ballasts.
2.04.00 All luminaires and their accessories and components shall be of type readily
replaceable by available Indian makes.
2.05.00 Fans & Regulator
2.05.01 Ceiling Fans, to be provided in non air-conditioned office / control room area shall
be suitable for operation on 240 V, 50 Hz, AC supply comprising of class F
insulated copper wound single phase motor, 1200mm sweep, aerodynamically
designed well balanced MS blades (3 Nos.), down rod, die cast aluminium
housing, capacitor, suspension hook, canopies etc. finished in stove enameled
white. Power factor of fans shall not be less than 0.9. Each fan shall cover
approximately 10sq.m. area.
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2.06.00 Switch Box
2.06.01 Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick
decorative, perspex cover. Switchbox shall be hot dip galvanised
2.07.00 Junction boxes
Junction box for lighting fixtures shall be deep drawn or fabricated type made of
min. 1.6 mm thick CRCA Sheet. The box shall be hot dip galvanised .
2.08.00 Conduits, Fittings & Accessories
Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for
normal area and galvanised heavy duty steel conduits with an additional epoxy
coating for corrosive area shall be offered. Alternatively glass reinforced epoxy
conduits with comparable compressive and impact strength with that of heavy
duty steel conduits may be offered.
2.08.01 Rigid Steel Conduits
(a.) Rigid steel conduits shall be heavy duty type,hot dip galvanised
conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical
stresses, threaded on both sides and threaded length shall be protected
by zinc rich paint. Conduits shall be smooth from inside and outside.
2.08.02 Flexible Steel Conduits
2.08.03 Flexible conduit shall be water proof and rust proof made of heat resistant lead
coated steel.
2.08.04 Pull-out Boxes
2.09.00 Pull out boxes shall be provided at approximately 4 (four) metre interval in a
conduit run .Boxes shall be suitable for mounting on Walls, Columns, Structures,
etc.. Pull-out boxes shall have cover with screw and shall be provided with good
quality gasket lining. Pull out boxes shall be weather proof type suitable for IP
:55 degree of protection. Pull out box & its cover shall be hot dip galvanised.
2.10.00 Lighting Wires
2.10.01 Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed,
stranded copper/aluminium wire for fixed wiring installation. colour of the PVC
insulation of wires shall be Red, Yellow, Blue and Black for R,Y,B phases &
neutral, respectively and white & grey for DC positive & DC negative circuits,
respectively. Minimum size of wire shall not be less than 1.5.sq.mm. for copper
and 4 sq.mm. for aluminium. The size of the lighting wires/ cables shall be
selected such that the total voltage drop from the LDB to the lighting fixture /
receptacle does not exceed 3%.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-06
ILLUMINATION

Page
9 of 13

2.11.00 Lighting Poles
2.11.01 The poles wherever required shall be of ERW tubes of specified lengths, stepped
tubular or swaged tubular and joined together. Lighting poles shall be painted
with two coats of red Oxide and Zinc chromate in Synthetic compound primer on
the exposed outside surface and with Bituminous paint all along the inside of the
pole and outside portion which shall be embedded in foundation at manufacturing
stage.
2.12.00 Lighting Masts
2.12.01 Minimum 12 nos. of Lighting Mast shall be provided for coal stockyard
illumination. Each lighting mast shall be provided with minimum 12 nos. of 2x400
W HPSV fixtures. Lighting Masts shall be of continuously tapered polygonal
cross section hot dip galvanised presenting a pleasing appearance. The Mast
shall be of 30M height with lantern carriage to enable raising / lowering for ease
of maintenance, including the Head Frame, Double Drum Winch, continuous
stainless steel wire rope, in built power tool, luminaries, suitable aviation warning
light, lightning along with necessary power cables within the mast. The mast shall
be delivered only in three sections & shall be joined together by slip stressed fit
method at site. No site welding or bolted joints shall be done on the mast.
2.13.00 Lighting fixtures shall generally be group controlled directly from lighting panel.
However, in office areas, control shall be provided through switch boxes. Each
switch shall control a maximum of three fluorescent fixtures.
2.14.00 Wiring shall run throughout in separate conduits. Wires of different phases shall
run in different conduits. Wiring for lighting circuits and receptacle circuits shall
be carried out in separate conduits and from separate feeders.
2.15.00 Lighting panels etc. shall be earthed by two separate and distinct connections
with earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single
phase receptacles etc. shall be earthed by means of separate earth continuity
conductor. The earth continuity conductor 14 SWG GI wire shall be run
alongwith each conduit run. Cable armours shall be connected to earthing
system at both the ends.
3.00.00 TESTS
3.01.00 All acceptance and routine tests as per the specification and relevant standards
shall be carried out. Charges for these shall be deemed to be included in the
equipment price.
3.02.00 Selection of samples for acceptance test & routine test and acceptance criteria
for all the items shall be as per relevant I.S
3.03.00 Acceptance Test and Routine Test
3.03.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and
routine test, as per relevant specified standards.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-06
ILLUMINATION

Page
10 of 13

3.03.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to
physical and dimensional checks.
3.04.00 Galvanizing Tests
3.04.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and
shall be inspected visually.
3.04.02 In addition following tests shall be conducted as acceptance tests.
(a.) Uniformity of coating - The coating of any article shall withstand four
1minute dips in standard copper sulphate solution without the formation of
an adherent red spot of metallic copper upon the basic metal.
(b.) The quality of cadmium/zinc plating on items with screw threads shall be
free from visible defects such as unplated areas, blisters and modules
and shall be inspected visually.
(c.) In addition, the plating thickness shall be determined microscopically/
chemically or electronically.
4.00.00 COMMISSIONING CHECKS
1. On completion of installation work, the Contractor shall request the Project
manager for inspection and test with minimum of fourteen (14) days
advance notice.
2. The Project manager shall arrange for joint inspection of the installation for
completeness and correctness of the work. Any defect pointed out during
such inspection shall be promptly rectified by the Contractor.
3. The installation shall be then tested and commissioned in presence of the
Project manager.
4. The contractor shall provide all, men material and equipment required to
carry out the tests.
5.
All rectifications, repair or adjustment work found necessary during
inspection, testing and commissioning shall be carried out by the
Contractor without any extra cost. The handing over the lighting installation
shall be effected only after the receipt of written instruction from the
Employer/his authorized representative.
6.
The testing shall be done in accordance with the applicable Indian
Standards and codes of practices. The following tests shall be specifically
carried out for all lighting installation.
(a) Insulation Resistance.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-06
ILLUMINATION

Page
11 of 13

(b) Testing of earth continuity path.
(c) Polarity test of single phase switches.
(d) Functional checks.
7. The lighting circuits shall be tested in the following manner :
(a)
All switches ON and consuming devices in circuit, both poles
connected together to obtain resistance to earth.
(b) Insulation resistance between poles with lamps and other consuming
devices removed and switches ON.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-06
ILLUMINATION

Page
12 of 13

ANNEXURE-A
Sl No. Location Average
Illumination
Level(Lux)
Type of Fixture
(a) Switchgear rooms

200 Industrial trough type
fluorescent
(b) Control room,
computer room,
control equipment
room
300 Mirror optics with anti-glare
features
(c) Offices, conference
rooms,etc.
300 Decorative mirror optics
type
(d) Battery rooms

100 Totally enclosed corrosion
proof
(e) Transformer yard

10(general)
50(on
equipment)
HPSV flood light

(f) Diesel generating
room, Compressor
room, pump house
etc.

150 HPSV medium
bay/Industrial trough type
fluorescent
(g) Fuel oil pump house

150 Flame proof fluorescent
fixtures suitable for
division-2 hazardous area
(h) Cable galleries 50 Industrial trough type
fluorescent
(i) Street lighting-
primary roads -
secondary roads

20
10

HPSV street lights
Degree of Protection IP54
(j) Outdoor storage
handlingand
unloading area
20 HPSV flood light
(k) DM plant,water
treatment plant

150 Industrial trough
type/corrosion proof
fluorescent
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO: CS-0260-156-2(R)
SUB-SECTION-IIIB-06
ILLUMINATION

Page
13 of 13

(l) Chemical stores 150 Corrosion proof fluorescent
(m) Permanent stores 150 Industrial trough type/HPSV
(n) Workshop.general
work bench
150 Industrial trough type
fluorescent
(o) Laboratory
General
Analysis area

150
300

Mirror optics fluorescent
Corrosion resistant,
fluorescent
(p) Garage/Car Parking 50 Industrial trough type
fluorescent
(q) Switchyard and all
outdoor areas
20(general
50(on strategic
equipment)
HPSV flood light
(r) Stone picking area 300 HPSV dust tight well glass
fixture (flood light type)
(s) Transfer points,
crusher house,
bunker house.
100 HPSV dust tight medium
bay or well glass fixture.
(t) Conveyor galleries 70 HPSV dust tight well glass
fixture.
(u) Stair cases 100 Min. one fixture at every
landing.
NOTE:- Any additional fixtures required to take care of the dark patches /
shadows shall also be provided.

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BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


CABLING, EARTHING & LIGHTNING
PROTECTION

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07
CABLING EARTHING AND
LIGHTNING PROTECTION

Page
1 of 22

CABLING, EARTHING & LIGHTNING PROTECTION
date of opening of bid. In case of conflict between this specification and those (IS
codes, standards, etc.) referred to herein, the former shall prevail. All work shall
be carried out as per the following standards/ codes as applicable.
IS:513 Cold rolled low carbon steel sheets and strips.
IS:802 Code of practice for the use of Structural Steel in Overhead
Transmission Line Towers.
IS:1079 Hot Rolled carbon steel sheet & strips
IS:1239 Mild steel tubes, tubular and other wrought steel fittings
IS:1255 Code of practice for installation and maintenance of power
cables upto and including 33 KV rating
IS:1367 Part-
13
Technical supply conditions for threaded Steel fasteners. (Hot
dip galvanized coatings on threaded fasteners).
IS:13947 Degree of protection provided by enclosures for low voltage
switchgear and control gear
IS:2309 Code of Practice for the protection of building and allied
structures against lightning.
IS:2629 Recommended practice for hot dip galvanising of iron & steel
IS:2633 Method for testing uniformity of coating on zinc coated articles.
IS:3043 Code of practice for Earthing
IS:3063 Fasteners single coil rectangular section spring washers.
IS:6745 Methods for determination of mass of zinc coating on zinc
coated iron & steel articles.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
2 of 22

IS:8308 Compression type tubular inline connectors for aluminium
conductors of insulated cables
IS:8309 Compression type tubular terminal ends for aluminium
conductors of insulated cables.
IS:9537 Conduits for electrical installation.
IS:9595 Metal arc welding of carbon and carbon manganese steels -
recommendations.
IS:13573 Joints and terminations for polymeric cables for working
voltages from 6.6kv upto and including 33kv performance
requirements and type tests.
BS:476 Fire tests on building materials and structures
IEEE:80 IEEE guide for safety in AC substation grounding
IEEE:142 Grounding of Industrial & commercial power systems
DIN 46267
(Part-II)
Non tension proof compression joints for Aluminium
conductors.
DIN 46329 Cable lugs for compression connections, ring type ,for
Aluminium conductors
VDE 0278 Tests on cable terminations and straight through joints
BS:6121 Specification for mechanical Cable glands for elastomers and
plastic insulated cables.
Indian Electricity Act.
Indian Electricity Rules.
1.02.00 Equipment complying with other internationally accepted standards such as IEC,
BS, DIN, USA, VDE etc. will also be considered if they ensure performance and
constructional features equivalent or superior to standards listed above. In such a
case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in
English of the latest revision of the standards alongwith copies of all official
amendments and revisions in force as on date of opening of bid and shall clearly
bring out the salient features for comparison.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
3 of 22

2.00.00 DESIGN AND CONSTRUCTIONAL FEATURE
2.01.01 Transformer yard and Switchyard
In transformer yard and switchyard area, cables shall be laid in RCC concrete
trenches with RCC covers. Inter-pole cabling in switchyard shall be in GI
conduits/shallow trenches. Minimum clear height of trestle shall be 3mtr and for
Rail/road crossing it shall be as per rail/road crossing norms.
2.01.02 False floors are not to be provided for cabling purpose.
2.01.03 Cable entry
Cable entry from outdoor underground/cable routes to the buildings, if any,
shall be above the finished floor level of the building to avoid water entry in to
the room through the trenches.
2.01.04 Trenches
PCC flooring of built up trenches shall be sloped for effective drainage with sump
pits and sump pumps.
2.01.05 No sub zero level cable vault/trenches shall be provided below control
building/switchgear rooms in main plant and switchyard areas.
2.-01.06 FOR COAL HANDLING PLANT THE FOLLOWING SHALL ALSO BE
APPLICABLE :
a) All overhead cable routes shall be along the route of the conveyor gallery
on a separate supporting structures and cables shall be laid in vertical
trays. The bottom of the steel shall be such that the existing facilities,
movement of trucks/human beings etc. does not get affected. The cable
trestle shall have a minimum 600mm clear walk way and shall have
maintenance platforms as required. The bottom of the steel supporting
structure shall be generally at 3.0M above the grade level except for
rail/road crossings where it shall be at 8.0M above grade level. Tap offs
from the overhead cable trestle can be through shallow trenches with prior
approval of the Employer. Directly buried cable, if essential, shall not
have concentration of more than 4 cables on one route.
b) Cable trenches shall be provided only in Switchgear/MCC rooms.
c) Cables shall not be routed through the conveyor galleries except for the
equipment located in the conveyor galleries for a particular conveyor i.e.
protection switches, receptacles etc.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
4 of 22

d) Cables for PCS and BSS shall be routed along the conveyors through
GI conduits.
3.00.00 EQUIPMENT DESCRIPTION
3.01.00 CABLE TRAYS, FITTINGS & ACCESSORIES
3.01.01 Cable trays shall be ladder/perforated type as specified complete with matching
fittings (like brackets, elbows, bends, reducers, tees, crosses, etc.) accessories
(like side coupler plates, etc. and hardware (like bolts, nuts, washers, G.I. strap,
hook etc.) as required.
3.01.02 Cable trays, fittings and accessories shall be fabricated out of rolled mild steel
sheets free from flaws such as laminations, rolling marks, pitting etc. These
(including hardware) shall be hot dip galvanized as per relevant IS. Cable trays
shall be ladder type for power/control cables and shall be perforated type for
instrumentation cables.
3.01.03 Cable trays shall have standard width of maximum 600 mm and standard length
of 2.5 metre. Minimum thickness of mild steel sheets used for fabrication of
cable trays and fittings shall be 2 mm. The thickness of side coupler plates shall
be minimum 3 mm. Typical details of cable trays, fittings and accessories are
shown in the enclosed drawings
3.01.04 Cable troughs shall be required for branching out few cables from main cable
route. These shall be U-shaped, fabricated of mild steel sheets of minimum
thickness 2 mm and shall be hot dip galvanised as per relevant IS. Troughs shall
be standard width of 50 mm & 75 mm with depth of 25 mm
3.01.05 FRP Cable Trays shall be provided for cable routing in Port end area from TP-4
onwards.
(1) FRP cable Trays shall be made of Fibre Glass Reinforced Pultruded
Sections only, and shall be flame retardant, ultraviolet light resistant
suitable for application in coastal area.
(2) The tray construction shall have high degree of finish and shall be free from
sharp edges, burrs of projections to avoid damage to cables, All straight
lengths and accessories shall be supplied with pre-drilled holes for coupler
plate connections. The material for coupler plates and accessories, bends,
tees etc and cable tray support system shall be same as for cable trays.
The inside depth of cable trays shall be 100 mm and minimum thickness
shall be 5mm.
(3) The FRP cable tray and support system, suitable for specified loads, shall
be manufactured in accordance with NEMA-FG1-1993.
(4) FRP cable trays and support system shall meet the following specifications:
1. SIDE RUNNER : FRP Channel

2. RUNG SPACING : 300mm

3. RADIUS OF BENDS : 300mm (min)
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
5 of 22

4. SUPPORT SPAN : 1.5m 2.0m

5. LOADING Uniformly Distributed Load (UDL)

300 mm wide tray : 60 KG\M

150 mm wide tray : 30 KG\M

In addition to the above a 70 kg concentrated load at center span with
a safety factor of 2 shall be considered.

6. Fasteners : All hardware shall be of SS 316 only.

3.02.00 SUPPORT SYSTEM FOR CABLE TRAYS
3.02.01 Cable tray support system shall be pre-fabricated similar or equivalent to
"Unistrut make.
3.02.02 Support system for cable trays shall essentially comprise of the two components
i.e. main support channel and cantilever arms. The main support channel shall
be of two types: (i) C1:- having provision of supporting cable trays on one side
and (ii) C2:-having provision of supporting cable trays on both sides. The support
system shall be the type described hereunder
a.

Cable supporting steel work for cable racks/cables shall comprise of
various channel sections, cantilever arms, various brackets, clamps, floor
plates, all hardware such as lock washers, hexagon nuts, hexagon head
bolt, support hooks, stud nuts, hexagon head screw, channel nut,
channel nut with springs, fixing studs, etc.
b. The system shall be designed such that it allows easy assembly at site
by using bolting. All cable supporting steel work, hardware fittings and
accessories shall be prefabricated factory galvanised.
c. The main support and cantilever arms shall be fixed at site using
necessary brackets, clamps, fittings, bolts, nuts and other hardware etc.
to form various arrangements required to support the cable trays.
Welding of the components shall not be allowed. However, welding of
the bracket (to which the main support channel is bolted) to the overhead
beams, structural steel, insert plates or reinforcement bars will be
permitted. Any cutting or welding of the galvanised surface shall be
brushed and red lead primer, oil primer & aluminium paint shall be
applied.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
6 of 22

d. All steel components, accessories, fittings and hardware shall be hot dip
galvanised after completing welding, cutting, drilling and other machining
operation.
e. The typical arrangement of flexible support system is shown in the
enclosed drawings and described briefly below:
The main support channel and cantilever arms shall be fabricated out of
minimum 2.5 thick rolled steel sheet conforming to IS.
f. Cantilever arms of 300 mm, 600 mm and 750 mm in length are
required, and shall be as shown in the enclosed drawing. The arm
portion shall be suitable for assembling the complete arm assembly on to
component constructed of standard channel section. The back plate shall
allow sufficient clearance for fixing bolt to be tightened with tray in
position.
3.02.03 The size of structural steel members or thickness of sheet steel of main support
channel and cantilever arms and other accessories as indicated above or in the
enclosed drawings are indicative only. Main support channels may be supplied in
any suitable lengths to minimise the wastage. Nevertheless, the support system
shall be designed by the bidder to fully meet the requirements of type tests as
specified. In case the system fails in the tests, the components design
modification shall be done by the Bidder without any additional cost to the
Employer.
3.03.00 Pipes, Fittings & Accessories
3.03.01 Pipes offered shall be complete with fittings and accessories (like tees, elbows,
bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.)
The size of the pipe shall be selected on the basis of maximum 40% fill criteria
3.03.02 GI Pipes shall be of medium duty as per IS:1239
3.04.00 Junction Boxes
Junction box shall be made of fire retardant material. Material of JB shall be
Thermoplastic or thermosetting or FRP type. The box shall be provided with the
terminal blocks, mounting bracket and screws etc. The cable entry shall be
trough galvanized steel conduits of 20mm diameter. The JB shall have suitable
for installing glands of suitable size on the bottom of the box. The JB shall be
suitable for surface mounting on ceiling \ structures. The JB shall be of grey color
RAL 9002. All the metal parts shall be corrosion protected. Junction box surface
should be such that it is free from cratings, blisterings, wrinkling, colour blots
\striations. There should not be any mending of repair of surface, JBs will be
provided with captive screws so that screws dont fall off when cover is opened.
JBs mounting brackets should be of powder coated MS. Type test reports for the
following tests shall be furnished:-
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
7 of 22

(a) Impact resistant for impact energy of 2 Joules (IK07) as per BS
EN50102
(b) Thermal ageing at 70 deg C for 96 hours as per IEC60068-2-2Bb.
(c) Class of protection shall be IP 65.
(d) HV test.
Terminal blocks shall be 1100 volts grade, 10 Amps rated, made up of
unbreakable polyamide 6.6 grade or better, complete with insulating barriers. Clip
on type terminals, washers, nuts and identification strips. Marking on terminal
strips shall correspond to the terminal numbering in wiring diagrams. All metal
parts shall be non ferrous. WAGO terminal of cage clamp with lugs shall also be
acceptable. All terminal blocks shall be suitable for terminating on each side two
(2) nos. stranded copper conductors of size upto 2.5 sq. mm each.
Contractor shall submit detailed cross-sectional and general arrangement
drawings of Employers approval.
3.05.00 Terminations & Straight Through Joints
3.05.01 Termination and jointing kits for 33kV, 11 kV and 3.3 kV grade XLPE insulated
cables shall be of proven design and make which have already been extensively
used and type tested. Termination kits and jointing kits shall be pre-moulded
type, taped type or heat shrinkable type. 33kV and 11 kV grade joints and
terminations shall be type tested as per IS: 13573. 3.3 kV grade joints and
terminations shall be type tested as per VDE 0278. Critical components used in
cable accessories shall be of tested and proven quality as per relevant product
specification/ESI specification. Kit contents shall be supplied from the same
source as were used for type testing. The kit shall be complete with the
aluminium solderless crimping type cable lugs & ferrule as per DIN standard.
3.05.02 Straight through joint and termination shall be capable of withstanding the fault
level of 40 kA for 0.12 sec with a dynamic peak of 100 kA for 11 kV system and
25 kA for 1 sec with a dynamic peak of 62.5 kA for 3.3 kV system. Straight
through joints shall have provisions for shield connection and earthing wherever
required and complete with all accessories and consumables suitable for storage
without deterioration at a temperature of 50 deg. C with shelf life of more than
five years. 1.1 kV grade straight through joints shall also be of proven design.
3.05.03 1.1 KV grade STJ shall be of proven design.
3.05.04 Motor terminal boxes should of sufficient size to accommodate the selected
cables. In case the cable sizes can not be accommodated, power Junction
boxes shall be provided with cable interconnection between Junction boxes and
motor terminal box.
3.06.00 Cable glands
3.06.01 Cable shall be terminated using double compression type cable glands. Cable
glands shall conform to BS:6121 and be of robust construction capable of
clamping cable and cable armour firmly without injury to insulation. Cable glands
shall be made of heavy duty brass machine finished and nickel chrome plated.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
8 of 22

Thickness of plating shall not be less than 10 micron. All washers and hardware
shall also be made of brass with nickel chrome plating Rubber components shall
be of neoprene and of tested quality.
3.06.02 Cable lugs/ferrules
3.06.03 Cable lugs for power cables shall be tinned copper solderless crimping type
conforming to IS: 8309 suitable for aluminium compacted conductor cables.
Cable lugs and ferrules for control cables shall be tinned copper conforming to
IS:8309 . The cable lugs for control cables shall be provided with insulating
sleeve and shall suit the type of terminals provided on the equipments.
3.07.00 Trefoil clamps
3.07.01 Trefoil clamps for single core cables shall be pressure die cast aluminum or fiber
glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts,
washers, etc. Trefoil clamps shall have adequate mechanical strength to
withstand the forces generated by the system short circuit current of 105 KA
peak.
3.08.00 Cable Clamps & Straps
3.08.01 The cable clamps required to clamp multicore cables on vertical run shall be
made up of Aluminium strip of 25x3 mm size. For clamping the multicore cables,
self-locking, de-interlocking type nylon clamps/straps shall be used. The
clamps/straps shall have sufficient strength and shall not get affected by direct
exposure to sun rays and outdoor environment
3.09.00 Receptacles
3.09.01 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot
dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5
mm. The boxes shall be provided with two nos. earthing terminals, gasket to
achieve IP55 degree of protection, terminal blocks for loop-in loop-out for cable
of specified sizes, mounting brackets suitable for surface mounting on
wall/column/structure, gland plate etc. The ON-OFF switch shall be rotary type
heavy duty double break, AC23 category, suitable for AC supply. Plug and
Socket shall be shrouded Die-cast Aluminium. Socket shall be provided with lid
safety cover. Robust mechanical interlock shall be provided such that the switch
can be put ON only when the plug is fully engaged and plug can be withdrawn
only when the switch is in OFF position. Also cover can be opened only when the
switch is in OFF position. Wiring shall be carried out with 1100 V grade PVC
insulated stranded aluminium/copper wire of adequate size. The Terminal blocks
shall be of 750 V grade
3.09.02 For Coal handling plant 415V, TPN 63A welding sockets with switch having
degree of protection of IP-55 shall be provided in the following areas.
1) 1 no. on each floor of TPs and 2 nos. on each floor of the crusher
house building.

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2) At 50 mtr. Interval (starting from one end) on both sides of the
conveyor galleries. At 50mtr. Interval on one side of yard conveyor.
3) 1 no. in each Switchgear/MCC rooms, Pump houses and in
stacker/reclaimer machines.
4) Maximum three (3) nos. of receptacles can be connected to one circuit.
These receptacles shall be energised through welding distribution board.
3.10.00 Galvanising
3.10.01 Galvanising of steel components and accessories shall conform to IS:2629,
IS:2633 & IS 4759. Additionally galvanising shall be uniform, clean smooth,
continuous and free from acid spots
3.10.02 The amount of zinc deposit over threaded portion of bolts, nuts, screws and
washers shall be as per IS:1367. The removal of extra zinc on threaded portion
of components shall be carefully done to ensure that the threads shall have the
required zinc coating on them as specified. However nuts and bolts of size lesser
than M12 can be electro galvanised / electro plated.
3.11.00 Welding
3.11.01 The welding shall be carried out in accordance with IS: 9595. All welding
procedures and welders qualification shall also be followed strictly in line with
IS:9595
3.12.00 Expansion Fastner
3.12.01 Expansion Fastener shall be 'HILTI' make HSA-KA type or equivalent. Expansion
fastener shall only be used wherever insert plates are not available for supporting
the cable structure.
4.00.00 INSTALLATION
4.01.00 Cable tray and Support System Installation
4.01.01 Cables shall run in cable trays mounted horizontally or vertically on cable tray
support system which in turn shall be supported from floor, ceiling, overhead
structures, trestles, pipe racks, trenches or other building structures. All cable
trays shall be in vertical configuration in boiler, CHP & ESP areas.
4.01.02 Horizontally running cable trays shall be clamped by bolting to cantilever arms at
an interval of 2000 mm. Vertically running cable trays shall be bolted to main
support channel by suitable bracket/clamps on both top and bottom side rails at
an interval of 2000 mm. For vertical cable risers/shafts cable trays shall be
supported at an interval of 1000mm. Fixing of cable trays to cantilever arms or
main support channel by welding shall not be accepted. Cable tray installation
shall generally be carried out as per the enclosed drawings.
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4.01.03 The cantilever arms shall be positioned on the main support channel with a
minimum vertical spacing of 300 mm unless otherwise indicated in the relevant
tray layout drawings
4.01.04 All cable way sections shall have identification, designations as per cable way
layout drawings and painted/stenciled at each end of cable way and where there
is a branch connection to another cable way. Minimum height of letter shall be
not less than 75 mm. For long lengths of trays, the identification shall be painted
at every 10 meter. Risers shall additionally be painted/ stenciled with
identification numbers at every floor.
4.01.05 In certain cases it may be necessary to site fabricate portions of trays, supports
and other non standard bends where the normal prefabricated trays, supports
and accessories may not be suitable. In such cases the Contractor shall fabricate
at site suitable sections of trays, supports and accessories to make the
installation complete for the specific purpose after obtaining Project Manager's
prior approval, which shall be neat in appearance and shall match with the
prefabricated sections in the dimensions. They shall be applied with one coat of
red lead primer, one coat of oil primer followed by two finishing coats of
aluminium paint.
4.02.00 Conduits/Pipes/Ducts Installation
The Contractor shall be fully responsible for properly embedding conduit pipe
sleeves wherever necessary for cabling work. All openings in the floor/roof/wall /
cable tunnel/cable trenches made for conduit installation shall be sealed and
made water proof by the Contractor.
4.02.01 GI pull wire of adequate size shall be laid in all conduits before installation.
Metallic conduit runs at termination shall have two lock nuts wherever required
for junction boxes etc.
4.02.02 Conduit runs/sleeves shall be provided with PVC bushings having round edge at
each end. All conduits/pipes shall have their ends closed by caps until cables are
pulled. After cables are pulled, the ends of conduits/pipes shall be sealed with
Glass wool/Cement Mortar/Putty to prevent entrance of moisture and foreign
material
4.02.03 Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or
by other approved means. Conduits /pipe support shall be installed square and
true to line and grade with an average spacing between the supports as given
below,
Conduit /pipe size (dia). Spacing
Upto 40 mm 1 M
50 mm 2.0 M
65-85 mm 2.5 M
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100 mm 3.0 M
4.02.04 For bending of conduits, bending machine shall be arranged at site by the
contractor to facilitate cold bending. The bends formed shall be smooth.
4.03.00 Junction Boxes Installation
4.03.01 Junction boxes shall be mounted at a height of 1200mm above floor level or as
specified in the drawings or as decided by Project Manager and shall be
adequately supported/mounted on masonry wall by means of anchor fasteners/
expandable bolts or shall be mounted on an angle, plate or other structural
supports fixed to floor, wall, ceiling or equipment
4.03.02 Cable Installation (for cables upto & including 33kV grade)
4.03.03 Cable installation shall be carried out as per IS:1255 and other applicable
standards. Cable drums shall be unloaded, handled and stored in an approved
manner on hard and well drained surface so that they may not sink. In no case
shall be drum be stored flat i.e. with flange horizontal. Rolling of drums shall be
avoided as far as possible. For short distances, the drums may be rolled
provided they are rolled slowly and in proper direction as marked on the drum. In
absence of any indication, the drums may be rolled in the same direction as it
was rolled during taking up the cables. For unreeling the cable, the drum shall be
mounted on suitable jacks or on cable wheels and shall be rolled slowly so that
cable comes out over the drum and not from below. All possible care shall be
taken during unreeling and laying to avoid damage due to twist, kink or sharp
bends. Cable ends shall be provided with sealed plastic caps to prevent damage
and ingress of moisture.
4.03.04 While laying cable, ground rollers shall be used at every 2 mtr interval to avoid
cable touching ground. The cables shall be pushed over the rollers by a gang of
people positioned in between the rollers. Cables shall not be pulled from the end
without having intermediate pushing arrangements. Pulling tension shall not
exceed the values recommended by cable manufacturer. Selection of cable
drums for each run shall be so planned so as to avoid using straight through
joints. Care should be taken while laying the cables so as to avoid damage to
cables. If any particular cable is damaged, the same shall be repaired or
changed to the satisfaction of Project Manager.
4.03.05 Cables shall be laid on cable trays strictly in line with cable schedule furnished.
Where specific cable layouts are not shown on drawings, Contractor shall route
these as directed by the Project Manager
4.03.06 Power and control cables shall be laid on separate tiers. The laying of different
voltage grade cables shall be on different tiers according to the voltage grade of
the cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and
cables of subsequent lower voltage grades on lower tiers of trays. Single core
cable in trefoil formation shall be laid with a distance of four times the diameter of
cable between trefoil center lines and clamped at every 2mtr. All multicore cables
shall be laid in touching formation. Power and control cables shall be secured
fixed to trays/support with self locking type nylon cable straps with de-interlocking
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facilities. For horizontal trays arrangements, multicore power cables and control
cables shall be secured at every five meter interval. For vertical tray
arrangement, individual multicore power cables and control cables shall be
secured at every one meter by nylon cable strap. After completion of cable laying
work in the particular vertical tray, all the control cables shall be binded to
trays/supports by aluminium strips at every five meter interval and at every bend.
4.03.07 Bending radii for cables shall be as per manufacturers recommendations and
IS:1255.
4.03.08 Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC
pipe.
4.03.09 In each cable run some extra length shall be kept at suitable point to enable one
LT/two HT straight through joints to made, should the cable develop fault at a
later stage. Control cable termination inside equipment enclosure shall have
sufficient lengths so that shifting of termination in terminal blocks can be done
without requiring any splicing.
4.03.10 Wherever few cables are branching out from main trunk route troughs shall be
used.
4.03.11 The installation work shall be carried out in a neat workman like manner & areas
of work shall be cleaned of all scraps, water, etc. after the completion of work in
each area every day. Contractor shall replace RCC/Steel trench covers after the
Installation work in that particular area is completed or when further work is not
likely to be taken up for some time.
4.03.12 Separation
In vertically stacked trays, at least 300mm clearance shall be provided between :
- HT power & LT power cables,
- LT power & LT control cables
4.03.13 Segregation
1) Segregation means physical isolation to prevent fire jumping.
2) All the cables of one stream shall be segregated from the cables of the
other stream and shall run on either side of the trestle.
4.03.14 All field switches for equipments corresponding to a stream located within a
radius of 4-5 mtr. shall be wired out to a field junction box and from field junction
box to control panel/Input Output cabinet by screened instrumentation cables.
4.03.15 Directly Buried Cables
a) Cable trenches shall be constructed for directly buried cables.
Construction of cable trench for cables shall include excavation,
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preparation of sieved sand bedding, riddled soil cover, supply and
installation of brick or concrete protective covers, back filling and
compacting, supply and installation of route markers and joint markers.
Laying of cables and providing protective covering shall be as per
IS:1255 and the enclosed drawings showing cabling details.
b) RCC cable route and RCC joint markers shall be provided wherever
required. The voltage grade of the higher voltage cables in route shall
be engraved on the marker. Location of underground cable joints shall
be indicated with cable marker with an additional inscription Cable
Joint. The marker shall project 150 mm above ground and shall be
spaced at an interval of 30 meters and at every change in direction.
They shall be located on both sides of road crossings and drain
crossings. Top of cable marker/joint marker shall be sloped to avoid
accumulation of water/dust on marker.
4.03.16 Cable tags shall be provided on all cables at each end (just before entering the
equipment enclosure), on both sides of a wall or floor crossing, on each
duct/conduit entry, and at every 20 meters in cable tray/trench runs. Cable tags
shall also be provided inside the switchgear, motor control centers, control and
relay panels etc. where a number of cables enter together through a gland plate.
Cable tag shall be of rectangular shape for power cables and control cables.
Cable tag shall be of 2 mm thick aluminum with number punched on it and
securely attached to the cable by not less than two turns of 20 SWG GI wire
conforming to IS:280. Alternatively, the Contractor may also provide cable tags
made of nylon, cable marking ties of TY-CAB or equivalent type with cable
number heat stamped on the cable tags
4.03.17 While crossing the floors, unarmoured cables shall be protected in conduits upto
a height of 500 mm from floor level if not laid in tray.
4.04.00 Cable Terminations & Connections
4.04.01 The termination and connection of cables shall be done strictly in accordance
with cable termination kit manufacturer instructions, drawings and/or as directed
by Project Manager. Cable jointer shall be qualified to carryout satisfactory cable
jointing/termination. Contractor shall furnish for review documentary
evidence/experience reports of the jointers to be deployed at site.
4.04.02 Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing,
soldering, drilling, cutting, taping, preparation of cable end, crimping of lug,
insulated sleeving over control cable lugs, heat shrinking (where applicable),
connecting to cable terminal, shorting and grounding as required to complete the
job to the satisfaction of the Project Manager.
4.04.03 The equipment will be generally provided with undrilled gland plates for
cables/conduit entry. The Contractor shall be responsible for punching of gland
plates, painting and touching up. Holes shall not be made by gas cutting. The
holes shall be true in shape. All cable entry points shall be sealed and made
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vermin and dust proof. Unused openings shall be effectively sealed by 2mm thick
aluminium sheets.
4.04.04 Control cable cores entering control panel/switchgear/MCC/miscellaneous panels
shall be neatly bunched, clamped and tied with self locking type nylon cable ties
with de interlocking facility to keep them in position.
4.04.05 The panels where a larger number of cables are to be terminated and cable
identification may be difficult, each core ferrule shall include the complete cable
number as per the drawings. The ferrules shall be indelible interlocking type and
shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix
letter S alongwith cable numbers and coiled up after end sealing.
4.04.06 All cable terminations shall be appropriately tightened to ensure secure and
reliable connections.
4.04.07 It is the responsibility of the Contractor to terminate the cables at motor terminals
in correct phase sequence to ensure the proper direction of rotation.
5.00.00 EARTHING SYSTEM
5.01.00 Earthing system shall be in strict accordance with IS: 3043 and Indian Electricity
Rules/Acts.
All buildings / structures shall be interconnected together by min. two parallel
conductors. Contractor shall furnish the detailed design calculations for the
earthing system. Contractor shall obtain all necessary approvals for the system.
5.02.00 The earth conductors shall be free from pitting, laminations, rust, scale and other
electrical, mechanical defects
5.03.00 The material of the earthing conductors shall be as follows :
1) Conductors above ground level and in built up
trenches.
- Galvanized steel
2) Conductors buried in earth - Mild steel
3) Earth electrodes - Mild steel rod

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5.04.00 The sizes of earthing conductors for various electrical equipments shall be as
below:
Equipment Earth conductor
buried in earth
Earth conductor
above ground level
& in built-up
trenches
a) Main earth grid 40 mm dia.MS rod 65x8mm GS flat
b) 33KV/11KV switchgear/
equipment 415V switchgear
--- 65x8mm GS flat
c) 3.3 kV switchgear / 415 V
MCC/ Distribution boards /
Transformers
--- 50x6mm GS flat
d) LT Motors above 125 KW --- 50 x 6mm GS flat
25 KW to 125 KW --- 25 x 6mm GS flat
1KW to 25 KW --- 25 x 3mm GS flat
Fractional House power motor

--- 8 SWG GS wire
e) Control panel & control desk --- 25 x 3 mm GS flat
f) Push button station / Junction
Box
--- 8 SWG GI wire
g) Columns, structures, cable
trays and busduct enclosures
--- 50x6mm GS flat
h) Crane, rails, rail tracks & other
non-current carrying metal
parts
25x6mm GS flat
5.05.00 Metallic frame of all electrical equipment shall be earthed by two separate and
distinct connections to earthing system, each of 100% capacity, Crane rails,
tracks, metal pipes and conduits shall also be effectively earthed at two points.
Steel RCC columns, metallic stairs, and rails etc. of the building housing
electrical equipment shall be connected to the nearby earthing grid conductor by
one earthing ensured by bonding the different sections of hand rails and metallic
stairs. Metallic sheaths/screens, and armour of multi-core cables shall be earthed
at both ends. Metallic Sheaths and armour of single core cables shall be earthed
at switchgear end only unless otherwise instructed by the Employer. Every
alternate post of the switchyard fence shall be connected to earthing grid by one
GS flat and gates by flexible lead to the earthed post. Railway tracks within the
plant area shall be bonded across fish plates and connected to earthing grid at
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several locations. Portable tools, appliances and welding equipment shall be
earthed by flexible insulated cable. One separate core in the trailing/flexible
cables shall be used for earthing purposes of the moving machines. PLC
equipment shall be earthed separately as per the recommendations of the PLC
manufacturer.
5.06.00 Each continuous laid lengths of cable tray shall be earthed at minimum two
places by G.S. flats to earthing system, the distance between earthing points
shall not exceed 30mtr. Wherever earth mat is not available Contractor shall do
the necessary connections by driving an earth electrode in the ground.
5.07.00 Neutral points of HT transformer shall be earthed through NG resistors. The
Contractor shall connect the NGR earthing point to earth electrodes by suitable
earth conductors.
5.08.00 Neutral connections and metallic conduits/pipes shall not be used for the
equipment earthing. Lightning protection system down conductors shall not be
connected to other earthing conductors above the ground level.
5.09.00 Connections between earth leads and equipment shall normally be of bolted
type. Contact surfaces shall be thoroughly cleaned before connections.
Equipment bolted connections after being tested and checked shall be painted
with anti corrosive paint/compound.
5.10.00 Suitable earth risers as approved by Project Manager shall be provided above
finished floor/ground level, if the equipment is not available at the time of laying
of main earth conductor.
5.11.00 Connections between equipment earthing leads and between main earthing
conductors shall be of welded type. For rust protection the welds should be
treated with red lead compound and afterwards thickly coated with bitumen
compound. All welded connections shall be made by electric arc welding.
5.12.00 Resistance of the joint shall not be more than the resistance of the equivalent
length of conductors.
5.13.00 Earthing conductors buried in ground shall be laid minimum 600 mm below grade
level unless otherwise indicated in the drawing. Back filling material to be placed
over buried conductors shall be free from stones and harmful mixtures. Back
filling shall be placed in layers of 150 mm.
5.14.00 Earthing conductors embedded in the concrete floor of the building shall have
approximately 50 mm concrete cover.
5.15.00 A minimum earth coverage of 300 mm shall be provided between earth
conductor and the bottom of trench/foundation/underground pipes at crossings.
Earthing conductors crossings the road can be installed in pipes. Wherever
earthing conductor crosses or runs at less than 300 mm distance along metallic
structures such as gas, water, steam pipe lines, steel reinforcement in concrete,
it shall be bonded to the same.
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5.16.00 Earthing conductors along their run on columns, walls, etc. shall be supported by
suitable welding / cleating at interval of 1000mm and 750mm respectively.
5.17.00 Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded
below permanent moisture level. Minimum spacing between electrodes shall be
600mm. Earth pits shall be treated with salt and charcoal if average resistance of
soil is more than 20 ohm metre.
5.18.00 On completion of installation continuity of earth conductors and efficiency of all
bonds and joints shall be checked. Earth resistance at earth terminations shall be
measured in presence of Employers representatives. All equipment required for
testing shall be furnished by contractor.
5.19.00 Earthing conductor shall be buried at least 2000mm outside the fence of
electrical installations. Every alternate post of the fences and all gates shall be
connected to earthing grid by one lead.
6.00.00 LIGHTNING PROTECTION SYSTEM
6.01.01 Lightning protection system shall be in strict accordance with IS:2309
6.01.02 Lightning conductor shall be of 25x6mm GS strip when used above ground level
and shall be connected through test link with earth electrode/earthing system
6.01.03 Lightning system shall comprise of air terminations, down conductors, test links,
earth electrode etc. as per approved drawings
6.02.00 Down Conductors
1. Down conductors shall be as short and straight as practicable and shall
follow a direct path to earth electrode.
2. Each down conductor shall be provided with a test link at 1000 mm
above ground level for testing but it shall be in accessible to
interference. No connections other than the one direct to an earth
electrode shall be made below a test point.
3. All joints in the down conductors shall be welded type.
4. Down conductors shall be cleated on outer side of building wall, at 750
mm interval or welded to outside building columns at 1000 mm interval.
5. Lightning conductor on roof shall not be directly cleated on surface of
roof. Supporting blocks of PCC/insulating compound shall be used for
conductor fixing at an interval of 1500 mm.
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6. All metallic structures within a vicinity of two meters of the conductors
shall be bonded to conductors of lightning protection system.
7. Lightning conductors shall not pass through or run inside GI Conduits.
8. Testing link shall be made of galvanized steel of size 25x 6mm.
7.00.00 QUALITY ASSURANCE PROGRAMME
7.01.00 Bidder shall furnish detailed Quality Assurance Program and Quality Plans for all
materials and accessories to be supplied and installed under the scope of the
specification as per General Technical Conditions of technical specification. The
Quality Plans shall include all tests/ checks as per relevant National/International
Standards and the requirements of this specification including tests listed in this
section.
8.00.00 TESTS
8.01.01 All equipment to be supplied shall be of type tested design. The contractor shall
submit for Owner's approval the reports of all the type tests as listed in this
specification and carried out within last ten years from the date of bid opening.
These reports should be for the test conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been
either conducted at an independent laboratory or should have been witnessed by
a client.
8.01.02 In case the contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in the case of type test
report(s) are not found to be meeting the specification requirements, the
contractor shall conduct all such tests under this contract at no additional cost to
the owner either at third party lab or in presence of client/owners representative
equipment price.
8.01.04 The type test reports once approved for any projects shall be treated as
furnished by the manufacturer conforming similarity and No design change.
8.02.00 Type Test reports shall be furnished for the following
8.02.01 Cable termination kit and straight through joints should have been tested as per
IS: 13573 for above 3.3 kV class and as per VDE 0278 for 3.3 kV class.

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8.03.00 Routine/ Acceptance Tests
8.03.01 Routine Tests
a) Routine tests as per specification and applicable standards shall be
carried out on all equipments/items covered in the specification.
b) Physical & dimensional check on all equipments as per approved
drawings/standards.
c) HV/IR as applicable.
d) Check/measurement of thickness of paint/zinc coating/nickel-chrome
plating as per specification & applicable standard.
8.03.02 Acceptance Test
a) Galvanising Tests as per applicable standards
b) Welding checks
c) Deflection tests on cable trays:
One piece each of 2.5m length of cable tray of 300mm & above shall be
taken as sample from each offered lot. It shall be supported at both end
& loaded with uniform load of 76 kg/meter along the length of cable tray.
The maximum deflection at the mid-span of each size shall not exceed
7mm.
d) Proof load tests on cable tray support system
i) Tests on Main Support Channel shall be done if only C1 Channel
are in scope of supply and cantilever arms shall be fitted on one
side. This test shall be carried out as follows:
A 2.5 m length of C1 channel fixed to the concrete wall/ steel
structure as per actual site installation conditions. 6 nos. of 750
mm cantilever arms shall be attached to C1 channel as shown
in enclosed drawing. Each arm uniformly loaded to a working
load of 100 kg over the out board 600 mm. A point load of 100
kg shall than be applied to arm 2, followed by a uniform proof
load of twice the working load on all the arms; deflection shall
be measured at points shown in the enclosed drawings at the
following load intervals.
i) Working load
ii) Working load + Point load
iii) Off load
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iv) Proof load + Point load
v) Off load
The deflection measured at working loads shall not exceed
16mm. The permanent deflection after removing the
combination of working load and point load shall not exceed 10
mm at the arm tips and 6 mm on the channel. No collapse of
the structure shall occur with a combination of proof load and
point load applied
ii) Test on Main Support Channel shall be done with C2 channel and
cantilever arms fitted on both sides, if C2 channels are in scope of
supply. If this test is carried out then test (i) above shall not be
done. This test shall be carried out as follows:
A 3.5 m length of main support channel C2 for cantilever arms
fixing on both sides shall be fixed at each end to rigid structure
as per the fixing arrangement as shown in the enclosed
drawing. Six (6), 750 mm cantilever arms shall be attached to
each sides and each arm uniformly loaded to a working load of
100 kg over the out board 600 mm. A point load of 100 kg shall
than be applied to arm 2, followed by a uniform proof load of
twice the working load on all the arms; deflection shall be
measured at points shown in the enclosed drawings at the
following load intervals.
i) Working load
ii) Working load + Point load
iii) Off load
iv) Proof load + Point load
v) Off load
The deflection measured at working loads shall not exceed
16mm. The permanent deflection after removing the
combination of working load and point load shall not exceed 10
mm at the arm tips and 6 mm on the channel. No collapse of the
structure shall occur with a combination of proof load and point
load applied
iii) Nut slip characteristic test (it shall support minimum load of 350kg
before nut slips with a bolt torque of 65 NM). This test shall be
carried out as follows:
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The length of channel C1 section 200 mm long shall have fitted
bracket with the one bolt fixing as shown in drawing enclosed.
With loads applied at the position shown in drawing, nut slip shall
be determined with bolt torques of 30 NM, 50 NM and 65 NM. No
fewer than three measurements shall be made for each torque
setting.
A minimum loading of 350 kg shall be obtained before nut slip with
a bolt torque of 65 NM.
Die-Penetration test shall be carried out to check weld integrity.
e) The above acceptance tests shall be done only on one sample from each
offered lot.
9.00.00 COMMISSIONING
9.01.01 The Contractor shall carry out the following commissioning tests and checks after
installation at site. In addition the Contractor shall carry out all other checks and
tests as recommended by the Manufacturers.
9.01.02 Cables
a) Check for physical damage
b) Check for insulation resistance before and after termination/jointing.
c) HT cables shall be pressure tested (test voltage as per IS:7098)
before commissioning.
d) Check of continuity of all cores of the cables.
e) Check for correctness of all connections as per relevant wiring
diagrams. Any minor modification to the panel wiring like
removing/inserting, shorting, change in terminal connections etc., shall
be carried out by the Contractor at no extra cost.
f) Check for correct polarity and phasing of cable connections.
g) Check for proper earth connections for cable glands, cable boxes,
cable armour, screens, etc.
h) Check for provision of correct cable tags, core ferrules, and tightness
of connections.
9.02.00 Cable trays / supports and accessories
1) Check for proper galvanizing/painting and identification number of the
cable trays/supports and accessories.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-07

Page
22 of 22

2) Check for continuity of cable trays over the entire route.
3) Check that all sharp corners, burrs, and waste materials have been
removed from the trays supports.
4) Check for earth continuity and earth connection of cable trays.
9.03.00 Earthing and Lightning protection system
1) Earth continuity checks.
2) Earth resistance of the complete system as well as sub-system.

9.04.00 GENERAL COMMISSIONING CHECKS (Application to all electrical equipments)
(a.) Check for name plate details according to specification.
(b.) Check for physical damage, if any.
(c.) Check for tightness of all bolts, clamps & connecting terminals.
(d.) Check for earth connection.
(e.) Check for cleanliness of insulators & bushings.
(f.) Check for lubrication of all moving parts.
(g.) Check for provision of heater.
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MI N.
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CABLES
3. J KV
l l Kv
FOR
r0
22KV & 33KV
D1 750 900 1050
d BETWEEN CABLES OF SAME CLASS
XSOOMM BETWEEN CABLES OF OEFT CLASS
(40oMM
BETWEEN t/C POWER CAELE AND
COMMUNI CATI ON CA8LE.
(3OQMM
BETWEEN MULTICORE POWER
CABLE & COMMUNI CATI ON CABLE.
d
-
OVERALL OIAME1ER OF THE BIGGER OF THE TWO CABLES
X
-
SPAONG SHALL BE TAKEN EOTH HORIZONTALIY AND
\RTICALLY.
I . SI NGLE CORE CABLES SHALL BE RUN I N TREFOI L FORMATI ON AND SHALL BE BOUND BY
SELFLOCKING CABLE NES AT E\ERY 75O MM
2. CABLE IDENTIFTCATION
TAG SHALL BE NED AT BOTH ENDS OF THE CABLE AND ALSO AT AN
I NTERVAL OF I O METRES.
3. IF THE MINIMUM
CLEARENCE AS INDICATED THE ABO! TABLE FOR CABLES OF DIFFERNT
CLASSES ARE NOT FEASIBLE,BRICK
BARRIERS SHALL BE USED BETMEN ADJACENT CABLES.
4. G. I . PI PE SHALL BE PRO\ 4DED FOR ROAD CROSSI NG AT A MI NI MUM DEPTH
OF 600 FROM THE GRADE LE\L UNLESS OTHER WSE SPECTFIED.
5. ALL DTMENSTONS ARE t N MM (SCALE NTS)
Ks
FcA
rer,tOEP Pt,RlasE
tv'
v6
$
\-,^
) l
,
l/
tl
'ir
RA FOR IENDR PURPOS ONLY
u- h
le
- I V L
I F Kl .\'
REV
NO. OESCRIPTION oc(D
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oatf
CLEARED BT
NTTP
C I -i rrri t e
<J
.
(
A Go/ERNMENT oF tNDrA EMTERpRtsE
)
ENCINEERING DIVISION
PROJECT
STANDAND
TITLE
BURIED CABLES TRENCE FOR IIT & LT CASLES
srzE
A4
SCAI.E
NTS
DRG.
oo00-21 1-PoE-A-050
NO.
REV. NO
RB
CAD nLE NAIIE : SIAilD-2O0-6O-DI C

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


TRANSFORMERS

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-08
TRANSFORMERS

Page
1 of 5

TRANSFORMER


1.01.00 Transformers IEC:60076, IEC 60354, IEC:60726

Bushing CTs IEC :60044-1

Insulating oil IEC: 60296

2.00.00 TYPE

2.01.00 Out-door Mineral oil filled ONAN type, Three phase unit
Transformers

2.02.00 Dry type Epoxy cast resin/resin encapsulated air cooled
Transformers type, Three phase unit

3.00.00 FEATURES

Paint shade RAL 5012

Degree of protection :
Dry type transformer IP-23
Cable box, Marshalling box IP-55


4.01.00 Out-door Winding 55
o
C above ambient 50
o
C
Transformers oil 50
o
c above ambient 50
o
C.

4.02.00 Dry type Winding (by resistance method) : 90
o
C or lower
Transformers as permissible for class of insulation offered,
above ambient of 50
o
C

5.00.00 OPERATIONAL REQUIRTEMENTS

5.01.00 Tap Changer

Off-circuit, +/-5% in steps of 2.5% shall be provided. It shall be hand operated by
an external handle with position markings, pad locking facility in each position and
mechanical stops to prevent over cranking beyond extreme positions in case of
outdoor type transformers. In case of indoor transformers, it shall be with
shrouded bolted links.

5.02.00 Loading Capability

Continuous operation at rated KVA on any tap with voltage variation of +/-10%
corresponding to the voltage of the tap as well as in accordance with IEC 354.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-08
TRANSFORMERS

Page
2 of 5

5.03.00 Flux Density

Not to exceed 1.9 Wb/sq.m. at any tap position with +/-10% voltage variation from
voltage corresponding to the tap. Transformer shall also withstand following
overfluxing conditions due combined voltage and frequency fluctuations:

a) 110% for continuous rating.

b) 125% for at least one minute.

c) 140% for at least five seconds.

5.04.00 Noise Level :Not to exceed values specified in NEMA TR-1.


All transformers shall be suitable for cable or bus duct termination as
contemplated. If cable connection is envisaged, a dust tight cable box shall be
provided. Also, a sheet steel, vermin and dust proof marshalling box shall be
furnished with each transformer to accommodate temperature indicators, terminal
blocks for control cables etc. The transformer shall be provided with all fittings
and accessories to be complete in all respects for satisfactory operation.

6.01.00 OUTDOOR TRANSFORMERS

6.01.01 a) Tank

Shall be fabricated from tested quality steel and designed to withstand
continuous internal pressure of 35KN per sq.m. over normal pressure as
well as short circuit forces. The main tank body shall be capable of with
standing vacuum as per CBIP guidelines. All steel surfaces in contact with
insulating oil shall be painted with two coats of heat resistant oil in soluble
insulating paint. Tank shields, if provided, shall not resonate at natural
frequency of equipment.

b) Tank mounting

Transformer tank shall be mounted on bi-directional rollers. Suitable
locking arrangement shall be provided to prevent accidental movement of
transformer. Tank shall also be provided with lifting lugs and minimum four
jacking pads.

c) At least two adequately sized inspection openings, one at each end of the
tank for easy access to bushings and earth connections shall be provided.
6.01.02 Core shall be High grade non-ageing cold rolled grain oriented silicon steel
laminations.

6.01.03 Winding conductor shall be Electrolytic grade copper. Windings of 66kV and
below shall be uniformly Insulated.

6.01.04 Conservator tank of adequate capacity for expansion of oil from min. ambient to
100 deg.C. shall be provided. The transformers rated 7.5 MVA and above shall be
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-08
TRANSFORMERS

Page
3 of 5

provided with air bag breathing through silica gel breather. For lower rating
transformers, conventional single compartment conservator with dry air filling the
space above oil and connected to silica gel breather shall be provided.

6.01.05 Bushings shall be Porcelain.

6.01.06 Bushing CTs Shall be provided in the LV neutral side of adequate rating for REF
protection, Back up definite time earth fault protection (for HT transformers only),
WTI, etc.

6.01.07 Radiators shall be Tank mounted with shut off valves.

6.01.08 Insulating oil
No external inhibitors are permitted.
6.01.09 Marshalling box shall be provided with thermostatically controlled space heaters.
6.01.10 The insulation of core to core clamp shall be able to withstand a voltage of 2 KV
rms for one (1) minute.
6.01.11 Fittings

Transformer shall be provided with following fittings as minimum

a) Buchholz relay shall be provided with double float type with alarm and trip
contacts, alongwith suitable gas collecting device.

b) At least two numbers of spring operated pressure relief devices with
extension pipe to bring oil to plinth level along with electrically insulated
contact for alarm and tripping shall be provided for transformer rating
2MVA and above.

c) Diaphragm type explosion vent shall be provided for all transformers below
2 MVA rating.

d) Winding temperature indicator (WTI) and Oil temperature indicator (OTI),
Dial type (150mm) with alarm and trip contacts and max. reading pointer
along with resetting device shall be provided.

e) Magnetic oil level gauge with alarm contact shall be provided.

f) Oil level gauge Prismatic/toughened glass type.

6.02.00 DRY TYPE TRANSFORMERS

6.02.01 Enclosure

Enclosure shall be of a tested quality sheet steel of minimum thickness 2mm &
shall also accommodate cable terminations. The housing door shall be interlocked
such that it should be possible to open the door only when transformer is off. The
enclosure shall be provided with lifting lugs and other hardware for floor mounting.
CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-08
TRANSFORMERS

Page
4 of 5

6.02.02 Core

Shall be High grade non-ageing cold rolled grain oriented silicon steel laminations.
CRGO silicon steel.

6.02.03 Winding conductor Shall be electrolytic grade copper or aluminium.
Windings shall be of class F insulation.

6.02.04 Bushings Shall be Solid porcelain / RIP.

6.02.05 Bushing CTs Shall be provided in the LV neutral side with
adequate rating for REF protection, WTI, etc.
6.02.06 Fittings

Winding temperature Shall be Platinum resistance type temperature
Indicator (WTI) detector in each limb.

Thermistors Shall be embedded in each limb with alarm and trip
contacts for remote annunciation.

7.00.00 TRANSFORMER SIZING
7.01.01 Size of the transformer shall be decided based on following :
Size shall be greater than or equal to total KVA of continuous load
+ (coincident factor x total kVA of intermittent load other than valves)
+ 0.2 x total valves kVA
+ kVA of largest rated valve or damper motor
+ Employer's requirement, if any.
+ 10% margin on the sum of the above mentioned values.
Coincident factor of intermittent load, such as lifts, cranes, hoists etc shall be
taken as 0.5.
7.01.02 Normally 2 x 100% feeding arrangement shall be provided as shown in single line
diagram i.e. the total loads to be considered for sizing each transformer shall be
the loads working on both the buses. In case of 3 x 50% feeding arrangement, if
required, the loads to be considered on each transformer shall be the loads
working on any two of the buses.

CLAUSE NO.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-08
TRANSFORMERS

Page
5 of 5

8.00.00 TYPE TESTS

8.01.00 For each type and rating of transformers rated upto and including 2 MVA
8.01.01 The Contractor shall submit for Employers approval the reports of all the type
tests as listed in this specification and carried out within last ten years from the
date of bid opening. These reports should be for the tests conducted on the
equipment similar to those proposed to be supplied under this contract and the
have been witnessed by a client.In case the Contractor is not able to submit report
of the type test(s) conducted within last ten years from the date of bid opening, or
in case the type test report(s) are not found to be meeting the specification
requirements, the Contractor shall conduct all such tests under this contract at no
additional cost to the Owner either at third party lab or in presence of
client/owners representative and submit the reports for approval.
equipment price.
8.03.00 The type test reports once approved for any projects shall be treated as reference.
For subsequent projects of NTPC, an endorsement sheet will be furnished by the
manufacturer conforming similarity and No design change. Minor changes if any
shall be highlighted on the endorsement sheet.
8.04.00 Following is the list of type tests (for dry type & Outdoor transformers)
(a) Short circuit test
(b) Temp. rise test
(c) Lightning impulse voltage test on all three limbs and full wave LI on neutral
if grounded through NGR.
(d) Partial discharge test on dry type transformers only.
(e) Tank Pressure test on oil filled transformers
(f) Tank vacuum Test on oil filled transformers
(g) Noise level test as per NEMA TR-1
(h) Degree of protection test for marshalling box/ transformer enclosure.
(i) Zero sequence Impedance measurement
8.05.00 The following special tests on all transformers shall be conducted under this
contract as routine tests in addition to all routine tests as per IEC 60076:
(a) Oil leakage test for 24 hours
(b) Repeat no load loss tests after electrical tests.
(c) Measurement of capacitance & tan delta to determine capacitance
between winding and earth.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


INSTRUMENTS

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09
MEASURING INSTRUMENTS

Page
1 of 8

1.00.00 MEASURING INSTRUMENTS
1.01.00 Measuring instruments/equipment and subsystems offered by the Bidder shall be
from reputed experienced manufacturers of specified type and range of
equipment, whose guaranteed and trouble free operation has been proven.
Further, all instruments shall be of proven reliability, accuracy, and repeatability
requiring a minimum of maintenance. They shall comply with the acceptable
international standards and shall be subject to Employer's approval. All
instrumentation equipment and accessories under this specification shall be
furnished as per technical specifications, ranges, makes/numbers as approved
by the Employer during detailed engineering.
1.02.00 Every panel-mounted instrument requiring power supply shall be provided with a
pair of easily replaceable glass cartridge fuses of suitable rating. Every
instrument shall be provided with a grounding terminal and shall be suitably
connected to the panel grounding bus.
1.03.00 All local gauges as well as transmitters, sensors, and switches for parameters
like pressure, temperature, level, flow etc. as required for the safe and efficient
operation and maintenance as well as for operator and management information
(including all computation) of equipment under the scope of specification shall be
provided on as required basis within the quoted lump sum price.
1.04.00 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks,
valve manifolds and all the other accessories required for mounting/erection of
these local instruments shall be furnished, even if not specifically asked for, on
as required basis. The contacts of equipment mounted instruments, sensors,
switches etc. for external connection including spare contacts shall be wired out
in flexible/rigid conduits, independently to suitably located common junction
boxes. The proposal shall include the necessary cables, flexible conduits,
junction boxes and accessories for the above purpose. Double root valves shall
be provided for all pressure tapping where the pressure exceeds 40 Kg./sq.cm.
2.00.00 SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE AND
D.P.
2.01.00 ELECTRONIC TRANSMITTERS
Sr.
No.
Features Essential/Minimum Requirements
1. Type of Transmitter Microprocessor based 2 wire type, HART
protocol compatible.
2. Accuracy 0.1% of calibrated span ( minimum)
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09

Page
2 of 8

3. Output signal range 4-20 Ma DC (Analog) along with superimposed
digital signal (based on HART protocol)
10:1 for vacuum/very low pressure applications. 4. Turn down ratio
30:1 for other applications.
5. 0.1% of calibrated span for six months for
Ranges up to and including70 Kg/cm.

Stability
0.25% of calibrated span for six months for
Ranges more than 70 Kg/cm (g).
+/- 0.015% per deg.C at max span. 6. Zero and span drift
+/-0.11% per deg.C at min. span.
7. Load impedance 500 ohm (min.)
8. Housing Weather proof as per IP-55 with durable
corrosion resistant coating.
9. Over Pressure 150% of max. Operating pr.
10. Connection (Electrical) Plug and socket type
11. Process connection 1/2 inch NPT (F)
12. Span and Zero Continuous, tamper proof, Remote as well as
adjustability manual from instrument with zero
suppression and elevation facility.
-Diaphragm seal, pulsation dampeners, siphon
etc. as required by service and operating
condition.
-2 valve manifold for absolute pressure
transmitters (3-valve manifold for gauge/
vacuum pressure transmitters) and 5 valve
manifold for DP/level/flow transmitters.
13. Accessories
-For hazardous area, explosions proof enclosure
as described in NEC article 500.
14. Diagnostics Self Indicating feature
15. Power supply 24V DC 10%.
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09

Page
3 of 8

16. Adjustment/calibration
/maintenance
Total two (2) no. of hand- held type universal
calibrators compatible with HART protocol , shall
be provided (for all three units).
Note.
In case it becomes necessary to use a DP transmitter for pressure
measurement, then a 3-valve manifold should be used in place of 2-valve
manifold.
LVDT type is not acceptable.
Where the process fluids are corrosive, viscous, solid bearing or slurry
type, diaphragm seals shall be provided. Parts below the diaphragm shall
be removable for cleaning. The entire volume above the diaphragm shall
be completely filled with an inert liquid suitable for the application.
2.01.00 Temperature Elements
RESISTANCE TEMPERATURE DETECTOR ( RTD )
Sr.
No.
Features Essential/Minimum Requirements
1 Type of RTD. : Pt-100 (100 Ohms resistance at zero
degree centigrade)
2 No. of element : Duplex
3 Housing/Head : IP-55/Diecast Aluminium. Plug in
connectors are to be provided for
external signal cable connection.
4 Sheathing of RTD : Metal sheathed, ceramic packed
5 Calibration and accuracy : As per DIN-43760 Class-A
6 Characteristic : Linear with respect to temp, within 1/2
percent of top range value.
7 Accessories : Thermo well (as specified below) and
shall be spring loaded for positive
contacts with the well.
8 Standard : DIN-43760 for RTD and ASME PTC-19.3
for Thermo-well.

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09

Page
4 of 8

2.02.00 THERMO WELL
Thermo well shall be one piece solid bored type of 316SS of Step-less tapered
design (as per ASME PTC 19.3, 1974).
2.03.00 TEMPERATURE TRANSMITTER
Following type of 2-wire temperature transmitter (directly powered from 4-20mA
input cards of DDCMIS) shall be provided. The temperature transmitter shall be
fully compatible with thermocouples and RTDs being provided by the contractor.
Temperature compensation of the thermocouples shall be performed in the
temperature transmitter itself.

Single Input DIN-rail mounted Temperature Transmitter

These shall be suitable for mounting on DIN-rails in JBs. The specifications of the
JBs shall be same as indicated in Subsection INST CABLE with additional DIN-
rails and IP 65 Protection class. This temperature transmitter shall be the ones
which are especially designed for DIN-rail mounting with IP 20 protection class.
These shall have terminals for input/output provided on front side when mounted
on DIN-rail. Head mounted temperature transmitter with clamps to make it
suitable for DIN-rail mounting shall not be acceptable under this category.

Requirements for each of the above type of temperature transmitters

Output

: 2-wire (power supply from input card of Control System) with
4-20mA output with superimposed HART protocol signal.

Input : Same transmitter shall be capable to handle Pt-100 RTD ,
Thermocouples K&R types (input type to be selectable at
site through HART terminal)

Isolation : min. 500 V AC

EMC
compatibility
: as per EN 61326
0 to 85 deg C (without indicator)

Operating
ambient
temperature
:
0 to 70 deg C (with indicator)

Power
supply

compatible with input module of Control System

Accessories

Mounting arrangements including clamps etc.

Composite
Accuracy

(Refer
note 2)
RTD =<0.4% of 0-250 deg C span

T/C-K type =<0.4% of 0-600 deg C span
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09

Page
5 of 8

T/C-R type =<0.4% of 0-1000 deg C span

CJC accuracy (for thermocouples) shall be =< 1 deg C

Notes:-

1. In case of failure (open or burn-out) of RTD/thermocouple, temp.
Transmitter shall provide low temperature output.
2. Composite Accuracy is to be calculated as summation of all applicable
accuracies of temp transmitter, for converting sensor input to output in 4-
20 mA (e.g., basic accuracy, digital accuracy, D/A accuracy, etc.) and
temperature effect on these accuracies at ambient temperature of 50 deg
C, based on the figure/ formula given in the standard product catalogue
for span as specified above for various types of Temperature Elements
specified. All such accuracy/ temp effect figures in catalogue shall be first
converted to deg C, and then percentage of this converted accuracy in
specified span shall be calculated to compare with the specified
composite accuracy figures.
2.04.00 Hand held calibrator
Hand held calibrators (2 nos) shall be provided for adjustment/calibration/
maintenance of the HART compatible temperature transmitters.
SPECIFICATIONS FOR PR. GAUGE, D.P. GAUGE, TEMP. Gauge and Level
Gauge.
Sl.
No
FEATURES ESSENTIAL/MINIMUM REQUIREMENTS
Pr. Gauge/ DP
Gauge/
Draught
gauges
Temperature
Gauge
Level Gauge
1 Sensing
Element and
material
Bourdon for
high pressure,
Diaphragm/Bel
low for low pr.
Of 316 SS
Mercury in steel
for below 450C
and inert gas
actuated for
above 450C of
SS bulb and
capillary.
Tempered *
toughened
Borosilicate gauge
glass steel armoured
reflex or transparent
type.
2 Body
material
Die-cast
aluminium
Die-cast
aluminium
Forged carbon
steel/304 SS

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09

Page
6 of 8

3 Dial size 150mm 150 mm Tubular covering
entire range
4 End
connection
1/2 inch NPT
(M)
3/4" NPT (M) Process connection as
per ASME PTC and
drain/vent 15 NB
5 Accuracy 1% of span 1% of span 2%

6 Scale Linear, 270
arc graduated
in metric units
Linear, 270 arc
graduated in C
Linear vertical
7 Range
selection
Cover 125% of
max. of scale
Cover 125% of
max. of scale
Cover 125% of max.
of scale
8 Over range
test
Test pr. for the assembly shall be1.5 to the max. Design pr.
at 38C.
9 Housing Weather and
dust proof as
per IP-55
Weather and dust
proof as per IP-55
CS/304 SS leak proof
10 Zero/span
adjustment
Provided Provided --
11 Identification Engraved with service legend or laminated Phenolic name
plate
12 Accessories Blow out disc,
siphon,
snubber,
pulsation
dampener,
chemical seal
(if required by
process)
gauge
isolation valve
SS Thermo well Gasket for all KEL-F
shields for
transparent type vent
and drain valves of
Steel/SS as per
CS/Alloy process
Requirement.

13 Material of
Bourdon/
movement
316 SS / 304
SS
316 SS / 304 SS

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09

Page
7 of 8

Notes:-
*Bicolor type level gauges will be provided for applications involving steam and
water except for condensate and feed water services.
Length of gauge glass shall not be more than 1400 mm. If the vessel is higher,
multiple gauge glasses with 50 mm overlapping shall be provided.
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be
removable for cleaning. The entire volume above the diaphragm shall be
completely filled with an inert liquid suitable for the application.
2.02.00 PROCESS ACTUATED SWITCHES
FEATURES ESSENTIAL / MINIMUM REQUIREMENTS
Pressure/
Draft
Switches/
DP
Switches
Temperature
switches
Level switches
Capacitance types for oil and
dirty medium, water,
condensate application.
Float type switches for
applications as decided by
Employer during detailed
engineering.
Sensing
Element
Piston
actuated for
high
pressure
and
diaphragm
or bellows
for low pr./
vacuum
Vapor pressure
sensing, liquid
filled bellow type
with SS bulb and
capillary (10 m
minimum)
Capacitance/ Conductivity/
Ultrasonic type for acid and
alkali application.
Material 316 SS Bulb 316 SS/
capillary 304 SS
316 SS
End
connection
inch NPT
(F)
inch NPT (F) Manufacturer standard
Over range
proof
pressure
150% of
max. design
pr.
- 150% of max. design
pressure
Repeat-ability + 0.5% of full range
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-09

Page
8 of 8

No. of
contacts
2 No.+2NC. SPDT snap action dry contact
Rating of
contacts
60 V DC, 6 VA (or more if required by DDCMIS or PLC)*
Elect.
Connection
Plug in socket
Set point/
dead band
adjustment
Provided over full range
Enclosure Weather and dust proof as per IP-55
Accessories Siphon,
snubber,
chemical
seal,
pulsation
dampeners
as required
by process
Thermo well of
316 SS and
packing glands
All mounting accessories
Mounting Suitable for
enclosure/
rack
mounting or
direct
mounting
Suitable for rack
mounting or
direct mounting
-
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be
removable for cleaning. The entire volume above the diaphragm shall be
completely filled with an inert liquid suitable for the application.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


HT LOAD BREAK SWITCH AND
JUNCTION BOX

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-10
HT LOAD BREAK SWITCH
AND JUNCTION BOX

Page
1 of 2

H.T. LOAD BREAK SWITCH AND JUNCTION BOX

1.00.00 CODE AND STANDARDS

IS:3427, IS:2208, IS:9920

2.00.00 TYPE

2.01.00 3.3.KV LOAD BREAK SWITCH PANEL

Metal enclosed, free standing, indoor, non draw-out type, IP-55 enclosure
protection, paint shade: RAL 9002. The panel shall be located in the MCC room
of S/R machine and shall be suitable for the fault level of the system.

2.02.00 JUNCTION BOX

Metal enclosed, free standing, suitable for outdoor location, I.P-65 enclosure
protection, paint shade-RAL-9002. 3.3 KV Junction Box shall be located at the
centre of the travel length of S/R machine and shall be suitable for the fault level
of the system.


Temperature rise of busbars shall not exceed 55 deg.C for silver plated joints
and 40 deg.C for other joints, over an ambient temperature of 50 deg.C.

4.00.00 OPERATIONAL REQUIREMENT

4.01.00 Load break Switch

a) Load break switch unit shall be provided with hinged front door and
suitable for front execution. The switch shall be mechanically interlocked
with the door so that the door can not be opened while the switch is in
closed position.

b) Constructional details, sheet steel thickness etc. shall be as per technical
specification of MCCs.

c) The switch unit shall perform satisfactorily even with the vibrations and
jerks due to operation of the machine.

d) Load break switch shall have shunt trip coil, ON indicating lamp, on/OFF
position mechanical indication, internal earth bus and earth switch which
shall be interlocked with the main switch.

e) Panel shall be identified on front as well as back side by large engraved
plate giving detailed feeder description. Identification labels/painted (Not
stickers) plates shall be provided inside the panel.

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-10
HT LOAD BREAK SWITCH
AND JUNCTION BOX

Page
2 of 2

f) The panel shall be designed to offer adequate level of safety to
operating/maintenance personnel. Means shall be provided to prevent
access to the live part to avoid accidents during service as well as
maintenance period. Contractor shall bring out the safety means
provided to achieve the same. A detailed instruction plate suitable for
wall mounting shall be provided for mounting on wall describing various
safety procedure/precautions for safe operation and maintenance.
Rubber mats shall be provided in front of the panels.

4.02.00 H.T. Junction box

a) Junction shall be adequately sized to facilitate the HT XLPE cable on one
side and EPR insulated trailing cable on the other side.

b) Constructional details, sheet steel thickness etc. shall be as per technical
specification of MCCs.

5.00.00 TYPE TESTS:

5.01.00 All equipment to be supplied shall be of type tested design. The contractor shall
submit for Employer's approval the reports of all the type tests as listed in this
These reports should be for the test conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been
either conducted at an independent laboratory or should have been witnessed by
a client.

5.02.00 However if the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the type
test report(s) are not found to be meeting the specification requirements, the
Contractor shall conduct all such tests under this contract, at no additional cost to
the Owner either at third party lab or in presence of client/owners representative

5.03.00 All acceptance and routine tests as specified below and in relevant standards
equipment price.


5.05.00 Type test reports for the following type tests on HT load break switch panel shall
be submitted:

1) Short circuit test
2) Degree of protection test
3) Power frequency withstand test
4) Impulse voltage withstand test

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


BATTERY

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SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
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BATTERY
1.00.00 BATTERY RATINGS
DC systems of 220V/110 V voltage level shall be provided for coal handling
plant. The system shall comprise of two batteries and two float-cum-boost
chargers. CHP battery shall be sized for a period of at least 30 minutes for the
CHP DC loads. The battery shall also be sized considering a minimum electrolyte
temperature of 15
0
C and an ageing factor of 1.2. The minmum capacity shall be
100AH for Nickel cadmium & 170AH for Lead Acid plante battery for 220 V DC
Battery and 90AH for Nickel Cadmium & 150AH for lead acid plante battery for
110 V DC Battery.
In addition to the above following criteria shall be followed for CHP batteries:
Battery sizing shall take into account the emergency lighting in CHP equipment
buildings as detailed elsewhere in technical specifications, in addition to
continuous DC loads of various Macs/Swgr and control panels. 220V DC load of
10 KW for employers use shall also be considered for battery sizing.
PART-A: NICKEL-CADMIUM BATTERY
2.01.00 All standards, specifications and codes of practice referred to herein, shall be the
date of opening of bid.
In case of conflict between this specification and those (IS codes, Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per
the following standards and codes:
IS : 10918 Specification for vented type Nickel Cadmium Batteries.
IS : 1069 Quality tolerances for water for storage batteries
Indian electricity rules
Indian Electricity Acts.
2.02.00 Equipment complying with other internationally accepted standards such as IEC.,
BS, VDE etc. will also be considered if they ensure performance and
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3.00.00 GENERAL TECHNICAL REQUIREMENT
3.01.00 Equipments
(a.) DC Batteries shall be stationary Nickel Cadmium Pocket plate type
conforming to IS:10918. For the purpose of design an ambient temperature
of 50 degree centigrade and relative humidity of 85% shall be considered.
(b.) DC batteries shall be suitable for standby duty. The batteries shall normally
be permanently connected to the load in parallel with a charger and shall
supply the load during emergency conditions when AC supplies are lost.
Batteries shall be suitable for a long life under continuous float operations
and occasional discharges. The batteries shall be boost charged at about
1.54 to 1.7 volts per cell maximum and float charged at about 1.42 V/cell.
(c.) The number of cells for the 220 volts and 110 volts shall be 169 & 85
respectively.
(d.) Batteries should be suitable for continuous operation for the maximum
ambient temperature as defined in technical parameters.
3.02.00 Construction Features
3.02.01 Containers
Containers shall be made of polypropylene plastic material. Containers shall be
robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging
type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc.
Electrolyte level lines shall be marked on container in case of translucent
containers.
3.02.02 Vent Plugs
Vent plugs shall be provided in each cells. They shall be anti splash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent
alkali from coming out. The design shall be such that the water loss due to
evaporation is kept to minimum. In addition the ventilator shall be easily removed
for topping up the cells and of such dimensions that the syringe type hydrometer
can be inserted into the vent to take electrolyte samples.
3.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS:10918.
The separators shall maintain the electrical insulation between the plates and
shall allow the electrolyte to flow freely. Separators should be suitable for
continuous immersion in the electrolyte without distortion.
The positive and negative terminal posts shall be clearly marked.

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3.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be
cleaned during normal life and prevent shorts within the cells.
3.02.05 Cell Insulator
Each cell shall be separately supported on PVC/porcelain/hard rubber insulators
fixed on to the racks with adequate clearance between adjacent cells. Minimum
distance between the adjacent cells shall be more than the budge allowed for two
cells in accordance with IS:1146.
3.02.06 Electrolyte
The electrolyte shall be prepared from battery grade potassium hydroxide
conforming to BS:1069.
The cells can be shipped either in charged condition or in dry condition
Necessary electrolyte for make-up shall be supplied separately.
3.02.07 Connectors and Fasteners
Nickel coated copper connectors shall be used for connecting up adjacent cells
and rows. Bolts, nuts and washers shall be effectively Nickel coated to prevent
corrosion. The thickness of Nickel coating of connectors should be not less than
0.02 mm. All the terminals and cells inter-connectors shall be fully insulated or
have insulation shrouds. End take off connections from positive and negative
poles of batteries shall be made by single core cables having stranded aluminium
conductors and XLPE insulation. Necessary supports and lugs for termination of
these cables on batteries shall also be supplied by the contractor. All connectors
and lugs shall be capable of continuously carrying the 30 minutes discharge
current of the respective batteries and through fault short circuit current which the
battery can produce and withstand for the period declared. Contractor shall
furnish necessary sizing calculations to prove compliance to the same. Suitable
number of Inter-rack connectors shall be supplied by the Bidder to suit the
battery room layout during detailed engineering.
3.02.08 Battery racks
Mild steel racks for all the batteries shall be provided. They shall be free standing
type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall
preferably be located in the single tier arrangement. However, batteries having a
complete cell weight of lower than 50 Kg could be located in the double tier
arrangement. The batteries racks and supports for cable termination shall be
coated with three (3) coats of anti-alkali paint of approved shade. Name plates,
resistant to alkali, for each cell shall be attached on to the necessary racks. The
bottom tier of the stand shall not be less than 150 mm above the floor.
Wherever racks are transported in dismantled conditions, match markings shall
be provided to facilitate easy assembly.
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3.02.09 Manufacturers Identification System
The following information shall be indelibly marked on outside of each cell.
(a.) Manufacturers name and trade marks
(b.) Country and year of manufacture.
(c.) Manufacturer type designation.
(d.) AH capacity at 5 hour discharge rate.
(e.) Serial number
4.00.00 THE FOLLOWING INFORMATION SHALL BE GIVEN ON THE INSTRUCTION
CARDS SUPPLIED WITH THE BATTERY:
(a.) Manufacturer's instructions for filling and initial charging of the battery
together with starting and finishing charging rate.
(b.) Maintenance instructions.
(c.) Designation of cell in accordance with IS:10918.
(d.) Storing conditions of electrolyte.
5.00.00 TESTS
5.01.00 GENERAL
(a.) The Contractor shall submit for Owners approval the reports of all the
type tests as per latest IS-1146 (for all applicable tests for containers) /
IS-10918 (for Ni-Cd Batteries) and carried out within last ten years from
the date of bid opening. These reports should be for the tests conducted
on the equipment similar to those proposed to be supplied under this
contract and the test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client. The
complete type tests shall be for any rating of battery in a particular group,
based on plate dimensions.
(b.) In case the Contractor is not able to submit report of the type test(s)
contract at no additional cost to the Owner either at third party lab or in
approval.
(c.) All acceptance and routine tests shall be as per Quality assurance and
Inspection table of batteries. Charges for these shall be deemed to be
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(d.) The type test reports once approved for any projects shall be treated as
sheet.
5.02.00 Commissioning checks.
All tests as listed below shall be carried out on sample cell selected at random by
the employer at site after completion of installation.
(a.) Physical Examination
(b.) Dimensions, Mass & layout
(c.) MARKING
(d.) Polarity and absence of short circuit.
(e.) Air pressure test
(f.) Ampere - hour capacity
(g.) Retention of charge
(h.) Insulation resistance
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments.
PART-B: LEAD ACID PLANTE BATTERY
6.01.00 All standards, specification and codes of practice, referred to herein, shall be the
latest edition including all applicable official amendments and revisions as on
date of opening of bid.
In case of conflict between this specification and those (IS Codes Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per
the following standards and codes :
IS : 266 Specification for sulphuric acid
IS : 1069 Specification for water for storage batteries
IS : 1146 Specification for rubber & plastic containers for lead acid storage
batteries.
IS : 1652 Specification for stationary cells and batteries, lead acid type (with
plant positive plates).
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IS : 3116 Specification for sealing compound for lead acid batteries.
IS : 8320 General requirements and methods of tests for lead acid storage
batteries.
IS : 6071 Specification for synthetic separators for lead acid batteries.
Indian Electricity Rules
Indian Electricity Acts
BS, VDE etc. will also be considered if they ensure performance and
7.00.00 GENERAL TECHNICAL REQUIREMENTS
7.01.00 Equipments
DC Batteries shall be stationary lead acid Plante positive plate type conforming
to IS:1652. For the purpose of design an ambient temperature of 50 degree
centigrate and relative humidity of 85% shall be considered.
DC Batteries shall be suitable for standby duty. The Batteries shall normally be
permanently connected to the load in parallel with a charger and shall supply the
load during emergency conditions when AC supplies are lost. Batteries shall be
suitable for a long life under continuous float operations and occasional
discharges. The batteries shall be boost charged at about 2.7 volts per cell
maximum and float charged at about 2.25V/cell:
The number of cells for the 220 Volts and 110 volts shall be 107 & 54
respectively.
Batteries should be suitable for continuous operation for the maximum ambient
temperature as defined in technical parameters.
7.02.00 Construction Features
7.02.01 Containers
Containers shall be made of transparent glass, hard rubber, suitable robust, heat
resistance, leak proof, non absorbent, acid resistant, non-bulging type and free
from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines
shall be marked on container in case of transparent containers. Float type level
indicator shall be provided in case of opaque containers. The stem portion of the
float should be long enough to prevent falling of the float inside the container
even if there is no electrolyte in the container. The marking for the electrolyte
level should be for the upper and lower limits. The material of level indicator shall
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be acid proof and oxidation proof. Container shall be closed/sealed lid type. Lid
and sealing compound shall be non-cracking type. The container made of hard
rubber and plastics shall be type tested as per IS : 1146. All type tests shall be
carried out for sealing compound as per IS:3116.
The pole sealing arrangement should be such that no acid particle gets
entrapped due to acid creep as a result of capillary action and it should be
possible to remove and refix the sealing to carry out the maintenance.
7.02.02 Vent Plugs
Vent plugs shall be provided in each cell. They shall be antisplash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent
acid from coming out. The design shall be such that the water loss due to
evaporation is kept to minimum. In addition the ventilator shall be easily removed
for topping up the cells and of such dimensions that the syringe type hydrometer
can be inserted into the vent to take electrolyte sample.
7.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS: 1652 as applicable.
The separators shall maintain the electrical insulation between the plates and
shall allow the electrolyte to flow freely. Separators should be suitable for
continuous immersion in the electrolyte without distortion. The positive and
negative post shall be clearly marked.
7.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be
cleaned during normal life and prevent shorts within the cells.
7.02.05 Cell Insulator
Each cell shall be separately supported on PVC/porcelain/hard rubber insulators
fixed on the racks with adequate clearance between adjacent cells. Minimum
distance between adjacent cells shall be more than the buldge allowed for two
cells in accordance with IS: 1146.
7.02.06 Electrolyte
The electrolyte shall be prepared from battery grade sulphuric acid conforming to
IS:266 and distilled water conforming to IS:1069. The cells shall be shipped dry
uncharged. The electrolyte shall be supplied separately.
7.02.07 Connectors and Fasteners
Lead or Lead coated copper connectors shall be used for connecting up adjacent
cells and rows. Bolts, nuts and washers shall be effectively lead coated to
prevent corrosion. The thickness of lead-coating of connectors should not be less
CLAUSE NO.

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SUB-SECTION-IIIB-11
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than 0.025 mm. The lead coating thickness shall be measured in accordance
with APPENDIX F of IS: 6848 (latest edition). All the terminals and cells inter-
connectors shall be fully insulated or have insulation shrouds. End take off
connections from positive and negative poles of batteries shall be made by single
core cables having stranded aluminium conductors and XLPE insulation.
Necessary supports and lugs for termination of these cables on batteries shall
also be supplied by the contractor. All connectors and lugs shall be capable of
continuously carrying the 30 minutes discharge current of the respective
Batteries and through fault short circuit current which the battery can produce
and withstand for the period declared. Contractor shall furnish necessary sizing
calculations to prove compliance to the same.
7.02.08 Battery racks
Wooden racks for all the batteries shall be provided. These racks shall be made
of good quality first class seasoned teak wood in line with CPWD specification.
They shall be free standing type mounted on porcelain/hard rubber/PVC pads
insulators. Batteries shall preferably be located in the single tier arrangement.
However, batteries having a complete cell weight of lower than 50 Kg could be
located in the double tier arrangement. The batteries rack and wooden support
for cable termination shall be coated with three (3) coats of anti-acid paint of
approved shade. Numbering tags, resistant to acid, for each cell shall be
attached on to the necessary racks. The bottom tier of the stand shall not be less
than 150 mm above the floor. Wherever racks are transported in dismantled
condition, suitable match markings shall be provided to facilitate easy assembly.
7.02.09 Manufacturers Identification Systems
The following information shall be indelibly marked on outside of each cell.
(a.) Manufacturer's name and trade marks
(b.) Country and year of manufacture.
(c.) Manufacturer type designation.
(d.) AH capacity at 10 hour discharge rate.
(e.) Serial number
8.00.00 TESTS
8.01.00 GENERAL
The Contractor shall submit for Employers approval the reports of all the type
tests as per the latest IS-1146 (for rubber & plastic containers for Lead acid
storage batteries) carried out with in the last 10 years from the date of bid
opening and the tests should have been witnessed by a client. The complete
type test reports shall be for any rating of battery in a particular group, based on
plate dimensions being manufactured by supplier.
8.02.00 In case the Contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in case the type test
report(s) are not found to be meeting the specification requirements, the
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Contractor shall conduct all such tests under this contract at no additional cost to
and submit the reports for approval. Routine and acceptance tests shall be as
per Quality assurance & inspection table of battery
8.03.00 All routine tests as per QA table and relevant standards shall be carried out.
Charges for these shall be deemed to be included in the equipment price.


8.05.00 COMMISSIONING CHECKS
All tests as listed below shall be carried out on sample cell selected at random by
the employer at site after completion of installation.
1) Verification of markings.
2) Verification of dimensions.
3) Test for capacities for 10 hrs discharge rate alongwith the test for voltage
during discharge.
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed
requirements the Employer shall have the option of asking the Contractor to
replace the same.

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


BATTERY CHARGER

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SUB-SECTION-IIIB-12
BATTERY CHARGER

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BATTERY CHARGER
date of opening of bid. In case of conflict between this specification and those (IS
codes, standards etc.) referred to herein, the former shall prevail. All work shall
be carried out as per the following standards and codes.
ANSI-C
37.90a
Guide for surge withstand capability tests
IS:5 Colours for ready mix paints.
IS : 694 PVC Insulated Cable for working voltages upto and including
1100 V.
IS : 1248 Specification for Direct acting indicating analogue electrical
measuring instruments.
IS:13947
Part-1
Degree of protection provided by enclosures for low voltage
switch gear and control gear.
IS : 13947 Specification for low voltage switch gear and control gear
IS : 3231 Electrical relays for power system protection.
IS : 3842 Application guide for Electrical relays for AC System
IS : 3895 Mono-crystalline semi-conductor Rectifier Cells and Stacks
IS : 4540 Mono crystalline semi-conductor Rectifier assemblies and
equipment.
IS:6005 Code of practice for phosphating of Iron and Steel.
IS:6619 Safety Code for Semi-conductor Rectifier Equipment.
IS:6875 Control switches (switching devices for control and auxiliary
circuits including contactor relays) for voltages upto 1000 V AC or
1200 V DC.
IS : 9000 Basic environmental testing procedures for electronic and
electrical items.
IS:13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500
V DC.
EEUA-45D Performance requirements for electrical Alarm Annunciation
System
Indian Electricity Rules
Indian Electricity Act.
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BS, VDE. etc. will also be considered if they ensure performance and
2.00.00 EQUIPMENT DESCRIPTION
2.01.00 PART-I BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY
(a.) The Battery Chargers as well as their automatic regulators shall be of
static type. Battery chargers shall be capable of continuous operation at
the respective rated load in Trickle mode i.e. Trickle charging the
associated DC lead-acid Batteries while supplying the D.C. loads. The
Batteries shall be Trickle charged at 2.25 Volts per cell. All chargers shall
also be capable of Boost charging the associated D.C. Battery at 2.0 to
2.7 Volts per cell at the desired rate. The Chargers shall be designed to
operate, as mentioned above, at an ambient air temperature of 50C.
(b.) Battery Chargers shall have a selector switch for selecting the battery
charging mode i.e. whether Trickle or Boost charging.
(c.) All Battery Chargers shall be provided with facility for both automatic and
manual control of output voltage and current. A selector switch shall be
provided for selecting the mode of output voltage/current control, whether
automatic or manual. Means shall be provided to avoid current/voltage
surges of harmful magnitude/nature which may arise during changeover
from Auto to Manual mode or vice-versa under normal operating
condition.
(d.) Soft start feature shall be provided to build up the voltage to the set value
slowly within fifteen seconds. The chargers shall have load limiters which
shall cause, when the voltage control is in automatic mode, a gradual
lowering of the output voltage when the DC load current exceeds the load
limiter setting of the Charger. The load limiter characteristic shall be such
that any sustained overload or short circuit in DC system shall neither
damage the Charger nor shall it cause blowing of any of the changer
fuses. The Charger shall not trip on overload or external short circuit.
After clearance of fault, the Charger voltage shall build up automatically
when working in automatic mode.
(e.) When on automatic control mode during Trickle charging, the Charger
output voltage shall remain within +/-1% of the set value for AC input
voltage variation of +/-10%, frequency variation of +3/-5%, a combined
voltage and frequency (absolute sum) variation of 10% and a continuous
DC load variation from zero to full load. Uniform and stepless adjustments
of voltage setting (in both manual and automatic modes) shall be
provided on the front of the Charger panel covering the entire Trickle
charging output range specified. Stepless adjustment of the load limiter
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setting shall also be possible from 80% to 100% of the rated output
current for Trickle charging mode.
(f.) During Boost charging, the Battery Chargers shall operate on constant
current mode (When automatic regulator is in service). It shall be possible
to adjust the Boost charging current continuously over a range of 50 to
100% of the rated output current for Boost charging mode. The charger
output voltage shall automatically go on rising, when it is operating on
boost mode, as the battery charges up. For limiting the output voltage of
the charger, a potentiometer shall be provided on the front of the panel,
whereby it shall be possible to set the upper limit of this voltage anywhere
in the output range specified for boost charging mode. All voltage and
current setting potentiometers shall be vernier type.
(g.) Energising the Charger with fully charged battery connected plus 10%
load shall not result in output voltage greater than 110% of the voltage
setting. Time taken to stabilise, to within the specified limits as mentioned
elsewhere, shall be less than fifteen seconds.
(h.) Momentary output voltage of the Charger, without the Battery connected
shall be within 94% to 106% of the voltage setting during sudden load
Change from 100% to 20% of full load or vice-versa. Output voltage shall
return to, and remain, within the limits specified as mentioned elsewhere
in less than 2 seconds after the above mentioned change.
(i.) The Charger manufacturer may offer an arrangement in which the voltage
setting device for Trickle charging mode is also used as output voltage
limit setting device for Boost charging mode, and the load limiter of the
trickle charging mode is also used as Boost charging current setting
device.
(j.) Suitable filter circuits shall be provided in all the Chargers to limit the
ripple content (peak to peak) in the output voltage to 1% irrespective of
the DC load, even when they are not connected to a battery.
(k.) The DC System shall be ungrounded and float with respect to the ground
potential when healthy. An earth fault relay shall be provided by the
Employer in the DC distribution board for remote annunciation.
2.02.00 PART-II BATTERY CHARGER FOR NICKEL-CADMIUM TYPE BATTERY
(a.) The Battery Chargers as well as their automatic regulators shall be of
static type. Battery chargers shall be capable of continuous operation at
the respective rated load in Trickle mode i.e. Trickle charging the
associated DC Nickel-Cadmium Batteries while supplying the D.C. loads.
The Batteries shall be Trickle charged at 1.4 to 1.42 Volts per cell. All
chargers shall be capable of Boost charging the associated D.C. Battery
at 1.53 to 1.7 Volts per cell at the desired rate. The Chargers shall be
designed to operate, as mentioned above, at an ambient air temperature
of 50C.
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(b.) Battery Chargers shall have a selector switch for selecting the battery
charging mode i.e. whether Trickle or Boost charging.
(c.) All Battery Chargers shall be provided with facility for both automatic and
manual control of output voltage and current. A selector switch shall be
provided for selecting the mode of output voltage/current control, whether
automatic or manual. Means shall be provided to avoid current/voltage
surges of harmful magnitude/nature which may arise during changeover
from Auto to Manual mode or vice-versa under normal operating
condition.
(d.) Soft start features shall be provided to build up the voltage to the set
value slowly within fifteen seconds. The chargers shall have load limiters
which shall cause, when the voltage control is in automatic mode, a
gradual lowering of the output voltage when the DC load current exceeds
the load limiter setting of the Charger. The load limiter characteristic shall
be such that any sustained overload or short circuit in DC system shall
not damage the Charger, nor shall it cause blowing of any of the charger
fuses. The Charger shall not trip on overload or external short circuit.
After clearance of fault, the Charger voltage shall build up automatically
when working in automatic mode.
(e.) When on automatic control mode during Trickle charging, the Charger
output voltage shall remain within +/-1% of the set value for AC input
voltage variation of +/-10%, frequency variation of +3 to -5%, a combined
voltage and frequency (absolute sum) variation of 10% and a continuous
DC load variation from zero to full load. Uniform and stepless adjustments
of voltage setting (in both manual and automatic modes) shall be
provided on the front of the Charger panel covering the entire Trickle
charging output range specified. Stepless adjustment of the load limiter
setting shall also be possible from 80% to 100% of the rated output
current for Trickle charging mode.
(f.) During Boost charging, the Battery Chargers shall operate on constant
current mode (When automatic regulator is in service). It shall be possible
to adjust the Boost charging current continuously over a range of 50 to
100% of the rated output current for Boost charging mode. The charger
output voltage shall automatically go on rising, when it is operating on
boost mode, as the battery charges up. For limiting the output voltage of
the charger, a potentiometer shall be provided on the front of the panel,
whereby it shall be possible to set the upper limit of this voltage anywhere
in the output range specified for boost charging mode. All voltage and
current setting potentiometers shall be vernier type.
(g.) Energising the Charger with fully charged battery connected plus 10%
load shall not result in output voltage greater than 110% of the voltage
setting. Time taken to stabilise, to within the specified limits as mentioned
elsewhere shall be less than fifteen seconds.
(h.) Momentary output voltage of the Charger, without the Battery connected
shall be within 94% to 106% of the voltage setting during sudden load
Change from 100% to 20% of full load or vice-versa. Output voltage shall
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return to, and remain, within the limits specified as mentioned elsewhere
in less than 2 seconds after the above mentioned change.
(i.) The Charger manufacturer may offer an arrangement in which the voltage
setting device for Trickle charging mode is also used as output voltage
limit setting device for Boost charging mode, and the load limiter of the
trickle charging mode is also used as Boost charging current setting
device.
(j.) Suitable filter circuits shall be provided in all the Chargers to limit the
ripple content (peak to peak) in the output voltage to 1% irrespective of
the DC load, even when they are not connected to a battery.
(k.) The DC System shall be ungrounded and float with respect to the ground
potential when healthy. An earth fault relay shall be provided by the
Employer in the DC distribution board for remote annunciation.
2.03.00 PRINTED CIRCUITS BOARDS (PCB)
PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with
99.8% pure copper foil, free of wrinkles, blisters, scratches and pinholes. The
contact surface of the edge connectors of the PCBs shall be plated with hard
gold to a minimum thickness of 5 microns. Component identification shall be
printed on PCB by silk screen method. All PCBs shall be tropicalised and
masked.
2.04.00 CONTACTORS
All Battery Chargers shall have an AC contactor on the input side. It shall be of
air break type and suitable for continuous duty. The operating coil shall be rated
for 415 Volts AC.
2.05.00 THERMAL OVERLOAD RELAY
A thermal overload relay incorporating a distinct single phasing protection (using
differential movement of bimetal strips) shall also be provided for the AC input.
The relay shall trip the above contactor.
2.06.00 RECTIFIER-TRANSFORMERS AND CHOKES
The rectifier transformer and chokes shall be dry and air cooled (AN) type. The
rating of the rectifier-transformers and chokes shall correspond to the rating of
the associated rectifier assembly. The rectifier-transformers and chokes shall
have class-B insulation with temperature rise limited to class-A insulation value.
2.07.00 RECTIFIER ASSEMBLY
The rectifier assembly shall be full wave bridge type and designed to meet the
duty as required by the respective Charger. The rectifier cells shall be provided
with their own heat dissipation arrangement with natural air cooling. The rectifier
shall utilise diodes/thyristors and heat sinks rated to carry 200% of the load
current continuously and the temperature of the heat sink shall not be permitted
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-12
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to exceed 85C absolute duly considering the maximum charger panel inside
temperature. The Contractor shall submit calculations to show what maximum
junction temperature will be and what the heat sink temperature will be when
operating at 200% and 100% load current continuously duly considering the
maximum surrounding air temperature for these devices inside the charger panel
assuming air ambient temperature of 50C outside the panel. Necessary surge
protection devices and rectifier type fast acting fuses shall be provided in each
arm of the rectifier connections.
2.08.00 DIGITAL INDICATING INSTRUMENTS
Digital indicating instruments with built in communication port for remote data
transfer shall be provided for all chargers. The instruments shall indicate DC
current, DC voltage & AC voltage and instrument shall be 96 x 96 sqmm, with
display accuracy 0.5%, 4 digit 7 segment LED/LCD display and RS 485 serial
Bus port.
2.09.00 AIR BREAK SWITCHES
All Chargers shall have AC input and DC output switches of air break, single
throw, load break and fault make type. The contacts of the switches shall open
and close with a snap action. Switches shall be rated for 120% of the maximum
continuous load. ON & OFF position of the switch shall be clearly indicated.
2.10.00 CONTROL AND SELECTOR SWITCHES
Control and selector switches shall be of rotory stayput type with escutcheon
plates showing the functions and positions. The switches shall be of sturdy
construction and suitable for mounting on panel front. Switches with shrouding of
live parts and sealing of contacts against dust ingress shall be preferred. The
contact ratings shall be atleast the following :
(a.) Make and carry continuously 10 Amps.
(b.) Breaking current at 220 V DC 0.5 Amp. (inductive)
(c.) Breaking current at 240 V AC 5 Amp. At 0.3 p.f.
2.11.00 FUSES
Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse
carriers which are mounted on fuse bases. Wherever it is not possible to mount
fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In
such cases one insulated fuse pulling handle shall be supplied for each charger.
Kick-off fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses.
2.12.00 INDICATING LAMPS
Three (3) indicating lamps shall be provided to indicate A.C. supply availability.
The indicating lamp shall be of panel mounting, filament type low wattage or
LEDs and capable of clear status indication under the normal room illumination.
The lamps shall be provided with series resistors (non-hygroscopic) preferably
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-12
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built in the lamp assembly and replaceable from front. The lamp covers shall be
preferably screwed type, unbreakable and moulded from heat resistant material
2.13.00 BLOCKING DIODE
Blocking diode shall be provided in the output circuit of each Charger to prevent
current flow from the D.C. Battery into the Charger.
2.14.00 ANNUNCIATION SYSTEM
Visual indications through indicating lamps/LEDs or annunciation facia as per
EEUA-45D shall be provided in all Chargers for the following:
(a.) A.C. supply failure
(b.) Rectifier fuse failure
(c.) Surge circuit fuse failure
(d.) Filter fuse failure
(e.) Load limiter operated
(f.) Charger trip
(g.) Battery on Boost
Potential free NO contacts of all above conditions shall be provided for
following remote alarms in the Employers Unit Control Board:
(h.) Battery on Boost
(i.) Charger trouble (this being a group alarm initiated by any of the faults
other than Battery on Boost)
2.15.00 NAME PLATES AND MARKING
The name plates shall be made of non-rusting metal/3 ply Lamicoid and shall
have black back-ground with white engraved letters and secured by screws.
These shall be provided near top edge on the front as well as on rear side of
Charger. Name plates with full and clear inscriptions shall also be provided on
and inside the panels for identification of the various equipments.
3.00.00 CONSTRUCTION
3.01.00 The Chargers shall be indoor, floor mounted, self supporting sheet metal
enclosed cubicle type. The Contractor shall supply all necessary base frames,
anchor bolts and hardware. The Charger shall be fabricated using cold rolled
sheet steel shall not less than 1.6 mm and shall have folded type of construction.
The panel frame shall be fabricated using cold rolled sheet steel of thickness not
less than 2.0 mm. Removable undrilled gland plates of at least 3.0 mm sheet
steel and lugs for all cables shall be supplied by the Contractor. The lugs for
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-12
BATTERY CHARGER

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cables shall be made of electrolytic copper with tin coat. Cable sizes shall be
advised to the Contractor at a later date for provision of suitable lugs and gland
plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers
shall be backed with fine brass wire mesh. All doors and covers shall be fitted
with synthetic rubber gaskets. The Chargers shall have hinged double leaf doors
provided on front and/or backside for adequate access to the Charger internals.
All the Charger cubicle doors shall be properly earthed. The degree of protection
of Charger enclosure shall be atleast IP-42.
3.02.00 All indicating instruments, control & selector switches and indicating lamps shall
be mounted on the front side of the Charger. Design of panels shall be based on
the following dimensions.
1) Overall height - Maximum 2350 mm

2) Operating handles - Maximum 1800 mm
(highest and lowest Minimum 350 mm
positions reached by
operators hands),
protective mechanical
indicators

3) Doors and panel - Maximum 1800 mm
handles and locks Minimum 300 mm
3.03.00 Electronic equipments shall be of modular design consisting of plug in modules in
standard 19 inches metallic racks with metallic card guides. The cards should be
provided with proper handles. Card to card wiring should be preferably through a
mother board. Unplanned jumpering and track modifications are not permitted.
Mechanical interlocks to prevent wrong insertion of cards should be provided.
Each card shall have its junction and test points identified. Maintenance aids
such as extension printed wiring boards and jumper leads shall be provided.
3.04.00 The layout of Charger components shall be such that their heat losses do not
give rise to excessive temperature within the Charger panel surface. Location of
the electronic modules will be such that temperature rise of the location, in no
case, will exceed 10C over ambient air temperature outside the Charger.
3.05.00 Each Charger panel shall be provided with an illuminating lamp and one 5 Amp.
Socket. Switches and fuses shall be provided separately for each of the above.
3.06.00 LOCKING FACILITIES SHALL BE PROVIDED AS FOLLOWING:
(a.) For locking Trickle/Boost selector switch in the trickle position only. This
would be used for having key mechanical interlock between Trickle/Boost
selector switch and isolator in D.C. distribution board which is being
procured separately by the employer.
(b.) The Charger enclosure door locking requirements shall be met by the
application of padlocks. Padlocking arrangement shall allow ready
insertion of the padlock shackle but shall not permit excessive movement
of the locked parts with the padlock in position.
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-12
BATTERY CHARGER

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3.07.00 WIRING
3.07.01 Each Charger shall be furnished completely wired upto power cable lugs and
terminal blocks ready for external connection. The power wiring shall be carried
out with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part-I). The
control wiring shall be of 1.1KV grade PVC insulated stranded copper conductors
of 2.5 sq.mm. conforming to IS:694. Control wiring terminating at electronic cards
shall not be less than 1.0 sq. mm. Control terminal shall be suitable for
connecting two wires with 2.5 sq.mm. stranded copper conductors. All terminals
shall be numbered for ease of connections and identification. At least 20% spare
terminals shall be provided for circuits.
3.07.02 Power and control wiring within panels shall be kept separate. Any terminal or
metal work which remains alive at greater than 415 V, when panel door is
opened, shall be fully protected by shrouding.
3.07.03 An air clearance of at least ten (10) mm shall be maintained throughout all
circuits, except low voltage electronic circuits, right upto the terminal lugs.
Whenever this clearance is not available, the live parts should be insulated or
shrouded.
3.08.00 PAINTING
Treatment as per IS:6005. Two coats of lead oxide primer followed by powder
painting with final shade of RAL9002 for complete panel except end covers &
RAL 5012 for end covers.
4.00.00 TESTS
4.01.00 GENERAL

1. All equipments to be supplied shall be of type tested design. The
Contractor shall submit for Owners approval the reports of all the type
tests as listed in this specification and carried out within last ten years
from the date of bid opening. These reports should be for the tests
conducted on the equipment similar to those proposed to be supplied
under this contract and the test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client.

a) Complete physical examination

b) Temperature rise test at full load.

c) Temperature rise test of rectifier assembly at 200% of full load.

d) Insulation resistance test.

e) High voltage (power frequency) test on power and control circuits
except low voltage electronic circuits.

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SECTION VI, PART-B
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f) Ripple content test at
i) No load
ii) Half load
iii) Full load

g) Automatic voltage regulator operation test at specified A.C.
supply variations at
i) No load
ii) Half load
iii) Full load

h) Load limiter operation test

i) Efficiency and power factor measurement.

j) Input and output surge withstand capability test. Surge Voltage as
per ANSI-C37.90a shall be applied for period not less than 2 sec.
At the following points of the Charger operating at 50 deg. C at
full load :
i) Across each A.C. input phase
ii) Across AC input line to ground.
iii) Across D.C. output terminals.
iv) Across each D.C. output terminal to ground
The Charger shall not exhibit any component damage and there
shall be no change in performance as per (g) and (h).

k) Environmental Tests
Steady state performance tests (g) and (h)) shall be carried out
before and after each of the following tests.
i) Soak Test
The electronic modules shall be subjected to continuous
operation for a minimum period of 72 hours. During last
48 hours, the ambient temperature shall be maintained at
50 deg. C. The 48 hour test period shall be divided into
four equal 12 hour segments. The input voltage during
each 12 hours shall be nominal voltage for 11 hours
CLAUSE NO.

SECTION VI, PART-B
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followed by 110% of nominal voltage for 30 minutes,
followed by 90% of nominal voltage for 30 minutes.
ii) Degree of protection test.

2. However if the Contractor is not able to submit report of the type test(s)
approval.

3. All acceptance and routine tests as specified below and in relevant

4. The type test reports once approved for any projects shall be treated as
sheet.

5.00.00 COMMISSIONING
5.01.00 The contractor shall carryout the following commissioning tests and checks after
installation of the equipment at site:
(a.) Complete physical examination.
(b.) Checking of proper operation of annunciation system.
(c.) Temperature rise test at full load.
(d.) Insulation resistance test.
(e.) Automatic voltage regulator operation.
(f.) Load limiter operation.
(g.) Dynamic response test.
Overshoot/Undershoot in output voltage of the Charger as a result of sudden
change in load from 100% to 20% and 20% to 100% shall be measured with the
Batteries connected/disconnected. Output voltage of the Charger connected with
Battery shall be within 94% to 106% of the voltage setting in above conditions
and shall return to, and remain, within the limits specified as mentioned
elsewhere, in less than 2 seconds (as applicable).

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-B

PART - B


CONTROL PANEL

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-13
CONTROL PANELS

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CONTROL PANELS

Programmable Logic Controller IEC: 1131
2.00.00 CONTROL TYPE
PLC based
3.00.00 PANEL CONFIGURATION
3.01.00 Control system for Stacker machines and Reclaimer machines

Each machine shall be provided with control desk in the operator cabin having
necessary push buttons, switches, joy sticks etc. to operate the entire machine.
OWS shall be mounted in front of the operator so that he can control the machine
through key board / mouse also. The other OWS, PLC processor panel and I/O
panel along with printer shall be housed in the MCC room of each machine. No
remote I/O panel is envisaged in the operator cabin.

3.02.00 Separate, vertical, free standing PLC & RIO panels with Perspex/glass door for
visual access to LEDs shall be provided for each stacker reclaimer machine.

3.03.00 Power distribution equipment i.e. Control transformers/ UPS/Power
Supplies/Backup Batteries/ MCBs etc shall be housed in a separate free standing
vertical panels.

3.04.00 Local control panels for Coal handling plant:

Local control panels for traveling trippers, metal detectors, sump pumps, SM &
ILMS, belt weighers and hoists shall be free standing, floor/wall mounting type.
They shall be provided with the necessary power equipment like switches, fuses,
contactors etc. and the required control equipment like selector switches, meters,
push buttons, indications, and annunciations etc.

Local control panels shall be provided for Coal sampling units, hydraulic scoop
coupling and dust suppression system. However control of these systems shall
be through main DDCMIS with starters located in the main MCCs only.

Necessary controls, indications and annunciations, as described elsewhere, for
all the above equipment shall be provided in main CHP control desk and
DDCMIS being procured by the employer under a separate package.
4.00.00 SYSTEM CONFIGURATION
4.01.00 Control shall be normally affected through OWS. Facilities to operate HT load
break isolator switch & LT breaker shall be provided on the control desk of each
machine.

CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-13
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All indicating instruments (i.e. Ammeters/ Voltmeters) shall be digital type and of
accuracy class 1. Ammeters shall be provided on control desk for all motors
rated 30 kW and above and for I/Cs and B/Cs of LT switchgear. Voltmeters shall
be provided on control desk for LT bus voltages.
4.02.00 Ammeters and Voltmeters shall be suitable for 4-20mA DC signals.
5.00.00 CONTROL SYSTEM
1). The control system for all the coal handling drives including conveyors,
Dust Suppression System, etc except for the Stacker and Reclaimer
machines shall be DDCMIS based being procured by the employer
under a separate package.

2). The control system for each stacker / reclaimer machine shall be PLC
based. PLC system on each machine shall be provided with 2x100%
processors in hot standby mode. Standby processor shall be energised
and continuously monitored for healthiness. In case a failure of working
processor, the standby processor shall take over the operation
automatically by bumpless transfer and necessary failure alarm shall be
provided. Both the work stations of a PLC system shall be suitable for
operation and also for programming hence software shall be provided
accordingly. The processor along with their accessories shall be housed
in a free standing vertical type PLC panel separate from control desk.
The operation and supervisory system shall consist of PC (latest
model), TFT monitors with key boards which shall be mounted as an
integral part of the control desk.

3). The processor along with OWS, printer etc. and control panels shall be
interlinked through independent dual data highway and dual I/O
communication links. The hot standby shall be hardware based and
there shall be dedicated link between the two processors for data and
program equalization.

4). The push button and selector switches mounted on control desk shall
send necessary signals through PLC.

5). The list of required annunciations shall be finalised during detail
engineering. Detailed alarms shall be displayed on OWS.

6). In addition to the controls from the control desk/keyboard/local control
panels, each drive shall be provided with local stop push button station
near the drive and shall be wired to PLC.

7). The PLC shall provide supervisory information for alarm, various types
of displays, status information, trending, historical storage of data etc.
and also perform self monitoring and diagnostic functions.
6.00.00 CONTROL PHILOSOPHY
1). Normal / local mode of operation shall be selected from the key board.
CLAUSE NO.

SECTION VI, PART-B
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SUB-SECTION-IIIB-13
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(a) In normal mode of operation, which shall be the default mode, all
drives shall be operated from control desk through keyboard.
Whenever required for maintenance, maintenance mode for
equipment will be selected from the keyboard of the operation,
Operation interlocks, except trip interlocks are locked using a
unique password. After maintenance, the drives shall be started
from OWS through all process interlocks, by re-entering the
password. Normal mode of operation can be selected then.
Irrespective of any PLC mode of operation, the running
equipment can be stopped from keyboard or from desk/panel or
from emergency stop push button.

7.00.00 TRAINING

Further to the relevant clause regarding training specified elsewhere, Bidder's
experienced personnel/engineers shall also provide training courses on offered
PLC system to Employer's engineers in the following areas:
(a.) Operator training
(b.) Hardware Maintenance training
(c.) Software training
(d.) Any other specialized training as required for system operation and
maintenance.
The maintenance training shall include lectures and hands on experience on
similar type of equipment / system at manufacturer works and recently
commissioned operating plant and / or training simulator. The Owner shall
require training of two hardware and two software engineers and the duration of
each course shall be minimum two weeks.
The details of hardware and software training shall be finalised during detailed
engineering and shall be subject to Employer's approval.
8.00.00 PLC EQUIPMENT AND SYSTEM REQUIREMENTS
8.01.00 Each PLC system shall consist of redundant processors, PCs with dual
processors (latest configuration with latest application software) & keyboard, I/O
modules, UPS / power supply with battery backup, printer etc. Each PC based
operating and programming workstation shall be fully equipped for operation and
control of the various systems. The configuration of PLC shall be as per enclosed
drawing. Details of various components shall be as given below :
a)

Processor Two (2) numbers. one as hot standby
b)

Memory Non volatile EPROM, Lithium or Ni-Cd battery for
360 hours backup, 20% spare capacity for future
use.
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-13
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c)

Selection Normal/Test/Program/Off facility shall be provided.
In test mode all outputs shall be blocked.
d)

Monitor & Keyboard Twenty inches (20 inches) TFT flat monitor with
resolution of 1280 x 1024 pixels non interfaced,
refresh rate min. 75Hz, with flat membrane type
keyboard/ mouse. Provision for erasing and
duplicating the user program and long storage
facility, forcing facility for changing the status of
inputs and outputs, timers and flags to facilitate
fault finding and other testing requirements shall
be provided. The numbers of OWS shall be as per
PLC configuration diagram.
e)

Processors & I/O
racks
Modular design. Possible to change any module
without disconnection of any wire. Keying in of
individual wire connectors shall be provided to
ensure that only the correct card is plugged on the
I/O module. Wiring between I/O cards & terminal
blocks shall be through prefab cables. Twenty
(20%) percent spare capacity in input output and
CPU memory modules shall be provided in each
rack over and above system requirement. One
additional Ethernet port shall be made available in
each PLC system so that wireless communication
modem can be connected by the Employer in
future. All Output cards shall be sourcing type and
Input cards shall be sinking type.
f)

Isolation between
Input, Output and
controller
1.5 KV with opto couplers.
g)

Indication Individual signal status of each Input / Output,
power supply status.
h)

Fail safe mode

On power supply failure / both PLCs failure /
communication failure etc. the output shall be
automatically switched over to fail safe mode. In
CPU, memory should exist where the sequence
was aborted. Further, in case of such failures,
operating drives / equipment shall be tripped or
kept running as per a pre-determined
programmable requirement finalised during detail
engineering.

i)

Fusing philosophy Individual fuses with blown fuse indicator for each
output. Individual fuses for each input/ group of
inputs, keeping in view of system availability.

j) Switching capacity Output modules shall be rated to switch on/off
coupling relays of 2.5 VA at 24V DC and solenoid
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SECTION VI, PART-B
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valves at 110 V AC. Coupling relays are provided
in HT/LT Switchgears.
k)

CRT/CPU and Input
output
communication links
Hundred percent redundant Communication links
through routed in separate GI conduits.
l)

Printer Color laser printer shall be suitable for A4 size
paper, 4 pages per minute, 600 dpi (black) and
heavy duty(>_ 30000 pages per month)
Number of printers shall be as shown in the tender
drawing PLC Configuration.

m)

Power supply i)

Two (2) nos 415V AC feeders shall be provided for
each control panel / desk and remotely located I/O
panels.

ii)

Power supply to control system of each machine
i.e., PLCs, I/Os, printer, OWS, and control desk
shall be fed through 2x100% UPS with battery
back-up rated for 30 minutes at full load. The UPS
shall be smart type line interactive complete with
software & hardware for remote management
along with features of surge suppression & AVR
facility. The UPS and batteries shall be rated for
20% spare capacity. Redundant DC power packs
shall be provided for DC loads.

iii)

ALL the batteries shall be sealed maintenance free
lead acid / Ni-Cd type.
n)

Command
hierarchy
Manual command shall prevail over auto
command. Protection command shall have priority
over all other commands.
o)

Databus Hundred percent redundant. Necessary interface
hardware and software in the PLC shall be
provided by Contractor for dual fibre connectivity
and interconnection with employers DDCMIS for
two way transfer of signals through OPC compliant
Ethernet link to be provided by Employer following
TCP/IP standards.
p)

Time
Synchronisation
system.
To be synchronised with DDCMIS
q)

Date
Insensitivity
No disturbance due to change of date/year.
r)

System reaction
time
Less than 100 msec. from input signal to output
signal including logic processing.

CLAUSE NO.

SECTION VI, PART-B
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s)

Display
response
Max 1 sec for control related displays. 2 to 3 sec
for other displays.
t) Feedback/field
interrogation
By 24V DC. Status feedback from MCC/field shall
be in the form of one changeover contact.
Discrepancy shall be alarmed. All analog signals
shall be routed through analog cards.
u)

Programming
format
Flow chart/Block logic ladder diagram. Tag based
addressing format shall be used for programming.
The same shall be submitted for owner's review
before programming of the system.
v)

Long time
storage &
retrieval
168 hours latest data on hard disc. Data to be
stored:
i)

Alarm list.
ii)

Five analog points at scan rate.
iii)

Fifteen analog points at one secs rate.
iv) Balance analog points at 5 minutes rate.
v) Binary points on status change.
vi) Log reports.

w)

Software All application software with locks and passwords
for PLC functioning like input/output scanning,
acquisitions, condition processing, control and
communication, operator interface of monitors,
display trends, curves, bar charts, historical
storage/ retrieval and alarm functions. Complete
set of documents for modifications / editing /
additions/ deletions of features in software.
Comprehensive list of all application/system
software.
x) Accessories Industrial grade furniture shall be provided along
with Control desk/OWS/printer.
y)

Software
license
The contractor shall provide software license for all
software being used in PLC based control system
including HMI. The software licenses shall be
provided for the project and shall not be
hardware/machine specific. All licenses shall be
valid for the continuous service life of the plant.
z) Software
upgrades
As a customer support the contractor shall
periodically inform the designated officer of the
employer about the software upgrades / new
CLAUSE NO.

SECTION VI, PART-B
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SUB-SECTION-IIIB-13
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releases that would be taking place after the
system is commissioned so that if required, same
can be procured and implemented at site.
8.02.00 Annunciation System
i) Facia Translucent glass/plastic window with engraving.

ii) Operation Through PLC.

a)
On occurrence
of trouble
Audible horn and flashing of facia lamp.

b) Acknowledge
button pressed
Audible horn and flashing of facia lamp shall stop.
Facia lamp will become steady.

c) Reset button
pressed
If fault is removed then facia lamp will go off.

d) Test button
pressed
All lamps will glow.

iii) Monitoring Power supply to annunciator shall be monitored.

9.00.00 DESK/PANEL CONSTRUCTION
a) Type Fabricated from cold rolled sheet steel
Frame thickness 2.0 mm
Enclosure thickness 1.6 mm
Gland plate thickness 3.0 mm

b) Switches AC22 category
c) Fuses HRC cartridge with visual operation indicator.

d) Name Plates &
Labels
Each panel shall be identified by a name plate. Panel
internal equipment shall be identified by paint marking.
Nameplates shall be non rusting metal or 3-ply
lamicoid, with engraved lettering and shall be subjected
to Owners approval.

e) Grounding 25 x 3 mm copper ground bus to be provided for each
panel

f) Space heater 240V AC, single phase, thermostatically controlled
space heaters to be provided.

g) Terminal block 650V grade. clip-on type.

h) Type Elmex - CATD type for CTs. Elmex - CSLT for other
application.
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i) Spare 20 percent.

j) Wiring 650V grade. PVC insulated stranded copper wire.

k) Panel Lighting Each free standing panel shall be provided with a door
switch operated fluorescent lamp and a 240V AC plug
point.

l) Painting Treatment as per IS: 6005. Two coats of lead oxide
primer followed by powder painting with final paint
shade of RAL 9002.

m) Degree of
enclosure
protection
For panels located in
i) Air conditioned areas : IP-32
ii)Other indoor areas : IP-52
iii)Outdoor areas : IP-55
iv)Dusty areas like : IP-65
Conveyor galleries, Transfer points,
Bunker area, Track hopper area,
Crusher house etc.

10.00.00 TYPE TESTS
10.01.00 All equipment to be supplied shall be of type tested design. The Contractor shall
submit for Owners approval the reports of all the type tests as listed in this
These reports should be for the tests conducted on the equipment similar to
those proposed to be supplied under this contract and the test(s) should have
been either conducted at an independent laboratory or should have been
witnessed by a client.
10.01.01 However if the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the type
test report(s) are not found to be meeting the specification requirements, the
Contractor shall conduct all such tests under this contract, at no additional cost to
10.01.02 All acceptance and routine tests as specified below and in relevant standards
equipment price.
CLAUSE NO.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
SUB-SECTION-IIIB-13
CONTROL PANELS

Page
9 of 9

10.02.00 Programmable logic controller
10.02.01 Following test reports shall be submitted for the equipment:
a). Dry heat withstand test
b). Variation of temperature immunity test
c). Variation immunity test
d). Temperature cycle test
e). Noise immunity test
f). Dielectric test.
10.02.02 Following tests shall be conducted under this contract as routine tests:
a). Tests on internal and external wiring.
b). Incoming power supply voltage and frequency variation test.
c). Test for verification of functional characteristics of I/Os.
d). Task transition test (for each task, the contractor will list out the user
accessible conditions which shall be used in the simulation of the task).
e). Functional testing of software and hardware in accordance with the
approved block logic diagram with simulation of the system with switches,
relays and solenoid valves etc. or equivalent loads.

SECTION-VI
PART-B

PART-B

CI VI L WORKS
CLAUSE NO. CONTENTS

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CONTENTS

Page
1 of 2

CLAUSE NO. DESCRIPTION
1.00.00 GENERAL
2.00.00 LAYOUT & LEVELS
3.00.00 DRAWINGS/DOCUMENTS
4.00.00 WORK DESCRIPTION
4.01.00 - Overhead / Ground Conveyor Galleries and
Trestles

4.04.00 Stacker Reclaimer Foundation
4.05.00 Control Buildings, MCC Buildings
4.06.00 Pump Houses
4.07.00 Toilets
4.08.00 Staircases
4.09.00 Trenches
5.00.00 Drainage & Water Supply Works
5.01.00 Drainage System
5.02.00 Internal and external water supply, drainage
6.00.00 COLOUR COATED AND OTHER SHEETING WORK
7.00.00 ROOF DETAILS
8.00.00 FLOOR AND GRADE DETAILS
9.00.00 BRICKWORK & ALLIED MASONRY WORKS
10.00.00 EARTHING MAT
11.00.00 FENCING
12.00.00 LOADING
13.00.00 DESIGN CRITERIA
14.00.00 CONCRETE
15.00.00 EXCAVATION DETAILS
15.01.00 Excavation in soil
15.02.00 Excavation in rock
15.03.00 Dewatering of deep foundations
15.04.00 Backfilling, disposal & stacking of materials
CLAUSE NO. CONTENTS

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CONTENTS

Page
2 of 2

16.00.00 Galvanising
17.00.00 Architectural Features
17.01.00 Glazing
17.02.00 False ceiling
17.03.00 Acid/Alkali Resistant Lining
17.04.00 Finishing Schedule
17.04.01 Flooring
17.04.02 Interior wall/ ceiling finish
17.04.03 Exterior finish
17.05.00 Door, windows & rolling shutters
17.05.01 Doors & Windows
17.05.02 Rolling Shutters
18.00.00 Painting
19.00.00 Miscellaneous
20.00.00 Vibration Isolation System
21.00.00 Packaging & Transportation
22.00.00 Plant Life
23.00.00 PTFE Bearing
24.00.00 Tests for Materials/Workmanship
25.00.00 Materials
26.00.00 Bituminous Roads
Annexure A
Criteria for Earthquake Resistant Design of structures
& Equipment

Annexure B Criteria for Wind Resistant Design of structures &
Equipment

SECTION-VI
PART-B

PART - B

SUB-SECTI ON-I I I D-01

CIVIL WORKS


NTPC-TAMIL NADU ENERGY CO. LTD.
POWER PROJECT (3x500 MW)
INPLANT COAL HANDLING SYSTEM
SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section - IIID-01
CHP CIVIL WORKS
Page 1 of 51

1.00.00 GENERAL
1.01.00 This section of the bidding document deals mainly with the technical specification
needed for the design and preparation of detailed drawings, getting the design and
drawings approved by the Engineering, fabrication, erection and construction of the
necessary civil, structural and architectural works associated with the coal handling
plant to be installed at NTPC -TAMIL NADU ENERGY COMPANY LIMITED POWER
PROJECT. The work shall have to be carried out both below and above ground level
and shall be involving, basements, equipment foundations, slabs, beams, columns,
footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, finishes,
complete architectural aspects, drainage, sanitation, water supply (from terminal
points to various buildings, conveyor galleries), and all other civil and structural works
associated with the Coal Handling Plant.
1.02.00 The specifications are intended for the general description of the work, quality and
workmanship. The specifications are not, however, intended to cover minutest details
and the work shall be executed according to the relevant latest Indian Standard
Codes / I. R. S. / I. R. C. specifications. In absence of the above, the work shall be
executed according to the best prevailing local Public Works Department practices or
to the recommendations of relevant American and British Standards or to the
instructions of the Engineer. List of I. S. Codes to be followed is mentioned in the
Technical Specifications. The Contractor is expected to get clarified on any doubts
about the specifications, etc. before bidding, in writing with the Employer in respect of
interpretation of any portions of this document.
1.03.00 The civil and structural design for the works under the scope of this contract shall be
carried out by an agency who should have designed Civil & Structural works
associated with at least one bulk material handling plant within the preceding seven
(7) years, reckoned as on date of bid opening.
The bidder may engage a consulting agency which meets the above requirements for
design, either in same or separate contracts.
The bidder is required to furnish in the bid documents, details regarding the design
experience of himself or the consulting agency engaged by him, meeting the above
requirements. The consulting agency proposed by the bidder for design shall be
subject to Owners approval.
2.00.00 LAYOUT AND LEVELS
2.01.00 The layout and levels of all structures, etc. shall be made by the Contractor at his
own cost from the general grid of the plot and bench mark given by the Engineer. He
shall provide all instrument, materials and men to the Engineer for checking the
layout and levels. However, the Contractor shall be fully responsible for correctness
of layout and levels.
3.00.00 DRAWINGS / DOCUMENTS
3.01.00 The drawings included in the Bidding Document provide a general idea about the
work to be performed under the scope of this contract. These are preliminary
drawings for bidding purposes only and are by no means the final drawings or show

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 2 of 51

the full range of the work under the scope. Work has to be executed according to
drawings prepared by the contractor and approved by the Engineering.
3.02.00 Conceptual arrangement of civil works supported by calculations shall be submitted
along with tender bids. Later on, detailed construction drawings and design
calculations for all civil works for static as well as dynamic analysis (wherever
essential) shall be submitted for approval prior to undertaking construction work.
3.03.00 Design calculations shall be done in STRAPP / M.S. Office (latest version) and
Drawings shall be prepared in Auto Cad (latest version). The analysis shall be done
by using STADD PRO / ANSYS / STRAPP (latest version). However design may be
carried out by manually, using computer work sheets or by using suitable software
programmes, as mutually agreed by Employer. Final calculations and drawings shall
be submitted in Compact Disc (CD) (2 Sets)
3.04.00 Civil Task drawings indicating various equipment loading and supporting
arrangement and floor loads shall be submitted along with design calculations. Soft
copies of all STAAD input files shall be submitted along with the design calculations
for all revisions.
3.05.00 Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works
shall be submitted structure wise and area wise for N.T.P.C. record. However each
drawing shall indicate approximate quantity of structure (Sectionwise) Concrete
(Grade wise) and reinforcement (Diameterwise.)
3.06.00 Structural steel fabrication drawings to be prepared by the contractor will not be
approved by the Employer. However, the Contractor for Employers reference shall
submit all fabrication drawings. Copy of detailed bar bending schedule as prepared
by contractor shall also be submitted to the Engineering and also to Engineer in
charge for the reference.
3.07.00 Approval of construction drawings prepared by the contractor shall not relieve the
Contractor of his responsibility regarding the adequacy of design and correctness of
the drawing.
4.00.00 WORK DESCRIPTION
It includes the Civil, Structural and Architectural works related mainly to the following
areas (but not limited to):
4.01.00 Overhead / Ground Conveyor Galleries and Trestles
Overhead conveyors shall be located in a suitably enclosed gallery of structural steel.
The overhead gallery shall consist of two vertical latticed girders having rigid jointed
portal frame at both ends. Cross beams at floor level supporting conveyor stringer
beams shall be made of single rolled steel beam or single channel section (ISMB or
ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of
the gallery (latticed girders shall be braced together in plan at the top and bottom).
Common end portal frame shall not be used for adjacent conveyor spans. Roof truss
shall be provided at upper node points of latticed girders to form an enclosure. The

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 3 of 51

maximum span of overhead gallery shall be limited to 25 meters unless higher span
is required due to site conditions, which shall be subject to approval of the Engineer.
The gallery should as far as possible be erected as a box section keeping all the
vertical and horizontal bracing tied in proper position. The gallery should be checked
for all erection stresses that are likely to develop during handling and erection and if
required, temporary strengthening of gallery members during erection shall be made.
Seal plates under the conveyor galleries shall be provided in such a way that
complete gallery bottom shall form a leak proof floor.
The ground conveyors shall be located in suitably enclosed gallery of structural steel
consisting of rigid portal frames spaced at regular intervals and suitably braced.
Plinth protection along with drains shall be routed along the ground conveyors.
For double stream conveyor gallery, two side and one central walkway of width 800
mm and 1100 mm respectively shall be provided. The width of two side walkways for
single stream conveyor gallery shall be 800 mm and 1100 mm respectively. Both
sides of central and side walkways shall be provided with pipe handrails all along the
conveyor gallery. Hand railing should not be supported on conveyor supporting
stringers. The walkways shall be chequered plate construction with anti - skid
arrangement. The anti - skid arrangement will consist of welding of 10 mm square
steel bars at a maximum spacing of 500 mm along the length of the gallery. Where
the slope of walkway is more than 10
o
, chequered plate steps with nosing and toe
guard shall be provided. The floor of conveyor gallery all along the gallery length,
shall be provided with minimum 12 gauge thick seal plates and other drainage
arrangements as specified elsewhere
Conveyor gallery shall have permanently colour coated steel sheet covers on roof
and both sides. However in roof, a panel of minimum 1.5 m x 1.5 m area at about 6.0
m center shall be provided with translucent sheets of polycarbonate material for
natural lighting. A continuous slit opening of 500 mm shall be provided on both sides
just below the roof sheeting. Adequate provision of windows shall be kept on both
sides of conveyor gallery as appended in Mechanical Section (Belt conveyor
system). Windows shall be provided with wire mesh as specified elsewhere in this
specification.
Cross - over with chequered plate platform and ladder for crossing over the
conveyors shall be provided at approximately every 100 M intervals of conveyor.
Crossover shall preferably be located over four-legged rigid trestle location.
For railway tracks passing below overhead conveyor gallery and along conveyors,
the railway clearances both underground as well as over ground shall have to be
adhered to for design, execution and erection of foundations, trestles, galleries etc.,
so that movement of locomotives and wagons is not hampered in any way during
execution and afterwards. However at the location where the overhead conveyor
gallery crosses road / rail line, minimum clearance of 8.0m above the road crest / rail
top shall be provided.
For calculation of coal load on moving conveyor, a multiplication factor 1.6 shall be
used to take care of inertia force, casual over burden and impact factor etc.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 4 of 51

Thus coal load per unit length of each moving conveyor shall be
Rated Capacity of Conveyor system 1100
------------------------------------------------ ---------

1.6

X
Conveyor Belt Speed

X
800
It should be noted that for structural design, unit weight of coal shall be assumed as
1100 Kgs. / Cu. M. instead of 800 Kgs. / Cu. M. considered for system sizing
purpose.
Conveyor Gallery structure shall be designed considering both conveyors operating
simultaneously.
Conveyor gallery and supporting trestles located between transfer houses / buildings
shall be arranged in any one of the following ways.
a) All gallery supporting trestles shall be four legged type only. One end of each
gallery span shall be hinged to the supporting trestle and the other end shall
be slide type. Slide type support shall be with P. T. F. E. bearings to allow
both rotation & longitudinal movements.
b) In between transfer houses / buildings, four legged trestles shall be placed at
a maximum interval of 90 metres. The arrangement shall be such so as to
ensure that force in the longitudinal direction (i. e. along the conveyor length)
of conveyor gallery of length not more than 90 m is transferred to any four
legged trestle. In the space between each successive four legged trestles,
two legged trestles shall be provided at regular intervals. The end supports
resting on the four-legged trestle can have either ends hinged or one hinge
and the other on slide type depending on the arrangements. Slide type
support shall be with P. T. F. E. bearings to allow both rotation & longitudinal
movements.
End of conveyor gallery which will be supported over transfer house, shall be so
detailed that only vertical reaction is transferred from conveyor gallery and no
horizontal force in longitudinal direction is transferred from conveyor gallery to
transfer house structure and vice - versa.
For trestles and trestle foundations for conveyor galleries located adjacent to existing
structures, over ground and under ground facilities, location and details of these
trestles and foundations shall have to be decided such that there is no interference
both underground as well as over ground with existing structures and facilities.
Trestle columns / ground conveyor portal column base shall be kept 300 mm higher
than the existing ground level.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 5 of 51

The over ground portion of the transfer house shall be framed structure of structural
steel work with permanently colour coated profiled steel sheet side cladding and R.
C. C. floors and roof over structural beams. However the lower portion of side
cladding for a minimum height of 0.9 m above the finished floor level shall be one
brick thick wall plastered on both side. In some areas like MCC floors etc., one brick
thick wall cladding shall be provided. Brick wall cladding shall be supported on
encased wall beams and suitably anchored to adjoining columns and beams.
Roof shall be provided with water proofing treatment as specified elsewhere.
Adequate steel doors and windows for proper natural lighting and ventilation shall be
provided. In addition to steel windows, panels of suitable size to suit the architectural
treatment and made of translucent sheets of polycarbonate material shall also be
provided on the side cladding for natural lighting.
The crusher house shall be framed structure of structural steel work with permanently
colour coated profiled steel sheet side cladding. However, panels of suitable size to
suit the architectural treatment and made of translucent sheets of polycarbonate
material shall also be provided on the side cladding for natural lighting. The lower
portion of side cladding for a height of minimum 0.9m above the finished floor level
shall be of one brick thick wall plastered on both faces. Floors and roof shall be of R.
C. C. supported on steel beams. Within this building cubicles are to be provided for
resting room of operators and these shall be constructed with one brick thick
brickwork having both sides plastered and roof slab. Roof shall be provided with roof
water proofing treatment as specified elsewhere. Adequate steel doors and windows
for natural lighting and ventilation shall be provided.
Ring Granulator Type Crushers shall be supported on R. C. C. deck, which in turn
will rest on suitable vibration isolation system consisting of springs and dampers.
This R. C. C. deck shall be isolated from the floor. However, the vibration isolation
system consisting of springs and dampers may rest on main building framework.
Detailed specification of vibration isolation system including the unbalanced force
(due to ring granulator), frequency and amplitude criteria and other design
requirements are appended elsewhere in this specification.
4.04.00 Stacker Reclaimer Foundation
Stacker - Reclaimer foundation shall be in R. C. C. and shall be designed as a
continuous wall or R. C. C. framed structures (in longitudinal & transverse direction).
Lateral tie beams between two rail supporting elements shall be provided at a regular
interval of approx. 3.0 m center. The foundation shall be designed for the most critical
combination of loads as furnished by the equipment supplier. R.C.C retaining wall on
both sides of the S/R foundation shall be provided as shown in the tender drawing.
The portion between the two rails shall be paved in concrete as per specification for
grade slab of ground level specified elsewhere. However no metallic hardener finish
over R. C. C. slabs is to be provided. Drains shall be provided along the rails for

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 6 of 51

drainage of rain / dust suppression / floor washing water. Drains shall be routed on
both sides of the foundation along the rail as shown in Tender Drawing. Drains shall
be connected to the network drainage system for finally discharge into coal settling
tank. RCC drains shall be provided in Coal Stockyard area with precast RCC covers.
4.05.00 Control building, M. C. C. Buildings
These shall be R. C. C. framed structures with columns, beams, slabs and
foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof
shall be provided with roof water proofing treatment, as specified elsewhere in the
Technical specification.
In case of control building suitable permanent interconnection shall be provided at
appropriate level with the existing respective buildings.
All air - conditioned areas, shall be provided with the suspended permanently colour
coated aluminium false ceiling system (details specified elsewhere).
Adequate aluminium doors and windows shall be provided for natural lighting,
ventilation and view.
4.06.00 Pump Houses
These shall be of R.C.C. or steel framed structure with columns, beams, slab and
foundations etc. cladding shall be of brick work with plastering on both sides. Roof
shall be provided with roof water proofing treatment as specified elsewhere.
Underground sump and water tanks shall be of R.C.C. Adequate number of doors,
Windows and Rolling Shutters shall be provided.
Galvanized steel ladder / rung ladder shall be provided for access to the roof level of
the pump house and water tanks.
4.07.00 Toilets
Toilet with potable water line facilities shall be provided in each of the following
locations:
(a.) Crusher House (Ground & Drive Floor)
(b.) In all M. C. C. Rooms
(c.) Control Building
Each unit shall have brick enclosure, and the following fittings.
i ) Squatting type, white, vitreous china Orissa 1 No.
pattern, W.C. pan with high level flushing
cistern ( C.I. ) and all requisite fittings


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 7 of 51

ii ) Bowl type Urinal with automatic flushing 2 Nos.
cistern ( C.I. ) and all requisite fittings

iii ) Wash Basin 630 mm x 450 mm with 2 Nos.
two taps and all requisite items

iv ) Mirror 600 mm x 450 mm x 5.5 mm thick 2 Nos.
with bevelled edges ( Superior sheet glass )

v ) C.P. Brass Towel Rod 600 x 20 mm 1 No.

vi ) Liquid Soap Container 2 Nos.

vii ) Washing Tap ( CP Brass ) 2 Nos.

viii ) Overhead Polyethylene water tank 1 No.
(min. 500 litres capacity)

ix ) Suitable provision for installation of water coolers.
4.08.00 Staircases
All roofs & floors of transfer houses shall be accessible through staircase. However,
for the pump houses, access to the roof will be provided by cage ladder
All stairs other than those of M. C. C. rooms and control rooms shall be of steel
(minimum 1000 mm wide)and maximum rise should not be more than 180 mm and
minimum tread width 250 mm. Stringers shall be of rolled steel channel( minimum
ISMC 250 )and tread shall be of steel gratings. Stairs shall be provided with 32 mm
dia nominal bore medium duty M. S. pipe hand rail.
Handrails (for staircases, around openings, in walkways etc.) shall be of standard
weight steel pipe of flush welded constructions, ground smooth using 32 mm nominal
bore medium class pipe provided with double rail, top rail about 1.0 metre above
platform level and pipe posts spaced not more than 1.5 metres apart. Angle handrail
post may be provided when specifically called for in drawings approved by
Engineering. Handrails around openings should have toe plates.
Smooth uniform curves and bends shall be provided at stair returns and also where
so ever required. Posts connected to curb plates shall have a neat closure at the
bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All
necessary fittings including inner dowels at splices, brackets, belts, bends, flanges
and chains, where required 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.
Treads and landing shall be suitable for the prescribed loading. The maximum width
of openings in gratings shall not exceed 40 mm. The minimum thickness of main bars
shall be 6 mm. The usual span of grating will not generally exceed 1.5 meters. Stair
case gratings shall be galvanized to grade 610g/m
2
.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 8 of 51

Out side stairs to transfer points shall be open type. However RCC slab shall be
provided at the top.
Stairs of control room and M. C. C. room shall be of R. C. C. construction, and
minimum 1200 mm wide, maximum rise should not be more than 180 mm and
minimum tread with 250 mm.
Numbers and arrangement (including enclosures etc.) of stair cases shall be such as
to meet the fire safety requirement as per guide lines of statutory regulatory bodies.
4.09.00 Trenches
All trenches for cables or any other underground facility as detailed out elsewhere
shall be of R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers /
chequered plate cover. Cable trenches as well as pre - cast covers shall be provided
with edge protection angles and lifting hooks. All embedments / block outs as
required and specified elsewhere in these specifications shall be provided. Proper
drainage arrangement shall be provided. Trench pre - cast cover weight shall not be
more than 65 Kgs. Trench covers near entry or at road crossings shall be designed
for 10 T wheel load at centre. Pre - cast covers shall be designed for central point
load of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection of
cables, up to top level and covered with pre - cast R. C. C. covers. For cable
trenches outside buildings, top level shall be 200 mm above G. L.
Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protection
all around cut outs / openings in floor slabs, edges of drains supporting
grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast covers,
supported edges of pre - cast cover, treads of RCC stairs.
5.00.00 Drainage & Water Supply Works
5.01.00 Drainage System:-
The drainage arrangements shall be so planned so as to ensure quick disposal of
drainage water without stagnation and / or overflow. It is envisaged to clean the
conveyor galleries, transfer points, crusher building, penthouse etc. with water
periodically.
Minimum 4 nos. down comers shall be provided in each transfer house / crusher
house. In case of conveyor galleries, the down comer shall be provided at every
trestle location.
Drainage of the complete coal stock pile, area around stacker and reclaimer rails etc.
shall be discharged into the coal slurry settling pond.
For Conveyors 8 A/B, 9 A/B(between TP-6 & TP-7), & TP-6 each down comer shall
lead the water / coal slurry to pit (of 2 Cu.M capacity) to allow settling of coal. The
water from the pit shall overflow into contractors R.C.C drain, which will lead the
discharge finally into owners drain routed alongside the nearby road.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 9 of 51

For Conveyors 1 A/B, 3 A/B, & 4 A/B, each down comer shall lead the water / coal
slurry to pit (of 2 Cu.M capacity) to allow settling of coal. The water from the pit shall
overflow into contractors R.C.C drain, which will lead the discharge finally into
existing drain/water body.

For Conveyors 6 A/B, 7 A/B, 15 A/B & 17 A/B, each down comer shall lead the
water/coal slurry into a R.C.C. drain, which will lead the discharge finally to the coal
settling pond.

For Crusher House, TP-5, TP-13, TP-14, TP-15 & TP-16, each down comer shall
lead the water / coal slurry into the peripheral drains (Brick drains with steel gratings
provided around the building) which will lead the water / coal slurry to contractors
RCC drain and finally to the coal settling pond.

For TP-1, TP-2, TP-3 & TP-4, each down comer shall lead the water / coal slurry into
the peripheral drains (Brick drains with steel gratings provided around the building)
which will lead the water/coal slurry to contractors RCC drain and finally to existing
drain/water body.

In case of Control rooms and M. C. C. buildings Pump houses, etc, water / coal slurry
coming from down comers shall discharge into peripheral drains (Brick drains with
steel gratings provided around the building) which will lead the water / coal slurry into
contractors R.C.C drain, which will lead the discharge finally into owners drain
routed alongside the nearby road.

Suitable kick plates/Curb beams shall be provided around the floor openings, stair
case landings, in the transfer points, crusher house and other buildings.

Contractors scope shall also include construction of necessary culverts under the rail
lines / roads as per railway / I. R. C. standards and approval of Railway culverts from
concern Railway authorities.

5.02.00 Internal and external water supply, drainage etc.:-
The scope for potable water supply includes all distribution systems, tanks, pipes,
fittings etc. as required and as described here or elsewhere in these specifications.
The scope for service water supply and dust control water supply shall be as
described elsewhere in these specifications.
For water supply, medium class galvanized mild steel pipes conforming to IS: 1239
shall be used.
The scope for drainage of surface water shall include design, layout and construction
of drains for and from buildings and drains required for coal stockyard area, drainage
up to main coal slurry settling tank including connection with the tank. Drainage
system shall be designed for maximum intensity of rainfall as 100 mm/hr and 60 %
runoff coefficient. All buildings (including transfer houses and crusher house) shall be
provided with open surface brick drains of minimum size of 300 mm width and 300
mm depth all around the periphery. All drains excepting the peripheral drains around

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 10 of 51

the transfer points, crusher house, control / M. C. C. buildings, pumps house etc.,
shall be of R. C. C. construction. All open drains shall have removable steel grating
designed for loads as specified under loading clause. Minimum thickness of grating
(Galvanised to 610 gm/m
2
) shall be 12 mm. However at entry or road crossing points
minimum thickness shall be 40 mm. The opening size of grating shall not be more
than 90 mm x 35 mm. All drains as well as pre - cast covers shall be provided with
edge protection angles and lifting hooks.
However, drains in coal stockyard area shall have pre cast R. C. C. covers. RCC pre
- cast cover weight shall not be more than 65 Kgs. RCC pre-cast covers near entry or
at road crossings shall be designed for 10 T wheel load at centre. RCC pre - cast
covers shall be designed for central point load of 75 Kgs.
The scope for foul water from toilets shall include layout and laying of sewers up to
the Employers main sewer line for sewerage system together with all fittings and
fixtures and inclusive of ancillary works such as connections, manholes and
inspection chambers within the building and from the building to the Employers
sewer line.
For rain water down comer and those to be used for conveying water / coal slurry
generated from cleaning of conveyor gallery and buildings floors, Galvanised MS
pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes) with welded
joints shall be used for MCC buildings, pump houses, penthouse, control rooms.
Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330
conforming to IS: 3589 with welded joints shall be used for all TPs, Crusher house,
and Conveyor galleries.

Galvanising shall be as per IS: 4736. The minimum mass of zinc coating shall not be
less than 400 gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall
be subjected to testing as per IS: 2633, for uniformity of coating. The zinc coating
shall be free from all defects as per IS: 2629.

All rain water down comers shall be provided with roof drain heads and complete with
shoes bends, junctions, sockets, adapters, brackets and finished with anti corrosive
painting over a coat or primer.

For design of building drainage system IS: 1742 shall be followed.
For sanitary / sewerage pipes above ground, sand cast iron pipes conforming to IS :
1729 with leak proof lead joints.
For underground drain pipes, minimum class NP - 2 pipes conforming to IS: 458. At
road crossings, concrete pipes of class NP 3 conforming to IS: 458 and at rail
crossing R.C.C. box culvert to be provided.
For sewerage below ground stoneware pipes conforming to IS: 651 with concrete
bedding and haunch.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 11 of 51

6.00.00 COLOUR COATED AND OTHER SHEETING WORK
Permanently colour coated sheet of approved shade and colour using galvanised
mild steel sheet of minimum 0.6mm BMT(bare metal thickness i.e. metal thickness
excluding thickness for coating and galvanizing) of grade SS255 as per ASTM
A653M/grade G250 as per AS 1397, coated with zinc of class designation Z275 or
high tensile steel of minimum 0.5mm BMT(bare metal thickness i.e. metal thickness
excluding thickness for zinc aluminium coating and colour coating ) of grade SS340-
class-4 as per ASTM A792M/grade G350 as per AS 1397, coated with aluminium
zinc alloy of class designation AZ150.
Steel shall be colour coated with permanent colour coating of PVF
2
(Poly Vinyl Di-
fluro) of minimum 20 microns Dry Film Thickness (DFT) over 5 micron DFT primer on
outside (exposed) face and PVF
2
coating of minimum DFT 12 microns over 5
microns primer on inside (internal) face. Coated surface shall be provided with a
protective guard film (polyethylene) of about 40 microns to avoid any damage to the
coating during handling.
For metal deck, minimum 0.8 mm (bare metal thickness i.e. metal thickness
excluding thickness for coating and galvanizing) of grade SS255 as per ASTM
A653M/grade G250 as per AS 1397, coated with zinc of class designation Z275,
troughed profile having nominal trough depth 44 mm and pitching of 130 mm shall be
used. However alternative profile meeting the strength, defection and other functional
requirements such as sections modulers and moment of inertia shall be provided. To
minimize the number of joints, the length of the sheet shall preferably be not less
than 4.5 cut pieces shall not be used, unless specifically approved by the Engineer.
However, the actual length shall be such so as to suit the purling / runner spacing.
No negative tolerance shall be allowed in bare metal thickness.
For wall cladding insulated / uninsulated and conveyor gallery sides and roof,
permanently colour coated sheet of troughed profile shall be used. The nominal
depth of trough shall be 30 mm.
The polycarbonate sheet to be used for cladding and glazing purpose in conveyor
galleries shall have toughed profile to match with the metal cladding profile. Minimum
2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of GE plastic
or equivalent approved make shall be used. The polycarbonate sheet shall be
installed along with the metal cladding so as to have a watertight lapping
arrangement. Suitable detailing shall be made to cater for the thermal expansion. IS :
14434 to be referred for other details.
Polycarbonate sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous
use under temperature 100
o
C), impact resistant and ultraviolet resistant sheet shall
be provided (as glazing) in transfer houses, pump houses, etc.
7.00.00 Roof Details
Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD
reinforcement bars placed at 200 mm center both ways at top and bottom.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 12 of 51

For efficient disposal of rain water, the run off gradient for the roof shall not be less
than 1: 100. This gradient can be provided either in structure or subsequently by
screed concrete M-15 (using 12.5 mm coarse aggregate) and / or cement mortar (1:
4). However, minimum 25 mm thick cement mortar (1: 4) shall be provided on top to
achieve smooth surface.
900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided
over roofs of all buildings. Parapet wall shall have suitable coping. External face of
parapet wall of the buildings provided with metal cladding shall also be finished with
metal cladding of design and colour as per approved architectural drawings.
Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet.
Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness
of 30 mm of M-15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished
with 12 mm 1 : 3 cement : sand plaster.
Roofs of all transfer houses, crusher houses, control rooms, M. C. C. rooms,
penthouse etc., shall have roof water proofing treatment. Roof water proofing
treatment shall be as follows:
(i) Application of polymerized mastic over the RCC roof to achieve smooth surface
as primer coat.
(ii) Application of high solid content liquid applied urethane based elastomeric
water proofing membrane over the primer coat, to give uniform joint less dry
film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898).
(iii) For efficient disposal of rain water, the run off gradient for the roof shall not be
less than 1: 100. This gradient shall be provided by screed concrete M-15
(using 12.5 mm coarse aggregate) and / or cement mortar (1:4) over the
elastomeric water proofing membrane with 25 mm thick cement mortar (1:4)
topping.
(iv) Wearing course at top, shall consist of 25 mm thick P. C. C. (M-15) cast in
panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter
galvanized chicken wire mesh and sealing of joints using sealing compound /
elastomeric water proofing membrane. Pathways for handling of materials and
movement of personnel shall be provided with 22 mm thick chequered cement
concrete tiles as per IS : 13801 for a width of 1000 mm in place of P. C. C.
8.00.00 Floors and Grade level details
The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia
HYSD reinforcement bars placed at 200 mm center both ways at top and bottom

Floors of transfer points shall have cross slope of not flatter than 1: 80, towards the
floor washing drainage outlets, for efficient drainage. For ground conveyor & crusher
house slope shall be 1:100.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 13 of 51

Chequered plates (used for floors, walkways etc.) shall be minimum 6 mm thick o/p
or as indicated on drawings. The chequered plate pattern shall be approved by
Employer / Engineer. Mild steel flats/angles of suitable size shall be welded to the
bottom portion of chequered plates at a designed spacing to stiffen chequered plates
suitably. Chequered plates shall be fixed by staggered welding of suitable size.
Floors of trenches shall have integral finish to concrete base.
Toe guard of size 100 x 6 mm shall be provided at various openings provided in
floors e.g. around stair case openings, chute openings and other similar cutouts. For
conveyor walkways, angle runner to act as toe guard shall be provided.
All along the periphery of R. C. C. floors (where no brick masonry walls are provided)
shall be provided with one brick thick 300 mm high brick wall and 700 mm high steel
hand rails all around over this brick work.
The grade slab shall consists of 230 mm thick rubble soling (63 mm downgraded
hard stone aggregate as per IRC specification, watering and compaction to minimum
of 90% Standard Proctor density, including filling the interstices of stone aggregates
with sand), over well compacted earth, overlaid by 75 mm thick P. C. C. M-7.5 and
100 mm thick R. C. C. of grade M-20 with minimum 8 mm dia bars placed at 200 mm
C / C in either direction respectively. There will be minimum 50 mm thick metallic
hardener finish over the R. C. C. slab.
All buildings (including transfer houses and crusher house) and ground conveyors
shall be provided with 750 mm wide plinth protection all around. It consists of 50 mm
thick P.C.C. M-20 grade with 12 mm maximum size aggregate over 200 mm thick
stone soling using 40 mm nominal size rammed, consolidated and grouted with fine
sand.
An area of 5 m width all round the transfer houses and crusher house shall be paved.
This paving will be in addition to plinth protection. The paving construction shall be as
per specifications for the grade slab at ground level. However, 50 mm thick metallic
hardener finish is not required to be provided in paved area.
Plinth level of all buildings shall be kept at least 500 mm above the finished grade /
formation level.
9.00.00 Brickwork and allied masonry works
All brick walls shall be non - load bearing in-filled panel walls.
All brickwork shall be designed as per Indian Standards and shall be plastered on
both faces. All external walls shall be minimum one brick thick in 1: 6 cement: sand
mortar. Brick walls shall be provided with 12 mm and 18 mm thick 1: 6 cement: sand
plaster on smooth and rough face of the brick work respectively.
Bricks to be used in brickwork shall be of minimum Class designation 50.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 14 of 51

Brickwork cladding for various structures shall be so provided that there is a clear
gap of 40 mm between inside face of external brick wall and outside face of column
flange. Structural steel wall beams supporting brickwork shall be suitably encased
with plaster or 1: 2: 4 concrete as the case may be. In case of box type steel beam,
encasement shall be done with cement sand plaster in specified thickness and
proportions over G. I. wire netting of 0.9 mm thickness.
Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be
provided with drip course in 1 : 4 cement sand mortar.
50 mm thick Damp proof course shall be provided at plinth level for all brick wall.
All R. C. C. ceilings shall be rendered smooth and finished with whitewash unless
otherwise specified. Ceiling of control rooms, M. C. C. rooms (except areas provided
with false ceiling) shall be provided with 6 mm thick plaster.
10.00.00 Earthing Mat
40 mm Dia MS Rods as earthing mat, placed at a distance of 1.0M away and at
depths between 0.60M and 1.00M shall be supplied and laid all around the periphery
of buildings, structures, and outdoor equipment, as per the approved drawings.
Risers of 40 mm Dia MS Rods and connecting to the above Earthing mat shall also
be supplied and laid in position by the Contractor, as per the approved drawings.
Risers shall be laid up to a height of 300 mm above the local Ground level, at each of
the columns of the buildings on outside of the buildings, and minimum 2 (Two)
numbers for structures and outdoor equipment. The contractor also supply and lay
necessary number of 3.0 M deep vertical 40 mm Dia MS Rods Earthing electrodes
and connecting them to the Earthing mat, as per the approved drawings and the
supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing
mat with the Employer's earthing mat separately at two locations.
11.00.00 Fencing
Fencing with toe wall and steel gates shall be provided around the transformers.
Fencing shall comprise of PVC coated GI chain link fencing of minimum 8G
(including PVC coating) of mesh size 75 mm and of height 2.4 m above the toe wall.
The diameter of the steel wire for chain link fence (excluding PVC coating) shall not
be less than 12G. Fence posts shall be of pre cast R. C. C. of minimum M20 grade.
All corner posts will have two stay posts and every tenth post will have transverse
stay post. Suitable R. C. C. foundation for the post and stays shall be provided based
on prevailing soil conditions. Gates shall be sturdy with locking provisions.
Toe walls of brick masonry shall be provided between fence posts all along the run of
the fence with suitable foundation. Toe wall shall be minimum 200 mm above the
formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend
minimum 300 mm below the formation level. Toe wall shall be plastered on both
sides and painted with two coats of cement paint of approved colour and shade. Toe
wall shall be provided with weep holes at suitable spacing.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 15 of 51

12.00.00 LOADING
For consideration of loads on structures IS : 875 - Code of practice for structural
safety of buildings shall be followed. In addition to the dead load, live load,
equipment load (including impact / vibration). Temperature loads etc. various loading
conditions arising due to operation and maintenance of equipment shall be
considered in the design. The structure and equipment shall also be designed for
seismic loads as per the Criteria for Earthquake Resistant Design of Structures and
equipment" and the Criteria for Wind Resistant Design of Structures and equipment"
specified in the Annexure A and B respectively in Civil Section, whichever is
governing. Wind and seismic forces shall not be considered to act simultaneously.
The following minimum live loads shall be adopted for the design of various
structures. If actual expected load is more than the specified load, then actual load is
to be considered.
a ) Roofs 150 Kgs. / Sq. M. for accessible roofs and 75
Kgs. / Sq. M. for non - accessible roofs.
In addition to this coal dust load (Dead load) of
150 Kgs. / sq. m. on flat roofs & 75 Kgs. / sq. m.
on inclined roofs shall also be considered.

b ) R. C. C. floors

500 Kgs. / Sq. M.
c ) Stair and balconies

500 Kgs. / Sq. M.
d ) Toilet rooms

200 Kgs. / Sq. M.
e ) Chequered plate floors

400 Kgs. / Sq. M.
f ) Walkways (including
walkways in conveyor
galleries)

300 Kgs. / Sq. M.
g ) Conveyor galleries In addition to the live loads, loads due to cable
trays, fire fighting / service water pipes shall also
be considered @ 125 Kgs. / m ( minimum ) on
each of the longitudinal girder.
Roof-truss members are to be checked for
supporting fire fighting pipes/ Service water
pipes. Tentative locations and diameter for pipes
are shown in Tender Drawing.

h ) Road Culverts and its
allied structures including
R. C. C. pipe crossing &
road crossing of
trenches.

For class 'AA' loading and checked for class A
loading as per IRC standard.
i ) Channels / trenches In addition to earth pressure and water pressure,
etc. additional earth pressure due to surcharge of
2T / Sq. M. shall also be considered for design.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 16 of 51

j ) Covers for trenches /
channels
Covers for channels & trenches, shall be
designed for a live load of 0.4T Sq. M. and
loading as mentioned under clause in trenches,
whichever is critical.

k ) Sumps and tanks and
other underground
basement type structures
In addition to earth pressure with a surcharge of
2T / Sq. M. (or surcharge due to Railway loading
whichever is critical for Railway load bearing
structures etc.) and sub - soil water pressure etc.
These are also to be designed for the following
conditions :
i ) Water / liquid inside and no earth outside
(applicable only to such structures which are
liable to be filled up with water or any liquid ).
ii ) Earth with surcharge outside and no water /
liquid inside
iii ) For underground (basement) structures
protection against buoyancy during
execution and after execution shall be
ensured without superimposed loadings with
minimum factor of safety of 1.2 against
buoyancy.

l ) Unit weight of coal shall
be taken as 1100 Kgs. /
cum. for design
purposes.

If the erection load is higher than the specified live loads on any floor or part thereof,
then the erection loads are to be considered for the design.
Permissible increase in stresses of materials and bearing pressure of soil due to wind
load or seismic load shall be as per relevant I. R. S. and I. S. code.
13.00.00 DESIGN CRITERIA
The design of all R. C. C. structures shall be carried out as per code of practice for
plain and reinforced concrete for general building construction, IS : 456 ( latest ).
The steel structures shall be designed and fabricated as per code of practice for use
of structural steel in general building construction, IS : 800 ( latest ) and other
relevant IS Standards. Minimum size of the angle section to be used as structural
members shall be 50 X 50 X 6. Minimum weld size shall be 6 mm. Connections shall
be designed for 70 % of shear capacity of the member or the actual shear force,
whichever is higher.
The building shall conform to local bye - laws, rules and regulations for industrial
buildings and also B. I. S. publications, SP 32 and 41.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 17 of 51

Slotted holes shall not be assumed to act as expansion joint for relieving of stresses
and suitable bearings shall be provided at the supports.
All gallery supporting trestles shall be so proportioned that the transverse deflection
of gallery due to wind / seismic load should not exceed trestle height / 1000 as
stipulated in IS: 11592. This deflection condition shall be strictly followed. Peak wind
speed method shall be considered for checking the transverse defection.
The crusher and transfer house structures shall be so designed that transverse
deflection at places where conveyor galleries meet, should be equal to the respective
transverse deflection of conveyor supporting trestles. Stresses for all CHP structures
shall be checked for the higher of the forces obtained from gust factor method and
peak wind speed method. The permissible vertical deflection for beams supporting
drive machinery shall be restricted to span / 500 and for other beams it shall be
within span / 325.
Horizontal bracing system shall be provided at floor levels around the openings.
Shear force in steel columns shall be transferred to the pedestals / foundations
exclusively either through foundation bolts or the shear key arrangement.
For design of liquid retaining structures, IS : 3370 ( Part - I to IV ) ( latest ) shall be
followed. Face of the structure in contact with liquid shall be designed as un -
cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458,
IS : 783 should be followed.
For design of all underground structures / foundations, ground water table shall be
assumed at the formation level ( i. e. the adjoining ground level ).
Design of masonry walls shall be made as per IS : 1905.
Civil task drawing indicating various equipment loading and supporting arrangement
and floor loads to be submitted along with the design calculation.
For metal roofing and side cladding, the spacing of purlins/runners shall be such that
the deflection of metal sheet used is limited to span/250 under adverse loading
condition.
Minimum reinforcement shall be provided at the top face of the footing, even if, no
reinforcements are required as per design.
14.00.00 CONCRETE
All R. C. C. works to the done under this specification, unless specified otherwise
shall be design mix concrete. Minimum grade of concrete for various structures shall
be as follows:
a ) M30 - For underground / sub structural R. C. C. work.
b ) M25- For R. C. C. superstructure works including ground floor slabs,
trenches & drains.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 18 of 51

Minimum 75 mm thick P.C.C M-7.5 shall be provided as mud mat below all
foundations.
For concreting of underground structures requiring water tightness, plasticizer cum
water proofing admixture shall be added to the concrete mix.
Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting
etc. unless otherwise mentioned.
15.00.00 Excavation Details
15.01.00 Excavation in soil
Excavation for foundation shall be to the bottom of lean concrete and as shown on
drawing or as directed by the Engineer. The bottom of all excavations shall be
trimmed to required levels and when excavation is carried below such levels by error,
it shall be brought back to the specified level by filling with concrete of nominal mix
1 : 3 : 6 (cement: coarse sand: 40 mm down aggregates ), as directed by the
Engineer.
The Contractor shall ascertain for himself the nature of materials to be excavated and
the difficulties, if any, likely to be encountered in executing this work. Cofferdams,
sheet piling, shoring, bracing to maintain suitable slopes, draining etc. shall be
provided and installed by the contractor, to the satisfaction of the Engineer.
Surplus excavated materials shall be disposed off by the contractor at locations up to
a lead of 5 kms from the plant boundary wall as directed by the engineer.
The Contractor shall have to constantly pump out any water collected in excavated
pits and other areas due to rain water, springs etc. and maintain dry working
conditions at all times until the excavation, placement of reinforcement, shuttering,
concreting, Backfilling is completed. The Contractor shall remove all slush/muck from
the excavated areas to keep the work area dry. The Contractor, if required, shall
employ sludge pumps, for this purpose.
For other details, excavation clauses as given in Sub-Section III-D-02 are to be
referred.
15.02.00 Excavation in rock
For the work of excavation in rock, Contractor shall engage specialised agency
having experience of excavation in rock involving wedging and blasting. The agency
shall be subject to approval of Engineer and the Contractor shall furnish details of
relevant experience in support while seeking approval for the agency.
Blasting shall be resorted to only with the written permission of the Engineer. All the
statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc.
pertaining to the acquisition, transport, storage, handling and use of explosives etc.
shall be strictly followed.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 19 of 51

The contractor shall obtain Licenses from Competent Authorities for undertaking
blasting work as well as for procuring, transporting to site and storing the explosives
as per Explosives Act. The Contractor shall be responsible for the safe transport,
use, custody and proper accounting of the explosive materials.
Surplus excavated materials shall be disposed off by the contractor at locations up to
a lead of 5 kms from the plant boundary wall as directed by the engineer.
The Contractor shall have to constantly pump out any water collected in excavated
pits and other areas due to rain water, springs etc. and maintain dry working
conditions at all times until the excavation, placement of reinforcement, shuttering,
concreting, backfilling is completed.

15.03.0 De-watering of Deep Excavations

For deep underground structures like track hopper, machinery hatches, tunnels and
underground transfer houses, requiring open excavation with extensive de - watering,
completely dry working conditions during excavation, shuttering, placement of
reinforcement, concreting, water proofing of structures, backfilling and any other
operation shall be maintained by suitable de - watering method of suitable capacity.

15.04.00 Backfilling, Disposal and Stacking of materials
Backfilled earth shall be compacted to minimum 90 % of the standard proctor density
at OMC. Sand filling shall be compacted to minimum 80 % of the relative density.
Also refer Sub-section III D-02 for more details.
However, the backfill under the rail lines and roads shall be compacted to minimum
95 % of the standard proctor density at OMC unless otherwise stated by rail
Authorities.
The contractor is required to excavate upto any depth as shown on the drawings or
as directed by the Engineer. Lifting of excavated materials shall be done either by
manual or mechanical or both means if called for by the Engineer.
The disposal / stacking areas for excavated materials shall be indicated by the
Engineer. The carriage of excavated materials shall be done by the methods
mentioned below:
The excavated materials shall be carried beyond the initial lead of 50 m but upto 500
m by manual / animal labour or by mechanical means. If directed by the Engineer this
material shall be used directly for filling purposes.
For leads exceeding 500 m the Contractor shall transport the excavated materials by
mechanical means only and as directed by the Engineer. The Contractor may be
allowed to carry materials through Kuccha roads. Providing and maintaining of the
Kuccha roads shall be the responsibility of the Contractor. The transported material
shall be neatly stacked as directed by the Engineer.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 20 of 51

Some excavated materials required for filling purposes, may have to be carried upto
a lead of 500 m and stacked as per instructions of the Engineer. Excavated materials
carried beyond 500 m shall normally be for disposal purpose only. Double handling of
materials shall be avoided as far as possible. However, depending on site condition
excavated materials carried beyond a lead of 500 m may also be required to be
brought back for filling purpose.
Materials to be used for filling purpose shall be stone, sand or other inorganic
materials and they shall be clean and free from shingle, salts, organic matter, large
roots and excessive amount of sod, lumps, concrete or any other foreign substances
which could harm or impair the strength of the substances in any manner. All clods
shall be suitably broken to small pieces. When the materials are mostly rock
boulders, these shall be broken into pieces not larger then 150 mm size. Sand used
for filling shall be clean, medium grained and free from impurities. Fines less than 75
microns shall not be more than 20%. In any case, the materials to be used for filling
purposes shall have the prior written approval of the Engineer.
In case the materials have to be brought from pits / quarries, then it shall be the
Contractors responsibility for identification of such quarry areas, obtaining approval
from their use from concerned authorities, excavation / quarrying loading and
carriage of such material, unloading and filling at specified locations. The Contractor
shall pay any fees, royalties etc. that may have to be pain for utilisation of borrow
areas.
16.00.00 GALVANISING
All burrs and irregular edges of the structural steel members to be galvanised shall
be ground smooth before galvanising.
Purity of Zinc to be used for galvanising shall be 99.5 % as per IS : 209 ( latest
edition ).
The weight of the zinc coating shall be at least 610 Gms. / m
2
unless noted
otherwise.
17.00.00 Architectural Features
All architectural features of buildings like control rooms, crusher houses, M. C. C.
rooms, transfer houses and conveyor galleries etc. shall be detailed by contractors
qualified architect. Necessary projections, fins etc. in addition to the minimum
specified elsewhere in this specification shall be provided as required. The
Contractor for Employers approval shall submit detailed architectural drawings along
with colour schemes. Nothing extra shall be payable for any changes required while
getting the drawings / schemes approved and for executing the same.
In case structural column base plates are proposed below the floor level, the same
shall be encased with adequate cover up to the finished floor level with minimum M -
20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skin
reinforcement of the encasing.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 21 of 51

17.01.00 Glazing
Window glazing for various locations shall be as below:
(i) In transfer houses, crusher house and pump houses etc:
Polycarbonate sheet (Details described elsewhere).
(ii) In Switchgear / M. C. C. buildings
(a) In air conditioned (A / C) areas:
Double glazing with two 6 mm thick clear toughened safety glass hermetically sealed
and separated by 12 mm thick gap for thermal insulation at partition of A / C and non
A / C areas.
(b) In toilets:
Ground glass of minimum thickness 4 mm.
(c) In other areas:
Toughened glass of minimum thickness 4 mm
The above mentioned glass thickness are bare minimum only and actual thickness
will depend on the panel size of the glazing to be provided.
17.02.00 False Ceiling
All air - conditioned areas, shall be provided with the suspended permanently colour
coated aluminium false ceiling system with corrosion resistance aluminium alloy
panels of minimum thickness 0.5 mm.
50 mm thick mineral wool insulation (as per IS: 8183) having a density of 32 kg/cum
for glass wool or 48 kg/cum for rock wool, bound in polythene bags shall be laid on
top of panels. Additional hangers and height adjustment clips shall be provided for
returns air grills, light fixtures, A. C. ducts etc.
Under deck insulation shall be provided on the ceiling (underside of roof slab) and
underside of floor slab of air - conditioned areas depending upon the functional
requirements. This under deck insulation shall consist of 50 mm thick mineral wool
insulation mat conforming to IS: 8183 having a density of 32 kg/cum for glass wool or
48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G x 25 mm
mesh wire netting and shall be fixed to the ceiling with 14G wire ties.
17.03.00 Acid / Alkali Resistant Lining
Battery Room

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
CHP CIVIL WORKS
Page 22 of 51

For Floor and dado, bitumen primer followed by 12 mm thick bitumastic 6 mm thick
potassium silicate mortar bedding and 20 mm thick A. R. tiles shall be provided.
Dado height shall be minimum 2.0 m from floor.
M. S. Grating / Chequered plate cover and any other steel structure likely to come in
contact with chemicals shall be provided with epoxy coating 150 microns thick over
epoxy primer.
Acid / Alkali resistant lining material shall conform to the following:
Bitumen primer shall conform to IS: 158.
Bitumastic compound shall conform to IS: 9510. Where the height of bitumastic layer
on vertical surface is more than 2.0 m, the bitumastic layer shall be reinforced with
diamond pattern expanded metal steel sheets conforming to IS: 412.
A. R. tiles shall conform to IS: 4457.
Mortar: Potassium silicate and resin type mortars shall conform to IS : 4832 Parts I
and II respectively.
17.04.00 FINISHING SCHEDULE
The contractor's scope also includes all doors, windows, glazing, rolling shutters,
finishes, damp proofing, inserts, anchor bolts, embedments, stairs, nosing, railings,
toe - guards, ladders, edge protection angles, etc.
The Contractor shall adhere to the finishing schedule as given.
17.04.01 Flooring
I. P. S. (cement concrete flooring) with metallic hardener topping shall be provided for
all floors in transfer houses, including ground floors of transfer houses, ground
conveyors, operating floor of pump houses, M. C. C. rooms, cable vault / cable
spreader rooms, maintenance and unloading areas, general storage areas and all
other areas in plant buildings where heavy duty flooring is required.
Heavy Duty Ceramic Tiles (matt finish) shall be provided for toilets, pantry, office
rooms, laboratories, conference rooms, all control rooms and control equipment
rooms.
Well polished Kota stone shall be provided for staircases, passages, lobbies and
general circulation areas.
False flooring with 2 mm thick anti - static flexible PVC tiles over particle board shall
be provided for computer room (if specific requirement is there)
The nominal total thickness of floor finish shall be 50 mm i.e. underbed and topping.
The floor shall be laid on an already laid and matured concrete base.

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Sunken R. C. C. slab shall be provided in false flooring area and toilet area so as to
keep the finished floor level of these areas same as that of the surrounding area.
Wherever specified metallic hardener topping shall be 12 mm thick using uniformly
graded iron particles, properly treated.
Wherever specified Heavy duty ceramic tiles of size 300 x 300 x 7 mm thick
(minimum) of reputed manufacturer (Kajaria, Spartek or equivalent) of approved
finish, shade and colour to be used. The tiles shall have a scratch resistance of
minimum 5 on Mohrs scale and shall have a bending strength of 350 Kgs. / cm
2
.
Paving details shall be similar to grade slab excluding metallic hardener.
Skirting in general shall be 150 mm high. Dado in toilets and pantries shall be up to
2.1 m height from finished floor level. Skirting and dado shall match with the floor
finish.
17.04.02 Interior Wall / Ceiling Finish
For all air - conditioned areas and stair case acrylic emulsion paint of approved make
and shade over 2 mm thick plaster of paris punning shall be provided.
For toilets and pantries minimum 5 mm thick decorative coloured ceramic tiles of
approved make and shade with approved pattern up to 2.10 m. height from finished
floor level shall be provided. Oil bound distemper over plaster of paris punning above
2.10 m height shall be provided.
For all other areas oil bound distemper ( IS : 428 ) of approved shade over 2 mm
thick plaster of paris punning shall be provided.
For battery room and other areas coming in contact with acid / alkali fumes, chemical
resistant chlorinated rubber paint shall be provided above 2.1 m height. Up to 2.1 m
height from finished floor level acid alkali resistant tiles shall be provided as specified
elsewhere.
All R. C. C. ceilings shall be white washed.
17.04.03 Exterior Finish
Permanently colour coated M. S. / High tensile steel metal cladding ( non - insulated )
of approved colour combination shall be provided for transfer points, conveyor
galleries, elevator shafts, and parapet walls of buildings where metal cladding is
specified. The cladding sheets shall be coated with silicon modified paint as specified
elsewhere.
Water proofing cement paint / textured paint shall be provided for the under
mentioned areas:
(a.) All buildings with R. C. C. framework unless specified otherwise in this
specification.

(b.) Brick work in the lower portion of metal cladding.

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(c.) Fire walls
(d.) Projections and facia : R. C. C. parapets ( excepting parapets of buildings
where metal cladding is specified )
(e.) Exterior brick walls.
17.05.00 DOORS, WINDOWS AND ROLLING SHUTTERS.
17.05.01 Doors and Windows
All doors, windows and ventilators of control room building, S and T control room and
M. C. C. buildings shall have Electro colour coated (anodised) aluminium frame work
with glazing. All doors of office and toilet areas shall be of factory made pre-
laminated particle board (M D F exterior grade). All other buildings shall have steel
doors, windows and ventilators.
Single glazed panels with aluminium framework shall be provided as partition
between two air - conditioned areas wherever clear view is necessary.
Coal conveyor galleries shall have steel windows of openable type. The window
shutters shall be provided with M. S. louvers.
All steel doors shall consist of double plate flush door shutters. The door shutter shall
be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous
vertical 20 G stiffeners at the rate 150 mm centre to centre. Side, top and bottom
edges of shutters shall be reinforced by continuous pressed steel channel with
minimum 18G. The door shall be sound deadened by filling the inside void with
mineral wool. Doors shall be complete with all hardware and fixtures like door closer,
tower bolts, handles, stoppers aldrops, etc.
Windows of coal galleries shall be provided with welded wire fabric of 1.6 mm thick
wire as per IS: 4948 and 12 mm x 30 mm mesh size.
Wherever functionally required rolling shutters shall be provided and these shall be
electrically operated.
In transfer points, windows near floors shall be steel and openable types. The
window shutters shall be provided with MS louvers. Windows / ventilators at higher
level can be of steel with fixed glazing. All openable windows shall be provided with
suitable stays.
All windows and ventilators on ground floor of all switchgear and M. C. C. buildings
shall be provided with suitable anodized aluminium grill.
Fire - Proof doors with panic devices shall be provided at all fire exit points as per the
recommendations of statutory regulatory bodies These doors shall generally be as
per IS : 3614 ( Part I and Part II ). Fire rating of the doors shall be as per
requirements of statutory regulatory bodies. However minimum rating shall be 2
hours. These doors shall be double cover-plated types with mineral wool insulation.

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Hollow extruded section of minimum 3 mm wall thickness as manufactured by INDAL
or equivalent shall be used for all aluminium doors, windows, and ventilators.
All doors should have opening as indicated in the drawings. Doors and windows on
external walls of the buildings having brick enclosures i.e. enclosure other than with
permanently colour coated steel sheet cladding, shall be provided with sunshade
over the openings with width 600 mm more than the opening width. Projections from
the wall for the sunshade shall be 450 mm over window openings and 750 mm over
door openings. Minimum size of door provided should be 2.1 m high and 1.2 m wide,
except for toiler rooms, where door may be 0.75 m wide. All doors ( other than those
in W/C and urinal area ) shall be double plate flush door shutters. For W/C and
urinals area, wooden panel doors shall be provided. Area of windows shall be at least
10 % of the floor area of the respective building. The area of translucent
polycarbonate sheet panels shall also be at least 10 % of the floor area of the
respective building.
Monorail doors shall be provided with steel stays / chains etc for convenient
operation of the shutters.
The louvre blade shall be Z shaped and made out of 18G sheets in EZ7 steel
frames. The frames shall be of ISMC 100.
17.05.02 Rolling Shutters
Rolling Shutters/ grills shall be with motor drives, gear arrangement including all
accessories and shall conform to IS: 6248. All electrical work shall be in strict
accordance with the relevant Indian Electricity Rules.
After installing the shutters, the Contractor shall test the performance of the shutter in
presence of the Engineer. The shutters shall be smoothly operable under all ambient
conditions. All control and locking devices shall give fault free performance.
18.00.00 PAINTING
Painting of all steel structures, including seal plates, hand rails, steel doors &
windows, ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc.
shall be with paints as per following:
18.01.00 Materials
Zinc silicate primer (minimum 100 micron Dry Film Thickness - DFT) shall be
inorganic (Ethyl) self curing high built (Solid by volume minimum 60%) formulation as
per BS : 5493 (Inorganic Zinc rich systems).
Intermediate (Under) coat (minimum 100 micron DFT) shall be of polyamide cured
titanium di-oxide / micaceous iron oxide pigmented high performance (solid by
volume minimum 60%) epoxy coating as per BS : 5493 ( two pack chemical resistant
under coats).
Finish coat (minimum 75 micron DFT) shall be of polyamide cured colored pigmented
high performance (solid by volume minimum 60%) epoxy coating as per BS: 5493
(two pack chemical resistant finishes).

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Final finish coat (minimum 25 Micron DFT) shall be of polyurethane colour pigmented
(solid by volume minimum 40%) as per BS: 5493 (two pack chemical resistant
finishes).
All paints including primer shall be of reputed brand / manufacturer and as approved
by the engineer.
18.02.00 Preparation of Surface
The surfaces shall be blast cleaned to near white metal surface (Sa 2 ) i.e. 2nd
quality (requiring at least 95% of the surface completely cleaned) as given in BS :
4232 . For blast cleaning shot blasting shall be used.
Approved type of abrasives shall only be used for blast cleaning of steel surfaces by
shot blasting. Suitable enclosure shall be provided to carry out the blast cleaning
operation. If required prior approval from the factory inspector / pollution control
board etc. shall be obtained regarding the method of blast cleaning and abrasives
used therein.
Immediately after blast cleaning of the steel surfaces, primer coat shall be applied
onto the surfaces.
18.03.00 Application of paint
The contractor shall submit the total painting scheme and works shall be started after
the approval of the scheme, from the engineer.
Painting works shall be carried out on structural as per the approved scheme. The
total painting scheme to be submitted to the engineer shall include the following:
i) Method of blast cleaning giving the details and sizing of various equipment
required, abrasive used, enclosure provided to avoid contamination of the
adjoining area, expected productivity on an eight (08) hour shift working etc.
ii) Arrangement of airless spray with the equipment rating.
iii) Drying time to be allowed before the application of subsequent coat.
iv) Recommended paint for primer, intermediate (under) coat, finish coat and
final finish coat with their brand name and designation, considering the
requirements of BS : 5493 for long range (typical time to first maintenance 10
to 20 years), life for exterior exposed non polluted inland atmosphere.
v) Number of coat and the thickness of each coat to be applied to achieve the
specified thickness of each coat i.e. primer, intermediate (under), finish and
final finish coats.
vi) Environmental conditions i.e. ambient temperature and humidity at the time of
application of the paint.

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vii) Quality control setup for painting i.e. checking of surface preparation,
thickness of each coat, quality of applied paints vis--vis the approved sample
etc.
viii) Method of touch up painting for surfaces damaged during handling, transit,
erection, welding, subsequent to painting, removal of the temporary supports
etc.
ix) Reference of relevant Indian / International standards for the testing and
acceptance.
Before application of inorganic zinc silicate primer, the steel surfaces shall be blast
cleaned to near white metal surface (Sa 2 ).
Primer paint and intermediate (Under) coat shall be done by airless spray. However
finish coat and final finish coat can be applied either by spray and or brush.
All subsequent coats shall be applied only after acceptance of the previous applied
coat. Inaccessible surfaces shall be primer painted before shop assembly.
For final touch up painting of surfaces, which are damaged during handling, transit,
erection, etc. surfaces shall be well prepared, by rubbing the entire damaged area
using wire brush, emery paper etc. and shall be provided with minimum 100 micron
(DFT) of self priming high build epoxy based primer followed by intermediate, finish
and final finish coats as described elsewhere in this document. Touch up painting of
areas welded subsequent to painting and areas exposed after removal of temporary
supports shall also be carried out in same way.
Rectification of the damaged painted surfaces on account of welding / handling etc.
of each coat shall be done by touch up painting, before the application of next coat,
using minimum 100 micron (DFT) self priming high build epoxy based primer
followed by various coats in sequence of thickness as specified elsewhere.
18.04.00 Acceptance Criteria
All painted surfaces shall be uniform and pleasing in appearance.
Dry film thickness of each coat shall be checked and measured by using elcho-
meter. The thickness as measured shall not be less than the minimum thickness
specified for the coat of paint under relevant clauses of the technical specification.
Measurement of paint thickness shall be as per SSPC : The society for Protective
Coatings Paint Application Standard no. 2 titled Measurement of Dry Coating
thickness with magnetic gages.
Colour, texture shall match exactly with the approved sample.


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19.00.00 Miscellaneous
19.01.00 Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings,
pedestals, cable trenches, pits etc., Plywood form work shall be used for all over
ground exposed work like columns, beams, floors and ceilings in control room and M.
C. C. buildings.
19.02.00 Monorail girders and fixtures shall be provided for monorails at the locations as
required and as described elsewhere in these specifications or drawings. Monorail
openings in the walls shall be provided with steel frame doors preferably sliding type
or otherwise open able inside, access platforms and ladders.
19.03.00 Steel frame around openings in roof and on external walls for mounting of exhaust
fans shall be provided.
19.04.00 Ready mix non - shrink cementitious grout of reputed manufacturer as approved by
the Employer shall be used for grouting of block outs and foundation bolts,
underpinning of base plates and machine bases. Crushing strength of grout shall be
one grade higher than the foundation concrete. Minimum crushing strength shall be
30 N / mm2 unless higher strength requirement is specified by the equipment
supplier or the grout manufacturers.
19.05.00 The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m
above the ground except for rail / road crossing where it shall be 8m above the rail
top / road crest/ground. Further in bunker areas it shall be 8 m above the ground.
19.06.00 Polysulphide Sealing Compound shall be two-part polysulphide sealant and shall be
from approved manufacturer, conforming to IS : 12118. Materials shall consist of
polysulphide polymer and a curing agent. Gun grade material shall be used unless
otherwise specified. The application of the sealant shall be strictly followed as per
manufacturers guidelines.
20.00.00 VIBRATION ISOLATION SYSTEM
These specifications are meant for the design, supply and erection of vibration
isolation system for supporting coal crushers ( ring granulators ).
20.01.00 Supporting Arrangement
20.01.01 The crushers shall be supported on vibration isolation system consisting of steel
helical springs and viscous dampers. The supporting arrangement for each crusher
shall consist of an R. C. C. deck supported on steel helical spring units and viscous
damper units which in turn shall be supported on girders. The girders shall be an
integral part of the crusher house building.
The part of the structure consisting of the R. C. C. deck, springs and viscous
dampers shall hitherto be referred to as spring supported foundation. The part of
the structure, which is below the spring shall hitherto be called supporting structure.
20.01.02 The Contractor should do the Engineering / design, supply and erection of vibration
isolation system consisting of steel helical spring units and viscous dampers

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supporting the top deck which in turn would support the coal crushers. The vibrations
isolation system supplied shall be of a proven make. The Contractor or his sub -
contractor who designs and supplies the system should have designed, supplied and
installed such systems for not less than five machines of speeds and unbalance
forces comparable to the machine proposed by the vendor. The vibration isolation
systems installed by the contractor or his sub - contractor in such machines should
have been working satisfactorily for atleast five years.
20.02.00 Scope of Work
20.02.01 Scope of work shall include the following :
20.02.01.1 Engineering
20.02.01.1.1 Design of the vibration isolation system using steel helical springs and viscous
dampers to support an R. C. C. top deck supporting the coal crusher. This includes
the static and dynamic analysis of the vibration isolation system with the R. C. C. top
deck and the coal crusher.
20.02.01.1.2 Structural design of the R. C. C. top deck including preparation of General
Arrangement drawings, detailed reinforcement drawings, bar - bending schedules
etc.
20.02.01.1.3 Calculation of loads on the structure supporting the springs and viscous dampers,
their points of application and the stiffness requirements of the supporting structure.
20.02.01.1.4 Drawings showing embedments and their locations and details on the R. C. C. top
deck.
20.02.01.1.5 Drawings showing blockouts, recesses etc. on the top deck.
20.02.01.1.6 Design of the supporting structure, including preparation of detailed drawings and bill
of materials.
20.02.01.2 Supply including packing and transportation to site
20.02.01.2.1 Steel helical spring units and viscous dampers, including associated auxiliaries for
installation of the spring units and dampers like steel shims, adhesive pads etc.
20.02.01.2.2 Frame ( s ) for pre-stressing of spring elements.
20.02.01.2.3 Suitable hydraulic jacks system including electric pumps, high pressure tubes etc.
required for the installation, alignment etc. of the spring units, two extra hydraulic
jacks, one hand operated pump and spares for the hydraulic jack system as required.
20.02.01.3 Erection and Commissioning
20.02.01.3.1 Complete erection and commissioning of the vibration isolation system including :

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20.02.01.3.2 Pre-stressing of spring elements, placing of spring elements in position, checking
clearances on the shuttering of the R. C. C. top deck, construction of the supporting
structure and the R. C. C. top deck, releasing to pre-stress in spring elements and
making final adjustments and alignments after machine installation etc.
20.02.01.3.3 The scope of work shall be deemed to include all activities which may not have been
explicitly mentioned but are reasonably implied for the successful completion of the
work for which these specifications are intended.
20.02.01.3.4 This part of the specifications is for vibration isolation system. For the construction of
the supporting structure for the crusher and the top deck, the relevant parts of the
specification should be referred to.
20.02.01.4 Documentation
20.02.01.4.1 Submission of detailed design calculation, analysis ( static and dynamic ) and
drawings for Employers acceptance and approval.
20.02.01.4.2 Furnishing methodology of providing shuttering and its removal as well as concreting
of deck slab, installation of springs and dampers and the sequence of operation.
20.02.01.4.3 Furnishing installation and maintenance manual indicating equipment, procedure
etc., necessary for installation, maintenance of vibration isolation system.
20.02.01.4.4 Furnishing a check list for confirming the readiness of the civil fronts for the
installation of vibration isolation system and equipment required at each stage
installation.
20.02.01.4.5 Bill of materials of various elements such as springs, visco-dampers, with their rating,
stiffness etc., included in supply.
20.02.01.4.6 Detailed specifications of the vibration isolation system and various items included in
the supply and the standard (local or international) to which they conform.
20.02.01.4.7 Proposed erection strategy of the entire system.
20.02.02 Design Requirements for Crusher ( Ring Granulator ) Foundation
20.02.03 Dynamic Analysis
Detailed dynamic analysis shall be done for the top deck together with springs and
dampers and the natural frequencies and amplitudes of vibration shall be
determined. A mathematical model of the top deck shall be formulated with three -
dimensional beam / plate finite elements for the purpose of analysis with the spring
idealised with vertical and horizontal stiffnesses. The mass of the machine together
with that of the top deck shall be considered for the analysis.
Natural frequencies upto at least 10 % above the operating speed shall be
determined and these frequencies shall be checked against the design criteria.

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Forced response dynamic analysis shall be carried out for the operating condition
unbalance forces using a sinusoidal forcing function. Unbalance forces as given by
this specifications shall be used for his purpose. The amplitudes shall be checked
against the design criteria. The dynamic forces from this analysis shall be used for
structural design with a suitable fatigue factor.
20.02.04 Isolation Efficiency
The vibration isolation system shall be designed for about 90 % isolation efficiency.
20.02.05 De-coupling
A ratio of the least 10 ( ten ) shall be ensured between the stiffness of the supporting
structure and the stiffness of the spring system in the vertical direction to achieve de-
coupling between the two ( the stiffness of the spring system being lower ). This
ensures that dynamic analysis of the supporting structure need not be carried out.
20.02.06 Frequency Criteria
The frequency criterion has already been laid down implicitly by the isolation
efficiency criteria and de-coupling required.
The first bending mode frequency of the top deck shall be at least 20 % above the
operating speed.
20.02.07 Unbalance Forces
Unbalance forces arising out of all the following cases shall be considered for
checking the design and amplitudes.
20.02.07.1 Balance quality grade Q 40 as per VDI 2060 - 1966.
20.02.07.2 One hammer broken condition. The missing hammer shall be assumed to be closest
to the crusher non - drive end of the crusher.
20.02.07.3 Three hammers broken condition. All the three hammers broken shall be assumed to
be from the same suspension bar and located at the non - drive end of the crusher.
20.02.08 Amplitude Criteria
The calculated amplitudes (mean to peak values) shall not exceed following limits
under the specified conditions.
1) Operating speed of 750 RPM
20.02.08.1 150 microns for an unbalance force arising out of balance quality grade Q 40 as per
VDI 2060 - 1966.
20.02.08.2 300 microns in case of a one hammer broken condition.
20.02.08.3 Amplitudes need not be checked for a three hammer broken condition.

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2) Operating speed of 450 RPM
a) 200 microns for an imbalance force arising out of balance quality grade Q-40
as per VDI -2060-1966.
b) 400 microns in case of a one hammers broken condition.
c) Amplitude need not be checked for a three hammer broken condition.
3) For intermediate operating speed between 450 to 750 RPM the amplitude
limits can be linearly interpolated.
The amplitude limits mentioned above are in both vertical and horizontal directions.
The amplitudes shall be calculated at critical points on the top surface of the R. C. C.
deck. The amplitudes shall be checked for the most unfavorable superposition of
modes in any direction. However, phase difference between the maximum amplitude
occurring in different directions due to the rotating vetor may be considered while
superimposing the modes.
20.02.09 Transient Resonance
Transient resonance, which may occur during the start - up or coasting down
condition of the crusher, shall be checked, and the amplitudes in such a condition
should not exceed one - and - half times those at operating speed for each design
condition.
20.02.10 Strength Criteria
The following criteria shall apply for the design of top deck :
20.02.10.1 Dead loads, live loads, Seismic loads and dynamic loads shall be considered for the
design. The most unfavorable combination shall considered for design.
20.02.10.2 Seismic loads shall be assumed to act together with dynamic loads for a one
millimeter eccentricity in the rotor. However, seismic loads and dynamic loads arising
out of hammer breakage need not be considered together
20.02.10.3 Fatigue shall be considered while designing for dynamic forces. A fatigue factor of
2.0 shall be used on all dynamic forces to arrive at the equivalent static force for the
purpose of design.
20.02.10.4 Working stress method shall be used for the design of R. C. C. deck. In survival
condition, 10 % overstressing may be permitted.
20.02.10.5 The R. C. C. top deck shall be at least of M25 grade of concrete as per IS : 456 -
1978.
20.02.10.6 Fatigue need not be considered for the three hammer broken condition.

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20.02.10.7 For calculating unbalance forces, the heaviest hammer ( plain or toothed ) shall be
considered.
20.03.00 Approval of Designs and Drawings
All design calculation, drawings and documents shall be in English. All design
calculations and drawings shall be submitted to Employer for approval. However,
approval of such designs and drawings shall not relieve the contractor of his
responsibility regarding the adequacy of the foundation to carry the design forces.
20.04.00 Standards
Latest revisions of the following Codes shall be used for the design of the crusher
foundations.
20.04.01.1 IS : 456 Code of Practice for Plain and Reinforced concrete.
20.04.01.2 IS : 2974 ( Part IV ) Code of Practice for Design and Construction of Machine
Foundations ( Part IV ) for rotary type machine of low frequency.
20.04.01.3 IS : 1893 ( Criteria for Earthquake Resistant Design of Structures ).
20.04.01.4 DIN 4024 Machine Foundations :
Flexible supporting structures for machines with rotating masses.
20.04.01.5 DIN 2089
Helical Compression Springs out of round wire and rod; calculation and Design.
20.04.01.6 DIN 2096
Helical Compression Springs out of round wire and rod; quality requirements for hot
formed compression springs.
20.04.01.7 VDI 2056 - Criteria for assessing mechanical vibrations of machines.
20.04.01.8 VDI 2060 - Criteria for assessing the state of balance of rotating rigid bodies.
21.00.00 Packaging and Transportation.
All the equipment shall be suitably protected coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at site till the
time of erection. While packing all the materials the limitations from the point of view
of availability of railway wagon sizes in India should be taken into account. The
contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing.


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22.00.00 Plant Life
The plant shall be designed for a minimum operating life of 30 years under the
conditions of operation. Assurance shall be given that plant components are
adequate for this lifetime. If there are any exceptional items of the plant on which an
assurance of meeting this clause cannot be given, life of such components and the
difficulties associated with them shall be stated.
23.00.00 PTFE (Poly Tetra Fluoroethylene) Bearing
The bearing shall be of reputed make and manufacturer as approved by the
Engineer, for required vertical load and end displacement/rotation. PTFE bearing
shall be sliding against highly polished stainless steel and the coefficient of friction
between them shall be less than 0.06 at 55 kg/sq.cm. In order to prevent cold flow in
PTFE surface it shall be rigidly bonded by a special high temperature resistance
adhesive to the stainless steel substrata. The stainless steel surface that slides
against the PTFE is mirror polished. The stainless steel shall be bonded to the top
plate by special high strength adhesive. The thickness of stainless steel plate shall
be between 1.0 mm to 1.5 mm.
24.00.00 TESTS FOR MATERIAL / WORKMANSHIP
All tests required for all materials, quality of workmanship or any other tests as
desired by the Engineer shall be at contractors cost.
25.00.00 MATERIALS
25.01.00 For Civil, Structural and Architectural works
Employer will not supply any material. All materials including cement, reinforcement
steel and structural steel, whatsoever required for execution and completion of the
entire scope of work covered under this specification shall be arranged by the
contractor at his own cost. All materials procured by the contractor shall meet the
quality requirements specified in this specification.
The contractor shall keep sufficient stock of cement and steel at site at any point of
time when the work is in progress excluding what has been already incorporated in
the works, so that any disruption / delay in availability of these materials during
procurement will not affect the progress of work at site. The minimum quantity of
such materials in stock at site shall not be less then the Requirement of one ( 1 )
month in case of Cement and Requirement of two ( 2 ) Consecutive months in case
of Steel.
25.02.00 Structural steel
25.02.01 Mild Steel
25.02.01.01 Rolled sections shall conform to Grade-E250A of IS 2062:2006 in as rolled and semi
killed condition.
25.02.01.02 Plates up to 20mm thickness shall conform to Grade - E250A of IS 2062:2006 in as
rolled and semi killed condition.

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25.02.01.03 Plates beyond 20mm and up to 40 mm shall conform to Grade E250B of IS
2062:2006 as rolled in killed condition.
25.02.01.04 Plates beyond 40mm shall conform to Grade E250B of IS 2062:2006 in normalized
and ultrasonically tested quality.
25.02.01.05 Pipes for handrail shall conform to medium grade of IS : 1161.
25.02.01.06 Chequered plates shall conform to IS : 3502. Tensile properties shall conform to
E250A of IS:2062 : 2006.
25.02.01.07 Seal plates shall conform to IS : 1079 ( semi - skilled quality )
25.02.02 Medium & High Tensile Steel
(a.) Rolled section shall conform to IS: 2062:2006 Grade E350, Semi Killed.
(b.) Plates up to 20 mm thickness shall conform to IS: 2062:2006 Grade E350,
Semi Killed.
(c.) Plates beyond 20 mm and 40mm shall be as per IS: 2062:2006 Grade E350,
Killed type.
(d.) Beyond 40mm shall conform to IS: 2062:2006 Grade E350, in normalized
condition and ultrasonically tested quality.
25.02.03 All plates up to and including 40mm thickness shall be ultrasonically tested on audit
basis to check the laminations.
25.03.00 Cement (for all overground structures):
Fly ash based Portland pozzolona cement conforming to IS: 1489 Part - I shall be
preferably be used. However, the contractor may use other types of cements
confirming to IS:269, IS:8112, IS:12269 & IS:455. However, Ordinary Portland
cement conforming to IS:269 or IS:8112 shall necessarily be used for crusher deck.
25.04.00 Reinforcement steel shall conform to:
a) Mild steel grade I of IS:432 part I and grade A of IS:2062.
b) High yield strength deformed bar of Gr. Fe 415 as per IS:1786 only shall be
used. However, high strength deformed steel bars, produced by thermo-
mechanical treatment process, of grade Fe 500, having elongation more than
14.5 percent and conforming to other requirements of IS: 1786 may also be
used for the reinforcement.
26.00.00 BITUMINOUS ROADS
26.01.00 Contents
This section deals with specifications for construction of flexible road pavements. The
details of work shall consist of :
a) Construction of sub grade

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b) Construction of Water Bound Macadam base and sub base
c) Bituminous surfacing
26.02.00 GENERAL REQUIREMENTS
26.02.01 The Contractor shall mobilise at site all equipment, including paver, roller, water
tanker, etc.
26.02.02 The Contractor shall carry out the survey and setting out works, including alignment,
layout, grading, curves etc.
26.02.03 The contractor shall also hire the services of a specialized agency, wherever
required.
26.03.00 Construction of Sub-grade
26.03.01 The subgrade shall be either in embankment, cutting or on the existing leveled
ground. The cutting and embankment works, wherever involved shall be carried out,
as per relevant specification of excavation and filling.
The excavation for laying of base and sub-base courses shall be carried out in the
required profile using box cutting. The lower 500 mm of the sub-grade shall be
compacted to 95% of the Proctor Density at Optimum Moisture Content, if not done
earlier; otherwise the top surface of the sub-grade shall be compacted using 8 to 10
Tonne roller with 6 passes. All undulations in the surface that develop due to rolling
shall be made good with material or quarry spoils, as the case may be and the sub
grade shall be re-rolled.
The finished surface shall be uniform, and conform to the lines, grades and typical
cross-section shown in the drawings, when tested with the template and straight
edge. The permissible variation shall be 25 mm in the longitudinal profile and 15 mm
in the cross profile.
The shoulders area shall also be compacted in the same way maintaining the
required profile on the top surface.
26.04.00 WATER BOUND MACADAM
Water bound macadam using crushed stone aggregate shall be used for construction
of sub- base and base material.
26.04.01 Materials
Coarse aggregates shall be of crushed or broken stone meeting the requirements of
IRC specification with respect to physical properties and grading. Grade I material
having size range of 90 to 45 mm shall only be used for subbase. Grade II and III
having size range of 63 to 45 mm and 53 to 22.4 mm respectively shall be used for
base construction.

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Moorum (Non Plastic Material) shall be used in the screenings as the filling material
to fill the voids in the coarse aggregate. The moorum shall be obtained from pits of
weathered disintegrated rocks. It should preferably contain silicious material and
natural mixture of clay of calcareous origin. The size of moorum shall not be more
than 20 mm.
26.05.00 Binding Materials
No separate binding material is required and the same moorum used as screening
material shall also serve the purpose.
26.06.00 Construction Operations
The construction operation shall involve preparation of base, spreading of coarse
aggregates followed by rolling, application of binding material, setting and drying. The
details of construction activities quantity and the quality of various materials to be
used shall be as per the stipulations of IRC specification.
The spreading shall be done from stockpile along the side of the roadway or directly
from the vehicle. The segregation of large and fine aggregates shall be avoided.
It may be ensured that the thickness of each compacted layer is not more than 100
mm for grading 1 material and 75 mm for grading 2 and 3 materials, for sub-base and
base respectively. The number of layers and actual thickness of the base and sub-
base shall depend upon the CBR value of the sub-grade. The surface evenness and
finishes of the Water Bound Macadam shall be checked and defects, if any, shall be
rectified. In no case shall depressions be filled up with screenings and binding
materials.
26.07.00 Bituminous Macadam
26.07.01 The work shall consist of construction, in a single course of 75 mm thickness of
compacted crushed aggregates, premixed with a bituminous binder, to serve as base
/ binder course, laid immediately after mixing, on a base prepared previously in
accordance with the requirements of these specifications and in conformity with the
line, grades and cross sections shown on the drawings or as directed by the
Engineer.
26.08.00 Materials
26.08.01 Bitumen
The bitumen shall be paving bitumen of suitable penetration grade within the range S
35 to S 90 or A 35 to A 90 (30 / 40 to 80 / 100), as per Indian standards
specifications for Paving Bitumen IS : 73. The actual grade of bitumen to be used
shall be decided by the Engineer appropriate to the region, traffic, rainfall and other
environmental conditions.


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26.08.02 Aggregates
The aggregates shall consist of crushed stone. They shall be clean, strong, durable
of fairly cubical shape and free from disintegrated pieces, organic or other deleterious
matters and adherent coating. The aggregates shall satisfy the physical requirements
set forth in IRC standards.
26.08.03 Proportioning of Materials
The bitumen content for premixing shall be 4 percent by weight of the total mix
except when otherwise directed by the Engineer.
The quantities of aggregates to be used shall be sufficient to yield the specified
thickness after compaction.
26.08.04 Construction Operations
The construction operation shall be carried out as per the stipulations of IRC
standards. This shall involve preparation of base, application of tach coat,
preparation and transportation of mix, spreading of mix, rolling, surface finish and
quality control. The mix shall be prepared in a hot mix plant of adequate capacity and
capable to yield a mix of proper and uniform quality works thoroughly coated
aggregates. The mix transferred from the tipper at site to the paver shall be spread
immediately by mixer, if self propelled. Mechanical road paver with suitable screeds
capable of spreading temping and finishing the mix trial to the specified lines, grades
and cross sections shall be used.
26.09.00 BITUMINOUS SURFACING
26.09.01 This shall involve laying and compacting of an open graded premix carpet of 25 mm
thickness in a single course composed of suitable small sized aggregates premixed
with a bituminous binder on a previously prepared base to serve as a wearing
course. This surface finish shall be provided directly on WBM or on Bituminous
Macadam depending on the type / category of road.
26.09.02 Materials
26.09.03 Binder
Bitumen of suitable grade conforming to IS: 73 shall be used as a binder.
26.09.04 Aggregates
Stone chips size, grading, physical properties shall be as specified in IRC standards.
26.09.05 Proportioning of different types of materials shall be as given in IRC specifications.
However, due to higher thickness of 25 mm, the quantity of material shall be
proportionately increased.

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26.10.00 Construction operations
26.10.01 The construction operations shall involve the preparation of base, application of tack
coat, preparation of premix, spreading and rolling followed by a seal coat. The details
of construction activities and the quantity of various materials to be used shall be as
per the stipulations of IRC specifications. A mechanical road paver finisher shall be
used for laying of premix carpet.
26.11.00 Seal coat
26.11.01 A premixed seal coat (type-B) for sealing the voids in the bituminous surface
comprising of a thin application of fine aggregate (Stone dust / grit) premixed with
bituminous binder shall be provided, as per the stipulations of IRC specifications.
26.11.02 Tack Coat
Tack coat of low viscosity conforming to IRC shall be applied, as mentioned in
Schedule of Items.
26.12.00 SHOULDERS
26.12.01 Content
This section deals with specifications for construction of shoulder (hard) on either
side of the pavement, in accordance with the requirements of these specifications
and in conformity with the lines, grades and cross sections shown on the drawings or
as directed by the Engineer.
26.12.02 Materials
Shoulder on either side of the road shall be of WBM using stone aggregate.
26.12.03 Size of shoulder
Shoulder (hard) dimensions shall be minimum 10m wide.
26.12.04 Construction operations
Except in the case of bituminous constructions, shoulders shall be constructed in
advance of the laying of pavement courses. The compacted thickness of each layer
of shoulder shall correspond to the compacted layer of the pavement course to be
laid adjacent to it. After compaction, the inside edges of shoulders shall be trimmed
vertical and included area cleaned of all spilled material before proceeding with the
construction of the pavement layer.
In the case of bituminous courses, work on shoulder (hard) shall start only after the
pavement course has been laid and compacted.

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During all stages of shoulder (earthen/hard) construction, the required cross-fall shall
be maintained to drain off surface water.
Regardless of the method of laying, all shoulder construction material shall be placed
directly on the shoulder. Any spilled material dragged on to the pavement surface
shall be immediately removed, without damage to the pavement and the area so
affected thoroughly cleaned.
26.12.05 Surface finish and quality control of works
The surface finish of construction shall conform to the requirements of IRC. Control
on the quality of materials and works shall be exercised by the Engineer in
accordance with IRC.
26.12.06 Brick edging
Brick edging shall be provided on both sides of the road all along the length. Fly ash
based bricks having strength not less than 7.5 MPa shall be used for this purpose,
unless otherwise specified. The edging shall be of one brick width and half brick
depth. In the case of hard shoulder, the brick edging shall not be provided. Trenches
shall be excavated after construction of the road and the bed of trenches shall be
compacted to a firm and even surface. The bricks shall be abutting to the wearing
course, true to line, gradient and in camber with the finished road surface at the
edges.
26.13.00 INSPECTION AND TESTING
The surfaces finish, alignment, profile, gradient, tolerance, quality control during
construction and characteristics of different materials shall be checked, as per the
requirements of IRC specifications, for road and bridge works.

All standards, specifications, acts and code of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions. Other
Indian, foreign Codes and Standards not listed here but referred to elsewhere within
this specification shall also be deemed to be part of this list.

In case of conflict between this specification and those (IS standards, codes etc.)
referred to herein, the former shall prevail.

Some of the relevant Indian standards, Acts and Codes applicable to this section of
the specification are listed below

IS : 383 Specification for coarse and fine aggregates from natural
sources for Concrete.
IS : 432 Specification for mild steel and medium tensile steel bars and
hard drawn steel wire for concrete reinforcement.

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IS : 456 Code of practice for plain and reinforced concrete.
IS : 458 Specification for concrete pipes.
IS : 516 Method of test for strength of concrete.
IS : 800 Code of practice for use of structural steel in general building
construction.
IS : 814 Specification for covered electrodes for metal arc welding for
weld steel.
IS : 816 Code of practice for use of metal arc welding for general
construction.
IS : 817 Code of practice for training and testing of metal arc welders.
IS : 875 (Pt. I to V) Code of practice for design loads other than earthquake) for
buildings and structures.
IS : 1038 Steel doors, windows and ventilators.
IS : 1172 Basic requirements for water supply, drainage and sanitation.
IS : 1361 Steel windows for industrial buildings.
IS : 1786 Specification for high strength deformed steel bars and wires
for concrete reinforcement.
IS : 1892 Code of practice for subsurface investigation for foundation.
IS : 1893 Criteria for earthquake resistant design of structures.
IS : 1904 Code of practice for design and construction of foundations in
soils; general requirements.
IS : 1905 Code of practice for structural safety of buildings - Masonry
walls.
IS : 1948 Specification for aluminium doors, windows and ventilators.
IS : 2062 Steel for general structural purposes.
IS : 2131 Method of standard penetration test for soils.
IS : 2212 Code of practice for brickwork.
IS : 2645 Specification for Integral cement water proofing compounds.
IS:2720 (Part-II,
IV TO VIII, XIV,
XXI, XXIII, XXIV,
XXVII TO XXIX,
XL)
Methods of test for soils - determination for water content etc
code of practice for earth work on canals.


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IS : 2911 Code of practice for design and construction of pile
foundations.
(Part-1/Sec.1) Driven cast in situ concrete piles.
(Part-1/Sec.2) Bored cast-in-situ concrete piles.
(Part-IV) Load test on piles.
IS : 2974 (Part - I
TO V)
Code of practice for design and construction of machine
foundations.
IS : 3370 (Part I
to IV)
Code of practice for concrete structures for the storage of
liquids.
IS : 3658 Code of practice for liquid penetrant flaw detection.
IS : 3664 Code of practice for ultra sonic testing by pulse echo method.
IS : 4326 Code of practice for earthquake resistant design and
construction of buildings.
IS : 4990 Specification for plywood for concrete shuttering work.
IS : 5624 Specification for foundation bolts.
IS : 7215 Tolerances for fabrication steel structures.
IS : 8112 Specification for 43 grade Ordinary Portland Cement.
IS : 9103 Specification for admixtures for concrete.
IS : 9595 Code of procedure of manual metal arc welding of mild steel.
IS : 10262 Recommended guidelines for concrete mix design.
IS : 13311 Method of non - destructive testing of concrete.
IS : 13755 Dust pressed ceramic tiles with water absorption of 3%, E6%
(Group B11a)


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ASTM 898 -89 Standard guide for use of high solid content, cold liquid-
applied elastomeric water proofing membrane for use with
separate wearing course.
AS/NZS 2728 Pre finished / pre painted sheet metal product for interior /
exterior building applications Performance requirements.
AS : 1365 Standards for steel manufacturing.
AS : 1397 A steel sheet & strip hot dipped-zinc-coated or Aluminium-
Zinc coated.
AS : 3566 Self drilling screws for building and construction industry.
IRC : 37 Guidelines for the design of flexible pavements.
- Manual on sewerage and sewage treatment (Published by
CPH & EEO) As updated.
Indian Explosives Act. 1940 as updated.

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ANNEXURE-A

CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND
EQUIPMENT
All structures and equipment shall be designed for seismic forces adopting the site
specific seismic information provided in this document and using the other provisions
in accordance with IS:1893 (Part 1):2002 and IS:1893 (Part 4):2005. Pending
finalization of Parts 2, 3 and 5 of IS:1893, provisions of part 1 shall be read along
with the relevant clauses of IS:1893:1984, for structures other than the buildings and
industrial structures including stack-like structures.
A site specific seismic study has been conducted for the project site. The peak
ground horizontal acceleration for the project site, the site specific acceleration
spectral coefficients (in units of gravity acceleration g) in the horizontal direction for
the various damping values and the multiplying factor (to be used over the spectral
coefficients) for evaluating the design acceleration spectra are as given at Appendix-I

Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding
horizontal values.

The site specific design acceleration spectra shall be used in place of the response
acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893
(Part 4). The site specific acceleration spectra along with multiplying factors specified
in Appendix-I includes the effect of the seismic environment of the site, the
importance factor related to the structures and the response reduction factor. Hence,
the design spectra do not require any further consideration of the zone factor (Z), the
importance factor (I) and response reduction factor (R) as used in the IS:1893 (Part 1
and Part 4).

Damping in Structures

The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:

a) Steel structures : 2%

b) Reinforced Concrete structures : 5%

c) Reinforced Concrete Stacks : 3%

d) Steel stacks : 2%

Method of Analysis
Since most structures in a power plant are irregular in shape and have irregular
distribution of mass and stiffness, dynamic analysis for obtaining the design seismic
forces shall be carried out using the response spectrum method. The number of
vibration modes used in the analysis should be such that the sum total of modal
masses of all modes considered is at least 90 percent of the total seismic mass and
shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak

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response quantities shall be performed as per Complete Quadratic Combination
(CQC) method or by an acceptable alternative as per IS:1893 (Part 1).
In general, seismic analysis shall be performed for the three orthogonal (two principal
horizontal and one vertical) components of earthquake motion. The seismic response
from the three components shall be combined as specified in IS:1893 (Part 1).
For buildings, if the design base shear (V
B
) obtained from modal combination is less
than the base shear (V
B
) computed using the approximate fundamental period (T
a
)
given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate
multiplying factor, the response quantities (e.g. member forces, displacements,
storey forces, storey shears and base reactions) shall be enhanced in the ratio of V
B
/
V
B.
However, no reduction is permitted if V
B
is less than V
B
.
For regular buildings less than 12m in height, design seismic base shear and its
distribution to different floor levels along the height of the building may be carried out
as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1) and using site specific
design acceleration spectra. The design horizontal acceleration spectrum value (A
h
)
shall be computed for the fundamental natural period as per clause 7.6 of IS:1893
(Part 1) using site specific spectral acceleration coefficients with appropriate
multiplying factor given in Appendix-I.
Further, the spectral acceleration coefficient shall get restricted to the peak spectral
value if the fundamental natural period of the structure falls to the left of the peak in
the spectral acceleration curve.
Design/Detailing for Ductility for Structures
The site specific design acceleration spectra is a reduced spectra and has an in-built
allowance for ductility. Structures shall be engineered and detailed in accordance
with relevant Indian/International standards to achieve ductility.


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Annexure-I

SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND
EQUIPMENT

The various site specific seismic parameters for the project site shall be as follows:

1) Peak ground horizontal acceleration : 0.16g

2) Multiplying factor to be applied to the site specific
horizontal acceleration spectral coefficients (in units
of gravity acceleration g) to obtain the design
acceleration spectra

a) for moment resisting steel frames designed
and detailed as per IS:800 and moment
resisting RC frames designed and detailed
as per IS:456 : 0.053

b) for braced steel frames designed and
detailed as per IS:800 : 0.040

c) for moment resisting RC frames designed
and detailed as per IS:456 and IS:13920 : 0.032

d) for design of structures not covered under
2 (a) to 2 (c) above and under 3 below : 0.053

3) Multiplying factor to be applied to the site specific
horizontal acceleration spectral coefficients (in units
of gravity acceleration g) for design of equipment
and structures where inelastic action is not relevant
or not permitte : 0.107

Note: g = Acceleration due to gravity

The horizontal seismic acceleration spectral coefficients are furnished in subsequent
pages.


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ANNEXURE I

HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS
(In units of g)

Time Period
Damping Factor (as a percentage of critical damping)

(Sec) 2% 5%
0.000 1.000 1.000
0.030 1.000 1.000
0.050 1.518 1.359
0.100 2.674 2.062
0.120 3.104 2.301
0.153 3.790 2.665
0.155 3.790 2.687
0.200 3.790 2.687
0.250 3.790 2.687
0.300 3.790 2.687
0.350 3.790 2.687
0.400 3.790 2.687
0.450 3.790 2.687
0.500 3.790 2.687
0.550 3.790 2.687
0.600 3.790 2.687
0.650 3.790 2.687
0.700 3.790 2.687
0.750 3.790 2.687
0.763 3.790 2.687
0.773 3.740 2.687
0.800 3.615 2.598
0.850 3.402 2.445
0.900 3.213 2.309
0.950 3.044 2.187
1.000 2.892 2.078
1.050 2.754 1.979
1.100 2.629 1.889
1.150 2.515 1.807
1.200 2.410 1.732
1.250 2.314 1.662
1.300 2.225 1.598
1.350 2.142 1.539
1.400 2.066 1.484
1.450 1.994 1.433

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ANNEXURE I

(In units of g)

Time Period

(Sec) 2% 5%
1.500 1.928 1.385
1.550 1.866 1.341
1.600 1.808 1.299
1.650 1.753 1.259
1.700 1.701 1.222
1.750 1.653 1.187
1.800 1.607 1.154
1.850 1.563 1.123
1.900 1.522 1.094
1.950 1.483 1.066
2.000 1.446 1.039
2.050 1.411 1.014
2.100 1.377 0.990
2.150 1.345 0.967
2.200 1.315 0.945
2.250 1.285 0.924
2.300 1.257 0.903
2.350 1.231 0.884
2.400 1.205 0.866
2.450 1.180 0.848
2.500 1.157 0.831
2.550 1.134 0.815
2.600 1.112 0.799
2.650 1.091 0.784
2.700 1.071 0.770
2.750 1.052 0.756
2.800 1.033 0.742
2.850 1.015 0.729
2.900 0.997 0.717
2.950 0.980 0.704
3.000 0.964 0.693
3.050 0.948 0.681
3.100 0.933 0.670
3.150 0.918 0.660
3.200 0.904 0.649
3.250 0.890 0.639

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ANNEXURE I

(In units of g)

Time Period

(Sec) 2% 5%
3.300 0.876 0.630
3.350 0.863 0.620
3.400 0.851 0.611
3.450 0.838 0.602
3.500 0.826 0.594
3.550 0.815 0.585
3.600 0.803 0.577
3.650 0.792 0.569
3.700 0.782 0.562
3.750 0.771 0.554
3.757 0.770 0.553
3.800 0.752 0.547
3.850 0.733 0.540
3.900 0.714 0.533
3.950 0.696 0.526
4.000 0.679 0.520


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ANNEXURE-B
CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT

All structures shall be designed for wind forces in accordance with IS: 875 (Part-3)
and as specified in this document. See Annexure B for site specific information.

Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind
Speed method as defined in the standard.

Along wind forces on slender and wind sensitive structures and structural elements
shall also be computed, for dynamic effects, using the Gust Factor or Gust
Effectiveness Factor Method as defined in the standard. The structures shall be
designed for the higher of the forces obtained from Gust Factor method and the Peak
Wind Speed method.

Analysis for dynamic effects of wind must be undertaken for any structure which has
a height to minimum lateral dimension ratio greater than 5 and/or if the fundamental
frequency of the structure is less than 1 Hz.

Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc.
should be examined and designed/detailed accordingly following the
recommendations of IS:875(Part-3) and other relevant Indian standards.

It should be estimated if size and relative position of other structures are likely to
enhance the wind loading on the structure under consideration. Enhancement factor,
if necessary, shall suitably be estimated and applied to the wind loading to account
for the interference effects.

Damping in Structures

The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:

a) Welded steel structures : 1.0%

b) Bolted steel structures : 2.0%

c) Reinforced concrete structures : 1.6%

d) Steel stacks : As per IS:6533 &
CICIND Model Code
whichever is more
critical.


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SITE SPECIFIC DESIGN PARAMETERS

The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the
project site shall be as follows:

a) The basic wind speed V
b
at ten
metres above the mean ground level : 50 metres/second

b) The risk coefficient K
1
: 1.08

c) Category of terrain : Category-2

Note: Notwithstanding the values of the above mentioned parameters, the design
wind pressure so computed at any point shall not be taken less than 1500 N/Sq.
meter for all classes of structures, i.e. A, B & C, as defined in IS: 875 (Part-3).

SECTION-VI
PART-B

PART - B

SUB-SECTI ON-I I I D-02

FOUNDATION SYSTEM AND
GEOTECHNICAL DATA


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Geotechnical Data

Page 1 of 6

FOUNDATION SYSTEM AND GEOTECHNICAL DATA
1.00.00 SOIL DATA AND FOUNDATION SYSTEM
Bearing capacity for design of foundations and field bore log data are given at
Annexure - I of this specification.
1.01.00 Soil Data
1.01.01 Employer has carried out detailed geotechnical investigation in the areas pertaining
to this package. The detailed geotechnical investigation report comprising of
Boreholes, Laboratory tests, Chemical analysis, etc. in respect of the sub-strata
prevailing at site will be made available for the Bidder's study at the Employer's
office, if required. The onus of correct assessment / interpretation and understanding
of the existing subsoil condition / data is on the Bidder.
1.01.02 Within the plant area, Finished Ground Level (FGL) is RL 4.10 as shown in General
Layout Plan (GLP). Controlled filling of thickness 2.0 to 2.5 m with pond ash has
been done over Natural Ground Level (NGL) to achieve the FGL as indicated above.
Top of pond ash is covered with 300 mm thick earth cover.
1.02.00 Foundation System
The requirements for the foundation system to be adopted are as given in
subsequent clauses.
(a.) All structures/equipment shall be supported either on suitable open foundations
(isolated, combined, raft) or on pile foundations.
(b.) The roads, ground floor slabs, trenches, channels/drains and other lightly
loaded structures (such as staircase foundation with foundation loading
intensity less than 2 T / M
2
) may be supported on open / shallow foundations
resting 1.0 m in virgin / controlled compacted filled up soil.
(c.) No other foundation shall rest on the filled up ground / soil.
(d.) All foundations shall be designed in accordance with relevant parts of the latest
revisions of Indian Standards.
(e.) For design purpose water table shall be considered at Ground Level
(f.) A combination of open and pile foundations shall not be permitted under the
same equipment / structure / building.
1.02.02 Open Foundations
In case open foundations are adopted, following shall be adhered to.
(a.) The minimum width of foundation shall be 1.0 m.
(b.) The minimum depth of foundation shall be as given at Annexure-I
(c.) Minimum founding level, bearing capacity and permissible settlements shall be
as given in the Annexure - 1 to this specification.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Geotechnical Data

Page 2 of 6

1.02.03 Pile Foundations
i) The pile foundation shall be of RCC, Cast-in-situ bored piles as per IS:2911.
Pile boring shall be done using self erecting Rotary Hydraulic Rigs. Two
stage flushing of pile bore shall be ensured by airlift technique duly approved
by the Employer.
ii) The minimum diameter of pile shall be 600 mm. The allowable load capacity
of the pile in different modes (vertical compression, lateral and pullout) shall
be limited to the values given at Annexure - I. However, the pile capacities to
be adopted shall be the least of the estimated design values and that
obtained from the initial pile load tests.
iii) Only straight shaft piles shall be used. Minimum cast length of pile above
cutoff level shall be 1.0 m.
iv) The bidder shall furnish design of piles (in terms of rated capacity, length,
diameter, termination criteria to locate the founding level for construction of
pile in terms of measurable parameter, reinforcement for job as well as test
piles, locations of initial test piles etc.) for Engineers approval.
v) The piling work shall be carried out in accordance with IS:2911 (Relevant
part) and accepted construction methodology. The construction methodology
shall be submitted by the Contractor for Engineer's approval.
vi) Number of initial load tests to be performed for each diameter and rated
capacity of pile shall be one (1) in each mode (i.e 1 vertical, 1 lateral & 1
pullout) in Vallur plant area and one (1) number in each mode (i.e 1 vertical,
1 lateral & 1 pullout) at Ennore port area.
vii) The initial pile load test shall be conducted with test load upto three times the
estimated pile capacity. In case of compression test (initial test) the method
of loading shall be cyclic as per IS:2911 (relevant part).
viii) Load test shall be conducted at pile cut of level (COL). If the water table is
above the COL the test pit shall be kept dry through out the test period by
suitable de-watering methods. Alternatively the vertical load test may be
conducted at a level higher than COL. In such a case, an annular space
shall be created to remove the effect of skin friction above COL by providing
an outer casing of suitable diameter larger than the pile diameter.
Number of routine pile load tests to be performed for each
diameter/allowable capacity of pile shall be as under :
i) Vertical : 0.5% of the total number of piles provided.
ix)
ii) Lateral : 0.5% of the total number of piles provided.
x) The routine tests on piles shall be conducted upto test load of one and half
times the allowable pile capacity. Piles for routine load tests shall be
approved by the Employer.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Geotechnical Data

Page 3 of 6

xi) In case, routine pile load test shows that the pile has not achieved the
desired capacity or pile(s) have been rejected due to any other reason, then
the Contractor shall install additional pile(s) as required and the pile cap
design shall accordingly be reviewed and modified, if required.
xii) Testing of piles and interpretation of pile load test results shall be carried out
as per IS:2911 (Part-4). Contractor shall ensure that all the measuring
equipment and instruments are properly calibrated at a reputed laboratory /
institute prior to their use. Settlement / movement of the pile top shall be
made by Linear Variable Differential Transducers (LVDT) having a least
count of 0.01mm.
xiii) The test load on initial test piles shall be applied by means of reaction from
anchor piles / rock anchors alone or combination of anchor piles / rock
anchors and kentledge.
xiv) Low Strain Pile Integrity test shall be conducted on all test piles and job piles.
This test shall be used to identify the routine load test and not intended to
replace the use of static load test. This test is limited to assess the
imperfection of the pile shaft and shall be undertaken by an independent
specialist agency. The test equipment shall be of TNO or PDI make or
equivalent. The process shall confirm to ASTM.
xv) Contribution of frictional resistance of filled up soil if any, shall not be
considered for computation of frictional resistance of piles.
xvi) The borehole data indicates that a part of soft clay at many locations may
cause drag down force or negative skin friction on piles. This may be
considered in the computation of frictional resistance of piles, wherever
applicable.
1.03.00 Special Requirements
1.03.01 Details of treatment for foundations / underground structures required to counteract
soil / water chemical environment, cement type, grade of concrete, type of
reinforcement, cover to reinforcement and protective coating to foundations, etc.
shall be as mentioned in Annexure-1 of this specification.
1.04.00 Excavation, Filling and Dewatering
1.04.01 For excavation works, comprehensive dewatering with well point or deep wells
arrangement wherever required shall be adopted. Scheme for dewatering and design
with all computations and back data for dewatering shall be submitted for the owners
information. The water table shall be maintained at 0.5m below the founding depth.
1.04.02 Excavation for shallow foundations shall be covered with PCC immediately after
reaching the founding level. In case of any local loosening of soil or pockets are
encountered at founding level during excavation the same shall be removed and
compensated by PCC M 7.5. The final layer of about 300 mm thickness above the
founding level shall be excavated by suitable means, so as to avoid disturbance to
founding stratum.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Geotechnical Data

Page 4 of 6

1.04.03 Backfilling around foundations, pipes, trenches, sumps, pits, plinths, etc. shall be
carried out with approved material in layers not exceeding 300 mm compacted
thickness and each layer shall be compacted to 90% of standard proctor density for
cohesive soils and to 75% of relative density for non cohesive soils.
1.04.04 The founding level for trenches/channels shall be decided as per functional
requirement. The bottom of excavation shall be properly compacted prior to casting
of bottom slab of trenches / channels.
1.04.05 CBR tests for pavement/road design shall be carried out by the Contractor after earth
filling (if applicable) has been completed upto the formation level.
1.04.06 Following details shall be submitted by the Bidder before start of work at site (if
applicable):
(a.) Scheme for initial pile load tests in vertical, lateral and uplift modes along with
supporting design calculations and methodology for installation of working piles
and the complete piles installation data for individual pile including the pile test
result for all piles (for reference only).
1.05.00 Sheeting & Shoring
The contractor shall ascertain for himself the nature of materials to be excavated and
difficulties, if any, likely to be encountered in excavation, executing the work. Coffer
dams, sheeting and shoring, bracing and maintaining suitable slopes, draining etc.
shall be provided and installed by the Contractor, to the satisfaction of the Engineer.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Geotechnical Data

Page 5 of 6

Annexure-I
SOIL DATA AND FOUNDATION SYSTEM
a) Logs of representative boreholes from this area are enclosed with this Annexure.
b) The foundation system to be adopted for different structures shall be as given in
Table 1 below
Table 1: Foundation system
STRUCTURE TYPE OF
FOUNDATION TO
BE ADOPTED
TP5, TP6, TP13, TP14, TP15, TP16 in plant area,
Crusher house, Stacker reclaimer, Conveyor trestles,
MCC / Control Room, CHP pump house in Vallur
plant area, TP1, TP2, TP3, TP4 at Ennore port
Piles
MCC / Control Room, Conveyor trestles over ground
at Ennore port
Open / Pile

c) The minimum founding level and the corresponding net allowable bearing pressure
shall be as given in Table 2 below.
Table 2: Net Allowable Bearing Pressure
Net Allowable Bearing Pressure
T/m
2
Structure
Founding
Level
Isolated for a
permissible
settlement of
40 mm
(width 1-6m)
Rafts (width >6m
upto 8.0m) for a
permissible
settlement of
75mm
RL (+) 1.4 M

10 13
MCC / Control Room,
Conveyor trestles over
ground at Ennore port
RL (-) 0.6 M

13 16
The net allowable bearing pressure higher than above mentioned values shall not be
permitted. At intermediate levels the bearing capacity shall be same as the net
allowable bearing pressure corresponding to the immediate shallower level
mentioned above.
d) Permissible Settlement of Foundations:
For open foundations, the total permissible settlement and differential settlement
shall be governed by IS: 1904 and from functional requirements whichever is more
stringent. However, total settlement shall be restricted to the following:
Isolated / Strip 40 mm
Raft (widths greater than 6 m)

75 mm
In case the total permissible settlement is to be restricted to less than as above
specified from functional requirements, then the net allowable bearing pressure shall
be reduced after review in consultation with Engineer.


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Geotechnical Data

Page 6 of 6

e) Minimum dia of pile, minimum length and allowable vertical compression capacity of
piles shall not exceed the following:
Pile dia
(mm)
Pile length
below COL
*

(m)
Vertical
capacity (T)
Lateral capacity
(T)
Uplift
capacity
(T)
760 32 250 10 80
600 27 140 7 50
* Cut Off Level (COL) is assumed at 1.5 m below Natural Ground Level (NGL). If the
COL is either shallower or deeper than the assumed COL, then the length of pile
shall be worked out and the length arrived by design or minimum length specified
above, whichever is conservative shall be adopted. Pile of diameter less than 600
mm is not permitted.
f) The criteria for Pile Termination (founding level) shall be as given below:
The termination level of the pile shall be decided based on the following criterion
i) Minimum length of the pile below COL (cut off level) shall be as specified above
ii) In each pile group one reference pile shall be identified in consultation with the
Engineer for conducting SPT (Standard Penetration Test) in the pile bore. Pile
group or group of piles for reference pile may be considered as 50-70 piles. At
the pile termination level SPT N value shall be greater than 40. However,
based on the available details the Engineer may reduce frequency of reference
piles.
g) Special Requirements:
Structures Type of cement Reinforcement
All underground structures.
Port land slag
cement Or
OPC blended with
GGBS upto 60%
TMT
Concrete Grade for all structures M30, Concrete shall be dense and
durable
Cover to Reinforcement Minimum cover to foundations shall be
50mm.
- Exposure condition shall be considered as Severe as per IS 456
- Cover to reinforcement to be more by 15mm than normal cover

SECTION-VI
PART-B

PART - B

QUALI TY ASSURANCE

SECTION-VI
PART-B

PART - B

SUB-SECTI ON-I I I E-01

COAL HANDLING PLANT

CLAUSE NO. QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIIE-01
COAL HANDLING PLANT

Page
1 of 7

1.01.00 Brakes and Clamps
1.01.01 Final testing of brakes shall include load, HV/IR & heat run tests.
1.02.00 Monorails and Hoists
1.02.01 All electric hoist shall be tested as per IS 3938 and chain pulley block shall be tested
as per IS 3832.
1.03.00 Chutes, Hoppers & Liners
1.03.01 Rack & Pinion Gates/Flap Gates/Rod Gates
a) MPI/DP test shall be conducted on rack and pinion / rod / weld joint
b) Functional checks on the gates shall be carried out alongwith respective
actuator, if applicable.
1.04.00 Belt Conveyor System
The details of the checks to be carried out in the various equipments are to be
submitted by the Contractor for Owners approval. However, some indicative checks
on different items are given below which should necessarily form a part of the Quality
Assurance Plan to be agreed with the Owner.
1.04.01 Idlers
a) Check for run out and free movement shall be carried out on idlers. Run out
shall be restricted as per IS:8598
b) Test for dust proofness, water proofness and dynamic friction factor of the
Idlers shall be conducted at shop. The detailed procedures for the same shall
be submitted for review and approval.
1.04.02 Belting
(a) Rubber cover of finished belt shall be checked for tensile strength and
elongation at break before and after ageing. Rubber cover shall also be
checked for abrasion, tear strength and hardness.
(b) For finished belts, checks for elongation at 10% nominal tensile strength,
tensile and elongation at break in longitudinal (warp) direction and tensile in
transverse (weft) direction shall be carried out.
(c) Adhesion test between ply to ply and cover to ply shall be carried out.
(d) Troughability test and Test for fire resistance shall be carried out.
(e) Test for procedure qualification for belt vulcanizing joint (at site) shall be
done. Procedure for belt vulcanizing joint shall be discussed and finalized
during FQP finalization.
(f) There will be a limitation on the no. of repairs allowed on the belts. Following
will be the acceptance norm for the cover repairs.
i) The maximum size of a repair shall be limited to a size equivalent to
one fifth the belt width. No single dimension shall exceed one fifth(1/5)
of belt width.
ii) Small local repair by dough filling of size 25mm x 25mm to a limited
extent shall not be counted of repairs. However, in case of cluster of
repairs, same shall be counted as a patch repair.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIIE-01
COAL HANDLING PLANT

Page
2 of 7

iii) The maximum number of patch repair shall not exceed 5 per 100 mts.
However, the total number of patch and dough filling repairs shall not
exceed 10 per 100 meters.
(g) In addition to above, Steel Cord belt shall also be tested for following.
i. Cord dia and breaking strength
ii. Finished belt shall be tested for cord pull-out strength before and after
aeging, peeling resistance.
iii. Dynamic cord pull out test
iv. Cord dia, pitch and number of cords
(h) In no case shall the cover thickness or the width of belt be less than that
given in specification.
1.04.03 Pulleys
a) In addition to chemical, mechanical, hardness, microstructure as per
applicable material specification, pulleys shaft forgings shall be subjected to
ultrasonic testing.
b) 100% MPI/DPT on all welds shall be conducted and 10% RT/UT on butt
welds shall be conducted.
c) Static balancing of pulleys shall be carried out after rubber lagging.
d) Checks on rubber lagging to include abrasion loss, shore hardness test, peel-
off strength test and physical properties. Peel-off strength shall be 10 Kg/Cm,
Abrasion loss shall be less than 250 cubic mm when tested as per DIN
53516.
1.04.04 Belt Vulcanizing Machine
a) Check for tensile strength shall be carried out on a sample vulcanized belt
joint for each type of belt in shop. However if such test has been done earlier,
the report for same shall be submitted for verification.
b) Complete assembly shall be tested at shop for temp. and pressure
developed.
1.04.05 Pull Chord & Belt Sway Switches
a. Acceptance tests
i) Over all dimension and functional test.
ii) HV & IR test
iii) Degree of protection test report.
1.04.06 Zero Speed Switch, Under Belt Switch and Chute Blockage Switch
a Acceptance test
i) Burn in test at 50 degree C for 48 hours shall be done for electronic
switches.
ii) Over all dimension and functional test shall be carried out.
iii) HV & IR
iv) Degree of protection test


SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIIE-01
COAL HANDLING PLANT

Page
3 of 7

1.05.00 Drive Equipments
1.05.01 Gear Boxes :
(a) In addition to checks for physical, chemical, hardness, microstructure as per
relevant standard, the shaft and gear/pinion forgings shall be subjected to
ultrasonic testing.
(b) MPI to be carried out on Gears/Pinions after machining. Case depth,
hardness and MPI after hardfacing shall be checked to ensure freedom from
defects.
(c) Gear reducer shall be checked for reduction ratio, backlash and contact
pattern. No load shop trial run to be conducted on gear boxes to check for oil
leakage, temperature rise, noise level and vibration.
1.05.02 Flexible Coupling
(a) Ultrasonic testing shall be conducted on forgings for gear sleeve and gear
hub, if gear coupling is provided.
(b) MPI shall be carried out after machining to ensure freedom from cracks.
1.05.03 Fluid Coupling
(a) Dynamic balancing shall be carried out for the rotating parts.
(b) Check for leak tightness of the coupling shall be carried out.
(c) Functional test on fusible plug for each type of coupling shall be conducted at
shop.
(d) All couplings to be run tested at shop on no load
(e) Check for temperature rise, torque-speed, torque-slip characteristics and over
speed test shall be included during performance test of one coupling of each
type preferably at full load.
1.06.00 Belt Scales
submitted by the Contractor for Employers approval. However, some indicative
checks are given below which should necessarily form a part of the quality assurance
plan to be agreed with the Employer.
1.06.01 Mounting arrangement/Overall dimensional check shall be carried out on the Belt
Scales.
1.06.02 Belt scale shall be calibrated with test weight/test chain in static at works and with
test weight for dynamic condition at site.
1.06.03 All electronic modules shall be subjected to burn in test at 50 Degree C for 48 hours.
1.06.04 General check for load cell shall be carried out.
1.06.05 Test report for degree of protection on enclosure shall be furnished.
1.06.06 Accuracy/performance check shall be demonstrated at site.
1.07.00 Dust Control & Miscellaneous Systems
The details of the checks to be carried out on the various equipments are to be
submitted by the Contractor for Owners approval. However some indicative checks
on different items are given below which should necessarily form a part of the Quality
Assurance Plan to be agreed with by the Owner.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIIE-01
COAL HANDLING PLANT

Page
4 of 7

1.07.01 Pumps
(a) All materials should be of tested quality and test certificates to be provided.
(b) DPT of machined shaft and impeller shall be done.
(c) Shaft forgings to be also subjected to ultrasonic testing.
(d) Impellers to be dynamically balanced to ISO 1940 Gr.6.3
(e) All pressure parts shall be hydraulically tested at 150% of the shut-off head or
200% of rated head, whichever is higher for 30 minutes. No leakage is
allowed.
(f) All pumps to be performance tested as per Hydraulic Institute Standard/Indian
Standard. Performance test to include check for noise, vibration level and
temperature rise.
1.07.02 Valves & Specialities
(a) Valves and Specialities shall be tested as per relevant standards / codes.
(b) Seat Leakage and hydraulic test to be carried out as per relevant standards /
codes.
1.07.03 Pipes and Fittings
Pipes and fittings shall be tested as per relevant standards / codes.
1.07.04 AIR COMPRESSORS:
a) All pressure parts shall be hydraulically tested at not less than 150% of
design pressure for a duration of 30 minutes prior to painting.
b) All other parts including inter-connecting piping shall be hydraulically tested
wherever possible, as per relevant codes.
c) Ultrasonic testing shall be carried out on all forgings and Rotors for dia 50mm
and above. MPI/DP test shall be done on machined areas of the components.
d) During assembly all clearances and alignments shall also be checked and
recorded.
e) Rotor shall be statically and dynamically balanced.
f) Performance Test (Shop Test)
i) Performance test on the compressor shall be carried out in
accordance with ISO:1217/eq. The test shall also include
demonstration of loading and unloading mechanism (Capacity control)
and operation of safety valve.
ii) Vibration and Noise level measurement shall be done during shop
performance test.
1.07.05 AIR RECEIVER
a) Each finished vessel shall be hydraulically tested to 150% of the design
pressure for a duration of 30 minutes.
b) NDT on weld joints shall be as per respective code requirements or the
minimum as specified below:
(i) 100 % DPT on root run of butt welds.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIIE-01
COAL HANDLING PLANT

Page
5 of 7

(ii) 100% DPT on all finished butt welds and fillet welds
(iii) 10% RT on butt welds which shall include all T- joints.
1.08.00 Dust Extraction and Ventilation Systems
1.08.01 Fan
(a) All materials should be of tested quality and test certificates should be
provided.
(b) Dynamic balancing of the fan impellers to be carried out.
(c) Shop run test shall be conducted on all centrifugal fans including check for
noise and vibration level.
(d) Performance test shall be conducted on one fan of each type at shop for
capacity, pressure, efficiency and power consumption.
1.08.02 Valves and Specialities
Refer 1.07.02 above
1.08.03 Pipes and Fittings
Refer 1.07.03 above
1.09.00 Vibrating Screening Feeders
(a) Shaft forgings to be checked for ultrasonic testing in addition to check for
chemical, mechanical, hardness, microstructure etc. as per applicable
material specification
(b) Following minimum NDT requirements to be ensured for welds:
i) Butt welds - 10% UT/RT and 100% MPI/DPT.
ii) Fillet Welds - 10% MPI/DPT.
(c) Shop trial run test shall be conducted to checks for speed (RPM), amplitude
(stroke), temperature rise and noise level.
1.10.00 Crushers
The details of the checks to be carried out for various components are to be
submitted by the Contractor for Owners approval. However, some indicative checks
on different items are given below which should necessarily form part of the Quality
Assurance Plan to be agreed with the Owner.
(a) All plates equal to or above 25mm thickness shall be ultrasonically tested.
(b) Shaft forgings and suspension bars to be checked for ultrasonic testing in
addition to check for chemical, mechanical, hardness, microstructure etc. as
per applicable material specification.
(c) Following minimum NDT requirements to be ensured for welds:
(d) Crusher rotor to be dynamically balanced. Procedure to be submitted for
approval.
(e) No-load trial run test to be carried out at shop to check for speed (RPM),
temperature rise, noise level and vibration.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIIE-01
COAL HANDLING PLANT

Page
6 of 7

1.11.00 Travelling Trippers & Bunker Sealing Arrangement
Mobile Trippers
(a) Shaft and wheel forgings Ultrasonic test in addition to check for chemical,
mechanical, hardness, microstructure etc. as per applicable material
specification shall be conducted.
(b) Following minimum NDT requirements to be ensured for welds:
(c) Shop trial run test shall be carried out and shall include check for noise level
and vibration.
1.12.00 In-Line Magnetic Separators
i) Overall Dimensional, Visual check alongwith control panel.
ii) HV & IR.
iii) Operation, temperature rise, lifting capacity, force index and gauss strength.
1.13.00 Metal Detectors
i) Functional test including sensitivity, Burn in test, operation of liquid spray
marker, detection of smallest piece of different materials as specified.
ii) Test report for Degree of protection test to be furnished.
1.14.00 Coal Sampling Units
(a) Free carriage and cutter movement, speed of cutter and dust door closing
and sealing shall be tested for samplers.
(b) No load test shall be carried out for crushers.
1.15.00 Elevators (Rack and Pinion Type)
submitted by the contractor for owners approval. However, some indicative checks
on different items are given below which should necessarily form part of the quality
assurance plan to be agreed with the owner.
1.15.01 All forgings shall be subjected to ultrasonic test to ensure free from internal defects in
addition to check for chemical and mechanical properties.
1.15.02 10% of the welds selected at random shall be subject to DP test.
1.15.03 All forged components shall be subjected to DPI/MPI after machining.
1.15.04 Gear Reducer shall be checked for gear ratio, backlash, contact pattern. No load
shop trial run shall be conducted on gear boxes to check for oil leakage, temperature
rise, noise and vibration.
1.15.05 Buffer springs shall be subjected to load test as per relevant specifications. Material
certificates for springs shall also be furnished.
1.15.06 All components prior to assembly shall be checked for dimensions.
1.15.07 Function test of Elevator assembly shall be carried out.
1.15.08 All electrical equipments shall be of proven quality.

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
Sub-Section IIIE-01
COAL HANDLING PLANT

Page
7 of 7

1.15.09 Galvanized components/parts shall be checked for weight of Zn coating, thickness of
coating, uniformity of coating and adhesion test and visual examination as per IS
2633 and IS 2629.
1.16.01 All plates equal to or above 25mm thickness shall be ultrasonically tested.
1.16.02 Forgings/Castings for Shaft, Gears/Pinion, Axles, Rail Wheels, Bucket
Hub/Teeth/Blade etc., shall be subject to ultrasonic testing in addition to check for
chemical, mechanical, hardness and micro structure as per applicable material
specification
1.16.03 MPI/DPT shall be carried out on forgings/casting after machining/hardfacing if
applicable.
1.16.04 Following minimum NDT requirements shall be followed for welds:
i) Butt Welds in Tension - 100% UT/RT and 100% MPI/DPT.
ii) Butt Welds in Compression - 10% UT/RT and 10% MPI/DPT.
iii) Fillet Welds - 10% MPI/DPT.
1.16.05 Trial assembly of Stacker/Reclaimer, Sub-assemblies shall be carried out at shop.
Manufacturer shall furnish detail procedure for various sub assemblies such as wheel
bogies, base frame, slew deck, bucket wheel, boom, bucket wheel with shaft and
sample bucket etc. for NTPC approval.

SECTION-VI
PART-B

PART - B


INDUCTION MOTORS

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-02
INDUCTION MOTOR
PAGE 1 OF 1

INDUCTION MOTOR & SYNCHRONOUS MACHINE SQE_7

TESTS/CHECKS

TEMS/COMPONENTS

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u
a
l
i
c
/
L
e
a
k
/
P
r
e
s
s
u
r
e

T
e
s
t

T
h
e
r
m
a
l

C
h
a
r
a
c
t
e
r
i
s
t
i
c
s

R
u
n

o
u
t

D
y
n
a
m
i
c

B
a
l
a
n
c
i
n
g

A
l
l

t
e
s
t
s

a
s

p
e
r

I
S
-
3
2
5
/
I
S
-
4
7
2
2

/

9
2
8
3

V
i
b
r
a
t
i
o
n

O
v
e
r

s
p
e
e
d

T
a
n

d
e
l
t
a
,

s
h
a
f
t

v
o
l
t
a
g
e

&

p
o
l
a
r
i
s
a
t
i
o
n

i
n
d
e
x

t
e
s
t

Plates for stator frame,end shield, spider
etc.
Y Y Y Y Y
Shaft Y Y Y Y Y Y Y
Magnetic Material Y Y Y Y Y Y Y Y
Rotor Copper/Aluminium Y Y Y Y Y Y Y
Stator copper Y Y Y Y Y Y Y
SC Ring Y Y Y Y Y Y Y Y Y
Insulating Material Y Y Y Y Y
Tubes for Cooler Y Y Y Y Y Y Y
Sleeve Bearing Y Y Y Y Y Y Y
Stator/Rotor, Exciter Coils Y Y Y Y Y
Castings, stator frame,terminal box and
bearing housing etc.
Y Y Y Y Y Y
Fabrication & machining of stator, rotor,
terminal box
Y Y Y Y
Wound stator Y Y Y Y
Wound Exciter Y Y Y Y
Rotor complete Y Y Y Y Y
Exciter, Stator, Rotor, Terminal Box
assembly
Y Y Y
Accessories, RTD, BTD,CT, Brushes,
Diodes,Space heater, antifriction
bearing, cable glands, lugs, gaskets etc.
Y Y Y
Motor ( IS 325 / 4722/ 9283) Y Y Y Y Y Y Y1
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality
Plan indicating the practices & Procedure followed along with relevant supporting
documents during QP finalization. However, No QP for LT motor up to 50KW.
2. Makes of all major bought out items will be subject to NTPC approval.
Y1 = for HT Motor / Machines only.

SECTION-VI
PART-B

PART - B


LT SWITCHGEAR & BUSDUCT

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-03
LT SWITCHGEAR AND
BUS DUCT
PAGE 1 OF 3

LT SWITCHGEAR
(MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
ATTRIBUTES /
CHARACTERIS-TICS

ITEMS/ COMPONENTS/
SUB SYSTEM
ASSEMBLIY
M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

&

T
C

D
i
m
e
n
s
i
o
n
s

&

F
i
n
i
s
h

E
l
e
c
t
r
i
c
a
l

p
r
o
p
e
r
t
i
e
s

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

p
r
o
p
e
r
t
i
e
s

F
u
n
c
t
i
o
n
a
l

&

O
p
e
r
a
t
i
o
n
a
l

F
e
a
t
u
r
e
s

a
s

p
e
r

N
T
P
C

S
p
e
c
.

I
t
e
m

t
o

c
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

S
t
a
n
d
a
r
d
s

P
r
e
t
r
e
a
t
m
e
n
t

a
s

p
e
r

I
S

6
0
0
5

P
a
i
n
t

S
h
a
d
e
,

A
d
h
e
s
i
o
n
,

T
h
i
c
k
n
e
s
s

&

F
i
n
i
s
h

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k
s

M
i
l
l
i
-
v
o
l
t

d
r
o
p

T
e
s
t

I
R

H
V

I
R

T
e
s
t

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

R
o
u
t
i
n
e

t
e
s
t

a
s

p
e
r

N
T
P
C

s
p
e
c

A
l
l

R
o
u
t
i
n
e

t
e
s
t
s

a
s

p
e
r

N
T
P
C

s
p
e
c
.

&

I
S

Sheet Steel (IS : 513) Y Y Y Y Y
Aluminum Bus bar Material
(IS : 5082)

Y Y Y Y Y Y
Copper Bus bar Material
(IS : 613)

Y Y Y Y Y Y
Support Insulator (IS :
9431, IS : 10912, IEC :
660)

Y Y Y Y Y
Air Circuit Breaker (IS:
13947)
Y Y Y Y Y Y Y
Energy Meters (IS : 722)

Y Y Y Y Y Y
Power & Aux. Contactors
(IS : 13947)

Y Y Y Y Y Y
Protection & Aux. Relays
(IS : 3231)

Y Y Y Y Y Y
Control & Selector
Switches (IS : 6875)

Y Y Y Y Y Y
CTs & PTs (IS 2705 /
3156)
Y Y Y Y
MCCB (IS : 13947) Y Y Y Y Y
Indicating Meters (IS :
1248)
Y Y Y Y Y Y
Indicating Lamps (IS :
13947)
Y Y Y Y Y Y
Air Break Switches
(IS : 13947)
Y Y Y Y Y
Control Terminal Blocks Y Y Y Y

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-03
LT SWITCHGEAR AND
BUS DUCT
PAGE 2 OF 3

LT SWITCHGEAR
(MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
ATTRIBUTES /
CHARACTERIS-
TICS

ITEMS/
COMPONENTS/
SUB SYSTEM
ASSEMBLIY
M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

&

T
C

D
i
m
e
n
s
i
o
n
s

&

F
i
n
i
s
h

E
l
e
c
t
r
i
c
a
l

p
r
o
p
e
r
t
i
e
s

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

p
r
o
p
e
r
t
i
e
s

F
u
n
c
t
i
o
n
a
l

&

O
p
e
r
a
t
i
o
n
a
l

F
e
a
t
u
r
e
s

a
s

p
e
r

N
T
P
C

S
p
e
c
.

I
t
e
m

t
o

c
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

S
t
a
n
d
a
r
d
s

P
r
e
t
r
e
a
t
m
e
n
t

a
s

p
e
r

I
S

6
0
0
5

P
a
i
n
t

S
h
a
d
e
,

A
d
h
e
s
i
o
n
,

T
h
i
c
k
n
e
s
s

&

F
i
n
i
s
h

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k
s

M
i
l
l
i
-
v
o
l
t

d
r
o
p

T
e
s
t

I
R

H
V

I
R

T
e
s
t

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

R
o
u
t
i
n
e

t
e
s
t

a
s

p
e
r

N
T
P
C

s
p
e
c

A
l
l

R
o
u
t
i
n
e

t
e
s
t
s

a
s

p
e
r

N
T
P
C

s
p
e
c
.

&

I
S

Fuse (IS 13703) Y Y Y Y
Control
Transformer
(IS : 12021)
Y Y Y Y Y Y
Push Buttons (IS :
4794)
Y Y Y Y Y Y
Transducer (IEC :
60688)
Y Y Y Y Y Y
MCB (IS : 8828) Y Y Y Y Y Y
Breaker Handling
Trolley
Y Y Y Y Y Y
Synthetic Rubber
Gasket
(IS : 11149)
Y Y Y Y Y
LT SWITCHGEAR
(IS : 8623)
Y Y Y Y Y Y Y Y Y Y Y
Notes:

1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed
Quality Plan indicating the practice and procedure along with relevant supporting
documents.
2. Makes of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-03
LT SWITCHGEAR AND
BUS DUCT
PAGE 3 OF 3

LT BUSDUCT
ATTRIBUTES ,
CHARACTERISTICS

ITEM,
COMPONENTS,
SUB SYSTEM
ASSEMBLY

D
i
m
e
n
s
i
o
n

&

S
u
r
f
a
c
e

F
i
n
i
s
h

M
a
k
e
,

T
y
p
e
,

R
a
t
i
n
g

&

T
C

E
l
e
c
t
r
i
c
a
l

P
r
o
p
e
r
t
i
e
s

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

P
r
o
p
e
r
t
i
e
s

I
t
e
m

t
o

c
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

I
S

W
P
S

A
p
p
r
o
v
a
l
,

W
e
l
d
e
r

Q
u
a
l
i
f
i
c
a
t
i
o
n

W
e
l
d

Q
u
a
l
i
t
y

C
h
e
c
k

(

D
P

t
e
s
t

&

x
-
r
a
y

T
e
s
t
)

P
a
i
n
t

S
h
a
d
e
,

T
h
i
c
k
n
e
s
s
,

A
d
h
e
s
i
o
n

&

F
i
n
i
s
h

T
i
g
h
t
n
e
s
s

b
y

T
o
r
q
u
e

m
e
a
s
u
r
e
m
e
n
t

E
l
e
c
t
r
i
c
a
l

C
l
e
a
r
a
n
c
e
s

G
a
l
v
a
n
i
z
i
n
g

T
e
s
t

a
s

p
e
r

I
S

2
6
2
9
/

2
6
3
3
/

I
R

H
V

I
R

T
e
s
t

P
h
a
s
e

S
e
q
u
e
n
c
e

C
h
e
c
k

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

r
o
u
t
i
n
e

t
e
s
t

a
s

p
e
r

N
T
P
C

s
p
e
c
.

Aluminum Sheets /
Plates / Strips /
Flexibles / tubes
(IS : 5082 / 737)

Y Y Y Y Y Y Y
CRCA Flats / ISMC
(IS 2062)

Y Y Y Y Y
Neoprene / Synthetic
Rubber Gaskets (IS
11149 / 3400)

Y Y Y Y
Rubber Bellows (IS :
3400)

Y Y Y Y
Support Insulator
(BS : 2782,
IEC : 660, IS:10912)

Y Y Y Y
Galvanized Structure
& GI Earthing Flat
(IS : 2629 / 2633 /
4749 )

Y Y Y Y
Space Heater &
Thermostat

Y Y Y
LT Busduct (IS :
8623 PART 2)
Y Y Y Y Y Y Y Y Y Y Y
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed
documents.

SECTION-VI
PART-B

PART - B


LT POWER CABLE

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-04
LT POWER CABLES
PAGE 1 OF 3

QUALITY ASSURANCE & INSPECTION
L.T POWER CABLES
(1.1 KV PVC & XLPE CABLES)
Attributes /
Characteristics

Item / Components /
Sub System Assembly

M
a
k
e
,

R
a
t
i
n
g
,

T
y
p
e

&

T
C

D
i
m
e
n
s
i
o
n
/
s
u
r
f
a
c
e

f
i
n
i
s
h

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

C
o
m
p
o
s
i
t
i
o
n

E
l
e
c
t
r
i
c
a
l

P
r
o
p
e
r
t
i
e
s

S
p
a
r
k

T
e
s
t

H
o
t

s
e
t

t
e
s
t

(
X
L
P
E
)

L
a
y

l
e
n
g
t
h

/

S
e
q
u
e
n
c
e

A
r
m
o
u
r

c
o
v
e
r
a
g
e
,

C
r
o
s
s

o
v
e
r
,

l
o
o
s
e
n
e
s
s
,

G
a
p

b
e
t
w
e
e
n

t
w
o

a
r
m
o
u
r

w
i
r
e
/
s
t
r
i
p

S
e
q
u
e
n
t
i
a
l

m
a
r
k
i
n
g
/
s
u
r
f
a
c
e

f
i
n
i
s
h

/
c
a
b
l
e

l
e
n
g
t
h

T
e
n
s
i
l
e

s
t
r
e
n
g
t
h
,

e
l
o
n
g
a
t
i
o
n

b
e
f
o
r
e

&

a
f
t
e
r

a
g
e
i
n
g

o
f

i
n
s
u
l
a
t
i
o
n

&

o
u
t
e
r

s
h
e
a
t
h

T
h
e
r
m
a
l

S
t
a
b
i
l
i
t
y

o
f

i
n
s
u
l
a
t
i
o
n

a
n
d

o
u
t
e
r

s
h
e
a
t
h

*

A
n
t
i

t
e
r
n
i
t
e

t
r
e
a
t
m
e
n
t

o
n

w
o
o
d
e
n

d
r
u
m
s

C
o
n
s
t
r
u
c
t
i
o
n
a
l

/

r
e
q
u
i
r
e
m
e
n
t

a
s

p
e
r

N
T
P
C

S
p
e
c
.

R
o
u
t
i
n
e

a
n
d

a
c
c
e
p
t
a
n
c
e

t
e
s
t

a
s

p
e
r

R
e
l
e
v
a
n
t

S
t
a
n
d
a
r
d

a
n
d

N
T
P
C

s
p
e
c
i
f
i
c
a
t
i
o
n

F
R
L
S

T
e
s
t

Aluminum (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
XLPE Compound(IS-7098 Part-I) Y Y Y Y Y
FRLS PVC Compound(IS-5831 )
ASTM-D-2843/ ASTM-D-2863
IEC-754 Part-I
Y Y Y
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554 & 7098
Part-1)
ASTM-D-2843/ IS 10810 (Part- - 58 )
IEC-754 Part-I
Swedish Chimney SS 4241475 for
(F3 category)
Flammability test IEC-332 Part 3
Cat-B
Y Y Y Y Y Y Y

Y Y
Wooden drum (IS-10418) / Steel
drum
Y Y
Note: This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice
and procedure along with relevant supporting documents.

2. Not applicable for XLPE insulation

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-04
LT POWER CABLES
PAGE 2 OF 3

ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all
types & sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
2) High voltage test at room temperature
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size
of the cables on the cable drums selected at random as per sampling
plan mentioned in IS: 1554 Part 1 & IS 7098 Part-I
A) For Conductor
1) Annealing test For copper conductor only
2) Tensile test For aluminium conductor only
3) Wrapping test For aluminium conductor only
4) Resistance test
B) For Armour Wires / Formed Wires ( If applicable )
1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires only
8) Uniformity of Zinc coating For G S wires / Formed wires only
9) Adhesion test For G S wires / Formed wires only
10) Freedom from defects

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-04
LT POWER CABLES
PAGE 3 OF 3

C) For PVC / XLPE insulation & PVC Sheath
1) Test for thickness
2) Hot set test For XLPE insulation only
3) Tensile strength & Elongation before ageing
D) For completed cables
1) Insulation resistance test (Volume resistivity method)
E) Following tests shall be carried out and only one sample shall be taken
from each offered lot of all sizes for these tests:-
1) Tensile strength & elongation after ageing on PVC / XLPE insulation and
PVC outer sheath
2) Thermal stability test on PVC insulation and outer sheath
3) Oxygen index test on outer sheath
4) Smoke density rating test on outer sheath as per ASTM D 2843
5) Acid gas generation test on outer sheath as per IEC 754 (Part 1)
6) Flammability test as per IEC-332 - Part- 3 (Category- B) on completed
cable
7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable
F) Following tests shall be carried on one length of each size of offered
lot:
1) Surface finish, length measurement, sequence of cores, armour coverage,
Gap between two consecutive armour wires / formed wires

SECTION-VI
PART-B

PART - B


LT CONTROL CABLES

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-05
LT CONTROL CABLES
PAGE 1 OF 3

QUALITY ASSURANCE & INSPECTION
L.T CONTROL CABLES
(1.1 KV PVC CABLES)

Attributes /
Characteristics

Item / Components /
Sub System Assembly

M
a
k
e
,

T
y
p
e
,

R
a
t
i
n
g
,

T
.
C

D
i
m
e
n
s
i
o
n
/
s
u
r
f
a
c
e

f
i
n
i
s
h

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

C
o
m
p
o
s
i
t
i
o
n

E
l
e
c
t
r
i
c
a
l

P
r
o
p
e
r
t
i
e
s

S
p
a
r
k

T
e
s
t

L
a
y

l
e
n
g
t
h
/
S
e
q
u
e
n
c
e

A
r
m
o
u
r

c
o
v
e
r
a
g
e
,

c
r
o
s
s

o
v
e
r
,

l
o
o
s
e
n
e
s
s
,

g
a
p

b
e
t
w
e
e
n

t
w
o

a
r
m
o
u
r

w
i
r
e

S
e
q
u
e
n
t
i
a
l

m
a
r
k
i
n
g
/
s
u
r
f
a
c
e

f
i
n
i
s
h
/
c
a
b
l
e

l
e
n
g
t
h

T
e
n
s
i
l
e

s
t
r
e
n
g
t
h
,

e
l
o
n
g
a
t
i
o
n

b
e
f
o
r
e

&

a
f
t
e
r

a
g
e
i
n
g

o
f

i
n
s
u
l
a
t
i
o
n

&
o
u
t
e
r

s
h
e
a
t
h

s
h
e
a
t
h

T
h
e
r
m
a
l

s
t
a
b
i
l
i
t
y

o
f

i
n
s
u
l
a
t
i
o
n

a
n
d

o
u
t
e
r

s
h
e
a
t
h

A
n
t
i

t
e
r
m
i
t
e

t
r
e
a
t
m
e
n
t

o
n

w
o
o
d
e
n

d
r
u
m
s

C
o
n
s
t
r
u
c
t
i
o
n
a
l

f
e
a
t
u
r
e

a
s

p
e
r

N
T
P
C

S
p
e
c
.

R
o
u
t
i
n
e

&

A
c
c
e
p
t
a
n
c
e

t
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
a
n
d
a
r
d

&

p
a
g
e

2

&

3

o
f

t
h
i
s

t
a
b
l
e

F
R
L
S

T
e
s
t

Copper Conductor
(IS-8130)
Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
FRLS PVC Compound
IS-5831
ASTM-D-2843/ IS 10810
(Part-58 ) IEC-754 Part-1
Y Y Y Y
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554- 1)
ASTM-D-2843/ IS 10810
(Part-58 )
IEC-754 Part-1
Swedish Chimney: SEN
SS 424-1475( F3 category)
Flammability test IEC-332
Part-3 Cat-B
Y Y Y Y Y Y Y Y Y
Wooden drum (IS : 10418)
/ Steel drum
Y Y
1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed
quality plan indicating the Practice and procedure along with relevant supporting documents.

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-05
LT CONTROL CABLES
PAGE 2 OF 3

CONTROL CABLE

ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all
types & sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size
of the cables on the cable drums selected at random as per sampling
plan mentioned in IS: 1554 Part 1
A) For Conductor
1) Annealing test For copper conductor only
2) Resistance test
B) For Armour Wires / Formed Wires (If applicable)
1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires only
8) Uniformity of Zinc coating For G S wires / Formed wires only
9) Adhesion test For G S wires / Formed wires only
10) Freedom from defects

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-05
LT CONTROL CABLES
PAGE 3 OF 3

C) For PVC insulation & PVC Sheath
1) Test for thickness
2) Tensile strength & Elongation before ageing
D) For completed cables
1) Insulation resistance test (Volume resistivity method)
E) Following tests shall be carried out and only one sample shall be taken
from each offered lot of all sizes for these tests:-
1) Tensile strength & elongation after ageing on PVC insulation and PVC
outer sheath
2) Thermal stability test on PVC insulation and outer sheath
3) Oxygen index test on outer sheath
4) Smoke density rating test on outer sheath as per ASTM D 2843
5) Acid gas generation test on outer sheath as per IEC 754 (Part 1)
6) Flammability test as per IEC-332 - Part- 3 (Category- B) on completed
cable
7) Fire resistance test as per SS 4241475 (F3 Category) on completed cable
F) Following tests shall be carried on one length of each size of offered
lot:
1) Surface finish, length measurement, sequence of cores, armour coverage,
Gap between two consecutive armour wires / formed wires

SECTION-VI
PART-B

PART - B



CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-06
INSTRUMENTATION
CABLES
PAGE 1 OF 1

INSTRUMENTATION CABLE
TESTS

ITEMS

C
o
n
d
u
c
t
o
r

R
e
s
i
s
t
a
n
c
e

&

(
A
)

H
i
g
h

V
o
l
t
a
g
e

&

(
A
)

I
n
s
u
l
a
t
i
o
n

R
e
s
i
s
t
a
n
c
e

&

(
A
)

C
o
n
s
t
r
u
c
t
i
o
n
a
l

d
e
t
a
i
l
,

d
i
m
e
n
s
i
o
n
s

(
A
)

O
u
t
e
r
-
S
h
e
a
t
h
e
/
c
o
r
e

m
a
r
k
i
n
g
,

e
n
d

s
e
a
l
i
n
g

(
A
)

T
h
e
r
m
a
l

S
t
a
b
i
l
i
t
y

(
A
)

+

V
i
s
u
a
l
,

S
u
r
f
a
c
e

f
i
n
i
s
h

(
A
)

+

E
l
e
c
t
r
i
c
a
l

P
a
r
a
m
e
t
e
r
s

*
*

(
A
)

+

P
e
r
s
u
l
p
h
a
t
e

T
e
s
t

(
A
)

+

O
v
e
r
a
l
l
/
C
o
v
e
r
a
g
e
/
C
o
n
t
i
n
u
i
t
y

(
A
)

S
w
i
d
e
s
h

c
h
i
m
n
e
y

T
e
s
t

(
S
S
-
4
2
4
1
4
7
5
)

(
A
)

+
+

F
R
L
S

T
e
s
t

*

(
A
)

+
+

T
e
n
s
i
l
e

&

E
l
o
n
g
a
t
i
o
n

b
e
f
o
r
e

&

a
f
t
e
r

a
g
i
n
g

(
A
)

+
+

V
o
l
.

R
e
s
i
s
t
i
v
i
t
y
.

a
t

r
o
o
m

&

E
l
e
v
a
t
e
d

T
e
m
p
.

(
A
)

+
+

S
p
a
r
k

t
e
s
t

r
e
p
o
r
t

r
e
v
i
e
w

1. Instrument cable
twisted and shielded

Conductor (IS-8130) Y Y Y
Insulation (VDE-207) Y Y Y Y Y Y
Pairing/Twisting Y Y Y
Shielding Y Y Y
Drain wire Y Y Y Y Y
Inner Sheath Y Y Y Y Y Y
Outer Sheath Y Y Y Y Y Y
Over all cable Y Y Y Y Y Y Y Y Y
Cable Drums
(IS-10418)
Y Y
Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6)
Compensating cables shall be checked for Thermal EMF/Endurance test as per IS
8784.
Note : This is an indicative list of tests/checks. The manufacture is to furnish a
detailed Quality Plan indicating his practice & Procedure along with relevant
supporting documents during QP finalization for all item.
Note : - Routine Test A - Acceptance Test Y - Test Applicable
Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable)
* FRLS Tests: Oxygen / Temp Index (ASTM D-2863), Smoke Density Rating
(ASTM D 2843), HCL Emission (IEC-754-1)
** Characteristic Impedance, Attenuation, Mutual Capacitance, Cross Talk
(As applicable)
+ Sample size will be One No. of each size/type per lot.
++ Sample size will be One No. sample for complete lot offered irrespective of
size/type.

SECTION-VI
PART-B

PART - B


STATION LIGHTING

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-07
STATION LIGHTING
PAGE 1 OF 1

STATION LIGHTING

Item Components
Sub System
Assembly

Attributes
Characteristics

M
a
k
e
,

T
y
p
e

,

R
a
t
i
n
g
/

T
C

D
i
m
e
n
s
i
o
n

P
r
e
-
T
r
e
a
t
m
e
n
t

o
f

s
h
e
e
t

P
a
i
n
t

S
h
a
d
e

T
h
i
c
k
n
e
s
s

A
d
h
e
s
i
o
n

&

F
i
n
i
s
h

G
a
l
v
a
n
i
s
e

T
e
s
t

I
P

T
e
s
t

B
o
u
g
h
t

O
u
t

I
t
e
m
s
/

B
i
l
l

o
f

M
a
t
e
r
i
a
l

H
V

&

I
R

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k

a
s

p
e
r

s
p
e
c
.

C
o
n
s
t
r
u
c
t
i
o
n
a
l

F
e
a
t
u
r
e

a
s

p
e
r

N
T
P
C

s
p
e
c
.

R
o
u
t
i
n
e

T
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
d

a
n
d

s
p
e
c

A
c
c
e
p
t
a
n
c
e

T
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
d

a
n
d

s
p
e
c

I
t
e
m

t
o

c
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

s
t
a
n
d
a
r
d

Luminaries (IS-10322
Part-5 Sec.1)
Y Y Y Y

Y
Electronic Ballast Y
Y
Y Y
Lighting Wire (IS-694) Y
Y

Fans (IS-374) Y
Y

Pole (IS-2713) Y Y Y
Y
Y
Lamps (IS-9800, IS-
9974)
Y Y Y
Lighting Mast Y Y Y Y
Y
Y
Wall Mounted Lighting
Panel (IS-513, IS-5)
Y Y Y Y Y Y Y Y Y Y Y Y
Switch Box/ Junction
Box/Receptacles/ Local
Push Button Station,
Lighting Panel (IS-513,
2629, 2633, 4759,
6745)
Cable Gland (BS-6121) Y Y Y

Cable Lug (IS-8309) Y Y Y

Flexible Conduit Y
Y

Lighting Transformer
(IS-1117)
Y Y Y
Epoxy & Galvanised
Conduit (IS-9537, 2629,
2633, 4759, 6745)
Y Y
Y
Y
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan
indicating the practice and procedure along with relevant supporting documents.

2. Make of all major Bought Out Items will be subject to NTPC approval.

SECTION-VI
PART-B

PART - B


CABLING, EARTHING & LIGHTNING
PROTECTION

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-08
CABLING, EARTHING
& LIGHTING
PROTECTION
PAGE 1 OF 1

CABLING, EARTHING, LIGHTNING PROTECTION

ATTRIBUTES /
CHARACTERISTICS

ITEMS/COMPONENTS /
SUB SYSTEMS

D
i
m
e
n
s
i
o
n

P
a
i
n
t

s
h
a
d
e
,

p
a
i
n
t

t
h
i
c
k
n
e
s
s
,

a
d
h
e
s
i
o
n

P
r
e
-
t
r
e
a
t
m
e
n
t

o
f

s
h
e
e
t

I
P

p
r
o
t
e
c
t
i
o
n

P
r
o
o
f

l
o
a
d
*

S
u
r
f
a
c
e

f
i
n
i
s
h

D
e
f
l
e
c
t
i
o
n

t
e
s
t
*

H
V

&

I
R

G
a
l
v
a
n
i
s
e

T
e
s
t

(
I
f

A
p
p
l
i
c
a
b
l
e
)

F
u
n
c
t
i
o
n
a
l

B
o
u
g
h
t

o
u
t

i
t
e
m
s
/
B
i
l
l

o
f

m
a
t
e
r
i
a
l

R
o
u
t
i
n
e

t
e
s
t
s

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
a
n
d
a
r
d

&

s
p
e
c
i
f
i
c
a
t
i
o
n

A
c
c
e
p
t
a
n
c
e

t
e
s
t
s

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
a
n
d
a
r
d

&

s
p
e
c
i
f
i
c
a
t
i
o
n

C
o
n
s
t
r
u
c
t
i
o
n
a
l

f
e
a
t
u
r
e

a
s

p
e
r

N
T
P
C

Wall Mounted-Lighting Panel
(IS-513, IS:5, IS:2629, 2633,
6745)
Switch box/junction box/
Receptacles Panel (IS-513,
IS:5, IS:2629, 2633, 6745)
Cable glands(BS-6121) Y Y
Cable lug(IS-8309) Y Y
Lighting wire(IS-694) Y Y
Flexible conduits Y Y Y
Conduits (Galvanise & Epoxy)
IS-9537 & IS-2629, 2633, 6745
Y Y Y Y Y
RCC Hume Pipe (IS-458) Y
Cable termination & straight
through joint (VDE-0278)
Y Y Y
Cable Trays, Flexible supports
system & accessories IS-513,
2629, 2633, 6745
Y Y Y Y Y Y Y Y Y Y
Trefoil clamp Y Y
GI flats for earthing & lighting
protection (IS 2062, 2629,
6745, 2633)
Y Y Y Y Y
GI wire (IS-280) Y Y
Fire Sealing System ( BS 476) Y Y Y

Note: 1. This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan
2. * Deflection Test on cable trays and Proof Load test on cable trays support system will be as per
details given in the NTPC technical specification & approved MQP. The above acceptance tests
shall be done only on one sample from each size of offered lot.
3. Make of all items will be subject to NTPC approval.

SECTION-VI
PART-B

PART - B


CONTROL PANELS

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-09
CONTROL PANEL
PAGE 1 OF 1

CONTROL PANEL

Attributes
Characteristics

Item Components
Sub System Assembly

E
l
e
c
t
r
i
c
a
l

P
r
o
p
e
r
t
i
e
s

M
e
c
h
a
n
i
c
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

P
r
o
p
e
r
t
i
e
s

D
i
m
e
n
s
i
o
n
s

/

F
i
n
i
s
h

T
y
p
e
/

R
a
t
i
n
g
/
F
u
n
c
t
i
o
n
a
l

c
h
e
c
k

H
V
/
I
R

R
o
u
t
i
n
e

t
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
d
.

C
o
n
s
t
r
u
c
t
i
o
n
a
l

F
e
a
t
u
r
e
s

I
S
:
6
0
0
5

,
S
e
v
e
n

t
a
n
k

p
r
o
c
e
s
s

P
a
i
n
t

f
i
n
i
s
h
/

s
h
a
d
e
/
t
h
i
c
k
n
e
s
s

a
d
h
e
s
i
o
n

M
o
u
n
t
i
n
g
s

/

B
O
M
/

M
a
k
e
,

C
o
m
p
l
e
t
e
n
e
s
s

/

W
i
r
i
n
g

I
n
t
e
r
l
o
c
k

F
u
n
c
t
i
o
n
a
l

&

O
p
e
r
a
t
i
o
n

T
e
s
t
i
n
g

/

S
i
m
u
l
a
t
i
o
n

c
h
e
c
k

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

T
e
s
t

S
p
e
c
i
f
i
c
a
t
i
o
n

r
e
q
u
i
r
e
m
e
n
t

Sheet Steel (IS-513) Y Y Y
Aluminum / Copper Bus-bar
(IS-5082/IS-613/IS-1987)
Y Y Y Y
Support Insulator
(BS-2782/IEC-660/IS-10912)
Y Y Y Y
Control / Selector Switch
(IS-6875)
Y Y Y
Contractor/ MCB (IS-13947) Y Y Y
O/L Protection relays (IS-3231) Y Y
C.T /V.T/ Indicating Meter
(IS-2705/3156/1248)
Y Y Y
Fuse/ Fuse carrier
(IS-13703)
Y Y Y
Terminals/lugs/PVC wires
(IS-13947//IS-694)
Y Y Y Y Y
Timers(IS-3231) Y Y Y
LVS, Mosaics Y
Push Button/ Lamp/ (IS-6875) Y Y Y
Control Transformer
(IS-12021)
Y Y Y
Mimic, Annunciater Y Y
Gasket (IS-11149) Y Y Y Y Y
Fabrication Y
Pretreatment & Painting Y Y
Control panel Y Y Y Y Y

NOTE:

1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan

2. All major Bought out Items will be subject to NTPC approval.

SECTION-VI
PART-B

PART - B


CONTROL DESK WITH
PROGRAMMABLE LOGIC CONTROLLER

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-10
CONTROL DESK WITH PLC
PAGE 1 OF 1

PROGRAMMABLE LOGIC CONTROLLER

TESTS

ITEMS

V
i
s
u
a
l

G
A
,

B
O
M

,
L
a
y

O
u
t

o
f

c
o
m
p
o
n
e
n
t
s

D
i
m
e
n
s
i
o
n
s

P
a
i
n
t

S
h
a
d
e
/

T
h
i
c
k
n
e
s
s
/
A
d
h
e
s
i
o
n

A
l
i
g
n
m
e
n
t

o
f

S
e
c
t
i
o
n

C
o
m
p
o
n
e
n
t

R
a
t
i
n
g
/

M
a
k
e

/

T
y
p
e

W
i
r
i
n
g

I
R

&

H
V

R
e
v
i
e
w

o
f

T
C

f
o
r

i
n
s
t
r
u
m
e
n
t
s
/

D
e
v
i
c
e
s
/

R
e
c
o
r
d
e
r
s
,

I
n
d
i
c
a
t
o
r
s
/

M
o
s
a
i
c

I
t
e
m
s
/

T
r
a
n
s
d
u
c
e
r
s

A
c
c
e
s
s
i
b
i
l
i
t
y

o
f

T
B
S
/

D
e
v
i
c
e
s

I
l
l
u
m
i
n
a
t
i
o
n

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k

f
o
r

C
o
n
t
r
o
l

E
l
e
m
e
n
t

,

A
n
n
u
n
c
i
a
t
i
o
n

M
i
m
i
c

T
e
s
t

a
s

p
e
r

I
E
C

1
1
3
1

*

T
e
s
t

a
s

p
e
r

S
t
d

&

(

A
)

1. PLC Panel Y Y Y Y Y Y Y Y Y Y Y Y
2. Control Desk With PLC Y Y Y Y Y Y Y Y Y Y Y Y Y
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance
Programme in General Technical Conditions
2) This is an indicative list of test/ checks. The manufacturer is to furnish a detailed quality plan
indicating the Practice and Procedure alongwith relevant supporting documents.
*Applicable for PLC Y - Test Applicable , - Routine Test (A) - Acceptance Test

SECTION-VI
PART-B

PART - B


BATTERY CHARGER & BATTERIES

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-11
BATTERY CHARGER
PAGE 1 OF 4

BATTERY CHARGER

Attributes / Characteristics

Items / Components /
Sub- assembly

M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

D
i
m
e
n
s
i
o
n
a
l

c
h
e
c
k

a
n
d

P
a
i
n
t

s
h
a
d
e
,

t
h
i
c
k
n
e
s
s
,

a
d
h
e
s
i
o
n

&

F
i
n
i
s
h

c
h
e
c
k
s

C
o
m
p
l
e
t
e

p
h
y
s
i
c
a
l

e
x
a
m
i
n
a
t
i
o
n

f
o
r

c
o
n
s
t
r
u
c
t
i
o
n
a
l

f
e
a
t
u
r
e
s

a
s

p
e
r

a
p
p
r
o
v
e
d

d
r
g
s

R
i
p
p
l
e

C
o
n
t
e
n
t

T
e
s
t
,

L
o
a
d

L
i
m
i
t
e
r

o
p
e
r
a
t
i
o
n

&

A
V
R

O
p
e
r
a
t
i
o
n

T
e
s
t

O
p
e
r
a
t
i
o
n
a
l

&

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k
s

o
f

a
u
x
.

D
e
v
i
c
e
s

l
i
k
e

a
n
n
u
n
c
i
a
t
o
r
,

s
w
i
t
c
h
e
s
,

i
n
d
i
a
c
t
o
r
s

e
t
c
.

H
V

&

I
R

T
e
s
t

E
n
v
i
r
o
n
m
e
n
t
a
l

S
t
r
e
s
s

S
c
r
e
e
n
i
n
g

Battery Charger Y Y Y Y Y Y Y

Note 1 : This check list is applicable for Battery Charger of capacity upto 24 V / 48 V , 150
A DC.

2 : Separate approval of QP is not envisaged. Main Contractor / nominated inspection
agency will carry out the inspection as per above check-list and submit inspection
report to NTPC for their review / acceptance of the same.

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-11
BATTERY CHARGER
PAGE 2 OF 4

DC SYSTEM SQE_19
LEAD ACID BATTERY
ATTRIBUTES /
CHARACTERISTICS

ITEMS,
COMPONENTS, SUB
SYSTEM ASSEMBLY D
i
m
e
n
s
i
o
n
s

&

F
i
n
i
s
h

C
o
n
f
o
r
m
a
n
c
e

t
o

r
e
l
e
v
a
n
t

p
a
r
t

d
r
g
.

&

M
a
n
u
f
a
c
t
u
r
e
r
s

s
t
a
n
d
a
r
d
s

C
h
e
m
i
c
a
l

c
o
m
p
o
s
i
t
i
o
n

L
e
a
d

C
o
a
t
i
n
g

T
h
i
c
k
n
e
s
s

(
m
i
n
.

2
5

m
i
c
r
o
n
s
,

I
S
:

6
8
4
8

A
p
p
.
F
)

&

A
d
h
e
s
i
o
n

C
o
n
f
o
r
m
a
n
c
e

t
o

C
P
W
D

S
p
e
c
.

f
o
r

T
e
a
k

P
a
i
n
t

P
r
o
c
e
s
s

c
h
e
c
k
s
,

P
a
i
n
t

S
h
a
d
e
,

T
h
i
c
k
n
e
s
s
,

A
d
h
e
s
i
o
n

&

F
i
n
i
s
h

C
o
n
s
t
r
u
c
t
i
o
n
a
l

r
e
q
u
i
r
e
m
e
n
t
s

a
s

p
e
r

N
T
P
C
S
I
n
s
u
l
a
t
i
o
n

R
e
s
i
s
t
a
n
c
e

M
a
r
k
i
n
g

(

R
o
u
t
i
n
e

&

A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

C
h
e
c
k
i
n
g

o
f

P
o
l
a
r
i
t
y

&

a
b
s
e
n
c
e

o
f

s
h
o
r
t

c
i
r
c
u
i
t

(
R
o
u
t
i
n
e

&

A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

T
e
s
t

f
o
r

C
a
p
a
c
i
t
i
e
s

f
o
r

1
0

h
r
s
.

d
i
s
c
h
a
r
g
e

r
a
t
e

a
l
o
n
g

w
i
t
h

t
h
e

t
e
s
t

f
o
r

v
o
l
t
a
g
e

d
u
r
i
n
g

d
i
s
c
h
a
r
g
e

(

A
c
c
e
p
t
a
n
c
e

Container & Lids (IS :
1146)
Y Y
Vent Plugs Y Y
Sealing Compound
(IS : 3116)
Y Y
Positive & Negative
Plates
Y Y
Separators (IS : 6071) Y Y
Electrolyte
(Water / Sulphuric Acid)
(IS : 1069 / 266)
Y Y
Inter-cell Connectors &
Fasteners
Y Y Y
Battery Stand Y Y Y Y
Cell Insulators Y Y Y
Stack Assembly Y Y
Lead Acid Battery
(IS : 1652)
Y Y Y Y Y

Note: This is an indicative list of tests / checks. The manufacturer is to furnish a
detailed Quality Plan indicating the practice and procedure along with relevant
supporting documents.

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-11
BATTERY CHARGER
PAGE 3 OF 4

Ni- Cd BATTERY
ATTRIBUTES /
CHARACTERISTICS

ITEMS, COMPONENTS, SUB
SYSTEM ASSEMBLY
D
i
m
e
n
s
i
o
n
s

&

F
i
n
i
s
h

I
m
p
a
c
t

S
t
r
e
n
g
t
h

C
o
n
f
o
r
m
a
n
c
e

t
o

r
e
l
e
v
a
n
t

p
a
r
t

d
r
g
.

&

M
a
n
u
f
a
c
t
u
r
e
r
s

s
t
a
n
d
a
r
d
s

R
e
s
i
s
t
a
n
c
e

t
o

A
l
k
a
l
i

C
h
e
m
i
c
a
l

c
o
m
p
o
s
i
t
i
o
n

N
i
c
k
e
l

P
l
a
t
i
n
g

t
h
i
c
k
n
e
s
s

P
a
i
n
t

S
h
a
d
e
,

T
h
i
c
k
n
e
s
s
,

A
d
h
e
s
i
o
n

&

F
i
n
i
s
h

A
i
r

P
r
e
s
s
u
r
e

T
e
s
t

a
f
t
e
r

h
e
a
t

s
e
a
l
i
n
g

M
a
r
k
i
n
g

&

M
a
s
s

(
R
o
u
t
i
n
e

&

A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

A
i
r

P
r
e
s
s
u
r
e

T
e
s
t

(
A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

R
e
t
e
n
t
i
o
n

o
f

C
h
a
r
g
e

T
e
s
t

(

A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

A
H

T
e
s
t

(
A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

I
n
s
u
l
a
t
i
o
n

R
e
s
i
s
t
a
n
c
e

(
A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

P
o
l
a
r
i
t
y

&

a
b
s
e
n
c
e

o
f

s
h
o
r
t

c
i
r
c
u
i
t

(
R
o
u
t
i
n
e

&

A
c
c
e
p
t
a
n
c
e

T
e
s
t
)

Container & Lids Y Y Y Y
Vent Plugs Y Y Y
Perforated Steel Strips Y Y Y Y
Active Material for Positive &
Negative Plates
Y Y
Separators Y Y Y
Electrolyte Y Y
Inter-cell Connectors &
Fasteners
Y Y Y Y
Battery Stand Y Y Y
Cell Insulators Y Y Y
Stack Assembly Y Y Y Y Y Y
Ni-Cd Battery
( IS : 10918)
Y Y Y Y Y Y Y
Notes:

1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality
Plan indicating the practice and procedure along with relevant supporting documents.

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-11
BATTERY CHARGER
PAGE 4 OF 4

BATTERY CHARGER

Attributes / Characteristics

Items / Components /
Sub- assembly

M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

&

F
i
n
i
s
h

V
e
r
i
f
i
c
a
t
i
o
n

o
f

R
o
u
t
i
n
e

t
e
s
t

r
e
p
o
r
t
s

a
s

p
e
r

r
e
l
e
v
a
n
t

I
S

S
h
e
e
t

S
t
e
e
l

P
r
e
t
r
e
a
t
m
e
n
t

&

P
a
i
n
t
i
n
g

p
r
o
c
e
s
s

c
h
e
c
k
s

C
o
n
f
o
r
m

t
o

r
e
l
e
v
a
n
t

S
t
a
n
d
a
r
d

&

N
T
P
C

s
p
e
c

D
i
m
e
n
s
i
o
n
a
l

c
h
e
c
k

a
n
d

P
a
i
n
t

s
h
a
d
e
,

t
h
i
c
k
n
e
s
s
,

a
d
h
e
s
i
o
n

&

F
i
n
i
s
h

c
h
e
c
k
s

C
o
m
p
l
e
t
e

p
h
y
s
i
c
a
l

e
x
a
m
i
n
a
t
i
o
n

f
o
r

c
o
n
s
t
r
u
c
t
i
o
n
a
l

f
e
a
t
u
r
e
s

a
s

p
e
r

N
T
P
C

a
p
p
r
o
v
e
d

d
r
g
s

&

s
p
e
c
i
f
i
c
a
t
i
o
n

T
e
m
p
e
r
a
t
u
r
e

R
i
s
e

T
e
s
t

o
n

o
n
e

u
n
i
t

o
f

e
a
c
h

r
a
t
i
n
g

i
f

T
y
p
e

t
e
s
t
i
n
g

i
s

w
a
i
v
e
d

o
f
f

R
i
p
p
l
e

C
o
n
t
e
n
t

T
e
s
t
,

L
o
a
d

L
i
m
i
t
e
r

&

A
V
R

O
p
e
r
a
t
i
o
n

T
e
s
t

D
y
n
a
m
i
c

R
e
s
p
o
n
s
e

T
e
s
t

O
p
e
r
a
t
i
o
n
a
l

&

F
u
n
c
t
i
o
n
a
l

C
h
e
c
k
s

H
V

&

I
R

T
e
s
t

B
u
r
n
-
I
n

T
e
s
t

a
t

5
0
^
C

f
o
r

4
8

h
r
s

i
n

e
n
e
r
g
i
s
e
d

c
o
n
d
i
t
i
o
n
A
l
t
e
r
n
a
t
i
n
g

c
u
r
r
e
n
t

m
e
a
s
u
r
e
m
e
n
t

t
e
s
t

D
e
g
r
e
e

o
f

P
r
o
t
e
c
t
i
o
n

T
e
s
t

a
s

p
e
r

N
T
C
P

S
p
e
c
.

Rectifier Transformer and
Reactors IS : 4540, 2026)
Y Y Y Y Y
Electronic Components
including Potentiometer
(Vernier Type)
Y Y Y
Electronic Cards Y Y Y
PCB & racks for electronic
cards
Y Y
Control & Selector
Switches (IS : 6875)
Y Y Y
Indicating Meters (IS :
1248 )
Y Y Y
Indicating Lamps (IS:
13947)
Y Y Y
Air Break Switches / Fuses
( IS : 13947 / 13703 )
Y Y Y
Control Terminal Blocks
(IS : 13947)
Y Y
Control Transformer
(IS : 12021)
Y Y Y
Push Buttons (IS : 4794) Y Y Y
MCB (IS : 8828) Y Y Y
PVC insulated Copper
control wires (IS : 694)
Y Y
Sheet Steel (IS : 513) Y Y Y
Synthetic Rubber Gaskets Y Y
Annunciator Y Y Y
Battery Charger Y Y Y Y Y Y Y Y Y Y Y
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan
2. Makes of all major Bought out Items will be subject to NTPC approval.

SECTION-VI
PART-B

PART - B


L.T. INDOOR TRANSFORMER (DRY TYPE)

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-12
LT INDOOR
TRANSFORMER
(DRY TYPE)
PAGE 1 OF 1

L.T. INDOOR TRANSFORMER (DRY TYPE)

Attributes /
Characteristics

Items/Components
Sub Systems

V
i
s
u
a
l

&

D
i
m
e
n
s
i
o
n
a
l

c
h
e
c
k

M
e
c
h
a
n
i
c
a
l

p
r
o
p
e
r
t
i
e
s

E
l
e
c
t
r
i
c
a
l

s
t
r
e
n
g
t
h

T
h
e
r
m
a
l

P
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

P
r
o
p
e
r
t
i
e
s

N
D
T

/

D
P

/

M
P
I

V
o
l
t
a
g
e

R
a
t
i
o
,

V
e
c
t
o
r

G
r
o
u
p

&

P
o
l
a
r
i
t
y

M
a
k
e

/

T
y
p
e

/

R
a
t
i
n
g

/

M
o
d
e
l

/
T
C

/

G
e
n
e
r
a
l

P
h
y
s
i
c
a
l

I
n
s
p
e
c
t
i
o
n

W
P
S

&

P
Q
R

R
o
u
t
i
n
e

T
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

s
t
a
n
d
a
r
d

M
e
a
s
u
r
e
m
e
n
t

o
f

c
a
p
a
c
i
t
a
n
c
e

&

t
a
n

d
e
l
t
a

b
e
t
w
e
e
n

w
i
n
d
i
n
g

R
o
u
t
i
n
e

T
e
s
t

Enclosure door, H.V. &
L.V. Cable Box / Flange
Throat
Y Y Y
Copper Conductor Y Y Y Y
Insulating Material Y Y Y
CRGO Lamination & Built
Core
Y
Bushing / Insulator
(IS:2544 / 5621 / 2099)
Y Y Y
Gasket Y Y Y
Off-Circuit Tap Changer Y Y
Core Coil Assembly Y Y
Marshalling Box Y Y
WTI, Thermister, Terminal
Connector
Y Y
Welding Y
Complete Transformer
(IS:11171)
Y Y Y

SECTION-VI
PART-B

PART - B


ELECTRICAL ACTUATOR WITH
INTEGRAL STARTER

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC. NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-13
ELECTRICAL
ACTUATORS
PAGE 1 OF 2

ELECTRICAL ACTUATOR WITH INTEGRAL STARTER

Test/Attributes

Characteristics

ITEM/
COPONENT/
SUB SYSTEM
ASSEMBLY/
TESTING
R
P
M

N
o

L
o
a
d

C
u
r
r
e
n
t

I
R

&

H
V

T
e
s
t

M
o
u
n
t
i
n
g

D
i
m
e
n
s
i
o
n

A
l
l

r
o
u
t
i
n
e

T
e
s
t

a
s

p
e
r

S
t
a
n
d
a
r
d

&

S
p
e
c
i
f
i
c
a
t
i
o
n

C
o
r
r
e
c
t

P
h
a
s
e

S
e
q
u
e
n
c
e

O
p
e
r
a
t
i
o
n

&

S
e
t
t
i
n
g

o
f

l
i
m
i
t

S
w
i
t
c
h
/
T
o
r
q
u
e

S
w
i
t
c
h

S
t
a
l
l

T
o
r
q
u
e
/
C
u
r
r
e
n
t

(
A
)

H
a
n
d

W
h
e
e
l

o
p
e
r
a
t
i
o
n
/

A
u
t
o

d
e

c
l
u
t
c
h

f
u
n
c
t
i
o
n

(
A
)

F
u
n
c
t
i
o
n

o
f

A
u
x
.

l
i
k
e

P
o
t
e
n
t
i
o
m
e
t
e
r
,

s
p
a
c
e

h
e
a
t
e
r
,

p
o
s
i
t
i
o
n

i
n
d
i
c
a
t
o
r

E
P
T

o
u
t
p
u
t

G
r
e
a
s
e

l
e
a
k
a
g
e

L
o
c
a
l
/

R
e
m
o
t
e

(

O
p
e
n
-
S
t
o
p
-
C
l
o
s
e
)

O
p
e
r
a
t
i
o
n

S
a
f
e
t
y

c
h
e
c
k

(
S
i
n
g
l
e

p
h
a
s
i
n
g
,

P
h
a
s
e

c
o
r
r
e
c
t
i
o
n
,

T
r
i
p
p
i
n
g

e
t
c
.
)

(
A
)

ELECTRICAL
ACTUATOR WITH
INTEGRAL
STARTER(IS_9334)

Motor Y Y Y Y Y
Final Testing Y Y Y Y Y Y Y Y Y Y Y Y Y
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per
Quality Assurance Programme in General Technical Conditions
2) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the practices and procedure adopted along
with relevant supporting documents.

- Routine Test (A) - Acceptance Test Y - Test applicable

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-13
ELECTRICAL ACTUATORS
PAGE 2 OF 2

PROCESS CONTROL & PIPING
TESTS

ITEMS
V
i
s
u
a
l

G
A
,

B
O
M
,

L
a
y
o
u
t

o
f

c
o
m
p
o
n
e
n
t

&

c
o
n
s
t
r
u
c
t
i
o
n

f
e
a
t
u
r
e

D
i
m
e
n
s
i
o
n

P
a
i
n
t

S
h
a
d
e
/
t
h
i
c
k
n
e
s
s

F
l
a
t
t
e
n
i
n
g
,
f
l
a
r
i
n
g
,
h
y
d
r
o
t
e
s
t
,
h
a
r
d
n
e
s
s

c
h
e
c
k

a
s

p
e
r

A
S
T
M

s
t
a
n
d
a
r
d

(
A
)

C
o
m
p
o
n
e
n
t

R
a
t
i
n
g
s

W
i
r
i
n
g

M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

I
R

&

H
V

R
e
v
i
e
w

o
f

T
C

f
o
r

i
n
s
t
r
u
m
e
n
t
/
d
e
v
i
c
e
s

(
R
)

A
c
c
e
s
s
a
b
i
l
i
t
y

o
f

T
B
s
/
D
e
v
i
c
e
s

I
l
l
u
m
i
n
a
t
i
o
n
,
g
r
o
u
n
d
i
n
g

T
u
b
i
n
g

L
e
a
k
/
H
y
d
r
o

t
e
s
t
(
A
)

C
h
e
m
i
c
a
l
/
p
h
y
s
i
c
a
l

p
r
o
p
e
r
t
i
e
s

o
f

m
a
t
e
r
i
a
l

(
A
)

P
r
o
o
f

p
r
e
s
s
u
r
e

t
e
s
t
,
D
i
s
m
a
n
t
l
i
n
g

&

r
e
a
s
s
e
m
b
l
y

t
e
s
t
,
H
y
d
r
u
l
i
c

i
m
p
u
l
s
e

a
n
d

v
i
b
r
a
t
i
o
n

t
e
s
t

(
R
)

T
e
s
t
s

a
s

p
e
r

s
t
a
n
d
a
r
d
s

&

s
p
e
c
i
f
i
c
a
t
i
o
n

Local Instrument enclosure Y Y Y Y Y Y Y Y Y Y Y Y Y
Local instruments racks Y Y Y Y Y Y Y Y Y Y Y Y Y
Junction Box Y Y Y Y* Y Y Y
Gauge Board Y Y Y Y Y Y Y Y Y
Impulse pipes and tubes Y Y Y Y Y
Socket weld fittings ANSI B-
16.11
Y Y Y Y Y
Compression fittings Y Y Y Y Y Y
Instrument valves & Valve
manifolds
Y Y Y Y Y
Copper tubings ASTM B75 Y Y Y
*-applicable for painted junction boxes.
Note: R-Routine Test A- Acceptance Test Y Test applicable
Note: This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan indicating the
Practices and Procedure adopted alongwith relevant supporting documents.

SECTION-VI
PART-B

PART - B


AUXILIARY TRANSFORMER

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-14
AUXILIARY
TRANSFORMERS
PAGE 1 OF 2

AUX. TRANSFORMER

Attributes /
Characteristics

Items/
Components
Sub Systems

V
i
s
u
a
l

&

D
i
m
e
n
s
i
o
n
a
l

C
h
k
M
e
c
h
a
n
i
c
a
l

p
r
o
p
e
r
t
i
e
s

E
l
e
c
t
r
i
c
a
l

s
t
r
e
n
g
t
h

T
h
e
r
m
a
l

p
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

C
o
m
p
o
s
i
t
i
o
n

C
o
m
p
a
t
i
b
i
l
i
t
y

w
i
t
h

o
i
l

C
o
r
e

L
o
s
s
*
,

H
o
t

S
p
o
t

N
D
T

/

D
P
T

/

M
P
I

/

U
T

A
g
e
i
n
g

T
e
s
t
.

V
o
l
t
a
g
e

R
a
t
i
o
,

V
e
c
t
o
r

G
r
o
u
p

&

P
o
l
a
r
i
t
y
,

M
a
g
n
e
t
i
c

B
a
l
a
n
c
e

T
e
s
t

M
a
k
e

/

T
y
p
e

/

R
a
t
i
n
g

/

M
o
d
e
l

/

T
C

/

G
e
n
e
r
a
l

P
h
y
s
i
c
a
l

I
n
s
p
e
c
t
i
o
n
.

W
P
S

&

P
Q
R

R
o
u
t
i
n
e

T
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

t
e
s
t

R
o
u
t
i
n
e

T
e
s
t

Tank, H.V. & L.V.
Cable Box / Flange
throat
Y Y Y
Conservator /
Radiator / Cooler /
Pipes
Y Y Y
Copper Conductor
(IS:191)
Y Y Y Y
Insulating Material Y Y Y Y Y Y
CRGO Lamination &
Built Core
Y Y Y Y Y Y
Bushing / Insulator
(IS:2544 / 5621)
Y Y Y Y
Gasket Y Y Y Y Y
Transformer Oil
(IS:335)
Y
Off-Circuit Tap
Changer
Y Y
Core Coil Assembly
& Pre-tanking
Y Y
Marshalling Box Y Y Y Y

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-14
AUXILIARY
TRANSFORMERS
PAGE 2 OF 2

TRANSFORMER

Attributes /

Characteristics

Items/Compone
nts
Sub Systems

V
i
s
u
a
l

&

D
i
m
e
n
s
i
o
n
a
l

C
h
e
c
k
s

M
e
c
h
a
n
i
c
a
l

p
r
o
p
e
r
t
i
e
s

E
l
e
c
t
r
i
c
a
l

s
t
r
e
n
g
t
h

T
h
e
r
m
a
l

p
r
o
p
e
r
t
i
e
s

C
h
e
m
i
c
a
l

C
o
m
p
o
s
i
t
i
o
n

C
o
m
p
a
t
i
b
i
l
i
t
y

w
i
t
h

o
i
l

C
o
r
e

L
o
s
s
*
,

H
o
t

S
p
o
t

N
D
T

/

D
P
T

/

M
P
I

/

U
T

A
g
e
i
n
g

T
e
s
t
.

V
o
l
t
a
g
e

R
a
t
i
o
,

V
e
c
t
o
r

G
r
o
u
p

&

P
o
l
a
r
i
t
y
,

M
a
g
n
e
t
i
c

B
a
l
a
n
c
e

M
a
k
e

/

T
y
p
e

/

R
a
t
i
n
g

/

M
o
d
e
l

/

T
C

/

G
e
n
e
r
a
l

P
h
y
s
i
c
a
l

I
t
i
W
P
S

&

P
Q
R

R
o
u
t
i
n
e

T
e
s
t

a
s

p
e
r

r
e
l
e
v
a
n
t

t
e
s
t

V
a
c
u
u
m

&

P
r
e
s
s
u
r
e

T
e
s
t

R
o
u
t
i
n
e

T
e
s
t

WTI, OTI, MOG,
PRD, Breather,
Terminal
Connector,
Bucholz Relay,
Globe & Gate
Valve,
Y Y
Welding (ASME
Sect-IX)
Y Y
Complete
Transformer
(IS:2026)
Y Y

* Core Loss on first Job

Note:
1) This is an indicative list of tests / checks. The manufacturer is to furnish a detailed
documents.

2) All major Bought Out Items will be subject to NTPC approval.

SECTION-VI
PART-B

PART - B


(PRIMARY AND SECONDARY)

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-15
MEASURING
INSTRUMENTS
PAGE 1 OF 2

MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)
TESTS

ITEMS

D
i
m
e
n
s
i
o
n
s

(
R
)

M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

(
R
)

P
r
o
c
e
s
s

/

E
l
e
c
t
r
i
c
a
l

c
o
n
n
e
c
t
i
o
n

(
R
)

C
a
l
i
b
r
a
t
i
o
n

(
R
)

T
e
s
t

a
s

p
e
r

s
t
a
n
d
a
r
d
(
R
)

I
n
s
u
l
a
t
i
o
n

R
e
s
i
s
t
a
n
c
e

(
R
)

I
B
R

C
e
r
t
i
f
i
c
a
t
i
o
n

(
i
f

a
p
p
l
i
c
a
b
l
e

)
(
R
)

H
y
d
r
o

T
e
s
t
(
R
)

M
a
t
e
r
i
a
l

T
e
s
t

c
e
r
t
i
f
i
c
a
t
e

1. PR Gauge (IS-3624) Y Y Y Y Y
2. Temp. Gauge (BS-5235) Y Y Y Y Y
3. Pr./D.P.Switch(BS-6134) Y Y Y Y Y Y
4. Electronic Transmitter(BS-6447 / IEC-
60770)
Y Y Y Y Y Y
5. Temp. Switch Y Y Y Y Y Y
6. Recorder(IS-9319/ANSI C-39.4) Y Y Y Y Y Y
7. Vertical indicators Y Y Y Y Y
8. Digital Indicators Y Y Y Y Y
9. Integrators Y Y Y Y
10. Electrical Metering Instrument (IS-
1248)
Y Y Y Y Y Y
11. Transducer (IEC-688) Y Y Y Y Y Y
12. Thermocouples (ANSI-MC-96.1) Y Y Y Y Y Y
13. RTD(IEC-751) Y Y Y Y Y Y
14. Thermowell Y Y Y Y Y
R-Routine Test A- Acceptance Test Y Test applicable
Note: 1) Detailed procedure of Environmental Stress Screening Test shall be as per
Quality Assurance Programme in General Technical Conditions
detailed quality plan indicating the Practices and Procedure adopted
alongwith relevant supporting documents.

CLAUSE NO.

QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-15
MEASURING
INSTRUMENTS
PAGE 2 OF 2

TESTS

ITEMS

D
i
m
e
n
s
i
o
n
s

(
R
)

M
a
k
e
,

M
o
d
e
l
,

T
y
p
e
,

R
a
t
i
n
g

(
R
)

P
r
o
c
e
s
s

/

E
l
e
c
t
r
i
c
a
l

c
o
n
n
e
c
t
i
o
n

(
R
)

C
a
l
i
b
r
a
t
i
o
n

(
R
)

R
e
q
u
i
r
e
m
e
n
t

a
s

p
e
r

s
t
a
n
d
a
r
d

(
R
)

W
P
S

a
p
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15. Cold junction
compensation box
Y Y Y Y Y
16. Orifice plate(BS-1042) Y Y Y Y
*
Y Y
**
Y
**
Y Y
**
Y
17. Flow nozzle(BS-1042) Y Y Y Y
*
Y Y Y Y Y Y
18. Impact head type element Y Y Y Y Y
19. Level transmitter/float type
switch
Y Y Y Y Y Y Y Y
20. Flue Gas analyser Y Y Y Y
21. Dust emission monitors Y Y Y Y
*Calibration to be carried out
on one flow element of each
type and size if calibration
carried out as type test same
shall not be repeated.

** If applicable
R-Routine Test A- Acceptance Test Y Test applicable
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as
per Quality Assurance Programme in General Technical Conditions
detailed quality plan indicating the Practices and Procedure adopted
alongwith relevant supporting documents.

SECTION-VI
PART-B

PART - B


SAMPLING TESTING & QUALITY
ASSURANCE FOR CIVIL WORKS
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 1 OF 36

SAMPLING, TESTING AND QUALITY ASSURANCE FOR CIVIL WORKS
1.00.00 INTRODUCTION
1.01.00 This part of the specification covers the sampling, testing and quality assurance
requirement (including construction tolerances and acceptance criteria) for all civil
and structural works covered in this specification including excavation and filling,
cast in situ concrete and allied works, fabrication and erection of structural steel
works, masonry / sheeting and allied works, finishing items etc.
1.02.00 This part of the technical specification shall be read in conjunction with other Parts of
the technical specifications, general technical requirements & erection conditions of
the contract. Wherever IS code or standards have been referred they shall be the
latest revisions.
1.03.00 All tests required for all materials (bought by Contractor) and workmanship shall be
done / got done by the contractor at his own cost. The rate for respective items of
work or price shall include the cost for all works, activities, equipment, instrument,
personnel, material etc. whatsoever associated to comply with sampling, testing and
quality assurance requirement including construction tolerances and acceptance
criteria and as specified in subsequent clauses of this part.
2.00.00 QUALITY ASSURANCE PROGRAMME (QAP)
2.01.00 The Contractor shall adopt suitable Quality Assurance Programme (QAP) to ensure
that the equipments and services under the scope of contract whether manufactured
or performed within Contractors works or at his sub-Contractors premises or at the
Owners site or at any other place of work are in accordance with the specifications.
Such QAP shall be outlined by the Contractor and shall be finally accepted by the
Owner or his authorized representative after discussions before the start of work.
The QAP shall be generally in line with IS/ISO Systems. The QAP of the Contractor
shall generally indicate the following:
His organization structure for the management and implementation of the
proposed quality assurance programme
Quality System Manual
Design Control System
Documentation and Data Control System
Qualification data / details for Contractors key personnel.
The procedure for purchase of materials, parts, components and selection of
sub-contractors services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 2 OF 36

System for shop manufacturing and site erection controls including process,
fabrication and assembly.
Control of non-conforming items and system for corrective actions and
resolution of deviations.
Inspection and test procedure both for manufacture and field activities.
Control of calibration and testing of measuring testing equipment.
System for Quality Audits.
System for identification and appraisal of inspection status.
System for authorizing release of manufactured product to the Owner.
System for handling, storage and delivery.
System for maintenance of records, and
Quality plans for manufacturing and field activities detailing out the specific
quality control procedure adopted for controlling the quality characteristics
relevant to each item of work/ equipment/component.
3.00.00 SAMPLING, LABORATORY AND FIELD TESTING
3.01.00 The Contractor shall provide the facilities whatsoever required and also bear the cost
for all sampling, testing and quality assurance in the field and in the laboratory. The
Contractor shall carry out all sampling and testing in accordance with the relevant
Indian standards and / or international standards and this technical specification.
Where no specific testing procedure is mentioned, the tests shall be carried out as
per the best prevalent engineering practices and to the directions of the Engineer. All
sampling shall be done in the presence of the Engineer or his authorized
representative. The Contractor shall establish the QA&QC laboratory at site and all
field tests shall be done in the presence of the Engineer and / or his authorized
representative. The tests which cannot be carried out in the field laboratory shall be
done at a laboratory of repute such as CSMRS, NCBM, IITs, National Test House,
Kolkata etc. as agreed by the Engineer. The test samples for such test shall be jointly
selected and sealed by the engineer and thereafter these shall be sent to the
concerned laboratory through the covering letter signed by FQA representative of the
engineer. The cost of transportation and other associative cost including the test
charges shall be borne by the contractor. These cost shall deemed to be included in
the respective item of work in the contract. If the Engineer desires to witness such
tests at laboratory, Contractor shall arrange to conduct the test in his presence. At
least one set of mix design shall be carried out by contractor at NCB,Ballabgarh/
CSMRS, Delhi.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 3 OF 36

Before execution of any civil work the Contractor shall conduct full-scale suitability
tests on various construction and building material such as fine and coarse
aggregates, Cement, Reinforcement, construction chemicals, supplementary
cementitious Materials and Construction water to check their suitability for use from
reputed institutes such as NCB-Ballabhgarh, CSMRS-Delhi, IITs.
3.02.00 The recommendations and suitability of material for concreting and other building
materials like brick, cement, aggregates etc., shall be ascertained by contractor prior
to start of work.
Preliminary evaluation of aggregate and its evaluation for potential alkali-aggregate
reactivity as per following scope of work shall be done:-
A. Evaluation of Aggregates:
I. To carry out different tests on coarse aggregate sample i.e. specific
gravity, water absorption, sieve analysis, deleterious material;
soundness, crushing value, impact value, abrasion value, elongation
index and flakiness index, as per IS: 2386.
II. To carry out different tests on fine aggregate sample i.e. specific
gravity, water absorption, sieve analysis soundness, deleterious
material, silt content, clay content and organic impurities as per IS:
2386.
III. To prepare evaluation report based on test results of I) and II) above
and to advise regarding suitability of fine and coarse aggregates.
B. Evaluation of Aggregates for Potential Alkali-Aggregate Reactivity:
Evaluation for Potential Alkali-Aggregate reactivity as per following scope of
work:
I. To carry out petrographic analysis and accelerated Mortar bar Test on
aggregate samples (1N NaOH at 80 deg. Centigrade for 14 days as
per ASTM 1260, or the method established/ developed by CSMRS for
22days test).
II. To prepare a report based on test results of I) above and to advise
regarding suitability of aggregates and further testing required if any.
The contractor shall initiate the action with regard to the above mentioned evaluation
of aggregates and other building material, so as to ensure timely completion of these
tests thereby not affecting any project work. All records shall be submitted, unless
specified otherwise, as per the format developed by the Contractor and approved by
the Engineer.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 4 OF 36

3.03.00 The FQA laboratory set-up shall be constructed by the Contractor at his own cost at
site in line with the indicative field QA&QC laboratory set-up enclosed at Annexure-I.
The Laboratory building shall be constructed and installed with the adequate facilities
to meet the requirement of envisaged test setup. Temperature and humidity controls
shall be available wherever necessary during testing of samples. The Quality Plan
shall identify the testing equipments/ instrument, which the Contractor shall deploy
and equip the Field quality Laboratory for meeting the Field Quality Plan
requirements. The Contractor shall furnish a comprehensive list of testing
equipments/ instrument required to meet the planned/scheduled tests for the
execution of works for Owner acceptance/ approval. The contractor shall mobilize the
requisite laboratory equipment and QA&QC manpower at least 15 days prior to the
planned test activity as per the schedule of tests.
If any facility for testing or the trained personnel for conducting any special test is not
available with the Contractor then the Contractor may get the test done from reputed/
approved laboratory or out source the personnel as approved by Owner.
All equipments and instruments shall be calibrated before the commencement of
tests and then at regular intervals, as per the manufacturers recommendation and as
directed by the Owner. Contractor shall arrange for having the instruments/
equipments tested for their calibration at an NABL/NPL accredited agency and the
test report shall be submitted to the Owner.
Based on the schedule of work agreed with the Engineer-in-charge and the approved
FQP, the Contractor shall prepare a schedule of tests and submit them to the
Engineer-in-charge and organize to carry out the tests as scheduled/ agreed.
4.00.00 QA & QC MANPOWER
4.01.00 The Contractor shall appoint a dedicated, experienced and competent QA&QC in-
charge at site, preferably directly reporting to the Project Manager, supported as
necessary by experienced personnel, to ensure the effective implementation of the
approved QAP. An indicative structure of Contractors QA&QC manpower required to
be deployed at site is enclosed at Annexure-II. Based on the finalized L-2 network
and the approved Field Quality plan the Contractor shall finalize and submit a
deployment schedule of QA&QC personnel along with their details to Owner for
approval/ acceptance and further shall ensure their availability well before the start of
the concern activity.
The QA&QC in-charge shall have the organizational freedom and authority to
implement the requirements of these quality assurance arrangements, free from
commercial and programme restraints. The QA&QC setup of the Contractor shall
consist of qualified and experienced Civil, Electrical, Mechanical Engineers and
Laboratory assistants with their supporting staff both at their works and site.

CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 5 OF 36

4.02.00 The deployment of man power for QA & QC set up shall be affected on the basis of
agreed manpower deployment schedule, which shall be prepared by the contractor
based on the L-2 network and the same shall be submitted to the Engineer-in-charge
for acceptance.
5.00.00 FIELD QUALITY PLAN (FQP) AND MANUFACTURING QUALITY PLAN (MQP)
5.01.00 Well before the start of the work, the Contractor shall prepare the Field Quality Plans
(FQP) and obtain approval of Owner, which shall detail out for all the works,
equipments, services, quality practices and procedures etc in line with the
requirement of the technical specifications to be followed by the Contractor at site.
This FQP shall cover for all the items / activities covered in the contract/schedule of
items and required right from material procurement to completion of the work. The
Field Quality Plan (FQP) submission shall be furnished on the format No. QS-01-QAI-
P-09/F2-R1 for Owner approval. An Indicative Field Quality Plan for civil works is
enclosed at Annexure IV.
5.02.00 All materials / components and equipment covered under the scope of work, shall be
procured by the Contractor for the purpose of the contract, after obtaining the written
approval of the Owner, which are to be manufactured at shop/ factory of the
vendor/sub vendor shall be covered under a comprehensive quality assurance
programme. The Contractors purchase specifications and inquiries shall call for
Manufacturing Quality Plans (MQP) to be submitted by the sub-contractor/ sub-
supplier/ sub-vendor. The MQPs called for from the sub-contractor shall detail out for
all the components and equipment-various tests/inspection, to be carried out as per
the requirements of this specification and standards mentioned therein, quality
practices and procedures followed by contractors/ sub-contractors/ sub-suppliers
Quality Control Organization, the relevant reference documents and standards,
acceptance norms, inspection documents raised etc., during all stages of materials
procurement, manufacture, assembly and final testing/performance testing. Such
quality plans of the vendors shall be submitted to the Owner for approval in the
prescribed format No. QS-01-QAI-P-09/F1-R1 for Manufacturing Quality Plan and
such approved Quality Plans shall form a part of the purchase order/contract between
the Contractor and sub-contractor. The Quality Plans shall be submitted on electronic
form e.g. CD or E-mail in addition to hard copy, for review and approval of Owner.
After approval the same shall be submitted in compiled form on CD in addition to
hard copy.
5.03.00 The Contractor shall furnish copies of the reference documents/plant standards
/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans.
These Quality Plans and reference documents/standards etc. will be subject to
Owner approval without which manufacturer shall not proceed. These approved
documents shall form a part of the contract. In these approved Quality Plans, Owner
shall identify customer hold points (CHP), i.e. test/checks which shall be carried out in
presence of the Owner Engineer or his authorized representative and beyond which
the work shall not proceed without consent of Owner in writing. All deviations to this
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 6 OF 36

specification, approved quality plans and applicable standards must be documented
and referred to Owner along with technical justification for approval and
dispositioning.
5.04.00 With in three weeks of the release of the purchase orders /contracts for such bought
out items /components, a copy of the same without price details but together with the
detailed purchase specifications, quality plans and delivery conditions shall be
furnished to the Owner for reference/record by the Contractor along with a report of
the Purchase Orders placed so far for the contract.
5.05.00 Monthly progress reports on MQP/FQP submission/approval shall be furnished by the
Contractor on the format No. QS-01-QAI-P-02/F1-R0. List of items requiring Quality
Plans and Sub-supplier approval shall be finalized with the Contractor on the format
No. QS-01-QAI-P-01/F3-R1 during the post bid discussions.
6.00.00 BOUGHT OUT ITEMS (BOIs) AND SUB-VENDORS/ SUB-MANUFACTURERS /
SUB-SUPPLIERS
6.01.00 The Contractor shall enclose a comprehensive list of bought out items (BOIs)
envisaged in the contract for carrying out fabrication/ manufacturing/ erection/
construction/ commissioning activities etc and shall indicate the names of reputed
manufacturers for each of them in their bid proposal. The items envisaged by the
Contractor to be procured from these manufacturers shall meet the specification
requirement. Some of these major bought out items list (not exhaustive) is enclosed
at Annexure- III for which the Contractor shall submit the requisite details / lists of
manufacturers in their bid proposal.
6.02.00 The contractor shall identify the bought out items as per owners specification and
shall finalize the list of manufacturers/ vendors for each bought out items envisaged
in the contract during the post bid discussions stage. The BOIs shall conform to the
relevant IS/technical referred specifications for the highest quality/ grade of material
unless otherwise specified. All bought out items shall be procured from the
manufacturers approved by Owner and tested as per relevant IS Codes/Owner
Specification. To facilitate advance planning (well before the start of activity as per L-
2 network) of material testing/ approval of bought out items, representative samples
shall be procured by the Contractor (from approved vendors) and submitted to the
Engineer for his approval before bulk procurement at least two months prior to start of
works. In case of manufacturers test certificate is submitted for acceptance, it shall be
clearly traceable and correlated with the consignment received at site. Approval of
material / sample by the Engineer shall not relieve the Contractor of his responsibility,
for their conformance to the specification, as well as the requisite quality and
performance of material.
6.03.00 The list of manufacturers / sub-vendors of each of the BOIs identified / indicated by
the Contractor shall be discussed / reviewed by the Owner during post bid
discussions and the list of proposed manufacturers / sub-vendors for each of the BOI
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 7 OF 36

shall be agreed/ approved. The list of manufacturers for all the BOIs envisaged in
contract shall be included in the bid proposal and the same shall be discussed for
finalization during the post bid discussions before placement of award. Where the
manufacturers are placed in DR (Details required) category, the details of the
manufacturers / sub-vendors placed in the DR category shall be submitted to the
Owner for approval within the period agreed at the time of post bid discussions. The
Contractors proposal shall include vendors site facilities, expertise, facilities
established at the respective works, the process capability, process stabilization, QC
systems followed, experience list, etc. along with his own technical evaluation for
identified sub-Contractors proposed. The formats for furnishing above details shall be
given to the Contractor at post bid discussion stage. Monthly progress reports on
sub-Contractor detail submission / approval shall be furnished on format no. QS-01-
QAI-P-02/F1. The Owner shall furnish other relevant formats for information/
clarification for manufacturers / sub-vendors approval to the Contractor at the time of
post bid discussions (Main suppliers evaluation report Format No: QA-01-QAI-P-
04/F1-R0 and Sub supplier questionnaire Format no: QA-01-QAI-P-04/F2-R0). Such
manufacturers / sub-vendors approval shall not relieve the Contractor from any
obligation, duty or responsibility under the contract.
6.04.00 Structural Steel for site procurement shall be procured from main steel producers like
SAIL, TISCO, IISCO, RINL, Jindal Steels etc. In case some of the sections are not
available with main Producers and are proposed to be supplied from the re-rollers of
main steel producers, the name of such re-rollers will have to be cleared by corporate
quality assurance of NTPC for which details such as BIS approval, Main steel
producers approval, Past experience for production of sections of specified material,
details of machines plants testing facilities etc., confirmation that the process control
and manufacturing of steel sections by re-rollers shall be same as that of main steel
producers, that billets for re-rolling will be sourced from main steel producers only
shall be furnished with regards to re-roller.
Even after clearance of re-rollers, induction of billets with identified and correlated Mill
test certificates (TCs) in the process of re-rolling, sampling of steel, quality checks
thereof and stamping of final product for further identification and correlation with
TCs prior to dispatch will be in presence of authorised representative of main
Contractor.
Reinforcement steel shall be procured from main steel producers like SAIL, TISCO,
IISCO, RINL, Jindal Steels etc. and mill test certificates (TC) is to be obtained and
submitted to NTPC for co-relation. In case any size /diameter specified is not
available and are proposed to be supplied from the conversion agent of the main
Steel producer the name of such conversion agent / re roller shall have to be
approved by NTPC for which details such as BIS approval, Main steel producers
approval, Past experience for production of sections of specified material, details of
machines, plants testing facilities etc., and confirmation that the process control and
manufacturing of steel sections by re-rollers is the same as that of main steel
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 8 OF 36

producers, that billets for re-rolling are sourced from main steel producers only shall
be furnished with regards to re-roller.
7.00.00 STRUCTURAL STEEL WELDING REQUIREMENTS
7.01.00 The Contractor shall submit to the Owner Field Welding Schedule for field welding
activities in the format No.: QS-01-CQA-W11/F1, this format shall be furnished to the
Contractor at pre-award stage. The field-welding schedule shall be submitted to the
Owner along with all supporting documents, like welding procedures, heat treatment
procedures, NDT procedures etc. at least ninety days before schedule start of
erection work at site. The Contractor shall submit Welding Procedure Specification
(WPS) in the format No: QS-01-QAI-W-06/F1 for Owner approval/ acceptance, this
format shall be furnished to the Contractor during post bid discussion stage.
All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870 or other International
equivalent standard acceptable to the Owner.
All welding/brazing procedures shall be submitted to the Owner or its authorized
representative for approval prior to carrying out the welding/brazing.
All brazers, welders and welding operators employed on any part of the contract
either in the Contractors/ sub-Contractors works or at site or elsewhere shall be
qualified as per AWSD1.1/ASME Section-IX or BS-4871 or other equivalent
International Standards acceptable to the Owner.
Welding procedure qualification and Welder qualification test results shall be
furnished to the Owner for approval. However, where required by the Owner, tests
shall be conducted in presence of Owner/authorized representative.
No welding shall be carried out on cast iron components for repair.
All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
All Non-destructive examination shall be performed in accordance with written
procedures as per International Standards and as mentioned elsewhere in the
technical specification; The NDT operator shall be qualified as per SNT-TC-IA (of the
American Society of non-destructive examination). NDT shall be recorded in a
report, which includes details of methods and equipment used, result/evaluation, job
data and identification of personnel employed and details of co-relation of the test
report with the job. The records of RT (Films) and UT (inspection records or printed
reports if possible) shall be documented and produced to Owner.

CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 9 OF 36

8.00.00 QUALITY AUDIT
8.01.00 Owner reserves the right to carry out quality audit and quality surveillance of the
systems and procedures of the Contractors or their sub-Contractors quality
management and control activities.
The Contractor shall provide all necessary assistance to enable the Owner carry out
such audit and surveillance. The Contractor shall carry out an inspection and testing
Programme during manufacture in his work and that of his sub-Contractors and at
site to ensure the mechanical accuracy of components, compliance with drawings,
conformance to functional and performance requirements, identity and acceptability
of all materials parts and equipment. The Contractor shall carry out all
tests/inspection required to establish that the items/equipment conform to
requirements of the specification and the relevant codes/standards specified in the
specification, in addition to carrying out tests as per the approved quality plan.
8.02.00 Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Owner to reject the equipment/ facilities if it does
not comply with the specification when erected or does not give complete satisfaction
in service and the above shall in no way limit the liabilities and responsibilities of the
Contractor in ensuring complete conformance of the materials/equipment supplied to
relevant specification, standard, data sheets, drawings, etc.
9.00.00 GENERAL QA REQUIREMENTS
9.1.0 QA REQUIREMENTS FOR PROPERTIES, STORAGE AND HANDLING OF
COMMON BUILDING MATERIALS
1. All the materials like Bricks, Stones, Concrete Blocks, Lime, Cement, Water,
Aggregates, Sand, Reinforcement Steel, Structural Steel shall conform to the
relevant IS Codes/NTPC Technical Specification requirements.
2. All materials shall be stacked and stored by the Contractor as per IS-4082
and as per the requirements specified in NTPC Technical Specification.
3. All material shall be stacked separately.
4. Lime and cement shall be stored on a raised platform in Weather Proof, Dry &
Leak Proof Conditions stores.
5. Different consignment of different types of cement shall be stored separately
with clear identification mark.
6. Cement stored for more than 60 days in contractors godown shall be retested
to check their suitability for use.
7. Cement shall be consumed on first in first out basis.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 10 OF 36

8. Steel shall be stacked and stored consignment wise, on raised wooden
battens size wise and grade wise with identification mark.
9. For properties, storage and handling of all materials used shall comply to the
requirements of NTPC Technical Specification
10. The sheets/ packets(Profiled sheets for decking, roofing and cladding) shall
be stacked neatly clear off the ground at an angle to the ground, over a base
pallet to provide drainage.
11. The sheets/ packets(Profiled sheets for decking, roofing and cladding) must
be covered with water proof covering to protect from moisture rain and foreign
particles.
12. Water / moisture should not be allowed to stagnate on surface, or in between
layers of sheets/ packets(Profiled sheets for decking, roofing and cladding).
This can damage the coating , and cause corrosion.
9.2.0 QA REQUIREMENTS FOR SHEETING WORKS.
1. Colour coated sheet
i) Chemical & physical properties of raw material sheet as per relevant
codes.
ii) Bare Metal Thickness
iii) Thickness of coatings
iv) Type of coating/paint
v) Hardness of painted surface (2H pencil Hardness) (ASTM-D-3363)
vi) Flexibility Test (Bend test) as per IS-14246 ASTMD-328 at 180 degree
bends (twice the thickness of sheet). There should not be any crack.
vii) Dimensional check after profiling of sheets
viii) Salt spray test as per ASTM B-117/ IS:9844 for minimum 1000 hrs.
One sample per batch at random. (For true representative sampling,
three samples shall be taken from each batch out of which one sample
shall be sent for salt spray test .The batches shall be chosen at the
beginning of supply, another at the middle of supply and the third
towards the end of the supply)
ix) Cross hatch adhesion test as per IS: 14246

CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 11 OF 36

2. Bonded Mineral Wool Insulation
a) Thickness
b) Density
c) Thermal Conductivity
d) All other tests as per IS-8183.
3. Sheeting Installation
a) Workmanship including alignment
b) Level, Slope
c) Side and End Laps
d) Proper Installation of Flashing
e) Fixing including opening,(No gas cut opening shall be allowed at the
site , whenever opening is specified these shall be properly cut in the
factory and shall be filled with lipping/flashing for true shape/
dimension etc.)
f) Location, Installation of Lining & Installation.
4. All bought out items shall be procured from the manufacturers approved by
Engineer-in - charge and tested as per relevant IS Codes/ Specification.
5. The sheets/ packets shall be stacked neatly clear off the ground at an angle to
the ground, over a base pallet to provide drainage.
6. The packets/ sheets must be covered with water proof covering to protect
from moisture rain and foreign particles.
7. Water / moisture should not be allowed to stagnate on surface, or in between
layers. This can damage the coating, and cause corrosion.
9.3.0 QA REQUIREMENTS FOR ACID/ALKALI RESISTANT LINING
1. Acid Resistant Bricks/Tiles shall be tested for Water Absorption, Compressive
Strength, Resistance to Acid, Flexural Strength, Dimensions and all other
tests as per IS-4860 and IS-4457.
2. Acid and Alkali Resistant Bitumastic ready mixed paint shall be tested for all
tests as per IS-158.
CLAUSE NO.
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SUB-SECTION-IIIE-16
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3. Bitumastic shall be tested as per IS-9510.
4. Potassium Silicate, Resin type and Sulphur type Mortars shall be tested as
per IS-4832, Part I, II and III.
5. Surface preparation shall be checked as per IS-2395.
6. Application of Primer, laying of Acid Proof Bitumastic layer, Acid/Alkali
Resistant Tiles/Bricks, Chemical Resistant Epoxy Lining and Epoxy Paint shall
be as per NTPC Technical Specification.
7. Thickness of Acid and Alkali Lining shall be checked.
8. Epoxy painting shall be carried for required coating thickness and dry film
thickness.
9.4.0 QA REQUIREMENTS FOR RCC PILES - BORED CAST-IN-SITU PILES
1. Standard Penetration Test (SPT) as per IS-2131 and NTPC Technical
Specification to determine the founding level of piles.
2. Founding level of the piles shall be decided based on the criteria given in
NTPC Technical Specification.
3. Check for control of position and alignment of piles as per IS-2911 Part I/Sec-
2
4. Boring & Drilling : Drilling mud shall be tested for the following
Liquid limit of drilling mud (Bentonite Slurry) as per IS-2720 Part V.
Sand content of Bentonite powder (shall not be greater than 7%).
Density of freshly prepared Bentonite suspension shall be checked in
each pile bore before concreting and it should be between 1.034 and
1.10 gm/ml depending upon the pile dimension and type of the soil in
which the pile is to be installed. However, the density of bentonite
suspension after getting mixed with deleterious material in the pile
bore may be up to 1.25 gm/ml.
Marsh viscosity (when tested by marsh cone shall be between 30 to 60
seconds).
Differential free swell index.
pH value of Bentonite suspension (shall be between 9 and 11.5).
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Properties of drilling mud shall be checked prior to commencement of the
piling work and thereafter, minimum once per week or as found necessary by
the engineer. One sample consisting of 3 specimens shall be tested for the
above.
5. Check cleaning of pile bore
6. Concreting: All the checks/tests on concrete and concrete materials shall be
carried out as per FQP and IS-2911 Part I/Sec.2
a) Before starting concreting the contaminated drilled mud at the (slurry
collected in sampler tube) bottom of pile bore shall be tested for
density and sand content. Density should not be more than
1.25T/CuM.
b) For Working Piles: Minimum one sample consisting of 6 test cubes
shall be made for first ten piles. Out of these 3 shall be tested for 7
days cube strength and 3 for 28 days cube strength. Minimum one
sample of 6 test cubes for every 25 nos. of piles shall be tested , out of
these 3 shall be tested for 7 days cube strength and 3 for 28 days
cube strength
7. Reinforcement bars used for concreting of piles shall be of tested quality and
conform to the requirements of relevant IS codes.
a) Check distances between two adjacent main reinforcement bars and it
should be as specified in Technical Specification.
b) Check proper cover and central placement of reinforcement cage in
the pile bore by suitable concrete spacers/rollers. Check minimum
clear cover to reinforcement should be as specified in technical
specification.
8. Check cut off level of piles as per drawing.
9. Check recording of all data during installation of piles in prescribed pile data
sheet.
10. Slumps of concrete shall be tested at every one-hour interval.
11. Checking position and Alignment: Each pile shall be checked for its position
w.r.t. Specified location. Each pile shall be checked for its alignment.
Permissible limits for deviation shall be as specified elsewhere in the
Technical Specification.
12. Check for Pile Bore: On completion of boring and cleaning, the bottom of each
pile bore shall be checked from the samples collected from near the bottom of
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pile bore or any other method approved by the Engineer, to ensure that it is
free from pile bore spoil/debris and any other loose material before
concreting.
13. Low strain pile integrity test on all job piles and test piles shall be conducted
as specified in the Technical Specification. This test shall be suitably used to
identify the piles for routine tests.
14. High Strain dynamic test shall be done as per the technical specification. The
frequency of the test shall be as per the BOQ /technical specification.
9.5.0 QA REQUIREMENTS FOR RCC PILES LOAD TEST ON RCC PILES
1. Pile load testing shall conform to IS-2911 (Part IV) and the Technical
Specification.
2. Check all the equipment and instrument used are properly calibrated.
3. Initial load test shall be conducted to assess the safe load carrying capacity of
pile before start of work.
a) Cyclic vertical (compression) load test to assess safe vertical load
capacity.
b) Lateral load test to assess safe horizontal load capacity.
c) Pull out (Tension) load test to assess safe pull out load capacity.
4. Routine Load Test shall be conducted on Working Piles, to verify their load
carrying capacity.
a) Direct Vertical (Compression) load test for vertical load capacity.
b) Lateral load test for horizontal load capacity
5. All other tests on piles shall be carried out as specified in Technical
Specification.
6. Pile load-testing procedure and the test setup/scheme to be submitted for
approval from NTPC. The contractor shall use the test setup having
arrangement for reaction piles for both vertical compression and uplift
(tension) Load test (initial) on piles. The cost of reaction system/ piles shall
deem to be included in the cost of test piles.
7. All the gauges(pressure etc.) and the instruments shall be calibrated before
the start of the tests on test piles and working piles and the calibration record
shall be verified before start of execution of the test.
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9.6.0 QA REQUIREMENTS FOR PRE CAST CONCRETE WORKS
1. All the materials used in Pre cast Concrete work shall be tested and conform
to the requirements of IS codes and NTPC Tech. Specification. If the material
of the cast-in-situ concrete is already tested and part of the same is used for
precast concrete, further testing is not required, otherwise testing is required
for every 50 Cum. Of Concrete.
2. Concrete mix for Pre cast members shall conform to IS-456-2000 i.e. the
provisions of IS:456 shall apply.
3. All relevant QA requirements pertaining to cast in situ concrete shall be
applicable.
4. Load test on Pre cast members shall be carried out for the type of members
as decided by NTPC Engineer as per IS-456-2000.
5. Pre Cast Concrete member shall be checked for dimensions (length, cross
sectional dimensions, straightness, squareness, and flatness) and tolerances
shall be as per NTPC Technical Specification.
9.7.0 QA REQUIREMENTS FOR PLASTERING & ALLIED WORKS
1. Materials like sand, lime for preparation of putty, coarse aggregate, gypsum
etc. shall confirm to the relevant IS codes specified in NTPC Technical
Specification.
2. Check proper mixing of mortar
3. Plaster surface shall be checked for following defects and the remedial
measures for the same shall be adopted as per IS-1661.
a) Blistering
b) Bond filer or loss of adhesion.
c) Cracking and crazing
d) Efflorescence
e) Grinning
f) Irregularity of Surface Texture
g) Popping or blowing
h) Recurrent surface dampers
i) Softness or chalkiness
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4. Trueness of Plastering System:
Finished plaster surface shall not show any deviation more than 4mm when
checked with straight edge of 2 Mt. length.
5. Check thickness of plaster.

9.8.0 QA REQUIREMENTS FOR CONCRETING
All records of concreting, reinforcement, testing of materials, as-built dimensions, the
details of the rectification, etc, shall be maintained as given below. Copies of such
record shall be submitted to owner for their record and future reference.
a) Testing data / report of aggregates
b) Mix design details.
c) Testing records of admixture including dosage, workability and setting time.
d) Approved scheme for concreting.
f) Hourly records of concreting including pour card.
g) Protocol indicating the dimensional tolerance and details of inserts.
h) Bar bending schedule.
i) Location and details of mechanical anchoring used for reinforcement.
j) Protocol giving the details of checking of reinforcements before concreting
and conformance to the reinforcement details as shown in the construction
drawings.
k) Report on petrographic examination & potential reactivity of aggregate
l) All tests/checks shall be carried out as per FQP.
In addition to the above the following may also be ensured
i. Check temperature control of fresh concrete during hot weather.
ii. Plasticizer cum Retarder type mixture to be added in the concrete shall be
tested as per IS-9103/ ASTM C 494.
iii. REINFORCEMENT :
a) Check conformity of material to relevant IS codes.
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b) Check lapping/spacing of Reinforcement staggered as under no
circumstances more than 50% of bars at cross section shall be lapped.
iv. Sample test for mechanical bars grips shall be carried out upto the yield
strength of reinforcement of bars. The no. of tests to be carried out shall be
3% of the no. of bar grips used subject to a minimum of three.
v. Batching Plant shall be calibrated regularly at least once in a 3 months and
computerized output shall be taken for each batch of production of concrete.
The calibration if the batching plant shall be done by NABL accredited
laboratories/weights of NPL traceability.
vi. All precautions and control as specified in NTPC Technical Specification shall
be taken care of during concreting. IS 456-2000 shall be applicable for
acceptance of execution of concrete works & test results.
STAGING AND FORM WORK
Automatic climb form scaffolding systems shall be used. Slipform with
proven record for similar towers may be used subject to IS specific approval of
the owner. The design and detailed construction of the form work and the
scaffolding system shall be as described elsewhere in the technical
specification and shall be submitted to NTPC for approval.
Concrete shall have sufficient strength to with stand the anchoring loads of
scaffolding system. The concrete strength shall be continuously checked and
documented during the climbing process of the scaffolding.
Design and execution of the form work , staging, shuttering and scaffolding
shall conform to National Safety Council and all relevant IS Code provisions,
i.e. IS 2750, IS:4014, IS:4923, IS:800 etc. In case the IS Codes do not cover
the specific type of shuttering system, then any international Code of Practice,
as approved by the engineer, may be followed.
Deployment of vertical laser ray equipment for measuring the dimensions and
controlling the shape of the tower at all elevations and plan angles shall be
carried out.
9.9.0 QA REQUIREMENTS FOR STRUCTURAL STEEL WORK
9.9.1 Site Fabricated:
1. Physical and chemical properties of material as per relevant codes. Review
of correlated Mill Test Certificates or check testing in absence of MTC.
2. Ultrasonic test on plates above 40mm as per ASTM A435.
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3. Welding Procedure & Welders Qualification Test as per ASME Section
IX/AWS D1.1
4. Fillet Welds:
a) Check for size and visual examination.
b) Microetch examination on production test coupons for main fillet welds
with minimum one joint per built up beams, columns and crane girder
etc.
c) 25% weld length of tension member of crane girder shall be subjected
to Dye Penetration Test.
d) On all other fillet welds, DPT on 5% of weld length with minimum
300mm at each location shall be carried out.
5. Butt Welds:
a) DPT on all butt welds after back gouging
b) Mechanical testing of production test coupons with minimum one joint
per built up beam, column and crane girder.
c) 100% radiography test on butt welds of tension flange (bottom flange)
of crane girder. All other butt welds shall be subjected to Radiography
test on 10% weld length of each welder. Wherever RT is not feasible,
UT shall be carried out.
d) Full penetration welds (other than butt welds) shall be subjected to
Ultrasonic Testing in following quantum :
i) 100% UT on web to flange joint of crane girder.
ii) 10% UT on other full penetration joints.
6. Every 1
st
and further every 10
th
set of identical structure shall be checked for
control assembly in shop before erection.
7. All structure components/members shall be checked for dimensional
tolerances during fabrication and erection as per IS-7215 and IS-12843
respectively.
8. Check for Surface Preparation and Paint thickness.
9. In case of failure of any welds in SPOT RT/UT, the %age for retesting shall
be doubled at that particular location. Acceptance criteria of NDT on welds
shall be as per AWS D1.1.
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10. Low hydrogen electrode (AWS E-7018) for welding of High/Medium tensile
steel, for M.S (IS 2062 Gr. A/Gr. B, IS 8500) sections thickness above 20mm
shall be used. Preheating and Post weld heat treatment requirements shall be
complied as specified in the technical specs. /approved WPS.
9.9.2 Shop Fabricated:
In addition to requirement of Clause 9.9.01 above following provisions shall also
apply:
1. Sub-Vendor approval having requisite manufacturing facilities shall be
required from NTPC.
2. Manufacturing Quality Plan indicating stage inspection/CHP shall be
submitted for NTPC review and approval.
3. Pre-dispatch inspection shall be carried out inline with the approval MQP and
the dispatch shall be effected through MDCC.
4. Raw Material including plates and structural shall be procured from the
manufacturers as identified in the contract with MTC and co-relable
traceability.
9.10.0 ARCHITECTURAL & MISC. WORKS
1. Material used for floor finishes and allied work shall conform and tested as per
the requirements of relevant IS Codes specified in NTPC Technical
Specification.
2. Finishes shall be checked for the following:
Level, Slope, Plumb
Pattern & Symmetry
Alignment of joints, dividing strips etc.
Colour, Texture
Surface Finish
Thickness of Paint
Details of edges, junction etc.
Performance
Precautions specified for durability.
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3. For fabricated item like metal doors, windows, ventilators, louvers, rolling
shutters and grills etc. The following checks shall be carried out.
Overall Dimensions
Mullions Transoms
Doors & Windows shall operate without jamming
Doors, windows & frames etc. shall be on a true plane, free from wrap
or buckle.
All welds shall be dressed flush on exposed and contact surfaces.
Correctness of locations and smoothness of operation of all shop
installed hardware and fixtures.
Provision of hardware & fixtures to be installed at site.
Glazing beads shall be cut with mitered corners.
Glazing clips, fixing devices etc. shall be supplied in adequate nos.
Shop coats shall be properly applied.
Exposed aluminium surface shall be free from scratches, stains and
discoloration.
9.11.0 ROLLING SHUTTERS/GRILLS
After installing the shutters, the contractor shall test the performance of the shutter in
the presence of the engineer. The shutter shall be smoothly operable under all
ambient conditions. All controls and locking devices shall give fault free performance.
9.12.0 FIRE PROOF DOORS
1. Fire Proof doors shall be tested for the requirements mentioned in IS-3614
Part-I&II and The Technical Specification. The type test of the doors shall be
carried out at CBRI Roorkee for minimum 2 hours fire rating and its
Fabrication drawing shall also be approved by CBRI, Roorkee.
2. DFT of paint of Fire Proof Doors and its fittings and fixtures as per BOQ shall
be checked. The doors shall be finished with suitable fire retardant painting
system.

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9.13.0 GLASS AND GLAZING
1. Materials used in glass and glazing shall conform to the requirements of the
Technical Specification and IS Codes specified in the Technical Specification.
2. All installation shall be free from cracked, broken or damaged glass, edges of
large panes of thicker glass and heat insulating glass be inspected carefully
for chipped, cracked or underground edges.
3. Glazing shall be carefully done to avoid direct contact with metal frames.
4. All glasses shall be embedded in mastic for steel works and fixed by
neoprene gasket for aluminium works to give a leak proof installation.
5. On completion, the panes shall be free from dirt, stains, excess putty etc. to
the complete satisfaction of the engineer.
9.14.0 ROOF WATER PROOFING & ALLIED WORKS
1. Material used shall be tested and conforms to the requirements of IS
Codes/International Codes specified in NTPC Technical Specification.
2. All elastomeric membrane is fully dried to perform testing with water ponds
created on minimum 5% of area of nominal size 6m x 6m for height of 25mm
to 30mm at critical locations for a period of 48 Hrs. No dampness shall be
visible on the underneath side of roof (i.e. ceiling, parapet and wall junction
etc.). The above testing shall be carried out prior to application of wearing
course.
9.15.0 PAINTING & ALLIED WORKS.
1. Various materials used shall conform and tested for the requirements of
Indian/International Codes specified in the Technical Specification.
2. Surface to receive paint shall be prepared as per the requirement of technical
specification.
3. Painting shall be checked for thickness of different coats as specified in
schedule of items and the Technical Specification/Drawing.
10.00.00 CONSTRUCTION TOLERANCE AND ACCEPTANCE CRITERIA
10.1.0 Excavation and Filling
Tolerance
Finished surface level shall be within 20mm of the level shown in the drawing.
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Acceptance Criteria
Following acceptance criteria shall be followed.
a) When only one set of sample is tested, then all individual samples collected
and tested should pass without any deviation
b) For retest of any sample two additional samples shall be collected and tested,
and both should pass without any deviation.
c) Where a large number of samples are tested for a particular test then 9
samples out of every 10 consecutive samples tested shall meet the
specification requirement.
d) Tolerance on finished levels for important filling areas at approved interval
shall be + 20mm. However, for an unimportant area, tolerance upto +75mm
shall be acceptable at the discretion of the Engineer. However, these
tolerances shall be applicable for localised areas only.
10.2.0 Cast-in-situ concrete and Allied works
10.2.01 Tolerances
a) Cast-in-situ concrete
Unless otherwise specified, the tolerance in construction shall be as follows:
The dimensions of concrete as cast when compared with those on the
drawings shall be within the tolerance given below:
-----------------------------------------------------------------------------------------------------------------
Description of Item/ Structural Element Max Min
(mm) (mm)
-----------------------------------------------------------------------------------------------------------------
Faces of concrete in foundations
and structural members against which
back fill is placed +25 -10

Eccentricity of footing 2% of footing width in
the direction of placement
but limited to 50mm

Top surfaces of slabs and of concrete
to receive base plates to be grouted +5 -5

Alignment of beams, lintels, columns,
walls, slabs and similar structural
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elements +5 -5

Cross sectional dimensions of walls,
slabs and similar structural elements +5 -5

Deviation from specified dimensions
of cross-section of columns and beams +12 -6

Alignment of holding down bolts without
sleeves +1.5 -1.5

Alignment of holding down bolts with
sleeves +5 -5

Level of holding down bolt assemblies +10 -10

Embedded Parts ( in any direction). +5 -5

Level of embedment for equipment
support +1.5 0

Level of embedment for other
embedded parts +5 -5

Centers of pockets or holes
with greatest lateral dimension not
exceeding 150mm +10 -10

Variation in steps

Riser +1.5 +3.0

Tread -1.5 -3.0

(b) Reinforcement

Tolerance on placing of reinforcement and for cover shall be as per clause
12.3 of IS: 456.

Reinforcement shall be placed within the following tolerances:

a) For effective depth 200 mm or less 10mm

b) For effective depth more than 200 mm 15mm

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Tolerance for cover

Actual concrete cover should not deviate from the required nominal cover by +
10 mm

(c) Pre cast concrete

Tolerance on dimensions of pre-cast units shall be as follows:

1. Length: +/- 0.1 percent subject to minimum of +/- 5 mm and maximum
of + 10 mm.

2. Cross-sectional dimensions: +/- 3 mm or +/- 0.1 percent whichever is
greater.

3. Straightness or Bow: 1/750 of the length subject to minimum of +/- 5
mm and maximum of +/- 10 mm.

4. Squareness: When considering the squareness of the corner the
length of the two adjacent sides being checked shall be taken as the
base line. The shorter side shall not vary in length from the
perpendicular by more than 5 mm.

5. Flatness: The maximum deviation from a 1.5m straight edge placed in
any position on a nominal plant surface shall not exceed 5 mm.

(d) Formwork and staging

(i) Staging shall be checked for its soundness as a whole and for
adequacy of the joints and its foundations. Formwork joints shall be
inspected for soundness of connections. All joints shall be either
vertical or horizontal and shall be such as to avoid loss of liquid
through the formwork.

(ii) Dimensional tolerance for formwork shall be as per Clause 9.6 of IS :
14687 and 11.1 of IS : 456, which is reproduced as given below:

Deviation from specified dimensions of :
cross section of columns and beams : +12mm - 6mm

Deviation from dimensions of footings :

1) Dimensions in plan: + 50mm - 12 mm

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2) Eccentricity: 0.02 times the width of the
footing in the direction of
deviation but not more than
50 mm

3) Thickness 0.05 times the specified
thickness
The above tolerances apply to concrete dimensions only, and not to
positioning of vertical reinforcing steel or dowels.
(iii) Checklist for formwork shall be as per Clause 9.9 of IS : 14687.
Format as per Annexure-C of IS : 14687 shall necessarily be made for
all important structures including all machine foundations.
(a) The acceptance criteria of concrete shall be in accordance with clause no.16
of IS : 456. However in exceptional circumstances, and that too in non-critical
areas, the Engineer may accept concrete work which is marginally
unacceptable as per the criteria laid down in IS : 456. For such accepted
work, payment shall be made at a reduced rate pro rate to the concrete cube
strength obtained, against that stipulated.
(b) Unacceptable concrete work shall be dismantled by the Contractor and
replaced by fresh work, meeting the specification requirements. In the course
of dismantling, if any damage is done to the embedded items or adjacent
structures, the same shall be made good, by the Contractor, to the
satisfaction of the Engineer, at no extra cost to the Owner.
(c) Test shall be conducted for the water tightness of the liquid retaining
structures as per IS : 3370 and IS : 6494.
10.3.0 Fabrication and Erection of Structural Steel Work
10.3.1 Tolerances
I. Fabrication tolerances
(a) maximum permissible gap in built up members
(b) maximum permissible deviation in depth and/or width of girder at the
joints
(c) maximum permissible out-of-square of flanges in built-up girders
(d) tolerances on length of beams and girders and their components
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(e) permissible deviation in column heights
All tolerances for above shall be as per drg / IS : 7215
II. Erection tolerances
(a) permissible tolerances in erected steel columns
(b) permissible tolerances in erected steel trusses
(c) permissible tolerances in crane girder and rails
All tolerances for above shall be as per approved drg / IS : 12843

III. Requirement of pre-heating
Thickness of thickest
part at the area of
welding / heat affected
zone
Welding using other
than low hydrogen
welding electrodes IS
: 2062
Welding using low
hydrogen welding
electrodes or submerged
arc welding IS:2062
Upto 20 mm (including) None None
Over 20 mm to 40 mm
(including)
Not allowed 20
0
C
Over 40 mm to 63 mm
(including)
Not allowed 66
0
C

Over 63 mm Not allowed 110
0
C
(a) The acceptance criteria of Non Destructive Testing (NDTs) on welds shall be
as per AWS D1.1 (Dynamically Loaded Structures - tension welds). In case of
failure of any of the tests, the Contractor at his own cost shall also carry out
rectification of such defective welds. Retesting of the rectified joint, shall also
be carried out by the Contractor at his own cost.
(b) Every 1
st
and further every 10
th
set of identical structure shall be checked for
control assembly in shop before erection.
Embedded part
The tolerances for embedded parts shall be as specified under concrete works.
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10.4.0 Masonry & Allied works
11.4.1 Tolerances
(a) All masonry shall be built true and plumb within the tolerances prescribed as
below. Care shall be taken to keep the perpends properly aligned. Unless
specified otherwise the tolerances in construction of masonry works shall be as
below:
i) Deviation in verticality in total height of any wall of a building more than
one storey in height shall not exceed 12.5mm.
ii) Deviation from vertical within a storey shall not exceed 6mm per 3m
height.
iii) Deviation from the position shown on the plan of any brickwork more
than one storey in height shall not exceed 12.5mm.
iv) Relative displacement between load bearing walls in adjacent storeys
intended to be in vertical alignment shall not exceed 6mm.
v) Deviation of bed joint from horizontal in any length upto 12m shall not
exceed 6mm, and in any length over 12m it shall not exceed 12.5mm
total.
vi) Deviation from the specified thickness of bed-joints, cross-joints or
perpends shall not exceed 3mm.
b) The plastered surface shall be checked for
i) Blistering, bond failure or loss of adhesion, cracking, crazing,
efflorescence, grinning, irregularity of surface texture, popping or
blowing, recurrent surface dampness, softness or chalkiness defects
and the remedial measures for the same shall be adopted as per IS:
1661.
ii) The finished plastered surface shall not show any deviation more than
4 mm when checked with a straight edge of 2 metre length placed
against the surface.
iii) The thickness of the plaster shall be measured exclusive of the
thickness of key i.e., grooves or open joints in brickwork. The average
thickness of plaster shall not be less than the specified thickness. The
minimum thickness over any portion of the surface shall not be less
than the specified thickness by more than 3 mm for plaster thickness
above 12mm and 1 mm for ceiling plaster. Extra thickness required in
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 28 OF 36

dubbing behind rounding of the corners at junctions of wall or in
plastering of masonry cornices etc. shall be ignored.
Following acceptance criteria shall be followed:
General workmanship is being good and as recommended by the manufacturer
and approved by the Engineer.
Tolerances are within the specified limit.
Material test certificate is in compliance with the applicable codes/standards.
Bought out material is from the approved manufacturer / vendor.

Bought out material is matching with the approved sample.
10.5.0 Finishing & Allied works
11.5.1 Tolerances
a) The floor finish shall be checked specially for the following :
i.) Level, slope, plumb as the case may be
ii.) Pattern and symmetry
iii.) Alignment of joints, dividing strips etc.
iv.) Colour, texture
v.) Surface finish
vi.) Thickness of joints
vii.) Details of edges, junction etc.
viii.) Performance
ix.) Precautions specified for durability
Local depressions on account of faulty workmanship shall not be acceptable.
Tiles / natural stones with cracked or broken/chipped edges shall not be
acceptable.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 29 OF 36

b) The door, window, ventilator, partition during and after fitting and fixing etc
shall be checked for the following:-
i) Installation shall be at correct locations, elevations and in general on a
true vertical plane.
ii) Fixing details shall be strictly as shown on drawings.
iii) Assembly of composite units shall be strictly as per drawing, with
mastic caulking at transoms and mullions, gaskets, weather strips etc.
complete.
iv) All frames on external wall shall be mastic caulked to prevent leakage
through joint between frames and masonry.
v) All openable sections shall operate smoothly without jamming. Lock,
fasteners, etc, shall engage positively. Keys shall be non-
interchangeable.
vi) Cutting to concrete or masonry shall be made good and all abrasions
to shop paint shall be touched up with paint or same quality as shop
paint.
vii) Aluminium doors, windows, ventilators, partitions etc., shall be free
from scratches, stains or discolouration.
viii) Door and window shutters shall operate without jamming. The
clearance at head and jamb for door shutters shall not exceed 1.5 mm.
For double leaf doors, the gap at the meeting stiles shall not be more
than 2.5 mm.
10.6.0 For False ceiling system the following shall be checked for :-
i) As installed shall be true to shape, level.
ii) Correctness for the opening for the fixtures, colour and shade.
iii) All joints shall be in the same line and cross joints shall be securely fixed to
walls.
iv) There shall not be any sagging and/ or unevenness in the surface
11.6.1 Acceptance criteria
Ceiling panels shall be best quality material in thickness and properties called for in
the specification /schedule of items. Material Test Certificate to be submitted before
bulk supply.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 30 OF 36

Finished ceiling shall be at the correct plane and prevent an aesthetically pleasing
and uniform appearance, free from sags and warps. Joints and exposed grids shall
be in true lines and symmetrically placed in manner as shown in drawings. Cut outs
for light fixtures, diffusers and other relevant services shall be of exact dimensions
and in exact locations.
11.7.0 Water proofing
Water proofing shall be tested for water tightness by creating a pond of water
minimum 25 mm height on area of 6 m x 6 m, for the period of 48 hrs on fully dried
elastomeric membrane surfaces. Minimum 5% area of the roof shall be subjected to
water tightness test. Such test necessarily be conducted on vulnerable areas like
drain channel/ drain head. No dampness shall be visible on the underneath side of
roof (i.e. ceiling), parapet and wall junctions etc. which have been subjected for
testing. The above testing shall be carried out prior to application of wearing course.
11.8.0 Water Supply, Drainage & Sanitation
11.8.1 Tolerances
a) All soil pipes, waste pipes, ventilating pipes and all other pipes, when above
ground, shall be gas tight. All sewers and drain laid below ground shall be
watertight.
b) Obstruction / Straightness Test
The obstructions shall be checked by inserting a smooth ball, of diameter 13
mm less than the pipe bore at the high end of the sewer or drain. If absence
of any obstructions, such as yarn or mortar projecting through the joints, ball
shall roll down the invert of the pipe and emerge at the lower end. The
straightness shall be checked by means of a mirror at one end of the line and
lamp at the other. If the pipeline is straight, the full circle of the light may be
observed. The mirror will also indicate obstruction in the barrel, if the pipeline
is not straight.
c) Service pipes testing with water
The service pipes shall be slowly and carefully charged with water, allowing
all air to escape avoiding all shock or water hammer. The service pipe shall
then be inspected under working condition of pressure and flow, when all
draw off taps are closed. The service pipes shall be checked for satisfactorily
support and protection from damage corrosion and frost.
d) Fixtures etc.
All fixtures and fittings shall be connected by watertight joints. No dripping of
water shall be acceptable.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 31 OF 36

Following acceptance criteria shall be followed:
General workmanship is being good and is recommend by the manufacturer and
approved by the engineer.
Tolerances are within the specified limit.
Material test certificate is in compliance with the applicable IS Codes.
Bought out material is from the approved manufacturer / vendor.
Bought out material is matching with the approved sample.
12.00.00 QA REQUIREMENTS FOR ROAD WORK
Quality Assurance and testing requirements for roadwork shall be as per relevant
IRC Codes for Road .
13.00.00 SPECIAL ITEMS
1. Vibration Isolation System(V.I.S)
Stiffness values shall be checked. The permissible deviation shall be
as per DIN 2096.
For accepting values , following acceptance criteria shall be followed:
1. General workmanship is being good and as recommended by
the manufacturer and approved by the Engineer.
2. Tolerances are within the specified limit.
3. Material tests certificate (M.T.C.) is in compliance with the
applicable codes standards.
4. Bought out material is from the approved manufacturer /
vendor.
5. Bought out material is matching with the approved sample.
14.00.00 ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE PROGRAMME:
14.01.00 Indicative list of Field Quality Laboratory and Survey equipment list (Annexure-I)
14.02.00 Indicative QA&QC Manpower requirements (Annexure-II)
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 32 OF 36

14.03.00 Indicative list of Bought Out Items for Civil Works (Annexure III)
14.04.00 Indicative Field Quality Plan for Civil and structural steel works (Annexure-IV) Note:
The field quality plans attached is indicative and minimum required. However any
addition or deletion in the scope of work, during detailed engineering shall be
accordingly added/ deducted from the indicative Field Quality Plan)
14.05.00 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1
14.06.00 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R1
14.07.00 Status of items requiring Quality Plan and sub supplier approval. Format No.: QS-01-
QAI-P-02/F1-R0
14.08.00 List of items requiring quality plan and sub supplier approval. Format No.: QS-01-
QAI-P-01/F3-R0
14.09.00 Field Welding Schedule Format No.: QS-01-CQA-W-11/F1-R0
14.10.00 Welding Procedure Specification (WPS) Format No.: QS-01-QAI-W-06/F1-R0
14.11.00 Main suppliers evaluation report Format No: QA-01-QAI-P-04/F1-R0
14.12.00 Sub supplier questionnaire Format no: QA-01-QAI-P-04/F2-R0
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 33 OF 36

TYPICAL QA/QC LAB EQUIPMENT ANNEXURE - I
INDICATIVE FIELD QA&QC LABORATORY SET-UP
S. No Equipment Nos
1. Standard sieve analysis setup along with the sieve G.I.
frame , Motorized sieve shaker, Pans and Covers etc.
1 Set
2. Slump Testing Equipment - Slump test mould, temping
rod etc.
2 Set
3. Compression test for concrete cubes and bricks Cube
moulds, compression testing machine, cylinders,
temping rods, laboratory concrete mixer etc.
1 Set
4. Le-chatelier apparatus, Viacat apparatus, balance,
standard weights, gauging trowel
1 Set each
5. Rebound Hammer for NDT testing of concrete 1 Set
6. Thermostatically controlled laboratory Electric ovens
and Portable ovens.
1 Set each
7. Physical balances and Electronic balances. 1 Set each
8. Micro Meter, Vernier Calipers 1 Set each
9. Mhos scale for hardness test 1 Set
10. Electrical moisture meter (IS 287) for timber test 1 Set
11. Digital Elco-meter for paint thickness 1 Set
12. Standard Proctor test set-up and Core cutters for in-
situ density test set-up
1 Set each
13. NDT tests on welding DPT set-up, UT and RT (with
BARC approved source) set-up
1 Set each
14. Computerized Seismographs for blast vibration
monitoring, if required
1 Set each
15. Glass Jar, sedimentation pipette, Measuring Cylinders,
Containers, Evaporating dish, steam bath, desiccators,
muffle furnace, chemicals etc.
As required
16. Thermometer, Steel rules, Measuring wedge for bricks
etc.
As required
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 34 OF 36

NOTE:
1. The equipments listed above are indicative and required to be mobilised as
minimum requirement. Additional equipment if any, required for successful
completion of work shall be provided /arranged by the contractor.
2. All test reports/ inspection reports have to be computerized and maintained on
LAN with an access to the owner
3. Computers - 2 Nos shall be deployed with Windows operating system and
connected to the NTPC server
4. Based on the schedule (L2/L3 Network), Quality control & Quality Assurance
work plan shall be finalized by the contractor and the same shall be submitted
to the engineer-in-charge for acceptance/approval. The Finalized work plan
shall be maintained on the computer to be accessed by the owner for
database and day to day monitoring.
5. The CC may indicate the tests proposed to be outsourced, if any, to be
conducted at NTPC approved third party laboratories such as NCB, CSMRS,
IITs etc.
6. All laboratory / measurement / survey equipments to be used at site shall be
calibrated by NABL/NPL accredited laboratory / agency.
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 35 OF 36

Annexure II

INDICATIVE FIELD QA & QC MANPOWER STRUCTURE

NOTE:
1. The above organization setup is minimum, however their deployment shall be as per the agreed
deployment schedule. The contractor shall prepare a manpower deployment schedule in line
with the finalized L2 network the same shall be submitted to the engineer-in charge for
acceptance/ approval.
2. The contractor shall mobilize the QA& QC manpower in line with the finalized manpower
deployment schedule and shall ensure their availability well in advance (15 days approx.) of the
beginning of the concerned activity/ work.
3. The contractor shall further mobilize required number of skilled & supporting staff and additional
resources, if any to meet the work schedule.
4. All the areas / activities shown above shall headed by experienced and qualified engineers
supported by sufficient numbers of supervisors and supporting staff. The bidder shall indicate
the number of engineers and supervisors in their bid, which shall be discussed and finalized
before award of package.
PROJECT MANAGER
QA & QC MANAGER
QC ENGINEER-IN-CHARGE
QA&QC
LABORATORY
IN-CHARGE
CONCRETE & BUILDING MATERIALS
EVALUATION/ TESTING, CONCRETE
MIX DESIGN, PRODUCTION, AND
PLACING AND OTHER MISC WORKS-
CIVIL ENGINEERS
NDT ENGINEERS FOR STRUCTURAL
STEEL WORK R.T. LEVEL- II, UT
LEVEL-II NDT ENGINEERS
QUALITY ASSURANCE

DOCUMENTATIO
N- QAP, FQP,
MQP, MONTHLY/
QUARTERLY
REPORTS ETC.
CO-ORDINATION
AND
INTERACTION
WITH NTPC AND
SUB-
CONTRACTORS
TEST ON
BOUGHT OUT
ITEMS
THIRD PARTY
LABORATORY
SUPPROTING FIELD
AND LAB.STAFFF
SUPPROTING STAFF
EXCAVATION, FILLLING,
FOUNDATIONS, PILING -
GEOTECHNICAL ENGINEERS
CLAUSE NO.
QUALITY ASSURANCE

SECTION VI, PART-B
BID DOC NO.:CS-0260-156-2(R)
SUB-SECTION-IIIE-16
SAMPLING TESTING
FOR CIVIL WORKS
PAGE 36 OF 36

Annexure III

Indicative List of Bought Out Items for Civil Works

Sr.
No.
Bought Out Item Proposed Make Proposed list of
Manufacturers
1. Structural steel and
reinforcement steel

2. Cement
3. Doors including fire proof
doors, windows, ventilators,
partitions, louvers, rolling
shutters, etc

4. Finish paints etc
5. Concrete Admixtures,
chemical injection grouting,
waterproofing chemicals etc.

6. Permanently Colour Coated
Sheets

7. PVC Water stops

Note:

The bidder shall furnish the list of manufacturers of each bought out items in their bid,
which shall be reviewed and finalized during the post bid discussions with the
successful bidder.

SECTION-VI
PART-B

PART - B


INDICATIVE FIELD QUALITY PLAN
Page 1 of 16 1 PROJECT:
0 PACKAGE:
CONTRACT NO.
MAIN CONTRACTOR
1 2 4 5 6 7 8 9 D* 10
1 GENERAL REQUIREMENTS
A Setting up of Field QA&QC laboratory
As agreed / required
A Physical Once prior to start of work SR Functioning of laboratory equipment in proper
working condition to be verified on monthly basis
B Avialablility of requisite laboratory set
up and equipment in good working
condition well before
commencement of concerned activity
A Physical Once prior to start of
work and thereof monthly
SR
C Submission of QA & QC manpower
deployment schedule based on
agreed L-2 network .
- A Physical Once prior to start of
work

D Availability of QA& QC manpower
based on deployment schedule .
SR
E Sampling for testing of buliding
materials, concrete mix design etc. As agreed / required
A Physical Once per each source SR/TR Test report along with the recommendations from
specialist agency to be submitted to NTPC.
F Submission of schedule of tests to be
done monthly / quaterly and
maintenace of the same on a
computer connected to LAN of NTPC
for monitoring
SR
2
2.1 Nature, type of soil/rock before and during
excavations
B Visual Random in eah shift SR
2.2 Initial ground level before start of
excavations
B Measurement 100% SR
2.3 Final shape and Dimensions of
excavations.
B Measurement 100% SR
2.4 Final excavation lelvels As agreed / required B Measuement 100% SR
2.5 Side slope of final excavation As agreed / required B Measurement Random in eah shift SR
2.6 Excavation in Hard Rock- If required
i Receipt, Storage, accountability of
Explosive
B Physical Random in each week SR
ii Execution of Blasting Operation As agreed / required B Physical Random in eah shift SR
iii Submission of Blasting report to EIC As agreed / required C Physical Each blast
2.7 Excavation in Hard Rock (Blasting
Prohibited)
B Physical 100% SR
2.8 A
Suitability
B Visual Randon in each shift
2.8 B
i Grain size analysis Set of Seives,
Hydrometer etc.
B Physical One in every 2000 cum
for each type and source
of fill materials subject to
a min. of 2 samples
SR/TR
The parameters should not be worse than the
parameter of the existing soil in plant area
ii Liquid & plastic limit Mechanical liquid limit
device, grooving tools,
Evaporating
Disc,Spatula, Palette
knives, Balance oven
containers, etc.
a min. of 2 samples
SR/TR
Excavations-
Fill/ Backfill -
Suitability of borrow fill material- Applicable in case the earth is brought from an area, out of the NTPC aquired land area
Suitability of borrow fill material - If earth is brought from area within the NTPC acquired area
Format of
Record
Remarks Acceptance
Norms
Type of Check Quantum Of check Reference Document
Tech Specs and Const. Drawings
EXCAVATION AND FILLING IN FOUNDATION WORKS
Indian Explosive Act 1940/all statutory
norms, Tech Specs and Const. Drawings
3
Sl. No Characteristics / instruments Class# of
check
Activity and operation
IS:4081, Tech Specs and Const. Drawings
As per approved drawing/ scheme, Tech
Specs and Const. Drawings
As per technical specifications
IS:2720 (Pt.IV), Tech Specs and Const.
Drawings
IS:2720 (Pt.IV) , Tech Specs and Const.
Drawings
NTPC approved specialist blasting agency such as
CMRI, NIRM shall be deployed at site for trial
blasts, design blasts, blast vibration monitoring etc.
Seismographs shall be deployed at site for
monitoring of blast operation vibrations.
SUPPLIERS NAME AND ADDRESS:
LOGO
QP NO. :
REV. NO .:
DATE :
PAGE :
ITEM : CIVIL WORK
SUB-SYSTEM : GEOTECH INVI, FOUNDATIONS, EXCAVATION
& FILL, SITE LEVELLING, CONCRETE, ROAD, BUILDING ETC.
ANNEXURE- V
NTPC TAMIL NADU ENERGY CO LTD. POWER PROJECT (3X500 MW)
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
INDICATIVE FIELD QUALITY PLAN 1 of 21
0 PACKAGE:
CONTRACT NO.
MAIN CONTRACTOR
1 2 4 5 6 7 8 9 D* 10
Format of
Record
Remarks Acceptance
Norms
3
check
LOGO
QP NO. :
REV. NO .:
DATE :
PAGE :
ITEM : CIVIL WORK
ANNEXURE- V
iii Shrinkage limit -do- B Physical One in every 5000 cum
a min. of 2 samples
SR/TR
iv Free Swell Index Measuring cylinders,
etc.
of fill materials
SR/TR
v Chemical Analysis
a Organic Matter Oven chemical
balance, volumetric
flasks, burettes,
pipettes, conical flasks,
set of seives, measuring
cylinders etc.
of fill materials
SR/TR
b Calcium carbonate Reagents and
indicators,Burette,flasks
,funnels etc.
of fill materials
SR/TR
c pH value
of fill materials
SR/TR
d Total soluble sulphate
of fill materials
SR/TR
2.9 Standard proctor Test Optimum moisture content and max. dry
density before fill
As per IS: 2720, Proctor
needle apparatus,etc.
A Physical One in every 2000 cum
of fill materials
SR/TR
2.10 Moisture content Moisture content of fill before compaction As per IS: 2720,
balance, oven etc.
of fill materials
SR/TR
2.9
i) For foundation fill/
backfill one for every 10
foundations for each
compacted layer.
SR/TR
ii) For area filling, one
every 1000 SQM area for
each compacted layer.
SR/TR
ii Relative density (Density Index) As per IS: 2720,
balance oven etc.
A Physical ----do----- (i) & (ii) above SR/TR
iii Dry Density by proctor needle penetration As per IS-2720, proctor
nedle apparatus etc.
B Physical Random checks to be
carried out for each
compacted layer
SR/TR
3.0 CAST-IN-SITU CONCRETE
MATERIALS
3.1 CEMENT
i Storage in weather tight covered area on
raised platform.
as per IS: 4082 B Visual 100% covered storage SR/LB
ii Retesting for compressive Strength &
setting time if stored for more than 60
days in site shed
Vicat Apparatus,
standard sand
compression testing
machine etc.
A Physical At Random Test
Report

3.2 Coarse Aggregate
Degree Of Compaction Of Fill if borrowed from outside plant area / Backfill
IS 2720 (Pt. XXIX), Tech Specs and Const.
Drawings
i Dry density by core cutter method
---- OR----
Dry density in place by sand displacement
method
As per IS:
2720/compaction test
(core cutter), balance
etc.
A Physical
Each consignment of cement shall be duly
correlated with Manufacturers TC.
In case the cement is supplied by the contractor
random sample from each lot of delivery shall be
tested for Setting time and Compressive strength.
Acceptance norms shall be as per relevant IS
Part XXIII of IS-2720, Tech Specs and
Const. Drawings
IS:2720 (Pt.IV), Tech Specs and Const.
Drawings
IS:2720 (Pt.XI), Tech Specs and Const.
Drawings
IS:2720 Pt.XXII, Tech Specs and Const.
Drawings
IS 2720 (Pt. XXVIII), Tech Specs and
Const. Drawings
IS 2720 (Pt. XIV), Tech Specs and Const.
Drawings
IS 2720 (Pt.II), Tech Specs and Const.
Drawings
IS 2720 (Pt.VII), Tech Specs and Const.
Drawings
Part XXVI of IS-2720, Tech Specs and
Const. Drawings
Part XXVII of IS-2720, Tech Specs and
Const. Drawings
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
0 PACKAGE:
CONTRACT NO.
MAIN CONTRACTOR
1 2 4 5 6 7 8 9 D* 10
Format of
Record
Remarks Acceptance
Norms
3
check
LOGO
QP NO. :
REV. NO .:
DATE :
PAGE :
ITEM : CIVIL WORK
ANNEXURE- V
i Moisture content . B Physical Once for each stack of
100 Cum. or part there of
Except during monsoon
when this has to be done
every day before start of
concreting
SR/LB Accordingly water content of the concrete will be
adjusted
ii Specific gravity, bulk density, voids, water
absorption,
Balance, seives
(conforming to IS:460-
1962) etc.
B Physical Once for each source &
for every change of
source
SR/LB/
Test
Report
These tests will be carried out white establishing
design mix and the results to be intimated to
NTPC.
iii Particle, size & Shape-(Sieve analysis,
determination of material finer than 75
micron, flakiness index, elongation index,
angularity number)
Seives, balance oven ,
thickness guage ,length
gauge metal scoop etc.
B Physical One per 100 cum., or
part thereof/change of
source whichever is
earlier
SR/LB -do-
iv Deleterious materials & organic impurities
(determination of clay lumps, fine silt, fine
dust , light weight pieces , soft particle &
estimation of organic impurities.)
Balance, seives
(conforming to IS:460-
1962) etc.
B Physical Once per source/ on
every change of source
SR/LB/
Test
Report
Experts opinion regarding suitability of the
aggregates shall be obtained from the specialist
agency such as NCB BallbhGarh etc. finalised
during preaward. Results will be reported nearest
to 0.1% of clay lumps.
v Soundness reagents (sodium
sulphate or magnesium
sulphate )etc
SR/LB/
Test
Report
Experts opinion regarding suitability of the
aggregates shall be obtained from the specialist
agency such as NCB BallbhGarh etc. finalised
during preaward.
vi Alkali aggregate reactivity scales, weight, sieves,
glass graduates, mixing
bowl, trovel, container,
length comparetor, etc
SR/LB/
Test
Report
the quantity of dissolved silica , and reduction in
alkalinity to be reported and hence the aggregate
type (deleterious/innocuous) result should be
supported by petrographic examination
vii Petrographic examination screens , hand lens,
microscope etc
SR/LB/
Test
Report
Reporting of petrographic examination shall be
done as illustrated in IS 2386 ( part-VIII)-1963.
petrographic report shall be supported by the
analysis and recommendation by a specialist
instute.
viii Crushing value abrasion value and impact
value
standard apparatus for
these tests shall be
used
SR/LB/
Test
Report
-do-
ix Repeated Temp, Cycle Test of Aggregate
Test
Report
Applicable for Aggregate used in TG, BFP. Fan &
Mills Foundations. To be carried out at NIRM and
their expert opinion to be sought.
3.3 Fine Aggregate
i Bulkage/ moisture content balance , oven etc B Physical To be done every day
before start of work
SR/LB/
TR
Volume of sand and weight of water shall be
adjusted as per bulkage & moisture content.
ii Silt, Clay content and organic impurities
B Physical Once per source& for on
SR/LB/
TR
Acceptance limit as per relevant IS code
iII All other tests similar to coarse
aggregates as mentioned above.
B As above Refer S.No. 2.01.02 SR/LB/
TR
IS: 2386 Part-V, IS:383 , Tech Specs and
Const. Drawings
No residual expansion, , Tech Specs and
Const. Drawings
IS: 2386 Part-III IS:383 , Tech
IS: 2386 Part-VIII, IS:383 , Tech Specs and
Const. Drawings
IS:383, IS-2386 Part IV/, Tech Specs and
Const. Drawings
IS:2386 Part-III, IS : 456, IS : 383/Tech
Spec, Tech Specs and Const. Drawings
IS-2386, IS-383, Tech Specs and Const.
Drawings
IS: 2386 Part-II, IS:383 , Tech Specs and
Const. Drawings
IS:2386 Part-I, IS : 456, IS : 383/Tech
IS:2386 Part-II, IS : 456, IS : 383/Tech
IS: 2386 (Part-VII), IS:383 , Tech Specs
and Const. Drawings
IS:2386 Part-III, IS : 456, IS : 383/Tech
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
0 PACKAGE:
CONTRACT NO.
MAIN CONTRACTOR
1 2 4 5 6 7 8 9 D* 10
Format of
Record
Remarks Acceptance
Norms
3
check
LOGO
QP NO. :
REV. NO .:
DATE :
PAGE :
ITEM : CIVIL WORK
ANNEXURE- V
3.4 Water
i Test for sulphates and chlorides Buret, conical flask,
pipette etc
B Testing Once per each source
thereof quarterly.
SR/LB/
TR
ii Tests for ascertaining limit of solids
B Physical Once per each source
thereof quarterly.
SR/LB/
TR
iii Tests for pH Value pH meter B Testing Once per each source
thereof quarterly.
SR/LB/
TR
iv Initial set time for used water and distilled
water
Vicat appratus A Physical See Remarks See
Remarks
In case of doubt regarding development of
strength,. Initial set time with used water and
the distiled watershould meet the requirements of
clause 5.4.1.3 of IS 456
v Compressive strength of concrete with
used water and distilled water
Standard sand and
compression testing
machine
A Physical See Remarks See
Remarks
In case of doubt regarding development of
strength,. Compressive strength with used
water and the distiled water should meet the
requirements of clause 5.4.1.2 of IS 456
3.5 CONCRETE
i Proportions of materials for nominal mix
concrete As agreed / required
B Physical Random in each shift SR/LB/
Test
Report
ii Trial mix (Cubes compressive strength) as
per Mix Design
A Physical Min. 4 Trial Mixes with
admixtures and Without
admixtures With fly ash.
SR/LB/
Test
Report
For trial mix min. of 6 cubes for each mix, 3
specimen shall be tested at 7 days remaining 3
shall be for 28 days comp. Strength. Mix design
shall carried out at agency finalised during pre
award )
iii Crushing strength (works Tests cubes)
A Physical One set of 6 cubes per
50 M3 or part thereof for
each grade of concrete
per shift whichever is
earlier.
SR/LB/
Test
Report
Min. of 6 cubes for each mix, 3 specimen shall be
tested at 7 days remaining 3 shall be for 28 days
comp. Strength.
iv Workability - slump test Standard appratus for
different method used
for measuring
workability
B Physical One sample every 2 hrs.
from every mixing plant
SR/LB/T
R
Slump test for medium and high workability,
Compaction factor test for medium and low
workability, V.B. test for low to Very low workability
v Cement content
B Physical At random at the time of
batching.
SR/LB
vi Admixtures for Concrete from approved
sources
A Review of MTC Random in each shift Test
Report
Admixture of appd. Brand and tested quality shall
be used.
vii Water Tightness Test for Water Retaining
Structures As agreed / required
A Physical Each Structure Inspectio
n Report
viii Dimensions and visual exa-mination of
finished structure
B Physical/ visual 100% SR
3.6 CONCRETE CONVEYING, PLACING& COMPACTION
i Mixing of concrete mixing of concrete shall be done in a
approved mixer such as to produce a
homogenous mix
To be calibrated at the
time of starting and
subsequently once in
three months, and shall
confirm to IS:4925
time of mixing will be as given in IS 457
ii Calibration of Batching Plant batcher should comply
with reqirement of IS
457
A Physical To be calibrated at the
time of starting and
subsequently once in
three months, and shall
confirm to IS:4925
TR
Cement consumption at batching plant shall also

be obtained through comp. Output.Provision of
online printer is manadatory
Review of calibration chart/ Certificate, IS
457, Tech Specs and Const. Drawings
As per Tech. Specification./Appd. Drg./IS-
456
IS:1199 , Tech Specs and Const. Drawings
As per Table-9 of IS 456, Tech Specs and
Const. Drawings
IS:516, IS:456, Tech Specs and Const.
Drawings
IS:3370 , IS:6494 Tech Specs and Const.
Drawings
See Remarks, Tech Specs and Const.
Drawings
IS: 516 & IS:456, IS:10262, Tech Specs
and Const. Drawings
IS:3025 part 22 and 23 (for test procedure
), IS:456(for acceptance criteria ) , Tech
IS:3025, IS:456, Tech Specs and Const.
Drawings
IS:3025 part 18 (organic),IS:456 , Tech
See Remarks, Tech Specs and Const.
Drawings
Review of calibration chart/ Certificate,
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
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iii Handling and Transportation of concrete buckets,chutes,belts,co
nveyer etc
B Physical Random in each shift SR Free fall or drop shall be limited to 150 cm
unless permitted concrete should be placed within
30 min of its removal from mixure . Construction
methodology to be approved one week prior to
start of work.
iv Placement of concrete Visual B Physical Random in each shift SR No concrete shall be placed until the place of
deposit has been throughly inspected and
approved, the concrete shall be deposited in such
a manner to maintain, until completion of unit, a
plastic horizontal surface throughout
v Check for compaction and Curing
B Physical Random in each shift SR Exposed concrete surface shall be protected
against heating and drying for atleast 72 hrs after
placement, curing compound may be used
vi Cleanliness, provision of chute and
arrangement for transportation &
placement of concrete.
C Visual 100% SR
x check for segregation As agreed / required C Visual 100%
3.7 TEST/CHECK ON RCC STRUCTURE IN HARDENDED CONDITIONS
i Core Test
A Physical As required by NTPC
Engineer.
SR/LB/
Test
Report
Acceptable if average equivalent cube strength of
the cores is equal to at least 85% of the cube
strength of the grade of concrete specified for the
corresponding age and no indivisual conc has
result less than 75%`
ii Dimensional check on finished structures
& Dimensional tolerances
B Measurement Approved Drawing SR
iii Rebound Hammer test
A physical As required by the NTPC
engineer
SR
iv
3.8 REINFORCEMENT STEEL
i Physical and Chemical Properties for
each lot as per relevant IS codes
As required/ agreed A Review of MTC Each batch of delivery MTC
Applicable if steel is procured by Contractor

ii Cutting tolerance As agreed / required B Measurement Random in each shift SR Tolerance as per specifications
iii Freedom form cracks surface flaws,
Lamination. As agreed / required
B Visual Random in each shift SR To be checked at site. Steel collected from source
should be free from excessive rust. To be stored
as per Technical Specs.
3.9
I Check for bar bending schedule with
necessary laps. Spacers & Chairs
B Visual &
Measurement
Random in each shift SR
ii Check for cover, spacing of bars
B Visual &
Measurement
iii Check for bending of bars
B Visual &
Measurement
iv Check for spacers and chairs after the
reinforcement cage is put inside the
formwork
B Visual &
Measurement
v Acceptance of placement od
reinforcement before start of concreting As agreed / required
B Visual &
Measurement
beofre start of each
concreting
SR
3.10 STAGING AND FORMS
i Materials and accessories
B Visual Once before start of work SR Proper care should be taken in order to combat
corrosion. Proper care should be taken while
cleaning, moving and stacking the scaffolds
ii Soundness of staging, shuttering and
scaffolding
B Visual Once before start of work SR
iii Acceptance of formwork before start
concreting
B Physical / visual beofre start of each
concreting
SR
Approved Drawings, Tech Specs and
Const. Drawings
Const. Drawings
IS : 456/ Drawings & approved bar
bending, Tech Specs and Const. Drawings
schedule
As per manufacturer's spec.and as per
3696,4014, 4990, Tech Specs and Const.
PLACEMENT OF REINFORCEMENT STEEL
IS: 1852, IS:432, IS:1786, Tech Specs and
Const. Drawings
Const. Drawings
Const. Drawings
As per IS:456, IS 516, Tech Specs and
Const. Drawings
Check for period of curing as per IS 456 ,
As per relevant IS, Tech Specs and Const.
Drawings
As per provisions and tolerances, Tech
As per IS:456, Tech Specs and Const.
Drawings
IS : 1786, IS:432, IS:1566, Tech Specs and
Const. Drawings
IS : 1852, IS: 432, IS:1786, Tech Specs
and Const Drawings
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
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ITEM : CIVIL WORK
ANNEXURE- V
3.11
i Position and levels of embedded parts
B Physical/
measurement
100% SR Exposed surfsce of the embeded parts other than
holding down bolts are to be painted with primer
,chlorinated , rubber baed zinc phosphate
ii Position depth and size of bolt hole
B Physical/
measurement
iii Location verticality of pipe sleeve/opening
of bolt hold
B Physical/
measurement
iv Laying of rails under supervision of
NTPCs specilised agency.
B Physical/
measurement
v Welding / tieing of embeddment to
reinforce-ment
B Physical/
measurement
3.12 PRE-CAST CONCRETE
i Crushing strength compression strength
testing machine
A Physical one sample of six cubes
per 50 cum or part
thereof
SR/LB
a minimum of three specimen shall be tested for

28 days comp. strength
ii Workmanship free from visual defects
Visual
B Physical 100% SR The precast units shall be free from defects like
honeycombing, reinforcement exposure and
should have good finish. All relevant tests like
workability, cube test shall be carried out as per IS
456-2000 Same as applicable to cast in situ
concrete.
iii Dimension of finish structure
B Measurement 100% SR If the material already tested of the cast-in-situ
concrete and part of the same is used for precast
concrete, further testing is not required, otherwise
testing is required for every 50 Cum. Of Concrete.
iv Workability
slump test apparatus
B Physical one sample every two hrs
from mixing plant
SR/LB According to the mix design
v
Water cement ratio
batching
SR/LB According to the mix design
vi Cement content
batching
SR According to the mix design
vii Load Test
A Physical 5% or as desired by EIC SR
These tests shall also be carried out, in case of

doubt regarding grade of concrete and poor
quality.
3.13 JOINTS IN CONCRETE
i Check for the joint material - bitumen
impregnated fibre board, PVC water
stops, Sealing compound, Expanded
polystyrene board, Hydrophillic strip,
Acrylic polymer etc.
As per manufacturer
Standards
A Review of MTC Each batch of delivery MTC
ii Acceptance of installation of materials for

Joints in concrete
B Acceptance Each installation
randomly
3.14 DAMP PROOF COURSE
i
Check for the material - Hot bitumen and
water proffing materials etc
As agreed / required A Review of MTC
Each batch of delivery at
site
SR
ii Acceptance of damp proof course As agreed / required B Acceptance 100% SR
3.15 GROUTING
i Check for the material As agreed / required A Review of MTC Each batch of delivery SR Check for chemical, epoxy, resin grouts etc
Check for the type of mix - fluid mix,
plastic mix, stiff mix etc.
B Physical Prior to start of work
ii Check for the mixing, placement,
application and grout pressure
B Physical Random in each shift
SR
iii Check for the compressive strength As agreed / required A Physical Each batch of delivery SR
iv Acceptance of the grouts As agreed / required B Physical Each grout section SR
As per drawing, Tech Specs and Const.
Drawings
Tech Specs and Const. Drawings, IS
1838, IS 1834, IS12200
EMBEDDED PART(INCLUDING LAYING OF RAILS & ANCHOR FASTENERS)
Drawings
As per IS:456, Tech Specs and Const.
Drawings
Drawings
Drawings
IS:456/ As decided by NTPC Site Engr.
Incharge., Tech Specs and Const.
Drawings
Tech Specs and Const. Drawings, IS 702
IS:516&IS; 456, Tech Specs and Const.
Drawings
IS:1199 &IS:456, Tech Specs and Const.
Drawings
IS:1199 /tech spec, Tech Specs and Const.
Drawings
Drawings
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
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ANNEXURE- V
4.00 BRICK MASONARY
4.1 Test on Bricks
i Check for Dimensions , shape
A Measurement/
Physical Test
As per relevant IS Code/
One Sample for 30,000
Nos. or part thereof
Inspectio
n Report
Efflorescence shall be checked at each source.

ii compressive strength, water absorption,
warpage efflorescence.
Balance Oven
compression testing
machine etc.
B Measurement/
Physical Test
As per relevant IS Code/
One Sample for 30,000
Nos. or part thereof

Preconditioning of brick shall be done as per IS.
For comperssive strength, warpage and water
absorbtion
i Dimensions As agreed / required B Physical One sample from each
lot received at site.
SR/LB
ii Compressive Strength As agreed / required A Physical One sample from each
lot received at site
SR/LB
iii Water Absorption As agreed / required B Physical A set of 20 bricks (min.)
for each lot of 50000
bricks or part thereof.
SR/LB
4.2 Test on Mortar Compressive strength, consistency for
each portion of walls, plasters and
ceilings.
B Test At random LB Cement used in mortar shall confirm to either IS
269: 1976 or IS 455- 1976 sand shall confirm to IS
2116 -1980
4.3 Masonry construction Acceptance of Workmanship, verticality
and alignment
B Visual/ Physical 100% SR/LB
5.00 FINISHING AND ALLIED WORKS .
5.1 MATERIALS- FINE SAND, SAND
FOR PLASTERING
i Deleterious Material As agreed / required B Physical Once per source SR
ii Grading As agreed / required B Physical 50 Cum./or part thereof SR Table I of IS:2116
iii Galvanized hexagonal wire netting for lath
plastering
B Review of MTC Each batch of delivery SR
iv Check for the thickness and finishing of
plaster
B Visual/
Measurement
Random in each shift SR/LB
5.2 PLASTERING
i Check for defects and the remedial
measure for bond filler , blistering ,
cracking and crazing , efflorescence and
irregularity of surface texture
B Visual/ Physical Random in each shift SR
ii Truness of plastering system
B Visual/ Physical Random in each shift SR finished plaster surface shall not show any
deviation more than 4 mm when checked with
straight edge of 2 m length
iii Acceptance of Grooves and finishing As agreed / required B Acceptance 100% SR
5.3
i Check for Preparation of surface As agreed / required B Physical Random in each shift SR
ii Check for material - Size of chips As agreed / required B Physical Random in each shift SR
iii Acceptance of Grooves and finishing As agreed / required B Acceptance 100% SR
5.4 WATER PROOFING SYSTEM
i
Check for the material As agreed / required A
Physical and
Review of MTC
Each lot of delivery SR/ MTC
ii
Acceptance of water proofing system -
Application, fixing, laying
As agreed / required B Physical 100% SR
Water pounding test shall be done
5.5 FALSE CEILING
i) Check for the Materials - Glass
Reinforced Gypsum (GRG), Pre-painted
coil coated steel false ceiling system etc.
A Physical and MTC
Review
Each batch of delivery -do-
Test on Bricks(Fly Ash Based) IF FLYASH BRICKS ARE USED

Tech Specs and Const. Drawings,
As per relevant IS and Tech. Specs /
Manufacturer's TC
and Const. Drawings
IS 2250-1981, Tech Specs and Const.
Drawings
IS: 1077, Tech Specs and Const. Drawings
NTPC Tech. Specifn. and
relevant IS:3812
STONE GRIT PLASTER/ GRANULAR TEXTURED COAT FINISH
IS 2212, IS 1905 , Tech Specs and Const.
Drawings
, Tech Specs and Const. Drawings
As per IS 1661 , Tech Specs and Const.
Drawings
Tech Specs and Const. Drawings, IS: 1661
IS: 1077, IS:3495 part I ( Compressive
Strength) Part II ( Water Absorbtion) Part
III( Efflorescence) Part IV ( War page),
relevant IS:3812
relevant IS :3812
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ii) Acceptance of installation
B Physical /
measurements
Each installation -do- All supports , hangers , accessories shall be as
per Tech. Specifications/ approved manufacturer's
recommendations
6.00 PAINTING SYSTEM - All surfaces
6.1 Check for the Materials and
accessories
White wash, Distemper and all types of
Primer and Paints - Check for Shade,
type from brand and manufacturer as
approved by NTPC EIC
A Review of MTC Each batch of delivery SR/MTC
Mfr.s T.C. shall be correlated with the

consignment received.
6.2 Check for Surface prepration As agreed / required B Physical /visual Random in each shift SR
6.3 Check for DFT of painted surfaces
B Physical Each surface at random SR
6.4 Acceptance of painted surfaces
B Physical Each surface at random SR
7.00 DOORS , WINDOWS VENTILATORS & GRILL
7.1
Check for the material/ items for all
type of timber, flush doors,
Particle doors, wire guage,
Aluminium doors, Fire proof doors,
windows fittings, Anodized
aluminium works, Mortice locks,
Automatic operating system etc
received at site
Review of MTC / make or/and Physical
checks, tests report ( if MTC is not
available)
As agreed / required A
Review of MTC/
Physical
for each batch of delivery SR
7.2
Wood work in frames
Wood work in frames - Check for
dimensions, surface finish and rebating
etc.
As agreed / required B Physical
Random for each
installation
SR
7.3
Wardrobe shutter and show cases
i
Check for material as per IS 3087 and
3097 - from NTPC approved source
one sample for each
section for each lot of
delivery
SR
ii Acceptance of fixing after completion As agreed / required B Acceptance 100% SR
7.4 Pelmets
i
Check for material as per IS 3087/ 3097 -
from NTPC approved source
one sample for each
delivery
SR
ii Acceptance of fixing after completion As agreed / required B Acceptance 100% SR
7.5 MS Grills
i
Check for the material for section and
weight from NTPC approved source
As agreed / required A Physical
one sample for each
delivery
SR
ii Check for fabrication done at approved
workshop
As agreed / required B Physical Random SR
Acceptance of fixing of MS Grills As agreed / required B Acceptance Random SR
7.6
Fitting and fixtures - MS sliding
door bolts, tower bolts, pull bolt
lock, MS handles, Safety Chains,
brass locks, brass latch, hydraulic
floor springs & door closers, etc
Check for fitting items as per relavent IS
codes, tech specifications and BOQ- from
NTPC approved source
As agreed / required B
Physical and
acceptance
Five samples for each
item for each lot of
delivery
SR
7.7 Fitting and fixtures - Aluminium
sliding door bolts, tower bolts, pull
bolt locks, handles, door stoppers
etc.
Check for fitting items as per relavent IS
codes, tech specifications and BOQ- from
NTPC approved source
Physical and
acceptance
Five samples for each
item for each lot of
delivery
SR
Tech Specs and Const. Drawings, IS 3087/
3097
-do-
Tech Specs and Const. Drawings, IS 3087/
3098
and 3097
and 3098
BID DOC. NO.:CS-0260-156-2(R)
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ITEM : CIVIL WORK
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7.8 Fire proof doors
i a) Check for the Fire Proof Doors As required/ agreed A Review of MTC Each lot MTC

ii b) Check for DFT and Fire Retardency of
Paint
As required/ agreed B Physical Each Door SR/LB
7.9 Acceptance of all type fittings after
fixing
Acceptance of fittings after completion As agreed / required B
Physical and
acceptance
Random for each type of
fitting
SR
8.00 GENERAL STEEL WORK
8.1 Check for Material - Rolled Steel, Z
Sections, Plates etc.
Review of MTC/ make / Physical checks,
tests ( if MTC is not available)
Review of MTC for
each delivery
For each batch of
delivery
SR
8.2 Rolling shutters
i Check for surface finish and thickness of
plate of rolling shutters of approved make
and DFT
Random for each batch
of delivery
SR
ii
Acceptance of rolling shutters after fixing As agreed / required B
Physical and
acceptance
Random SR
8.3 Steel Glazed doors and T-iron
frames sections
i
Check for shape, tolerances, thickness,
welding and finishing of sections (Check
MTC whereever applicable)
Review of MTC for
each delivery
Random for each delivery SR
ii Acceptance of Steel Glazed doors and T-
iron frames sections after fixing
Physical and
acceptance
Random for each
installation
SR
8.4 Pressed steel pressed frames/
doors
i Check for shape, tolerances, thickness,
welding and finishing (Check MTC
whereever applicable)
Review of MTC for
each delivery
Random for each delivery SR
ii Acceptance of Pressed steel pressed
doors after fixing
Physical and
acceptance
Random for each
installation
SR
8.5 Fencing and Gates
i)
Check for Materials for fencing and
gates
PVC coated chain link fencing (IS 2720),
Welded wire mesh (IS 1566), Reinforced
barbed tape galvanised (IS 2629) etc.
A Review of MTC Each batch of delivery SR/MTC
Mfr.s T.C. shall be correlated with the

consignment received.
ii) Check for alignments, erection
painting, DFT etc.
B Physical /
measurements
Each installation
SR Erection shall be as per NTPC Tech. Specs.
ii) Acceptance of the installation and
working
B Physical /
measurements
Each installation
SR Erection shall be as per NTPC Tech. Specs.
8.6 Galvanised Chicken Wire Mesh Check for Guage and Dimensions from
NTPC approved Source
As agreed / required B Acceptance Random for each delivery SR
9.00
FLOOR FINISHES AND ALIED
WORKS
9.1 Cement Concrete Flooring
i Check for execution of concreting As agreed / required B Physical Random in each shift SR
ii
Check for providing and fixing glass/ PVC
strips in joints
As agreed / required B Physical Random in each shift SR
iii
Check for laying, polishing, curing,
finishing for terrazzo, marble chip flooring
iv Acceptance of lines, levels and finishing As agreed / required B Acceptance 100% SR
9.2 Acid and or alkali resistance tiles
As per Technical Specifications and
approved drawings, IS 3614 Part (I &II)
As per Technical Specifications and
approved drawings IS 3614 Part (I &II)
Tech Specs and Const. Drawings, IS4351,
IS2202
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SECTION-VI
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i
Check for tiles and alkali resistance
cement as per IS
Review of MTC for
each delivery
each batch of delivery SR
ii Acceptance of lines, levels and finishing As agreed / required B Acceptance 100% SR
9.3 Kota Stone, Granite and Marble
i
Check for quality, texture, thickness,
colour for each lot of delivery from
approved source
As agreed / required A Physical each batch of delivery SR
ii
Check for the preparation of surface,
laying, joints
iii
Acceptance for curing, polishing and
finishing
As agreed / required B Acceptance 100% SR
9.4
Ceramic Glazed Tiles, Vitrified /
glass mosaic tiles other tiles as
per specification
i
Check for tiles from NTPC approved
sources as per specification (Check MTC
Physical / review of
MTC
each batch of delivery SR
ii
Check for the preparation of surface,
laying, joints
iii
Acceptance for curing, polishing and
finishing
10.00
10.1
Check for size and surface finish of all
sanitory items and fixtures from NTPC
approved sources, (Check MTC
MTC
Each lot of delivery as per
Specifications
SR To be procured from NTPC approved source
10.2
Acceptance of installations of all sanitory
items and fixtures
10.3 SCI, CI, S&S Pipes & Fittings etc
i Check for Work man ship and finish As agreed / required B Visual Random SR
ii Check for Unit weight and Dimensions As agreed / required B Physical Random SR
iii Hydrostatic test As agreed / required A
Review of MTC for
each delivery
Specifications
SR
11.00
11.1
Check for size and surface finish of all
water supply, GI/ MS pipes and fittings,
Photo Voltaic Control System etc from
NTPC approved sources (Check MTC
MTC
each delivery as per
Specifications
11.2
Acceptance of installations of all water
supply, GI pipes and fittings
11.3 CI, S&S Pipes & Fittings
i Check for Work man ship and finish As agreed / required B Visual
Random as per
Specifications
SR
ii Check for Unit weight and Dimensions As agreed / required B Physical Random SR
iii Hydrostatic test As agreed / required A
MTC
Specifications
SR
11.4 Polyethylene Water Storage Tanks
i
Check for material of tanks from NTPC
approved sources
MTC
Specifications
SR
WATER SUPPLY AND ALL TYPES OF FITTINGS
SANITORY INSTALLATIONS
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ANNEXURE- V
ii
Aceptance for instllation and fitting (IS
12701)
12.00 DRAINAGE AND SANITATION
12.1 Sanitary appliances
i
Check for Viterous China, Glazed,
ceramic sanitary appliances (Water
closets, Wash basins, urinals) etc.
MTC
each delivery as per
Specifications
ii
Acceptance of installation of Viterous
China, Glazed, ceramic sanitary
appliances (Water closets, Wash basins,
urinals) etc.
12.2 SW Pipes and RCC Pipes
i
Check for size and surface finish of Pipes
from NTPC approved sources
As agreed / required A Physical 100% after delivery SR
ii Testing of Joints As agreed / required B Physical 100% SR
i Acceptance of installations of Pipes As agreed / required B Acceptance 100% SR
Acceptance tests shall be done as per
specifications
12.3 CI Pipes, Covers and Frames
i
Check for CI and SFRC covers and
frames as per IS 1726 and IS 12592 from
NTPC approved sources (Check MTC
MTC
Each lot of delivery SR
ii
Acceptance of installations of CI Pipes,
Covers and Frames
12.4 RCC manholes
Acceptance of RCC manholes after
completion
13.00 ALUMINIUM WORK
13.1
Check for section/ fixtures dimensions and
anodising from NTPC approved sources
Physical and
Review of MTC for
each delivery
one sample for each
delivery
SR
13.2 Acceptance of fixing after completion As agreed / required B Physical 100% SR
14.00 WATER PROOFING
14.1
Check for water proofing compoud,
Blown/ residual bitumen, PVC sheet, PVC
water stops, Geotextiles, Poly-scrim cloth,
elastomeric membrane, from NTPC
approved sources
Physical and
Review of MTC for
each delivery
one sample for each
delivery
SR
14.2 Acceptance of water proofing work As agreed / required B Physical 100%
15.00 GLASS AND GLAZING
15.1
Check for the material - check for MTC
and thickness of glass.
Physical and
Review of MTC
For structural glazing the technical parameters
shall be as per the technical specifications
15.2
Check for structural glazing cleaning
system
Physical and
Review of MTC
15.3
Acceptance of glass and glazing
installation work including cleaning system
As agreed / required B Physical 100% SR
16.00 FOUNDATION SYSTEM
16.1 SHALLOW FOUNDATIONS
i
Check for the foundation excavation -
Location, Layout, size, depth etc
As required / agreed B Physical Each location SR lines and levels to be checked
ii
Check for the foundation casting - Layout,
Shape, dimensitions, Reinforcement,
concreting, curing etc
As required / agreed B Physical Each foundation SR
lines and levels to be checked. Concrete Grade to
be checked as per Mix Design
Tech Specs and Const. Drawings , IS 4111
As per technical specifications and
construction drawings
Tech Specs and Const. Drawings, IS 1536,
IS 12592
IS 1285
construction drawings
IS 1285
Tech Specs and Const. Drawings, IS458,
IS 1536
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
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ITEM : CIVIL WORK
ANNEXURE- V
17.00
SHEETING AND OTHER WORKS
17.1 Check for Material like modular areated
panel, permanently colour coated sheets ,
metal decking , pre-engineered buildings,
AC sheeting, Fire proof doors and
insulations (all tests as per tehcnical
Specifications)
As per manufacturer
Standards
A Review of MTC Each batch of delivery MTC
1)FQP for structural steel shall also be

applicable.2) For aluminium door/windows, check
for anodisation as per Tech. Spec. 3) Fire proof
doors shall be procured from TAC Approved
parties as per relevant IS/Tech. 4) For aluminium
cladding grade of alminium to be checked.
17.2 Check for Storage at Site As agreed / required B Visual Random in each shift SR
17.3 Installation, lap alignment & workmanship.
B Visual/ Physical Random in each shift SR
17.4 Installation of lining &insulation &check
thermal insulationfor wall clading for
thickness , density , thermal conductivityn
at 50 deg c and all other tests as per
IS:8183
B Testing 100% SR
17.5 Check for the installation, alignments,

finishing etc
B Visual/ Physical Random in each shift SR/LB
17.6 Fasteners for sheeting work
B Review of TC
including 1000 hrs
salt spray test
100%
SR/LB
17.7 Acceptance of each type of installation As agreed / required B Visual/ Physical Each installation SR/LB
18.00 SPECIAL ITEMS
18.1 Bitumastic flooring / layering Check for the Bitumen grade and
suitability of filler material
B Review of MTC Each batch of delivery SR/MTC
18.2 Earthing Mat (Grounding System)

i Check for the earthing mat material
A Physical and MTC
Review
Each batch of delivery SR/MTC
ii Weld sizes & length Visual/Tape B Visual/

Measurement
100% Low hydrogen electrode as per NTPC approval
shall be used.
iii D P test DP test Kit A Physical 10% at random TR
iv Earth test Earthing test kit A Physical 100% SR Earthing required as per IS 3043
18.3 Insulations
i Check for the insulation material such as
Mineral Wools, Polysocyanyrate / regid
phenolic foam slabs etc.
A Physical and MTC
Review
ii Acceptance of installation of Insulations

B Physical Each installation SR
18.4 Aluminium Composite Panel
Cladding (Also refer FQP items for
sheeting)
i
Check for the material
A Physical and MTC
Review
ii
Acceptance of installation of Aluminium
Composite Panel Cladding
B Physical Each installation SR
Installation shall be done by specialist agency
18.5
Acid/ Alkali Resistance Treatment
i
Check for acid/ alkali resistance materials
- Bricks, vitreous tiles, mortar, sealing,
paints, coatings, sheets, fillers etc
A Physical and MTC
Review
ii Check for surface preparation As agreed / required B Physical Random in each shift
iii Acceptance of each type of installation As agreed / required B Physical Each installation SR DFT shall be checked for paints, coats
12436, IS 13204, IS 8183
Free from defect , Tech Specs and Const.
Drawings Tech Specs and Const. Drawings,
Relevant IS 3043
IS 4457, IS 4832
As per relevant IS and Tech. Specs /
Manufacturer's TC, IS 3043
Tech Specs and Const. Drawings, IS 73, IS
383
No gas cutting of sheets acceptable . Profile
sheets will be kept covered in weather proof
storage &stored at accurate height to avoid any
exposure of actual water. Principle of first in and
first out shall be apply for erecting the sheets.
BID DOC. NO.:CS-0260-156-2(R)
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ITEM : CIVIL WORK
ANNEXURE- V
19.00 ROAD WORKS
19.1 Construction of Sub-Grade and
earthen/hard soulders
i Standard proctor Test to determine
optimum moisture content and max. dry
density
of fill materials
SR/TR
In cutting or existing levelled ground - quantum of
check shall be one per 1000 SQM
ii Moisture content of fill before compaction
As per IS: 2720,
balance, oven etc.
of fill materials
SR/TR
In cutting or existing levelled ground - quantum of
check shall be one per 1000 SQM
iii Dry density by core cutter method
---- OR----
method
As per IS:
etc.
A Physical One in every 500 SQM
area for each compacted
layer.
SR/TR
Both for embankment and cut formation quantum
of check - One in every 1000 SQM area for each
compacted layer.
19.2 Water Bound Macadam (Non-
Bituminous) for base course and
sub-base course
i Aggregate Impact value Agrregate Impact value
Test Apparatus
A Physical One test per 200 cum of
Test aggregate
SR
ii Grading
Set of IS Sieves
B Physical One test per 100 cum of
aggregate
SR
iii Flakiness index and elongation index
Flakiness test gauge
B Physical One test per 200cun of
agregate
SR
iv Atterberg Limits of binding material Atterberg limits
determination
binding material
SR
v Atterberg Limits of portion of agreggate
passing 425 micron sieve
Atterberg limits
determination
A Physical One test per 100cum of
aggregate
SR
vi Standard proctor Test to determine
optimum moisture content and max. dry
density
of fill materials
SR
vii Moisture content of fill before compaction
As per IS: 2720,
balance, oven etc.
of fill materials
SR
viii Dry density by core cutter method
---- OR----
method
As per IS:
etc.
A Physical For area filling, one every
1000 SQM area for each
compacted layer.
SR
19.3 Bituminous Macadam for base and
binder course
i Quality of binder
Penetrometre with St.
needle
A Physical No. of samples per Lot &
tests as per IS:73, IS:217,
IS:8887 as applicable
SR
ii Aggregate Impact Value / Los angeles
abrasion value
Aggregate Impact
ValueTest apparatus
aggregate
SR
iii Flakiness Index and elongation index of
aggregates Flakiness test gauge
aggregate
SR
iv Stripping value of aggregate (Immersion
tray test)
As required / agreed
B Physical Initialy one set of 3
representative specimen
per source, and on every
change of source.
SR
v Water sensitivity of mix
A Physical Initialy one set of 3
change of source.
SR
As per Tech Specs and Const. Drawings,
Section 900 of MORTH specification, IS
2720 (Pt. XXIX)/ IS 2720 (Pt. XXVIII),
As perTech Specs and Const. Drawings,
Section 900 of MORTH specification,
Section 900 of MORTH specification
Section 900 of MORTH specification, IS 73
IS 2720 (Pt.VII), Tech Specs and Const.
Drawings,Section 900 of MORTH
specification
IS 2720 (Pt.II), Tech Specs and Const.
Drawings, Section 900 of MORTH
specification
IS 2720 (Pt. XXIX)/ IS 2720 (Pt.
XXVIII),Tech Specs and Const. Drawings,
As per Tech Specs and Const.
Drawings,Section 900 of MORTH
specification, IS 2720 (Pt.VII)
Section 900 of MORTH specification, IS
2720 (Pt.II)
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
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ANNEXURE- V
vi Grading of aggregates
Set of Sieves
B Physical Two test per day per
plant both on individual
constituents and mixed
aggregate from drier
SR
vii Water absorption of aggregate
Initially one set of 3
change of source.
SR
viii Soundness ( Magnesium and Sodium
Sulphate) As required as per
IS:2386
A Physical Once per source by each
method and on every
change of source
SR
ix Percentage of fractured faces
B Physical When gravel is used one
test per 50cum of
aggregates
SR
x Binder content and aggregate grading
Bitumen extractor
A Physical Periodic, subject to a min
of two tests per day per
plant
SR
xi Control of Temperature of binder and
aggregate for mixing and of the mix at the
time of laying and rolling
Thermometer
B Physical At regular close intervals SR
xii Rate of spread of mixed materials
B Physical Regular control through
checks of layer thickness
SR
xiii Density of compacted Layer
A Physical One test per 250 sqm of
area
SR
19.4 Bituminous Surfacing - Open
graded premix carpet and Seal
coat
i Quality of binder
Penetrometre with St.
needle
SR
ii Aggregate Impact Value / Los angeles
abrasion value
Aggregate Impact
ValueTest apparatus
aggregate
SR
iii Flakiness Index and elongation indexof
aggregates
Flakiness test gauge
aggregate
SR
iv Stripping value of aggregate (Immersion
tray test)
B Physical Initialy one set of 3
change of source.
SR
v Water absorption test A Physical Initialy one set of 3
change of source.
SR
vi Water sensitivity of mix
A Physical Initialy one set of 3
change of source.
SR
vii Grading of aggregates
Set of Sieves
aggregates
SR
viii Soundness ( Magnesium and Sodium
Sulphate) As required as per
IS:2386
A Physical Once per source by each
method and on every
change of source
SR
IS 73,Tech Specs and Const. Drawings,
BID DOC. NO.:CS-0260-156-2(R)
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ANNEXURE- V
ix Polished stone value As required as per
BS:812(Part 114)
B Physical As required SR
x Temperature of binder at application
Thermometer
xi Binder content
Bitumen extractor
A Physical One test per 500 cum&
not less than two tests
per day
SR
xii Rate of spread of materials
B Physical One test per 500 cum
and not less than 2 tests
per day
SR
xiii Percentage of fractured faces
Bitumen extractor
A Physical When gravel is used one
test per 50cum of
aggregates
SR
19.5 Tack Coat/ Prime coat/ fog coat
i Quality of binder
Penetrometre with
Standard needle
SR
ii Temperature of binder at application
Thermometer
iii Rate of spread of binder
B Physical One test per 500 cum
and not less than 2 tests
per day
SR
19.6 RCC Pavements Concrete - Material, Mix design, Trial
Mixes, Production, Transportation,
Placement, Compaction, Curing, Test on
green concrete, Test on hardened
concrete etc.
- - Refer FQP for concrete
Works
- FQP for Concrete Works shall be application for
all concrete works
19.7 Alignment, Level, Surface
regularity and rectification
i Horizontal alignment, Surface levels and
Surface regularity
B Physical As per section 900 of
MORTH specification
SR
ii Rectification
B Physical Each rectification SR
20.00
20.1 Deployment of approved Geotechnical
Investigation Agency - Check for
Equipments, Manpower etc
A Physical Once before
commencement of work
SR
20.2 Execution of Geotechnical Investigation -
Check for locations, type etc as per
scheme
B Physical Each Location SR
20.3 Collection of disturbed and undisturbed
samples , their packing and storage As required / agreed
B Physical each sampling SR
20.4 Conducting filed tests as per investigation
scheme- such as,
SPT/ERT/SCPT/PLT/PMT etc
B Physical each field test SR
20.5 Submittion of Field Borelogs in approved
format
B Review Within 24 hours after
completion of each BH
SR
20.6 Submittion of laboratory test schedule and
selection of samples for laboratory testing
A Review and
acceptance
as per consultation with
engineer during dispatch
of samples to approved
laboratory
SR
20.7 Submission of Final Geotechnical
investigation report along with
recommendations
B Physical After completion of
investigation work and
review of draft reports
-
As per technical specifications and relevant
IS Codes
IS Codes
IS Codes
IS Codes
IS Codes
IS Codes
IS Codes
GEOTECHNICAL INVESTIGATION WORK( IF APPLICABLE)
Refer FQP for concrete Works, , Tech
Specs and Const. Drawings, IRC & MOST
IS 73,Tech Specs and Const. Drawings,
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ITEM : CIVIL WORK
ANNEXURE- V
21.00 ANTI WEED TREATMENT
21.1

Check for the Anti-weed treatment
materials
A Physical and MTC
Review
Each batch of delivery SR
21.2 Execution of treatment

B Physical Random check for each
treatment
SR
22.00 Piling Works
22.01.01
100 mm Dia borehole As required A Physical 100%
SR/LB
2201.02 Pile layout Total station B Measurement 100%
SR/LB
22.01.03
Recording ground level As required B Measurement Random
SR/LB
22.01.04
Cleaning/Flushing of pile bore at 3 stage
after completion of bore, after lowering
reinforcement cage and just before
placing concrete.
As required B Visual Random
SR/LB
22.01.05
Size of bore and During boring of pile
record commencement of SPT/ core
recovery to ensure socketing length
equivalent in terms of the Diameter of the
pile below the socketing horizon.
As required B
Measurement 100% SR/LB
22.01.06
Pouring of sound concrete of required
grade to project above cutoff level.
As required B
Measurement 100% SR/LB
22.01.07
Pile termination level
SPT & core recovery A
Soil data As per NTPC
specifications
SR
22.02 Testing
22.02.01 Bentonite
As required B
Physical Once per source SR/LB
22.02.02
Density check on sample of mud
collected from pile bore bottom
Sample collection A
Physical As per Tech. Spec. SR/LB Tests to be done before placing concrete.
Samples to be collected from pile bore bottom.
22.02.03
Slump test of concrete, Cube Test (Works
Test Cubes)
Slump test cone. B
Physical 100% SR/LB
22.02.04
Initial pile load test, Vertical
(Compression), Lateral (horizontal) and
pullout (tension).
Calibrated dial gauges etc. as
required.
A
Testing 100% for 3 nos. for each
type/Tech. Spec.
SR/LB &
interpret
ation as
per
IS:2911
(Part 4)
In case of compression test method the loading
shall be cyclic.
22.02.05
Routine pile tests, compression and
horizontal
Calibrated dial gauges
etc. as required.
A Testing 100% for 0.5% of the
total number of piles
provided for each type of
test/Tech. Spec.
SR/LB &
interpret
ation as
per
IS:2911
(Part 4)
Routine Test shall be conducted by direct loading
method.
22.02.06
Integrity Tests NDT A Testing 100% Test
Report
CHP
Manufactur
er/ Sub-
supplier
Main-supplier For NTPC USE
REVIEWED BY APPROVAL SEAL
IS:2911 & Tech. Specs.
IS: 2911 & Tech. Specs.
As per Technical spec. & suppliers
manual
As per IS:2720 / tech. Specs.
As per NTPC Tech Spec.
As per Tech. Specs./IS 2911
As per IS:2911 (relevant part)
As per approved drawing
As per approved drawing
As per NTPC specifications
NTPC Tech. Specs
As per approved drawings
As per appd. Drawings
LEGEND: D * Records, indentified with Tick () shall be essentially included by supplier in QA documentation. DOC. NO.: CS - Project Code - XXX-X-QVC-G-001 REV: 0
Signature This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB
Categorization Witnessing & Accepting (As per NTPC QA&I System)
Category A FQA Engineer in association with Executing Engineer, Category B Executing Engineer, Category C Executing
Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate
APPROVED BY
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1.00
1.00.01
Issed by NTPC
Material- Visual Examination,
Identification and marking for
grade/ type of steel
B Visual Each plate/ Section MS steel conforming to IS 2062
and IS 8500 to be clearly
demarcated by application of
distinct coloured paint strips on
each piece/ off-cuts of respective
grades/ type of steel.
1.00.03
Procured by contractor
Structural steel procured from
NTPC approved sources-
Mechanical (YS, UTS, Elg, UT if
specified),,and Chemical
properties (CE as per IS)
A Review For each batch of
each section delivered
at site
SR
Correlated MTC shall be verified.

In the event of non submission of
MTC , sample shall be selected by
FQA for testing
1.01 PRE-WELDING REQUIREMENTS
1.01.01 Welding Procedure
Specification * (WPS*)
- A Review Each Welding
Process
WPS
*To be approved by CQA

1.01.02 PQR and Welder's Qualification
- A
Physical Each welder Test
Report

1.01.03 Welding consumables - B Physical Random in each shift SR
1.02 FIT-UP
1.02.01 Marking and Cutting
Tape, ruler etc
B Visual &
Measurement
Each plate/ Section SR
1.02.02 Match markings for trial
assembled components
-
B Physical Each fit-up SR
1.02.03 Weld Fit Up- Edge Preparation/
Gap/ Alignment Tape, ruler etc
B Physical Each fit-up SR
If required suitable stiffners shall

be provided to prevent deflection.
1.03 PRE HEATING (wherever applicable)
1.03.01 Pre-Heating Temperature
Thermal chalk
B Measurement Each pre-heating SR
1.03.02 Post Weld Heat Treatment

(PWHT), if required
Thermo couple
with time
temperature
recorder
A Time &
Temperature
Each PWHT SR

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STRUCTURAL STEEL MATERIAL
Technical Specification and
Construction Drawings, IS 2062, 8500
INDICATIVE FIELD QUALITY PLAN ANNEXURE- V
QP NO. :
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Activity and operation Type of Check Quantum Of check Reference Document Acceptance
Norms
Format of
Record
Remarks
Construction Drawings, ASME-IX/ AWS
D 1.1
PQR/ WQR, AWS-D1.1/ASME-IX,
Technical Specifi- cation and
Approved WPS, Latest NTPC
Construction Drawings/ Approved
Construction Drawings
Construction Drawings, IS 7215
Construction Drawings, Approved WPS
Construction Drawings, Approved WPS
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1.04 WELDING REQUIREMENTS
1.04.01 Sequence of welding
-
B Physical Random in each shift SR
1.04.02 Removal/ grinding of temporary
attachments -
B Measurement All cleats/ attachments SR
1.04.03 Completeness after welding-
Dimensions/ distortion Weld gauge
B Visual Each structure
component
SR
5.00 NON DESTRUCTIVE AND DESTRUCTIVE TESTING
5.01 Fillet Welds
5.01.01 i). Check for size and visual
examination
As required/
agreed
B Visual/
Measurement
100% SR As per requirement of NTPC
Engineer
5.01.02 ii). Microetch Examination on
production test coupons As required/
agreed
B Physical Main fillet weld with
min one joint per built
up beam, columns
and crane girders
SR
5.01.03 iii). Dye Penetration Test -

Crane Girder
As required/
agreed
B Physical 25% weld length of
tension member of
crane girder
SR
5.01.04 iv). Dye Penetration Test -
Except Crane Girder, fo all other
Fillet Welds
As required/
agreed
B Physical 5% of Weld length
with min. 300mm at
each loaction
SR
5.02 Butt Welds
5.02.01 i) Visual examination
As required/
agreed
B Visual Random in each shift SR As per requirement of NTPC
Engineer
5.02.02 ii) DPT
As required/
agreed
B Physical On all butt welds DPT
after back gouging.
IR All butt welds to be back gouged
before DPT
construction drawings, IS 822, AWS D
1.3
1.3
1.3
Construction Drawings, Agreed scheme
Construction Drawings, Approved Drg.
Construction Drawings, IS 822
1.1
1.1
1.2
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5.02.03 iii) Mechanical testing on
production test coupons
As required/
agreed
B Physical Min. one joint per built
up beams, coloums
and crane girder.
IR
Test on production test coupons

5.02.04 iv) Radiography Test
As required/
agreed
A Physical 100% radiography test
on butt welds of
tension flange (bottom
flange) of crane
girder. All other butt
welds shall be
subjected to 10% weld
length of each welder.
IR
Wherever RT is not feasible UT to

be carried out. In case of failure of
any welds in SPOT/RT or UT the
% of retesting shall be doubled at
that particular loaction.
Acceptance criteria of NDT on
welds shall be as per AWS D1.1.
5.03
5.03.01 i) Ultrasonic Testing
As required/
agreed
A Physical i) 100% UT on the
web to flange joint of
crane girder
IR
In case of failure of any welds in

SPOT/RT or UT the % of retesting
shall be doubled at that particular
loaction. Acceptance criteria of
NDT on welds shall be as per
AWS D1.1.
5.03.02 ii) Ultrasonic Testing
As required/
agreed
A Physical ii) 10% UT on other
full penetration joints
IR
6.00 FOUNDATION CHECKS

6.01 Dimensions and levels- Shape,
lines (including diagonal
Theodolite, Tape
etc
B Physical/
Measurement
Each Foundation SR
6.02 Foundation Bolts and

Embedments- Verticality,
Levels, pitch distance
Theodolite, Tape,
Piano wires etc
B Physical/
Measurement
Each Foundation SR
7.00 PRE-ASSEMBLY CHECKS

7.01 Punch Erection marks and
match marks on members
-
B Visual/
Physical
Each structural
member
Markings for -
Assembly designation, Part
number, Weight, Any other
important identifications.
7.02 Pre-assembly as per match
mark
-
B Visual/
Physical
Each structural
member
1.3
1.3
1.3
1.3
Full Penetration Welds (Other than butt welds)
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7.03 Camber, sweep and total length
after trial assembly of structure.
Theodolite, Tape,
plumb, piano
wires etc
B Visual/
Physical
Each structural
member
SR
7.04 Control assembly check at shop Theodolite, Tape,

plumb, piano
wires etc
B Visual/
Physical
Every first and tenth
set of identical
structure
8.00
8.01 Alignment, slopes, level,
tolerances of erected member
Theodolite, Tape,
plumb, piano
wires etc
B Measurement Each structural
member
SR
8.02 Tightening of bolts/ Torque

including foundation bolts with
lock nuts
Wrench/ Torque
wrench if
specified
B Visual/
Physical
Each structural
member
SR
8.03 Acceptance of erected structure Theodolite, Tape,

plumb, piano
wires etc
B Visual/
Physical
Each erected
structure
SR
9.00 PAINTING SYSTEM

9.01 Paining Materials and
accessories
-
A Review of
MTC

Mfr.s T.C. shall be correlated with
the consignment received.
9.02 Submission of painting
methodology -
B For Review of
painting
system
Before start of
painting work
9.03 Surface prepration As agreed /
required
B Physical
/visual
Each Erection Mark SR

9.04 Primer Thickness Elcometer B Measurement Each Erection Mark SR
9.05 DFT of paint Elcometer B Measurement Each Erection Mark SR
9.06 Acceptance of painted surfaces
Elcometer
B Visual and
measurement
Each Erection Mark SR
10.00
10.01 Material- Permanent mild steel
Bolts, mild steel Nuts, High
strength structural Bolts,
Washers-Dimensions,
properties, Class, storage along
with MTC
Screw gauge,
Vernier, Tape etc.
A Physical and
MTC Review
Once for each lot of
delivery
SR/MTC
10.02 Contact surfaces before bolting

-
B Physical Random before
asembly for bolting
SR
10.03 Inspection of the assembled
bolts -
B Physical Randomly in each
shift for assembeled
bolts
SR
10.04 Tensioning
As agreed /
required
B Physical Randomly during snug
tight test and after full
tensinoning
SR
10.05 Acceptance of installed bolts - B Physical Each bolt SR

ERECTION CHECKS
7215 and IS 12843
PERMANENT BOLTS AND NUTS AND WASHERS
Tech Specs and Const. Drawings,
Relevant code/ standards
4000
4000
4000
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
4 of 21
5 of 5
2 PROJECT:
0 PACKAGE:
CONTRACT NO.
MAIN CONTRACTOR
1 2 4 5 6 7 8 9 D* 10
check
LOGO
SUPPLIERS NAME AND
ADDRESS:
DATE :
3
QP NO. :
REV. NO .:
PAGE :
Norms
Format of
Record
Remarks
11.00 ELECTROFORGED GRATINGS
13.1 Check for the Material from
approved source
As agreed /
required
A Physical and
MTC Review
Once for each lot of
delivery
SR/MTC

Also refer the approved MQP
13.2 Acceptance of Erection,
alignment and each Installation
As agreed /
required
B Physical 100% SR
13.3 Painting system checks - As
above painting system
-
- - As above painting
system
SR As above painting system
Material and chemical composition A Review of MfrTC Once per Lot SR/LB

Site fabricationand fit up
As agreed /
required
B Physical Random SR/LB Cutting ,Bending , Welding shall be as per
technical specification, WPS approval,
fabrication of steel and welders
qualifiction shall be similar to Structural
steel (Fabrication & Erection)
Welding
As agreed /
required
A Physical As per technical
specifications
SR/LB
10% DPT after back gauging, 5%spot

radiography test on butt welds where
access not available. UT shall be carried
out with prior approval of . Engineer. In
case of failure of any welds in SPOT
RT/UT , the %age for retesting shall be
doubled at that particular location .
Acceptance criteria of Non Destructive
tests ( NDT) on welds shall be as per
AWS D1.1
Manufac
turer/
Sub-
supplier
Main-supplier For NTPC use
REVIEWED BY APPROVAL SEAL APPROVED BY
Categorization Witnessing & Accepting (As per owner QA&I System)
Category A FQA Engineer in association with Executing Engineer, Category B Executing Engineer, Category C
Executing Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate
LEGEND: D * Records, indentified with Tick () shall be essentially included by supplier in QA DOC. NO.: CS - Project Code - XXXX-XXX-QVC-G-002 REV: 0
Signature This document shall be read in conjunction with owner Tech. Specifications, BOQ, Drawings
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB
STAINLESS STEEL HOPPERS
BID DOC. NO.:CS-0260-156-2(R)
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
5 of 21

BID DOC NO.:CS-0260-156-2(R)
SECTION-VI
PART-C

PART - C

GENERAL TECHNICAL REQUIREMENTS

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SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
PAGE
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1.00.00 INTRODUCTION
This part covers technical requirements which will form an integral part of the
Contract. The following provisions shall supplement all the detailed technical
requirements brought out in the Technical Specifications and the Technical Data
Sheets.
2.00.00 BRAND NAME
Whenever a material or article is specified or described by the name of a
particular brand, manufacturer or vendor, the specific item mentioned shall be
understood to be indicative of the function and quality desired, and not restrictive;
other manufacturer's products may be considered provided sufficient information
is furnished to enable the Employer to determine that the products proposed are
equivalent to those named.
3.00.00 BASE OFFER & ALTERNATE PROPOSALS
The Contractor's proposal shall be based upon the use of equipment and
material complying fully with the requirements specified herein. It is recognized
that the Contractor may have standardized on the use of certain components,
materials, processes or procedures different than those specified herein.
Alternate proposals offering similar equipment based on the manufacturer's
standard practice may also be considered, provided the base offer is in line with
technical specifications and such proposals meet the specified design standards
and performance requirement and are acceptable to the Employer. Sufficient
amount of information for justifying such proposals shall be furnished to
Employer alongwith the bid to enable the Employer to determine the acceptability
of these proposals.
4.00.00 COMPLETENESS OF FACILITIES
4.01.00 Contractors may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and
designed in accordance with the specification requirement. All engineering and
associated services are required to ensure that a completely engineered plant is
provided.
4.02.00 All equipments furnished by the Contractor shall be complete in every respect,
with all mountings, fittings, fixtures and standard accessories normally provided
with such equipment and/or those needed for erection, completion and safe
operation & maintenance of the equipment and for the safety of the operating
personnel, as required by applicable codes, though they may not have been
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SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
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specifically detailed in the respective specifications, unless included in the list of
exclusions.
All similar standard components/ parts of similar standard equipment provided,
shall be interchangeable with one another.
5.01.00 In addition to the codes and standards specifically mentioned in the relevant
technical specifications for the equipment / plant / system, all equipment parts,
systems and works covered under this specification shall comply with all
currently applicable statutory regulations and safety codes of the Republic of
India as well as of the locality where they will be installed, including the following:
(a.) Bureau of Indian Standards (BIS)
(b.) Indian electricity act
(c.) Indian electricity rules
(d.) Indian Explosives Act
(e.) Indian Factories Act and State Factories Act
(f.) Indian Boiler Regulations (IBR)
(g.) Regulations of the Central Pollution Control Board, India
(h.) Regulations of the Ministry of Environment & Forest (MoEF), Government
of India
(i.) Pollution Control Regulations of Department of Environment, Government
of India
(j.) State Pollution Control Board.
(k.) Rules for Electrical installation by Tariff Advisory Committee (TAC).
(l.) Any other statutory codes / standards / regulations, as may be applicable.
5.02.00 Unless covered otherwise by Indian codes & standards and in case nothing to
the contrary is specifically mentioned elsewhere in the specifications, the latest
editions (as applicable as on date of bid opening), of the codes and standards
given below shall also apply:
(a.) Japanese Industrial Standards (JIS)
(b.) American National Standards Institute (ANSI)
(c.) American Society of Testing and Materials (ASTM)
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(d.) American Society of Mechanical Engineers (ASME)
(e.) American Petroleum Institute (API)
(f.) Standards of the Hydraulic Institute, U.S.A.
(g.) International Organisation for Standardization (ISO)
(h.) Tubular Exchanger Manufacturer's Association (TEMA)
(i.) American Welding Society (AWS)
(j.) National Electrical Manufacturers Association (NEMA)
(k.) National Fire Protection Association (NFPA)
(l.) International Electro-Technical Commission (IEC)
(m.) Expansion Joint Manufacturers Association (EJMA)
(n.) Heat Exchange Institute (HEI)
5.03.00 Other International/ National standards such as DIN, VDI, BS, etc. shall also be
accepted for only material codes and manufacturing standards, subject to the
Employer's approval, for which the Contractor shall furnish, alongwith the offer,
adequate information to justify that these standards are equivalent or superior to
the standards mentioned above. In all such cases the Contractor shall furnish
specifically the variations and deviations from the standards mentioned else
where in the specification together with the complete word to word translation of
the standard that is normally not published in English.
5.04.00 As regards highly standardized equipments National /International standards
such as JIS, DIN, VDI, ISO, SEL, SEW, VDE, IEC & VGB etc shall also be
considered as far as applicable for Design, Manufacturing and Testing of the
respective equipment. In addition, these standards shall be referred for the
design of machine foundations, wherever specifically mentioned in the
specifications. However, for those of the above equipment not covered by these
National / International standards, established and proven standards of
manufacturers shall also be considered.
5.05.00 In the event of any conflict between the codes and standards referred to in the
above clauses and the requirement of this specification, the requirement of
Technical Specification shall govern.
5.06.00 Two (2) English language copies of all-national and international codes and/or
standards used in the design of the plant, equipment, civil and structural works
shall be provided by the Contractor to the Employer within two calendar months
from the date of the Notification of Award.
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GENERAL TECHNICAL
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5.07.00 In case of any change in codes, standards & regulations between the date of bid
opening and the date when vendors proceed with fabrication, the Employer shall
have the option to incorporate the changed requirements or to retain the original
standard. It shall be the responsibility of the Contractor to bring to the notice of
the Employer such changes and advise Employer of the resulting effect.
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE
6.01.00 The functional guarantees of the equipment under the scope of the Contract is
given elsewhere in the technical specification. These guarantees shall
supplement the general functional guarantee provisions covered under General
Conditions of Contract.
6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.
7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY
CONSIDERATIONS
7.01.00 Design of Facilities
All the design procedures, systems and components proposed shall have already
been adequately developed and shall have demonstrated good reliability under
similar conditions elsewhere.
The Contractor shall be responsible for the selection and design of appropriate
equipments to provide the best co-ordinated performance of the entire system.
The basic requirements are detailed out in various clauses of the Technical
Specifications. The design of various components, assemblies and
subassemblies shall be done so that it facilitates easy field assembly and
dismantling. All the rotating components shall be so selected that the natural
frequency of the complete unit is not critical or close to the operating range of the
unit.
7.02.00 Maintenance and Availability Considerations
Equipment/facilities offered shall be designed for high availability, low
maintenance and ease of maintenance. The Contractor shall specifically state
the design features incorporated to achieve high degree of reliability/ availability
and ease of maintenance. The Contractor shall also furnish details of availability
records in the reference plants stated in his experience list.
Contractor shall state in his offer the various maintenance intervals, spare parts
and man-hour requirement during such operation. The intervals for each type of
maintenance namely inspection of the major equipment in the coal flow path,
clearly defining the spare parts and man-hour requirement for each stage.
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SECTION VI, PART-C
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GENERAL TECHNICAL
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Lifting devices i.e. hoists and chain pulley jacks, etc. shall be provided by the
contractor for handling of any equipment during erection and maintenance
activities.
Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist
/ crane shall be provided by the contractor for lifting the equipment and
accessories covered under the specification.
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY
CONTRACTOR
8.01.00 Contractors may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the technical
specification. All engineering and technical services required ensuring a
completely engineered plant shall be provided in respect of mechanical,
electrical, control & instrumentation, civil & structural works as per the scope.
Each main and auxiliary equipment/item of the plant including instruments shall
be assigned a unique tag number. The assignment of tag numbers shall be in
accordance with KKS system. In all drawings/documents/data sheets etc. KKS
tag number of the equipment/item/instrument etc. as applicable shall be
indicated.
The Contractor shall furnish engineering data/drgs. in accordance with the
schedule of information as specified in Technical Specification and data sheet.
8.02.00 The number of copies/prints / CD-ROMs/manuals to be furnished for various
types of documents is given in Annexure-I. Distribution schedule shall be
informed to successful Contractor.
8.03.00 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall include but not be
limited to the following :
8.03.01 INSTRUCTION MANUALS
The Contractor shall make First submission of instruction manuals for all the
equipments covered under the Contract by the end of one year from the date of
his acceptance of the Letter of Award. The Instruction manuals shall contain full
details required for erection, commissioning, operation and maintenance of each
equipment. The manual shall be specifically compiled for this project. After
finalization and approval of the Employer the Instruction Manuals shall be
submitted as indicated in Annexure-I. The Contract shall not be considered to be
completed for purposes of taking over until the final Instructions manuals have
been supplied to the Employer. The Instruction Manuals shall comprise of the
following.
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SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
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(a.) Erection Manuals
The erection manuals shall be submitted atleast three (3) months prior to
the commencement of erection activities of particular equipment/system.
The erection manual should contain the following as a minimum.
a) Erection strategy.
b) Sequence of erection.
c) Erection instructions.
d) Critical checks and permissible deviation/tolerances.
e) List of tool, tackles, heavy equipments like cranes, dozers, etc.
f) Bill of Materials
g) Procedure for erection.
h) General safety procedures to followed during erection/installation.
i) Procedure for initial checking after erection.
j) Procedure for testing and acceptance norms.
k) Procedure / Check list for pre-commissioning activities.
l) Procedure / Check list for commissioning of the system.
m) Safety precautions to be followed in electrical supply distribution
during erection
(b.) Operation & Maintenance Manuals
The O&M manual shall have the following Chapters:
1.0 Plant Description
(To contain the following sections specific to the equipment
supplied).
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GENERAL TECHNICAL
REQUIREMENTS
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1.1 Description of operating principle of equipment/ system with
schematic drawings/layouts.
1.2 Functional description of associated accessories/ controls.
Control interlock protection write-up.
1.3 Integrated operation of the equipment along with the intended
system.
(This is to be given by the supplier of the Main equipment by
taking into account the operating instruction given by the
associated equipment suppliers).
1.4 Exploded view of the main equipment, associated accessories
and auxiliaries with description. Schematic drawing of the
equipment along with its accessories and auxiliaries.
1.5 Design data against which the plant performance will be
compared.
1.6 Master list of equipments, Technical specification of the
equipment/ system and approved datasheet.
1.7 Identification system adopted for the various components (It will
be of a simple, process linked tagging system).
1.8 Master list of drawings (as built drawings) (Drawings be
enclosed in Separate volume).
2.0 Plant Operations
supplied) :-
2.1 Protection logic provided for the equipment along with brief
philosophy behind the logic, drawings etc.
2.2 Limiting values of all protection settings.
2.3 Various settings of annunciation/ inleterlocks provided.
2.4 Start up and shut down procedure for equipment along with the
associated systems in step by step mode.
2.5 Dos & dont on the equipments.
2.6 Safety precautions to be taken during normal operation.
Emergency instructions on total power failure condition/
lubrication failure/ any other condition.
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2.7 Parameters to be monitored with normal values and limiting
values.
2.8 Equipment isolating procedures.
2.9 Trouble shooting with causes and remedial measures.
2.10 Routine testing procedure to ascertain healthiness of the safety
devices alongwith schedule of testing.
2.11 Routing operational checks. Recommended logs and records.
2.12 Changeover schedule if more than one auxiliary for the same
purpose is given.
2.13 Preservation procedure on long shut down.
2.14 System/ plant commissioning procedure.
3.0 Plant Maintenance
supplied).
3.1 Exploded view of each of the equipments. Drawings along with
bill of material including name, code number and population.
3.2 Exploded view of the spare parts and critical components with
dimensional drawings (In case of Electronic cards, the circuit
diagrams to be given).
3.3 List of Special Tools and Tackles required for Overhaul/Trouble
shooting including special testing equipment required for
calibration etc.
3.4 Stepwise dismantling and assembly procedure clearly specifying
the tools to be used, checks to be made, records to be
maintained etc. along with exploded views, Clearances to be
maintained etc.
3.5 Preventive Maintenance schedules linked with running hours/
calendar period along with checks to be done.
3.6 Overhaul schedules linked with running hours/ calendar period
along with checks to be done.
3.7 Long term maintenance schedules especially for structural,
foundations etc.
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SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
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3.8 Consumable list along with the estimated quantity required
during normal running and during maintenance like Preventive
Maintenance and Overhaul.
3.9 List of lubricants with their Indian equivalent. Lubrication
Schedule. Quantity required for complete replacement.
3.10 Tolerances for fitment of various components.
3.11 Details of sub-vendors with their part no. in case of bought out
items.
3.12 List of spare parts with their part no., total population, life
expediency & their interchangeability with already supplied
spares to NTPC. Storage & preservation procedure of spares.
3.13 List of mandatory and recommended spare parts list along with
manufacturing drawings, material specification & quality plan for
fast moving consumable spares.
3.14 Lead time required for ordering of spares from the equipment
supplier.
3.14 (a) Instructions for Storage and preservation of spares.
3.15 General information on the equipment.
3.15.1 Modifications carried out in the equipment from its inception.
3.15.2 Equipment population in the country/ foreign country.
3.15.3 List of utilities where similar equipments have been supplied.
8.03.02 Project Completion Report
The Contractor shall submit a Project Completion Report at the time of handing
over the plant.
8.03.03 DRAWINGS
(a.) All documents submitted by the Contractor for Employer's review shall be in
electronic form (soft copies) along with the desired number of hard copies
as per Annexure-I . The soft copies shall be uploaded by the vendors in c-
folders, a web based system of NTPC ERP, for which a username and
password will be allotted to the new vendor by NTPC.
Similarly, the vendor can download the drawings/documents,
approved/commented by NTPC, through above site.

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The soft copies of identified drawings/documents shall be in pdf format,
whereas the attachment/reply to the submitted document(s) can be in
.doc,.xls,.pdf,.dwg or std. formats
(b.) Final copies of the approved drawings alongwith requisite number of hard
copies shall be submitted as per Annexure-I.
(c.) All documents/text information shall be in latest version of MS Office.
(d.) All drawings submitted by the Contractor including those submitted at the
time of bid shall be in sufficient detail indicating the type, size, arrangement,
weight of each component for packing and shipment, the external
connection, fixing arrangement required, the dimensions required for
installation and interconnections with other equipments and materials,
clearance and spaces required between various portions of equipment and
any other information specifically requested in the drawing schedules.
(e.) Each drawing submitted by the Contractor (including those of subvendors)
shall bear a title block at the right hand bottom corner with clear mention of
the name of the Employer, the system designation, the specifications title,
the specification number, the name of the Project, drawing number and
revisions. If standard catalogue pages are submitted the applicable items
shall be indicated therein. All titles, notings, markings and writings on the
drawing shall be in English. All the dimensions should be in metric units.
(f.) The drawings submitted by the Contractor (or their subvendors) shall bear
Employers drawing number in addition to contractors (their sub-vendors)
own drawing number. Employers drawing numbering system shall be made
available to the successful Contractor so as to enable him to assign
Employers drawing numbers to the drawings to be submitted by him during
the course of execution of the Contract.
(g.) The Contractor shall also furnish a Master Drawing List which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged to be
furnished by him during the detailed engineering to the Employer in line
with engineering information flow schedule (to be tied up with successful
Contractor). Such list should clearly indicate the purpose of submission of
these drawings i.e. FOR APPROVAL or FOR INFORMATION ONLY.
(h.) Similarly, all the drawings/ documents submitted by the Contractor during
detailed engineering stage shall be marked FOR APPROVAL or FOR
INFORMATION prior to submission. Further, space shall be identified on
each drawing for approval stamp and electronic signature.
(i.) The furnishing of detailed engineering data and drawings by the Contractor
shall be in accordance with the time schedule for the project. The review of
these documents/ data/ drawings by the Employer will cover only general
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conformance of the data/ drawings/ documents to the specifications and
contract, interfaces with the equipments provided by others and external
connections & dimensions which might affect plant layout. The review by
the Employer should not be construed to be a thorough review of all
dimensions, quantities and details of the equipments, materials, any
devices or items indicated or the accuracy of the information submitted. The
review and/ or approval by the Employer / Project Manager shall not relieve
the Contractor of any of his responsibilities and liabilities under this
contract.
(j.) After the approval of the drawings, further work by the Contractor shall be in
strict accordance with these approved drawings and no deviation shall be
permitted without the written approval of the Employer.
(k.) All manufacturing, fabrication and execution of work in connection with the
equipment / system, prior to the approval of the drawings, shall be at the
Contractors risk. The Contractor is expected not to make any changes in
the design of the equipment /system, once they are approved by the
Employer. However, if some changes are necessitated in the design of the
equipment/system at a later date, the Contractor may do so, but such
changes shall promptly be brought to the notice of the Employer indicating
the reasons for the change and get the revised drawing approved again in
strict conformance to the provisions of the Technical Specification.
(l.) Drawings shall include all installations and detailed piping and wiring
drawings. All pipe of 65NB and above shall be routed in detail and smaller
pipe shall be shown schematically or by isometric drawings. All drawings
shall be fully corrected to agree with actual as built construction.
(m.) Assessing & anticipating the requirement and supply of all piping and
equipment shall be done by the contractor well in advance so as not to
hinder the progress of piping & equipment erection, subsequent system
charging and its effective draining & venting arrangement as per site
suitability.
(n.) Any software used by the contractor shall be given to the project manager
and concerned engineer of employer. The contractor shall make the
engineer of the employer aware of the programme. Any computer aided
programme shall be approved subject to giving entire detail to the project
manager.
(o.) Drawings must be checked by the Contractor in terms of its completeness,
data adequacy and relevance with respect to Engineering schedule prior to
submission to the Employer. In case drawings are found to be submitted
without proper endorsement for checking by the Contractor, the same shall
not be reviewed and returned to the Contractor for re-submission. The
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contractor shall make a visit to site to see the existing facilities and
understand the layout completely and collect all necessary data / drawings
at site which are needed as an input to the engineering. The contractor
shall do the complete engineering including interfacing and integration of all
his equipment, systems & facilities within his scope of work as well as
interface engineering & integration of systems, facilities, equipment & works
under Employers scope and submit all necessary drawings/ documents for
the same.
(p.) All drawings shall be reviewed and approved by Engineering coordinator,
including the following drawings / data which require specific approval.
1. Data sheets for various equipments / systems.
2. Field testing procedures for various equipment and piping system.
3. Pre commissioning / commissioning procedures including flushing,
Chemical cleaning, steam blowing and hydro test etc. (Wherever
applicable) O&M manual shall also be reviewed and approved by
Employer. The content of O&M manual shall be as specified elsewhere
in the specification.
4. Guarantee test procedures (including model tests, if any).
5. Any other drawings that may be required by the Engineer from time to
time.)
6. Data furnished in the bid shall be binding on the contractor even if
superior to the technical specification requirement and any revision shall
be done with the Employers agreement.
(q.) The Contractor shall submit adequate prints of drawing / data / document
for Employers review and approval. The Employer shall review the
drawings and return soft copy to the Contractor authorizing either to
proceed with manufacture or fabrication, or marked to show changes
desired. When changes are required, drawings shall be re-submitted
promptly, with revisions clearly marked, for final review. Any delays arising
out of the failure of the Contractor to submit/rectify and resubmit in time
shall not be accepted as a reason for delay in the contract schedule
(r.) Upon review of each drawing, depending on the correctness and
completeness of the drawing, the same will be categorised and approval
accorded in one of the following categories :
CATEGORY I Approved
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CATEGORY II Approved subject to incorporation of comments/
modification as noted. Resubmit revised drawing
incorporating the comments
CATEGORY III Not approved. Resubmit revised drawings for approval
after incorporating comments/modification as noted.
CATEGORY IV For information and records.
(s.) Vendor shall resubmit the drawings approved under Category II and III
within three (3) weeks of receipt of comments on the drawings,
incorporating all comments. Every revision of the drawing shall bear a
revision index wherein such revisions shall be highlighted in the form of
description or marked up in the drawing identifying the same with relevant
revision Number enclosed in a triangle (eg. 1, 2, 3 etc).
In case Vendor does not agree with any specific comment, he shall furnish
the explanation for the same to NTPC EC for consideration. In all such
cases vendor shall necessarily enclose explanations along with the revised
drawing (taking care of balance comments) to avoid any delay and/or
duplication in review work.
It is responsibility of the Vendor to get all the drawings approved in the
Category I & IV (as the case may be) and complete engineering activities
within the agreed schedule. Any delay arising out of submission and
modification of drawings shall not alter the contract completion schedule.
Vendor shall not make any changes in the portions of the drawing other
than those commented. If changes are required to be made in the portions
already approved, the vendor shall resubmit the drawing identifying the
changes for Employers review and approval.
(t.) If Vendor fails to resubmit the drawings as per the schedule, construction
work at site will not be held up and work will be carried out on the basis of
comments furnished on previous issues of the drawing.
These comments will be taken care by the contractor while submitting the
revised drawing.
(u.) All engineering data submitted by the Contractor after final process
including review and approval by the Project Manager/ Employer shall form
part of the contract documents and the entire works covered under these
specification shall be performed in strict conformity with technical
specifications unless otherwise expressly requested by the Project
Manager in writing.

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(v.) As Built Drawings
After final acceptance of individual equipment / system by the Employer,
the Contractor will update all original drawings and documents for the
equipment / system to as built conditions and submit No. of copies, as per
Annexure-1.
8.04.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE
Prior to the award of Contract, a Detailed Engineering Information Submission
Schedule/Master Drawing List shall be tied up with the Employer. For this, the
Contractor shall furnish a detailed list of engineering information alongwith the
proposed submission schedule. This list would be a comprehensive one
including all engineering data / drawings / information for all bought out items and
manufactured items. The information shall be categorised into the following parts.
1. Information that shall be submitted for the approval of the Employer before
proceeding further, and Information that would be submitted for Employers
information only.
The Master Drawing List (MDL) shall be updated periodically and submitted to
the Employer, highlighting the changes made in the MDL.
The schedule should allow adequate time for proper review and incorporation of
changes/ modifications, if any, to meet the contract without affecting the
equipment delivery schedule and overall project schedule. The early submission
of drawings and data is as important as the manufacture and delivery of
equipment and hardware and this shall be duly considered while determining the
overall performance and progress.
8.05.00 ENGINEERING COORDINATION PROCEDURE
Identification of Principal Engineering Coordinators
8.05.01 The following principal coordinators will be identified by respective organisations
at time of award of contract
EMPLOYERS COORDINATORS
NTPC Engineering Coordinators (NTPC EC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
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NTPC SITE CO-ORDINATOR (NTPC SC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
VENDOR ENGINEERING CO-ORDINATOR (VENDOR EC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
8.05.02 All engineering correspondence shall be in the name of above coordinators on
behalf of the respective organisations.
8.05.03 Vendors Drawings
(a) The contractor shall furnish, discuss and finalise with the Employer, the
engineering information flow schedule at the time of award of the contract.
The dates for submission of drawings as finalised in the above engineering
schedule, shall be strictly adhered to. This is essential for the timely
completion of the project.
(b) A detailed drive list shall be furnished along with the tender. Further drive
list in the Employers format shall be submitted to the Engineering
coordinator within 60 days from the date of award of the contract.
(c) In any case, in order to achieve the project completion dates, the
contractor must strictly comply with engineering schedules.
(d) Final distribution copies of all approved drgs. (in Cat. I & IV) shall be
submitted by the contractor to the Engineer within two (2) weeks of the
approval.
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(e) Copies of all approved drgs. (in cat. I & IV) shall be submitted
incorporating all site modifications, if any, during construction, erection,
commission stages and performance and guarantee testing (till its
continuous operation) as As Built Drgs.
(f) The contractor shall use a single transmittal for drgs. Submission. This
shall include transmittal numbers and date, number of copies being sent,
names of the agencies to whom are all the copies being sent drg. numbers
and titles, remarks or special notes if any etc.
(g) All manufacturing and fabrication work in connection with the equipments
prior to the approval of the drg. shall be at contractors risks.
(h) Approval of contractors drgs. or work by the Engineer shall not relieve the
contractor of any of his responsibilities or liabilities under the contract.
8.05.04 Erection Drawings
(a) Contractor shall furnish erection drawings for the guidance of his/
Employers site staff at least 4 weeks before scheduled commencement of
erection or the first shipment, whichever is earlier. These shall generally
comprise of fabrication/assembly drawings, various component/part details
drawings, assembly, clearance, data requirements etc. The drawings shall
contain details of components/ equipment with identification numbers,
match marks, bills of materials, assembly procedures etc.
(b) For all major equipment apart from above details, assembly sequence and
instructions with check lists shall be furnished in the form of erection
manuals.
8.06.00 ENGINEERING PROGRESS AND EXCEPTION REPORT
8.06.01 Report giving the status of each engineering information including
(a) A list of drawings/engineering information which remains unapproved for
more than four (4) weeks after the date of first submission
(b) Drawings which were not submitted as per agreed schedule.
8.06.02 The draft format for this report shall be furnished to the Employer within four (4)
weeks of the award of the contract, which shall then be discussed and finalised
with the Employer.
8.07.00 TECHNICAL CO-ORDINATION MEETING
8.07.01 The Contractor shall be called upon to organise and attend monthly Design/
Technical Co-ordination Meetings (TCMs) with the Employer/Employers
representatives and other Contractors of the Employer during the period of
contract. The Contractor shall attend such meetings at his own cost at NEW
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DELHI / NOIDA or at mutually agreed venue as and when required and fully co-
operate with such persons and agencies involved during the discussions.
8.07.02 The Contractor should note that Time is the essence of the contract. In order to
expedite the early completion of engineering activities, the Contractor shall
submit all drawings as per the agreed Engineering Information Submission
Schedule. The drawings submitted by the Contractor will be reviewed by the
Employer as far as practicable within three (3) weeks from the date of receipt of
the drawing .The comments of the Employer shall then be discussed across the
table during the above Technical Co-ordination Meeting (s) wherein best efforts
shall be made by both sides to ensure the approval of the drawing.
8.07.03 The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these
meetings. The Contractor shall be equipped with necessary tools and facilities so
that the drawings/documents can be resubmitted after incorporating necessary
changes and approved during the meeting itself.
8.07.04 Should any drawing remain unapproved for more than six (6) weeks after its first
submission, this shall be brought out in the monthly Engineering Progress and
Exception Report with reasons thereof.
8.07.05 Any delays arising out of failure by the Contractor to incorporate Employers
comments and resubmit the same during the TCM shall be considered as a
default and in no case shall entitle the Contractor to alter the Contract completion
date.
8.08.00 DESIGN IMPROVEMENTS
The Employer or the Contractor may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes the
specification shall be modified accordingly.
If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any changing
the price and/or schedule of completion before the Contractor proceeds with the
change. Following such agreement, the provision thereof, shall be deemed to
have been amended accordingly.
8.09.00 EQUIPMENT BASES
A cast iron or welded steel base plate shall be provided for all rotating equipment
which is to be installed on a concrete base, unless otherwise specifically agreed
to by the Employer. Each base plate which supports the unit and its drive
assembly, shall be of a neat design with pads for anchoring the units, shall have
a raised lip all around, and shall have threaded drain connections.
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8.10.00 PROTECTIVE GUARDS
Suitable guards shall be provided for protection of personnel on all exposed
rotating and/or moving machine parts. All such guards shall be designed for
easy installation and removal for maintenance purpose.
8.11.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS
8.11.01 The Contractors scope includes all the first fill and one years topping,
requirements of consumables such as oils, lubricants including grease, servo
fluids, gases and essential chemicals etc. Consumption of all these consumables
during the initial operation and final filling after the initial operation shall also be
included in the scope of the Contractor. Contractor shall also supply a quantity
not less than 10% of the full charge of each variety of lubricants, servo fluids,
gases, chemicals etc. used which is expected to be utilised during the first year
of operation. This additional quantity shall be supplied in separate Containers.
8.11.02 As far as possible lubricants marketed by the Indian Oil Corporation shall be
used. The variety of lubricants shall be kept to a minimum possible.
Detailed specifications for the lubricating oil, grease, gases, servo fluids, control
fluids, chemicals etc. required for the complete plant covered herein shall be
furnished. On completion of erection, a complete list of bearings/ equipment
giving their location and identification marks shall be furnished to the Employer
alongwith lubrication requirements.
8.12.00 LUBRICATION
8.12.01 Equipment shall be lubricated by systems designed for continuous operation.
Lubricant level indicators shall be furnished and marked to indicate proper levels
under both standstill and operating conditions.
8.13.00 MATERIAL OF CONSTRUCTION
8.13.01 All materials used for the construction of the equipment shall be new and shall be
in accordance with the requirements of this specification. Materials utilised for
various components shall be those which have established themselves for use in
such applications.
8.14.00 RATING PLATES, NAME PLATES & LABELS
8.14.01 Each main and auxiliary item of plant including instruments shall have
permanently attached to it in a conspicuous position, a rating plate of non-
corrosive material upon which shall be engraved manufacturers name,
equipment, type or serial number together with details of the ratings, service
conditions under which the item of plant in question has been designed to
operate, and such diagram plates as may be required by the Employer.
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8.14.02 Each item of plant shall be provided with nameplate or label designating the
service of the particular equipment. The inscriptions shall be approved by the
Employer or as detailed in appropriate section of the technical specifications.
8.14.03 Such nameplates or labels shall be of white nonhygroscopic material with
engraved black lettering or alternately, in the case of indoor circuit breakers,
starters, etc. of transparent plastic material with suitably coloured lettering
engraved on the back. The name plates shall be suitably fixed on both front and
rear sides.
8.14.04 Items of plant such as valves, which are subject to handling, shall be provided
with an engraved chromium plated nameplate or label with engraving filled with
enamel. The name plates for valves shall be marked in accordance with MSS
standard SP-25 and ANSI B 16.34 as a minimum.
8.14.05 Hanger/ support numbers shall be marked on all pipe supports, anchors,
hangers, snubbers and restraint assemblies. Each constant and variable spring
support shall also have stamped upon it the designed hot and cold load which it
is intended to support. Suitable scale shall also be provided to indicate load on
support/hanger.
8.14.06 Valves and strainers shall be identified by tag number of a metal tap permanently
attached to non pressure parts such as the yoke by a stainless steel wire. The
direction of flow shall also be marked on the body.
8.14.07 Safety and relief valves shall be provided with the following :
a). Manufacturers identification.
b). Nominal inlet and outlet sizes in mm.
c). Set pressure in Kg/cm2 (abs).
8.14.08 All such plates, instruction plates, etc. shall be bilingual with Hindi inscription first,
followed by English. Alternatively, two separate plates one with Hindi and the
other with English inscriptions may be provided.
8.14.09 All segregated phases of conductors or bus ducts, indoor or outdoor, shall be
provided with coloured phase plates to clearly identify the phase of the system
8.15.00 TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of following
special tools and tackles required for the erection, assembly, disassembly and
proper maintenance of the plant and equipment and systems.
The price of each tool / tackle shall be deemed to have been included in the total
bid price. These tools and tackles shall be separately packed and sent to site.
The Contractor shall also ensure that these tools and tackles are not used by him
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during erection, commissioning and initial operation. For this period the
Contractor should bring his own tools and tackles. All the tools and tackles shall
be of reputed make acceptable to the Employer.
Sl. Description Qty.
1 Torque wrench required up to M24 bolts or maximum size in
package, whichever more
1 No
2 Bearing puller set to pull up to maximum bearing size in the
system
1 No
3 Hydraulic jack 50 T 2 No
4 Lifting trolley for LT circuit breakers 2 No
5 Electric powered winch with wire rope (7.5 T, 1500m
galvanised wire)
1 No
6 Bearing grease gun for all applications 2 No
7 Any other special tools as per manufacturers manual 1 No
8.16.00 WELDING
8.16.01 If the manufacturer has special requirements relating to the welding procedures
for welds at the terminals of the equipments to be performed by others the
requirements shall be submitted to the Employer in advance of commencement
of erection work.
8.17.00 COLOUR CODE FOR ALL EQUIPMENTS/ SERVICES
8.17.01 All equipment/ services are to be painted by the Contractor in accordance with
Employers standard colour coding scheme, which will be furnished to the
Contractor during detailed engineering stage.
8.18.00 PROTECTION AND PRESERVATIVE SHOP COATING
8.19.00 PROTECTION
All coated surfaces shall be protected against abrasion, impact, discoloration and
any other damages. All exposed threaded portions shall be suitably protected
with either metallic or a nonmetallic protection device. All ends of all valves and
pipings and conduit equipment connections shall be properly sealed with suitable
devices to protect them from damage. The parts which are likely to get rusted,
due to exposure to weather, should also be properly treated and protected in a
suitable manner. All primers/paints/coatings shall take into account the hot
humid, corrosive & alkaline, subsoil or overground environment as the case may
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8.20.00 PRESERVATIVE SHOP COATING
All exposed metallic surfaces subject to corrosion shall be protected by shop
application of suitable coatings. All surfaces which will not be easily accessible
after the shop assembly, shall be treated beforehand and protected for the life of
the equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides
and other coatings and prepared in the shop. The surfaces that are to be finish-
painted after installation or require corrosion protection until installation, shall be
shop painted with atleast two coats of primer.
Transformers and other electrical equipments if included shall be shop finished
with one or more coats of primer and two coats of high grade resistance enamel.
The finished colors shall be as per manufacturers standards, to be selected and
specified by the Employer at a later date.
8.20.01 Shop primer for all steel surfaces which will be exposed to operating temperature
below 95 degrees Celsius shall be selected by the Contractor after obtaining
specific approval of the Employer regarding the quality of primer proposed to be
applied. Special high temperature primer shall be used on surfaces exposed to
temperature higher than 95 degrees Celsius and such primer shall also be
subject to the approval of the Employer.
8.20.02 All other steel surfaces which are not to be painted shall be coated with suitable
rust preventive compound subject to the approval of the Employer.
8.20.03 All piping shall be cleaned after shop assembly.
8.20.04 Painting for Civil structures shall be done as per relevant part of technical
specification
9.00.00 QUALITY ASSURANCE PROGRAMME
9.01.00 The Contractor shall adopt suitable quality assurance programme to ensure that
the equipment and services under the scope of contract whether manufactured
or performed within the Contractors works or at his sub-contractors premises or
at the Employers site or at any other place of work are in accordance with the
specifications. Such programmes shall be outlined by the Contractor and shall be
finally accepted by the Employer/authorised representative after discussions
before the award of the contract. The QA programme shall be generally in line
with IS/ISO-9001.A quality assurance programme of the contractor shall
generally cover the following:
a). His organisation structure for the management and implementation of the
proposed quality assurance programme
b). Quality System Manual
c). Design Control System
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d). Documentation and Data Control System
e). Qualification data for Contractors key personnel.
f). The procedure for purchase of materials, parts, components and selection
of sub-contractors services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.
g). System for shop manufacturing and site erection controls including
process, fabrication and assembly.
h). Control of non-conforming items and system for corrective actions and
resolution of deviations.
i). Inspection and test procedure both for manufacture and field activities.
j). Control of calibration and testing of measuring testing equipment.
k). System for Quality Audits.
l). System for identification and appraisal of inspection status.
m). System for authorising release of manufactured product to the Employer.
n). System for handling, storage and delivery.
o). System for maintenance of records, and
(p) Quality plans for manufacturing and field activities detailing out the specific
quality control procedure adopted for controlling the quality characteristics
relevant to each item of equipment/component.
9.02.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE
9.02.01 All materials, components and equipment covered under this specification shall
be procured, manufactured, erected, commissioned and tested at all the stages,
as per a comprehensive Quality Assurance Programme. An indicative
programme of inspection/tests to be carried out by the contractor for some of the
major items is given in the respective technical specification. This is, however,
not intended to form a comprehensive programme as it is the contractors
responsibility to draw up and implement such programme duly approved by the
Employer. The detailed Quality Plans for manufacturing and field activities shall
be drawn up by the Contractor and will be submitted to Employer for approval.
Schedule of finalisation of such quality plans will be finalised before award.
Monthly progress reports on MQP/FQP submission/approval shall be furnished
on enclosed format No. QS-01-QAI-P-02/F1
9.02.02 Manufacturing Quality Plan will detail out for all the components and equipment,
various tests/inspection, to be carried out as per the requirements of this
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specification and standards mentioned therein and quality practices and
procedures followed by Contractors/ Sub-contractors/ sub-supplier's Quality
Control Organisation, the relevant reference documents and standards,
acceptance norms, inspection documents raised etc., during all stages of
materials procurement, manufacture, assembly and final testing/performance
testing. The Quality Plan shall be submitted on electronic media through c-
folders,a Web based system of NTPC-ERP in addition to hard copy, for review
and approval. After approval the same shall be submitted in compiled form on
CD-ROM.
9.02.03 Field Quality Plans will detail out for all the equipment, the quality practices and
procedures etc. to be followed by the Contractors "Site Quality Control
Organisation", during various stages of site activities starting from receipt of
materials/equipment at site.
9.02.04 The Contractor shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., as referred in
Quality Plans along with Quality Plans. These Quality Plans and reference
documents/standards etc. will be subject to Employers approval without which
manufacturer shall not proceed. These approved documents shall form a part of
the contract. In these approved Quality Plans, Employer shall identify customer
hold points (CHP), i.e. test/checks which shall be carried out in presence of the
Employers Project Manager or his authorised representative and beyond which
the work will not proceed without consent of Employer in writing. All deviations to
this specification, approved quality plans and applicable standards must be
documented and referred to Employer along with technical justification for
approval and dispositioning.
9.02.05 No material shall be despatched from the manufacturers works before the same
is accepted, subsequent to predespatch final inspection including verification of
records of all previous tests/inspections by Employers Project
Manager/Authorised representative and duly authorised for despatch by issuance
of Material Despatch Clearance Certificate (MDCC).
9.02.06 All material used for equipment manufacture including casting and forging etc.
shall be of tested quality as per relevant codes/standards. Details of results of
the tests conducted to determine the mechanical properties; chemical analysis
and details of heat treatment procedure recommended and actually followed
shall be recorded on certificates and time temperature chart. Tests shall be
carried out as per applicable material standards and/or agreed details.
9.02.07 The contractor shall submit to the Employer Field Welding Schedule for field
welding activities in the enclosed format No.: QS-01-QAI-P-02/F3. The field
welding schedule shall be submitted to the Employer along with all supporting
documents, like welding procedures, heat treatment procedures, NDT
procedures etc. at least ninety days before schedule start of erection work at site.
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9.02.08 All welding and brazing shall be carried out as per procedure drawn and qualified
in accordance with requirements of ASME Section IX/BS-4870 or other
International equivalent standard acceptable to the Employer.
All welding/brazing procedures shall be submitted to the Employer or its
authorised representative for approval prior to carrying out the welding/brazing.
9.02.09 All brazers, welders and welding operators employed on any part of the contract
either in Contractors/sub-contractors works or at site or elsewhere shall be
qualified as per ASME Section-IX or BS-4871 or other equivalent International
Standards acceptable to the Employer.
9.02.10 Welding procedure qualification & Welder qualification test results shall be
furnished to the Employer for approval. However, where required by the
Employer, tests shall be conducted in presence of Employer/authorised
representative.
9.02.11 For all pressure parts and high pressure piping welding, the latest applicable
requirements of the IBR (Indian Boiler Regulations) shall also be essentially
complied with. Similarly, any other statutory requirements for the
equipment/systems shall also be complied with. On all back-gauged welds
MPI/LPI shall be carried before seal welding.
9.02.12 Unless otherwise proven and specifically agreed with the Employer, welding of
dissimilar materials and high alloy materials shall be carried out at shop only.
9.02.13 No welding shall be carried out on cast iron components for repair.
9.02.14 All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
9.02.15 All non-destructive examination shall be performed in accordance with written
procedures as per International Standards, The NDT operator shall be qualified
as per SNT-TC-IA (of the American Society of non-destructive examination).
NDT shall be recorded in a report, which includes details of methods and
equipment used, result/evaluation, job data and identification of personnel
employed and details of co-relation of the test report with the job.
All Bar stock / forgings of diameter equal to or greater than 50mm shall be
ultrasonically tested. In general all plates of thickness equal to or greater than
40mm and for pressure parts, pates of thickness equal to or greater than 25mm
shall be ultrasonically tested unless as specified otherwise in respective
equipment specification.
9.02.16 The Contractor shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-contractors (BOI). All the
sub-contractor proposed by the Contractor for procurement of major bought out
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items including castings, forging, semi-finished and finished
components/equipment etc., list of which shall be drawn up by the Contractor
and finalised with the Employer, shall be subject to Employer's approval. The
contractors proposal shall include vendors facilities established at the respective
works, the process capability, process stabilization, QC systems followed,
experience list, etc. along with his own technical evaluation for identified sub-
contractors enclosed and shall be submitted to the Employer for approval within
the period agreed at the time of pre-awards discussion and identified in "DR"
category prior to any procurement. Monthly progress reports on sub-contractor
detail submission / approval shall be furnished on enclosed on format no. QS-01-
QAI-P-02/F2. Such vendor approval shall not relieve the contractor from any
obligation, duty or responsibility under the contract.
9.02.17 For components/equipment procured by the contractors for the purpose of the
contract, after obtaining the written approval of the Employer, the contractors
purchase specifications and inquiries shall call for quality plans to be submitted
by the suppliers. The quality plans called for from the sub-contractor shall set
out, during the various stages of manufacture and installation, the quality
practices and procedures followed by the vendors quality control organisation,
the relevant reference documents/standards used, acceptance level, inspection
of documentation raised, etc. Such quality plans of the successful vendors shall
be finalised with the Employer and such approved Quality Plans shall form a part
of the purchase order/contract between the Contractor and sub-contractor. With
in three weeks of the release of the purchase orders /contracts for such bought
out items /components, a copy of the same without price details but together with
the detailed purchase specifications, quality plans and delivery conditions shall
be furnished to the Employer on the monthly basis by the Contractor along with a
report of the Purchase Order placed so far for the contract. **
9.02.18 Employer reserves the right to carry out quality audit and quality surveillance of
the systems and procedures of the Contractors or their sub-contractors quality
management and control activities. The contractor shall provide all necessary
assistance to enable the Employer carry out such audit and surveillance.
9.02.19 The contractor shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-contractors and at site to ensure the
mechanical accuracy of components, compliance with drawings, conformance to
functional and performance requirements, identity and acceptability of all
materials parts and equipment. Contractor shall carry out all tests/inspection
required to establish that the items/equipment conform to requirements of the
specification and the relevant codes/standards specified in the specification, in
addition to carrying out tests as per the approved quality plan.
9.02.20 Quality audit/surveillance/approval of the results of the tests and inspection will
not, however, prejudice the right of the Employer to reject the equipment if it does
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not comply with the specification when erected or does not give complete
satisfaction in service and the above shall in no way limit the liabilities and
responsibilities of the Contractor in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard, data sheets,
drawings, etc.
9.02.21 For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.
9.02.22 Repair/rectification procedures to be adopted to make the job acceptable shall be
subject to the approval of the Employer/ authorised representative.
9.02.23 Environmental Stress Screening
All solid state electronic system / equipment / sub assembly shall be free from
infant mortile components. For establishing the compliance to this requirement,
the contractor / sub contractor should meet the following.
1) The Contractor / Sub contractor shall furnish the established procedure
being followed for eliminating infant mortile components. The procedure
followed by the Contractor / Sub contractor should be substantiated
along with the statistical figures to validate the procedure being followed.
The necessary details as required under this clause shall be furnished at
the stage of QP finalization.
Or
In case the Contractor / Sub contractor do not have any established
procedure to eliminate infant mortile components then two or 10% which
ever is less, most densely populated Panels shall be tested for Elevated
Temperature Cycle Test as per the following procedure.
Elevated Temperature Test Cycle
During the elevated temperature test which shall be for 48 hours, the
ambient temperature shall be maintained at 50 C. The equipment shall
be interconnected with devices and kept under energized conditions so
as to repeatedly perform all operations it is expected to perform in actual
service with load on various components being equal to those which will
be experienced in actual service.
During the elevated temperature test the cubicle doors shall be closed (or
shall be in the position same as they are supposed to be in the field) and
inside temperature in the zone of highest heat dissipating components /
modules shall be monitored. The temperature rise inside the cubicle
should not exceed 10 C above the ambient temperature at 50 C.
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In case of any failure during the test cycle, the further course of action
should be mutually discussed for demonstrating the intent of the above
requirement.
2) Burn in Test Cycle
The test shall be conducted on all the panels fully assembled and wired
including the panels having undergone the above mentioned elevated
temperature test.
The period of Burn in Test Cycle shall be 120 hrs and process shall be
similar to the elevated temperature test as above except that the
temperature shall be reduced to the ambient temperature prevalent at
that time.
During the above tests, the process I/O and other load on the system
shall be simulated by simulated inputs and in the case of control systems;
the process which is to be controlled shall also be simulated. Testing of
individual components or modules shall not be acceptable.
During the Burn in Test the cubicle doors shall be closed (or shall be in
the position same as they are supposed to be in the field) and inside
temperature in the zone of highest heat dissipating components /
modules shall be monitored. The temperature rise inside the cubicle
should not exceed 10 C above the ambient temperature.
The Contractor / Sub-contractor shall carry out routine test on 100% item
at contractor / sub-contractor's works. The quantum of check / test for
routine & acceptance test by employer shall be generally as per criteria /
sampling plan defined in referred standards. Wherever standards have
not been mentioned quantum of check / test for routine / acceptance test
shall be as agreed during detailed engineering stage.
9.02.24 The Contractor shall have suitable Field Quality Organisation with edquate
manpower at Employers site to effectively implement the field quality plan (FQP)
requirement for site activities. The contractor shall submit the details of proposed
FQA set-up (Organisation set up & manpower) depending upon the scope of
work involved for Employers approval. The FQA set up shall be in place at least
one month before the start of site activities.
9.03.00 QA DOCUMENTATION PACKAGE
The Contractor shall be required to submit the QA Documentation in two hard
copies and two CD ROMs, as identified in respective quality plan with tick (?)
mark.
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9.03.01 Each QA Documentation shall have a project specific Cover Sheet bearing name
& identification number of equipment and including an index of its contents with
page control on each document.
The QA Documentation file shall be progressively completed by the Suppliers
sub- supplier to allow regular reviews by all parties during the manufacturing.
The final quality document will be compiled and issued at the final assembly
place of equipment before despatch. However CD-Rom may be issued not later
than three weeks.
9.03.02 Typical contents of QA Documentation is as below:-
a). Quality Plan
b). Material mill test reports on components as specified by the specification
and approved Quality Plans.
c). Manufacturer / works test reports/results for testing required as per
applicable codes and standard referred in the specification and approved
Quality Plans.
d). Non-destructive examination results /reports including radiography
interpretation reports. Sketches/drawings used for indicating the method of
traceability of the radiographs to the location on the equipment.
e). Heat Treatment Certificate/Record (Time- temperature Chart)
f). All the accepted Non-conformance Reports (Major/Minor) / deviation,
including complete technical details / repair procedure).
g). CHP / Inspection reports duly signed by the Inspector of the Employer and
Contractor for the agreed Customer Hold Points.
h). Certificate of Conformance (COC) wherever applicable.
i). MDCC
9.03.03 Similarly, the contractor shall be required to submit two sets (two hard copies and
two CD ROMs), containing QA Documentation pertaining to field activities as per
Approved Field Quality Plans and other agreed manuals/ procedures, prior to
commissioning of individual system.
9.03.04 Before despatch / commissioning of any equipment, the Supplier shall make sure
that the corresponding quality document or in the case of protracted phased
deliveries, the applicable section of the quality document file is completed. The
supplier will then notify the Inspector regarding the readiness of the quality
document (or applicable section) for review.
If the result of the review carried out by the Inspector is satisfactory, the Inspector
shall stamp the quality document (or applicable section) for release.
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If the quality document is unsatisfactory, the Supplier shall endeavor to correct
the incompleteness, thus allowing to finalize the quality document (or applicable
section) by time compatible with the requirements as per contract documents.
When it is done, the quality document (or applicable section) is stamped by the
Inspector.
If a decision is made despatch, whereas all outstanding actions cannot be readily
cleared for the release of the quality document by that time. The supplier shall
immediately, upon shipment of the equipment, send a copy of the quality
document Review Status signed by the Supplier Representative to the Inspector
and notify of the committed date for the completion of all outstanding actions &
submission. The Inspector shall stamp the quality document for applicable
section when it is effectively completed. The submission of QA documentation
package shall not be later than 3 weeks after the despatch of equipment.
9.03.05 TRANSMISSION OF QA DOCUMENTATION
On release of QA Documentation by Inspector, one set of quality document shall
be forwarded to Corporate Quality Assurance Department and other set to
respective Project Site of Employer.
For the particular case of phased deliveries, the complete quality document to
the Employer shall be issued not later than 3 weeks after the date of the last
delivery of equipment.
9.04.00 PROJECT MANAGERS SUPERVISION
9.04.01 To eliminate delays and avoid disputes and litigation, it is agreed between the
parties to the Contract that all matters and questions shall be referred to the
Project Manager and without prejudice to the provisions of Arbitration clause in
Section GCC of Vol.I, the Contractor shall proceed to comply with the Project
Manager's decision.
9.04.02 The work shall be performed under the supervision of the Project Manager. The
scope of the duties of the Project Manager pursuant to the Contract, will include
but not be limited to the following:
a). Interpretation of all the terms and conditions of these documents and
specifications:
b). Review and interpretation of all the Contractors drawing, engineering
data, etc:
c). Witness or his authorised representative to witness tests and trials either
at the manufacturers works or at site, or at any place where work is
performed under the contract :
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d). Inspect, accept or reject any equipment, material and work under the
contract:
e). Issue certificate of acceptance and/or progressive payment and final
payment certificates
f). Review and suggest modifications and improvement in completion
schedules from time to time, and
g). Supervise Quality Assurance Programme implementation at all stages of
the works.
9.05.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
9.05.01 The word Inspector shall mean the Project Manager and/or his authorised
representative and/or an outside inspection agency acting on behalf of the
Employer to inspect and examine the materials and workmanship of the works
during its manufacture or erection.
9.05.02 The Project Manager or his duly authorised representative and/or an outside
inspection agency acting on behalf of the Employer shall have access at all
reasonable times to inspect and examine the materials and workmanship of the
works during its manufacture or erection and if part of the works is being
manufactured or assembled on other premises or works, the Contractor shall
obtain for the Project Manager and for his duly authorised representative
permission to inspect as if the works were manufactured or assembled on the
Contractors own premises or works.
9.05.03 The Contractor shall give the Project Manager/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the
Contractors account except for the expenses of the Inspectors. The Project
Manager/Inspector, unless the witnessing of the tests is virtually waived and
confirmed in writing, will attend such tests within fifteen (15) days of the date on
which the equipment is noticed as being ready for test/inspection failing which
the contractor may proceed with test which shall be deemed to have been made
in the inspectors presence and he shall forthwith forward to the inspector duly
certified copies of test reports in two (2) copies.
9.05.04 The Project Manager or Inspector shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the Contractor, or any
objection to any drawings and all or any equipment and workmanship which is in
his opinion not in accordance with the contract. The Contractor shall give due
consideration to such objections and shall either make modifications that may be
necessary to meet the said objections or shall inform in writing to the Project
Manager/Inspector giving reasons therein, that no modifications are necessary to
comply with the contract.
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9.05.05 When the factory tests have been completed at the Contractors or sub-
contractors works, the Project Manager /Inspector shall issue a certificate to this
effect fifteen (15) days after completion of tests but if the tests are not witnessed
by the Project Manager /Inspectors, the certificate shall be issued within fifteen
(15) days of the receipt of the Contractors test certificate by the Project Manager
/Inspector. Project Manager /Inspector to issue such a certificate shall not
prevent the Contractor from proceeding with the works. The completion of these
tests or the issue of the certificates shall not bind the Employer to accept the
equipment should it, on further tests after erection be found not to comply with
the contract.
9.05.06 In all cases where the contract provides for tests whether at the premises or
works of the Contractor or any sub-contractor, the Contractor, except where
otherwise specified shall provide free of charge such items as labour, material,
electricity, fuel, water, stores, apparatus and instruments as may be reasonably
demanded by the Project Manager /Inspector or his authorised representatives to
carry out effectively such tests on the equipment in accordance with the
Contractor and shall give facilities to the Project Manager/Inspector or to his
authorised representative to accomplish testing.
9.05.07 The inspection by Project Manager / Inspector and issue of Inspection Certificate
thereon shall in no way limit the liabilities and responsibilities of the Contractor in
respect of the agreed Quality Assurance Programme forming a part of the
contract.
9.05.08 To facilitate advance planning of inspection in addition to giving inspection notice
as specified at clause no 9.05.03- of this chapter, the Contractor shall furnish
quarterly inspection programme indicating schedule dates of inspection at
Customer Hold Point and final inspection stages. Updated quarterly inspection
plans will be made for each three consecutive months and shall be furnished
before beginning of each calendar month.
9.05.09 All inspection, measuring and test equipment used by contractor shall be
calibrated periodically depending on its use and criticality of the
test/measurement to be done. The Contractor shall maintain all the relevant
records of periodic calibration and instrument identification, and shall produce the
same for inspection by NTPC. Wherever asked specifically, the contractor shall
re-calibrate the measuring/test equipment in the presence of Project Manager /
Inspector.
9.06.00 ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE PROGRAMME:
9.06.01 Subcontractor approval Schedule Status / Exception Format No.:QS-01-QAI-
P-02/F1-R2
9.06.02 Quality Plan Schedule Status/ Exception Format No.: QS-01-QAI-P-02/F2-R2
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9.06.03 Field Welding Schedule Format No.: QS-01-QAI-P-02/F3-R1
9.06.04 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R1
9.06.05 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1
The above formats are enclosed as Annexures-III to VII.
10.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES
a). As soon as the facilities or part thereof has been completed operationally
and structurally and before start-up, each item of the equipment and
systems forming part of facilities shall be thoroughly cleaned and then
inspected jointly by the Employer and the Contractor for correctness of and
completeness of facility or part thereof and acceptability for initial pre-
commissioning tests, commissioning and start-up at Site. The list of pre-
commissioning tests to be performed shall be as mutually agreed and
included in the Contractors quality assurance programme as well as those
included elsewhere in the Technical Specifications.
b). The Contractors pre-commissioning/ commissioning/start-up engineers,
specially identified as far as possible, shall be responsible for carrying out
all the pre-commissioning tests at Site. On completion of inspection,
checking and after the pre-commissioning tests are satisfactorily over, the
commissioning of the complete facilities shall be commenced during which
period the complete facilities, equipments shall be operated integral with
sub-systems and supporting equipment as a complete plant.
c). The time consumed in the inspection and checking of the units shall be
considered as a part of the erection and installation period.
d). The check outs during the pre - commissioning period should be
programmed to follow the construction completion schedule. Each
equipment/system, as it is completed in construction and turned over to
Employer's commissioning (start-up) Engineer(s), should be checked out
and cleaned. The checking and inspection of individual systems should
then follow a prescribed commissioning documentation [SLs (Standard
Check List) / TS (Testing Schedule) / CS (Commissioning Schedule)]
approved by the Employer.
e). On completion of all precommissioning activities / tests and as a part of
commissioning the complete facilities shall be put on 'Trial Operation'
during which period all necessary adjustments shall be made while
operating over the full load range enabling the facilities to be made ready
for the Guarantee Tests
(f.) The duration of 'Trial Operation' of the complete facility as an integral unit
shall be fourteen (14) days. The Trial Operation shall be considered
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successful, provided that each item/part of the facility can operate
continuously at the specified operating characteristics, for the period of Trial
Operation with all operating parameters within the specified limits and at or
near the predicted performance of facility/equipment.
(g.) For the period of 'Trial Operation', the time of operation with any load shall
be counted. Minor interruptions not exceeding four (4) hours at a time
caused during the 14 days trial operation period shall not effect the total
duration of Initial Operation. If in the opinion of the Employer the
interruption is long, the Trial Operation shall be prolonged for the period of
interruption
(h.) A Trial Operation report comprising of observations and recordings of
various parameters to be measured in respect of the above Trial Operation
shall be prepared by the Contractor. This report, besides recording the
details of the various observations during trial operation shall also include
the dates of start and finish of the Trial Operation and shall be signed by
the representatives of both the parties. The report shall have sheets,
recording all the details of interruptions occurred, adjustments made and
any minor repairs done during the Trial Operation. Based on the
observations, necessary modifications/repairs to the plant shall be carried
out by the Contractor to the full satisfaction of the Project Manager to
enable the latter to accord permission to carry out the Guarantee tests on
the facilities. However, minor defects which do not endanger the safe
operation of the equipment, shall not be considered as reasons for with-
holding the aforesaid permission
(i.) Contractor shall furnish the commissioning organization chart for review &
acceptance of employer at least eighteen months prior to the schedule date
of synchronization of 1st unit. The chart should contain
(1.) Experience of the Commissioning Engineers.
(2.) Role and responsibilities of the Commissioning Organisation
members.
(3.) Expected duration of posting of the above Commissioning Engineers
at site.
10.01.00 Guarantee Tests
(a) The final tests as to the guarantees shall be conducted at Site, by the
Contractor. The Contractor's Commissioning and start-up Engineers shall
make the unit ready for such tests. Such test will be commenced, within a
period of three (3) months after the successful completion of Trial
Operation. Any extension of time beyond the above three months shall be
subject to Employer's approval.
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(b) These tests shall be binding on both the parties of the Contract to
determine compliance of the equipment with the performance guarantee.
(c) Any special equipment, tools and tackles required for the successful
completion of the Guarantee Tests shall be provided by the Contractor,
free of cost.
(d) The guarantee figures and design/performance parameters of the
equipment shall be proved by the Contractor during theswe Guarantee
Tests/ and or during the 'Trial operation' as detailed out elsewhere.
Should the results of these tests show any deterioration from the
guaranteed values, the Contractor shall modify the equipment as required
to enable it to meet the guarantees. In such case, the Guarantee Tests
shall be repeated and all cost for modifications including labour, materials
and the cost of additional testing to prove that the equipment meets the
guarantees, shall be borne by the Contractor.
(e) The specific tests to be conducted on equipment have been brought out
in the technical specification.
10.02.00 Test Codes
The provisions outlined in the ASME Performance Test Codes shall be used as a
guide for all the above test procedures unless otherwise specified in the technical
specifications.
11.00.00 TAKING OVER
Upon successful completion of Initial Operations and all the tests conducted to
the Employer's satisfaction, the Employer shall issue to the Contractor a Taking
over Certificate as a proof of the final acceptance of the equipment. Such
certificate shall not unreasonably be with held nor will the Employer delay the
issuance thereof, on account of minor omissions or defects which do not affect
the commercial operation and/or cause any serious risk to the equipment. Such
certificate shall not relieve the Contractor of any of his obligations which
otherwise survive, by the terms and conditions of the Contract after issuance of
such certificate.
12.00.00 TRAINING OF EMPLOYER'S PERSONNEL
12.01.00 The scope of service under training of Employers engineers (min. 12 nos.) shall
include a training module in the areas of Operation & Maintenance.
Such training should cover the following areas as a minimum in order to enable
these personnel to individually take the responsibility of operating and
maintaining the power station in a manner acceptable to the Employer:
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12.02.00 The scope of services under training shall also necessarily include training of
Employer's Engineering personnel covering a training module of upto 52 man
months. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & QA
etc. and shall include all the related areas like Design familiarization, training on
product design features and product design softwares of major equipment and
systems, engineering, manufacturing, erection, commissioning, training on
operating features of equipment, quality assurance and testing, plant visits and
visits to manufacturer's works, exposure to various kinds of problems which may
be encountered in fabrication, manufacturing, erection, welding etc.
12.03.00 Contractor shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Employer's approval. Consolidated
training period included above (i.e. 35 and 52 man months respectively for O&M
and Engineering) is indicative only. Employer reserves the right to reappropriate
the training period between O&M and engineering depending upon the details of
training module proposed by the Contractor.
12.04.00 Exact details, extent of training and the training schedule shall be finalised based
on the Contractor's proposal within two (2) months from placement of award.
12.05.00 In all the above cases, wherever the training of Employer's personnel is arranged
at the works of the manufacturer's it shall be noted that the lodging and boarding
of the Employer's personnel shall be at the cost of Contractor.
13.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION
In addition to the requirements given in Erection Conditions of Contract (ECC)
the following shall also cover:
a). Working platforms should be fenced and shall have means of access.
b). Ladders in accordance with Employers safety rules for construction and
erection shall be used. Rungs shall not be welded on columns. All the stairs
shall be provided with handrails immediately after its erection.
14.00.00 NOISE LEVEL
The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m
above floor level in elevation and at a distance of one (1) metre horizontally from
the nearest surface of any equipment / machine, furnished and installed under
these specifications, expressed in decibels to a reference of 0.0002 microbar,
shall not exceed 85 dBA.
15.00.00 PACKAGING AND TRANSPORTATION
All the equipments shall be suitably protected, coated, covered or boxed and
crated to prevent damage or deterioration during transit, handling and storage at
Site till the time of erection. While packing all the materials, the limitation from the
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point of view of the sizes of railway wagons available in India should be taken
account of. The Contractor shall be responsible for any loss or damage during
transportation, handling and storage due to improper packing. The Contractor
shall ascertain the availability of Railway wagon sizes from the Indian Railways
or any other agency concerned in India well before effecting despatch of
equipment. Before despatch it shall be ensured that complete processing and
manufacturing of the components is carried out at shop, only restricted by
transport limitation, in order to ensure that site works like grinding, welding,
cutting & pre-assembly to bare minimum. The Employer's Inspector shall have
right to insist for completion of works in shops before despatch of materials for
transportation.
16.00.00 ELECTRICAL ENCLOSURE
All electrical equipments and devices, including insulation, heating and ventilation
devices shall be designed for ambient temperature and a maximum relative
humidity as specified elsewhere in the specification,
17.00.00 INSTRUMENTATION AND CONTROL
All instrumentation and control systems/ equipment/ devices/ components,
furnished under this contract shall be in accordance with the requirements stated
herein, unless otherwise specified in the detailed specifications.
17.01.00 All instrument scales and charts shall be calibrated and printed in metric units
and shall have linear graduation. The ranges shall be selected to have the
normal reading at 75% of full scale.
All scales and charts shall be calibrated and printed in Metric Units as follows:
a) Temperature - Degree centigrade (deg C)
b) Pressure -
Kilograms per square centimetre (Kg/cm
2
).
Pressure instrument shall have the unit suffixed
with 'a' to indicate absolute pressure. If nothing
is there, that will mean that the indicated
pressure is gauge pressure.
c) Draught - Millimetres of water column (mm wc).
d) Vacuum - Millimeters of mercury column (mm Hg) or
water column (mm Wcl).
e) Flow - Tonnes/ hour
f) Flow (Liquid) - Tonnes / hour
g) Flow base - 760 mm Hg. 15 deg.C
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h) Density Grams per cubic centimetre.
17.02.00 All instruments and control devices provided on panels shall be of miniaturized
design, suitable for modular flush mounting on panels with front draw out facility
and flexible plug-in connection at rear.
17.03.00 All electronic modules shall have gold plated connector fingers and further all
input and output modules shall be short circuit proof. These shall also be
tropicalised & components shall be of industrial grade or better.
18.00.00 ELECTRICAL NOISE CONTROL
The equipment furnished by the Contractor shall incorporate necessary
techniques to eliminate measurement and control problems caused by electrical
noise. Areas in Contractors equipment which are vulnerable to electrical noise
shall be hardened to eliminate possible problems. Any additional equipment,
services required for effectively eliminating the noise problems shall be included
in the proposal. The equipment shall be protected against ESD as per IEC-801-
2. Radio Frequency interference (RFI) and Electro Magnetic Interference (EMI)
protection against hardware damage and control system mal-operations/errors
shall be provided for all systems.
19.00.00 INSTRUMENT AIR SYSTEM (AS APPLICABLE)
The instrument air supply system as supplied by the Contractor for various
pneumatic control & instrumentation devices like pneumatic actuators, power
cylinders, E/P converters, piping / tubing etc. shall be as per the details furnished
elsewhere.
Each pneumatic instrument shall have an individual air shut - off valve. The
pressure regulating valve shall be equipped with an internal filter, a 50 mm
pressure gauge and a built-in filter housing blow down valve.
20.00.00 TAPPING POINTS FOR MEASUREMENTS
Tapping points shall include probes, wherever applicable, for analytical
measurements and sampling.
For direct temperature measurement of all working media, one stub with internal
threading of approved pattern shall be provided along with suitable plug and
washer. The Contractor will be intimated about thread standard to be adopted.
The following shall be provided on equipment by the Contractor. The standard
which is to be adopted, will be intimated to the Contractor.
Temperature test pockets with stub and thermowell
Pressure test pockets
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21.00.00 ELECTRONIC MODULE/COMPONENT DETAILS
The Contractor shall have to furnish all technical details including circuit
diagrams, specifications of components, etc., in respect of each and every
electronic card/module as employed on the various solid state as well as
microprocessor based systems and equipment including conventional
instruments, peripherals etc.
It is mandatory for the Contractor to identify clearly the custom built ICs used in
the package. The Contractor shall also furnish the details of any equivalents of
the same.
22.00.00 JUNCTION BOXES
The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland
plates shall be removable type and made of 3 mm thick sheet steel. The boxes
shall be provided with detachable cover or hinged door with captive screws. Top
of the box shall be arranged to slope towards the rear of the box. The box shall
be hot dip galvanized and shall be provided with suitable neoprene gaskets to
achieve degree of protection of IP-55 as per IS: 2147. Adequate spacing shall be
provided to terminate the external cables. The boxes shall be suitable for
mounting on various types of steel structures. The terminal blocks provided shall
be of 650 V grade, rated for 10 A for control cables. Suitable numbering for
terminal blocks shall be done. In case of junction box for power cable, the box
shall be rated for maximum current carrying capacity. Terminal blocks shall be of
one piece, klippon RSF-1 or ELMEX CSLT-1 type with insulating barriers.
23.00.00 SPECIFIC REQUIREMENT FOR DC PANELS
23.01.00 DC starter shall essentially consists of following:
a) One (1) - Double pole 220 V D.C. air break switch and HRC fuses.
b) One (1) - Double pole 220 V D.C. contactor with 2 NO and 2 NC contacts.
c) Contactors and timers as required for the control scheme.
d) Overload relay (for alarm only).
e) Shunt and ammeter for motors rated 15 KW an above.
f) One (1) - Red indicating lamp to give motor 'ON' indication.
g) One (1) - Green indicating lamp to give motor 'OFF' indication.
h) Starting resistor.
The resistance shall be air cooled, stainless steel grid type, suitable for 220 V DC
and continuously rated. The resistance shall be provided with sheet steel covers
with louvers and canopy type top cover.

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ANNEXURE-I
S. NO. DESCRIPTION OF DOCUMENTS NO OF PRINTS NO. OF CD-
ROMs
1. Drawings "FOR APPROVAL"
i) Layout Drawings/P&IDs 6 2 CD-ROMs
ii) Other Drawings 2 2 CD-ROMs
2. Drawings "FOR INFORMATION" 2 2 CD-ROMs
3. Drawings "FINAL DRAWING" 15 4 CD-ROMs
4. Drawings "AS BUILT " 15 4 CD-ROMs
5. DATASHEETS,DESIGN
CALCULATIONS, PURCHASE
SPECIFICATIONS, etc. and Other type
of documents

i) For Approval 2 2 CD-ROMs
ii) Final 15 4 CD-ROMs
iii) Analysis reports of
equipments/piping/structures
components/system employing
software packages as detailed in
the specifications, including
input/output data
2 2 CD-ROMs
6. Erection manual "1
ST
SUBMISSION" 4 Sets 2 CD-ROMs
7. Erection manual "FINAL" 4 Sets 4 CD-ROMs
8 Operation & Maintenance manual "1
ST

SUBMISSION"
4 Sets 2 CD-ROMs
9 Operation & Maintenance manual
"FINAL"
4 Sets 4 CD-ROMs
10 Plant Hand Book "1
ST
SUBMISSION" 4 Sets 2 CD-ROMs
11 Plant Hand Book "FINAL" 4 Sets 4 CD-ROMs

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12 Commissioning and Performance
Procedure manual 1
ST
SUBMISSION
4 Sets 2 CD-ROMs
13 Commissioning and Performance
Procedure manual FINAL
4 Sets 4 CD-ROMs
14 Performance and Functional
GUARANTEES TEST REPORT
4 Sets 4 CD-ROMs
15 Project completion report 15 4 CD-ROMs
16 QA programme including Organisation
for implementation and QA system
manual (with revision-servicing)
1 1 CD-ROM
17 Vendor details in respect of proposed
vendors including contractors
evaluation report.
1 1 CD-ROM
18 Manufacturing QPs, Field QPs, Field
welding schedules and their reference
documents like test procedures, WPS,

i) For review/comment 2 2 CD-ROMs
ii) For final approval 2 2 CD-ROMs
19 Welding Manual, Heat Treatment
Manuals, Storage & preservation
manuals.

1
st
Submission 4 Sets 2 CD-ROMs
Final 4 Sets 4 CD-ROMs
20 QA Documentation Package for items /
equipment manufactured and
dispatched to site
2 Sets 2 CD-ROMs
21 QA Documentation Package for
field activities on equipment / systems
at site
2 Sets 2 CD-ROMs

SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
PAGE 41 OF 45

ANNEXURE-II
DOC. NO.:
REV. NO.:
DATE :
Project : Stage :
Package :
Supplier :
Contractor No. :
LIST OF ITEMS REQUIRING QUALITY PLAN
AND SUB-SUPPLIER APPROVAL

SUB-SYSTEM :
PAGE : OF
S.
N.

Item QP/
Insp.
Cat.
QP No.

QP
Sub.
Schedu
le
QP
approv
al
schedul
e
Proposed sub-
supplier
Place Sub-
supplier
s
approval
status /
category
Sub-
supplier
Details
submissi
on
schedule
Remar
ks

LEGENDS
1. SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY NTPC)
A For these items proposed vendor is acceptable to NTPC. To be indicated with letter A in the list alongwith the condition of approval, if any.
DR For these items Detailed required for NTPC review. To be identified with letter DR in the list.
NOTED For these items vendors are approved by Main Supplier and accepted by NTPC without specific vendor approval from NTPC. To be identified with NOTED.
2. QP/INSPN CATEGORY:
CAT-I : For these items the Quality Plans are approved by NTPC and the final acceptance will be on physical inspection witness by NTPC.
CAT-II : For these items the Quality Plans approved by NTPC. However no physical inspection shall be done by NTPC. The final acceptance by NTPC shall be on the basis
review of documents as per approved QP.
CAT-III : For these items Main Supplier approves the Quality Plans. The final acceptance by NTPC shall be on the basis certificate of conformance by the main supplier.
UNITS/WORKS : Place of manufacturing Place of Main Supplier of multi units/works.
FORMAT NO.: QS-01-QAI-P-1/F3-R0 1/1 Engg. Div. / QA&I

SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
PAGE 42 OF 45

ANNEXURE-III
DOC. NO.:
REV. NO.:
DATE :
Project : Stage :
Package :
Contractor :
Contractor No. :
STATUS OF ITEM REQUIRING QP&
SUB-SUPPLIER APPROVAL

PAGE : OF
S. N.

Item / Service QP/
Insp.
Cat.
QP Sub.
Schedule
Approval
schedule
Date
of
sub-
missi
on
Date
of
com
mt
Appl.
Status
Code
C/II/I
Proposed Sub-suppliers Place of
manufacturing
works
Approval
Status
Sub-
supplier
detail
submission
schedule
Remarks


SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
PAGE 43 OF 45

ANNEXURE-IV
DOC. NO.:
REV. NO.:
DATE :
Project : Stage :
Contractor :
Contractor No. :
System :
FIELD WELDING SCHEDULE
(To be raised by the contractor)
Welding Code:
PAGE : OF
Dimensio
ns
Heat treatment REF Sl.
No.
DRG No. for Weld
Location and
Identification mark
Descript
ion of
parts to
welded
Matl.
Spec.

Process
of
welding
Type of
Weld
Electrode
filler
spec.
WPS.
No.
Min.
pre-
heat Temp. Holdin
g time
NDT
method/
Quantum Spec.
No.
ACC Norm
Ref.
Remarks

NOTES:
SIGNATURE

SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
PAGE 44 OF 45

ANNEXURE-V
MANUFACTURING QUALITY PLAN

MFGR.s
LOGO
MANUFACTURERS NAME AND
ADDRESS
ITEM :

SUB-SYSTEM:
QP NO.:
REV.NO.:
DATE:
PAGE: . OF.
PROJECT :
PACKAGE :
CONTRACT NO. :
MAIN-SUPPLIER:
QUANTUM
OF
CHECK REMARKS

SL.
NO

COMPONENT &
OPERATIONS

CHARACTERISTICS

CLASS

TYPE
OF
CHECK

M C /
N
REFERENC
E
DOCUMENT

ACCEPTANC
E
Norms

Format of
Record

M C N
1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.

DOC. NO.: REV CAT..

MANUFACTURER/
SUB-SUPPLIER
MAIN-SUPPLIER

SIGNATURE
LEGEND: * RECORDS, INDENTIFIED WITH TICK ( ) SHALL BE
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, N: NTPC
P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE,
CHP: NTPC SHALL IDENTIFIED IN COLUM N AS W
FOR
NTPC
USE REVIEWED BY APPROVED BY APPROVAL
SEAL
FORMAT NO.: QS-01-QAI-P-09/F1-R1 1/1 ENGG. DIV./QA&I

SECTION VI, PART-C
BID DOC NO.:CS-0260-156-2(R)
GENERAL TECHNICAL
REQUIREMENTS
PAGE 45 OF 45

ANNEXURE-VI
FIELD QUALITY PLAN

MFGR.s
LOGO
SUPPLIERS NAME AND
ADDRESS ITEM :

SUB-SYSTEM :
QP NO.:
REV.NO.:
DATE:
PAGE: . OF.
PROJECT :
PACKAGE :
CONTRACT NO. :
MAIN-SUPPLIER:
SL.
NO

ACTIVITY AND
OPERATION

CHARACTERISTICS /
INSTRUMENTS

CLASS#
OF
CHECK

TYPE
OF
CHECK

QUANTU
M
OF
CHECK

REFERENC
E
DOCUMENT

ACCEPTANCE
NORMS

FORMAT OF
RECORD

REMARKS
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.

DOC. NO.:
REV

MANUFACTURER/
SUB-SUPPLIER
MAIN-
SUPPLIER

SIGNATURE
LEGEND: * RECORDS, INDENTIFIED WITH TICK ()
SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA
DOCUMENTATION.
LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR,
C=MINOR;
A SHALL BE WITNESSED BY NTPC FQA, B SHALL BE
WITNESSED BY NTPC ERECTION / CONSTRUCTION
DEPTT. AND C SHALL BE WITNESSED BY ERECTION
SUPPLIER (A & B CHECK SHALL BE NTPC CHP STAGE)

FOR
NTPC
USE REVIEWED BY APPROVED
BY
APPROVAL
SEAL
Format No.: QS-01-QAI-P-09/F2-r0 1/1 Engg. Div./QA&I

BID DOCUMENT NO.: CS-0260-156-2(R)
SECTION-VI
PART-D

PART - D

ERECTION CONDITIONS OF CONTRACT

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 1 OF 40


1.00.00 GENERAL

1.01.00 The following provisions shall supplement the conditions already contained in the
other parts of these specifications and documents and shall govern that portion of the
work of this contract which is to be performed at site. The erection requirements and
procedures not specified in these documents shall be in accordance with the
recommendations of the equipment manufacturer, or as mutually agreed to between
the Employer and the Contractor prior to commencement of erection work.

1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project Co-
ordinator, nominate another responsible officer as his representative at Site suitably
designated for the purpose of overall responsibility and co-ordination of the Works to
be performed at Site. Such a person shall function from the Site office of the
Contractor during the pendency of Contract.

2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES

2.01.00 In addition to the local laws and regulations, the Contractor shall also comply with the
Minimum Wages Act and the Payment of Wages Act (both of the Government of
India) and the rules made there under in respect of its labour and the labour of its
sub-contractors currently employed on or connected with the contract.

2.02.00 All registration and statutory inspection fees, if any, in respect of his work pursuant to
this Contract shall be to the account of the Contractor. However, any registration,
statutory inspection fees lawfully payable under the provisions of the Indian Boiler
Regulations and any other statutory laws and its amendments from time to time
during erection in respect of the plant equipment ultimately to be owned by the
Employer, shall be to the account of the Employer. Should any such inspection or
registration need to be re-arranged due to the fault of the Contractor or his Sub-
Contractor, the additional fees for such inspection and/or registration shall be borne
by the Contractor.

3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING

The welding of all pressure parts and high pressure piping shall be in accordance
with the following requirements :

3.01.00 Qualification of Weld Procedures

Only qualified welding procedures as per ASME Section IX shall be used by
contractor at site. Procedure qualification records along with WPS shall be submitted
to NTPC for review. Welding procedure shall indicate all essential and non-essential
parameters as per ASME Section IX. Makes of welding consumables shall be subject
to employers approval.

3.02.00 Welder's Qualification

Only welders, who are qualified in accordance with the latest applicable requirements
of the Indian Boiler Regulations, shall be permitted to perform any welding work on

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 2 OF 40

the pressure parts and its attachment welding. In addition to such statutory
qualification requirements, the welders shall also undergo a satisfactory pre-
production qualification test to be conducted by the Contractor at site as per ASME
Sec IX in presence of employers representative(s), prior to performing work under
these specifications. The services of an independent testing laboratory shall be
retained by the Contractor to perform welder qualification tests for welders.

All the welders carrying out welding at site shall carry an identification badge, which
shall indicate the category and the grade of welding for which they have been tested
and authorised to carry out welding. All such badges shall be countersigned by the
Employer.

3.03.00 Records

Welders performance shall be monitored regularly and record of their performance
shall be maintained by contractor in a manner acceptable to the employer.
Contractor shall maintain such records including record of procedure qualification &
welder qualification and hand-over to the employer at the end of work.

3.04.00 Marking

On completion of each welded joint, the welder shall mark his regularly assigned
identification mark near the joint. The welder's identification numbers, inspection
stamps or code symbol stamps and any other information shall not be directly
stamped on any alloy steel piping. In alloy steel piping, all such information shall be
stamped on separate marking plate which shall be tack welded on pipe near the
weld.

4.00.00 HEAT TREATMENT

4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds, shall be
performed in accordance with the requirements of applicable code. Local post weld
stress relieving heat - treatments shall be adopted only in cases where it is normally
impracticable to subject the entire assembly as such for stress relieving operations.
Heating may be by means of electric induction coils or electric resistance coils. Oxy-
acetylene flame heating or exothermic chemical heating methods will not be
permitted. Complete recording of the temperatures through out the stress relieving
cycle of the material and the weld subjected to heat treatment shall be made by
means of a potentiometric recorder. Recorders other than those of potentiometric
type shall not be used for such temperature recording during stress relieving
operations.

The contractor & employers representative, at start and at the end of HT Cycle shall
sign the time and temperature charts for heat-treatment.

4.02.00 After setting up the weld joint for heat treatment operation, the Employer's signature
shall be obtained on the strips chart of the recorder prior to starting of heat treatment
cycle. The right hand corner of the strip chart at the starting point of the heat
treatment cycle shall contain details like the weld number, material, diameter and
thickness, method of heating adopted, prescribed ranges of heat treatment

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 3 OF 40

temperatures, date of heat treatment, reference to item number of the Field welding
Schedule (as specified at clause no 7.00.00- of this chapter) etc.

5.00.00 WELD EDGE PREPARATION

Preparation at site of weld joint shall be in accordance with details acceptable to the
Employer. Wherever possible, machining or automatic flame cutting shall be used for
edge preparation. Hand flame cutting will be permitted only where edge preparation
otherwise is impractical. All slag shall be removed from cuts and all the hand cuts
shall be ground smooth to the satisfaction of the Employer. Flame cutting of alloy
steel pipe shall be avoided. Wherever such cutting is done, a 200mm length at the
cut face shall be removed by machining. Pneumatic hand tools such as edge
preparation, tube cutting machine can be used.

6.00.00 CLEANING AND SERVICING

6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose
scales before being erected. All the pipelines shall be thoroughly blown and/or
flushed. Each steam and water tubes shall be blown with compressed air and shall
be subjected to 'ball test' before erection to ensure that no obstructions exist. A
system for recording of all such operations shall be developed and maintained in a
manner to ensure that no obstructions are left inside the tubes and no tubes are left
uncleaned and untested.

6.02.00 All valves and valve actuators, and dampers and damper actuators, if any, shall be
thoroughly cleaned and serviced prior to pre-commissioning tests and/or Initial
Operations of the plant. A system for recording of such servicing operation shall be
developed and maintained in a manner acceptable to the Employer and to ensure
that no valves or dampers including their actuators are left unserviced.

6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing - up to
remove all traces of oil preservations.

7.00.00 FIELD WELDING SCHEDULE

The Contractor shall submit to the Employer, a certified and complete field welding
schedule for all the field welding activities to be carried out in respect of the pressure
parts involved in the equipment furnished and erected by him, at least 90 days prior
to the scheduled start of erection work at site. Such schedule will be strictly followed
by the Contractor during the process of erection. The above field-welding schedule to
be issued by the Contractor shall contain the following:

(a.) Drawing No (s)
(b.) Location of the weld
(c.) Size of the weld (outside diameter and thickness)
(d.) Type of joints
(e.) Material specifications
(f.) Size of fillet on backing ring, when the type of joint is with backing ring

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 4 OF 40

(g.) Electrode/ filler metal specifications
(h.) Number of welds per unit
(i.) Quantity of filler metal per weld
(j.) Indication of required Non-destructive Examination (NDE) for each weld
(k.) Pre-heat temperatures for welding
(l.) Process of welding
(m.) Post-welding heat treatment temperature ranges, duration, under as specified
at clause no 4.00.00- of this chapter entitled "Heat Treatment".
(n.) Qualification details of weld procedures to be adopted as specified under as
specified at clause no 3.01.00- of this chapter entitled 'Qualification of Weld
Procedures'.

8.00.00 SITE RUN MISCELLANEOUS PIPING

Sketches or diagrams of the proposed routings of all piping, not already indicated
and routed on the shop drawings which were reviewed by the Employer, shall be
submitted to the Employer for review, Employer's acceptance of such site routings
shall be obtained before the piping is erected. All these site run piping shall be
installed in such a manner as to present an orderly and neat installation. They shall
be located as to avoid obstruction of access and passages. Valves, instruments or
any other special items shall be located convenient for operation by the operating
personnel. Pipe runs shall be plumb or level except where pitch for drainage is
required. Pipe runs that are not parallel to the building structure, walls or column
rows shall be avoided so that deflection of pipes between hangers does not exceed 6
mm. No miscellaneous pipe shall be routed and installed above or adjacent to
electrical equipment.

9.00.00 THERMAL EXPANSIONS

All piping installation shall be such that no excessive or destructive expansion forces
exist either in the cold condition or under condition of maximum temperature. All
bends, expansion joints and any other special fittings, necessary to provide proper
expansion, shall be incorporated. During installation of expansion joints and anchors,
care must be taken to make sure that full design movement is available at all times
for maximum to minimum temperature and vice-versa.

10.00.00 PIPING SUPPORTS

10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,
reliable and complete pipe installation. All supports shall be properly leveled and
anchored when installed. The anchors shall be so placed that thermal expansion will
be absorbed by bends without subjecting the valves or equipment to excessive
strains.

10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the
pipe into place. Other means shall be used to securely hold the pipe in place till the
pipe support is completely assembled and attached to the pipe and building

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 5 OF 40

structures and spring support is set to accommodate the pipe way. All temporary
rigging shall be removed in such a way that the pipe support is not subjected to any
sudden load. All piping, having variable spring type supports, shall be held securely
in place by temporary means during the hydraulic test of pipe system. Constant
support type spring hangers used during hydraulic test shall be pinned or blocked
solid during the test. After complete installation and insulation of the piping and filling
of the piping with its normal operating medium, the pipe support springs shall be
adjusted to the cold positions. If necessary, the spring support shall be re-adjusted to
the hot positions after the line has been placed for service at its normal maximum
operating temperature conditions. Electric arc welding only shall be used to weld all
pipe supports to structural steel members that form part of the building supporting
structure. The structural beams shall not be heated more than necessary during
welding of supports and such welds shall run parallel to the axis of the span. All lugs
or any other attachments welded to the piping shall be of the same material as the
pipe.

11.00.00 PRESSURE TESTING

11.01.00 On completion of erection of pressure parts, a hydraulic test in accordance with the
requirements of the Indian Boiler Regulations shall be performed by the Contractor.

11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the
pressure parts shall be tested along with pressure parts. All blank flanges or any
removable plugs required for openings not closed by the valves, and piping provided,
shall be furnished by the Contractor. The pressurization equipment including water
piping from the supply, needed for the above test shall also be furnished by the
Contractor. Any defects noticed during the testing are to be rectified and the unit re-
tested. If any welding is done on the pressure parts after the Hydraulic test, the
Hydraulic test for that portion of pressure parts shall be repeated.

11.03.00 Thy hydraulic test shall be considered successful only on certification to that effect by
the concerned inspecting Authority as per the provisions of the Indian Boiler
Regulations and the Employer.

12.00.00 THERMOWELLS AND FLOW NOZZLES

12.01.00 All the thermowells and flow nozzles in the equipment furnished under the technical
specifications shall be installed as a part of this work.

12.02.00 All thermowell connections incorporated in the steam service shall be plugged during
the pressure testing and the blow out of steam piping systems. Upon completion of
the blow out operation, all thermowells shall be installed and seam welded. Similarly,
all flow nozzles in the steam lines shall also be installed only on completion of steam
blowing operations unless otherwise agreed to by the Employer, depending upon the
sequence of cleaning and purging operations to be adopted by the Contractor at the
field.

13.00.00 INSULATION, LAGGING AND CLADDING

The provision of insulation, lagging and cladding of the various equipments and
portion of the equipment covered under the Contract, shall be furnished by the

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 6 OF 40

Contractor as specified elsewhere or agree to separately in writing. Welds required
for holding insulation on pressure parts shall be carried out by IBR qualified welder.

13.01.00 Protection of Equipment during Insulation Applications

All equipment and structures shall be suitably protected from damage while applying
insulation after completion of insulation. All equipment and structures shall be
thoroughly cleaned and remove insulating materials which might have fallen on them.

14.00.00 CODE REQUIREMENTS

The erection requirements and procedures to be followed during the installation of
the equipment shall be in accordance with the relevant Indian Electricity Rules &
Codes, Indian Boiler Regulations, ASME codes and accepted good practices, the
Employer's Drawings and other applicable Indian recognised codes and laws and
regulations of the Government of India.

15.00.00 ELECTRICAL SAFETY REGULATIONS

15.01.00 In no circumstances will the Contractor interfere with fuses and electrical equipment
belonging to the other Contractor or Employer.

15.02.00 Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other Contractor or Employer, he shall:

(a.) Satisfy the Employer that the appliance is in good working condition;

(b.) Inform the Employer of the maximum current rating, voltage and phases of the
appliances;

(c.) Obtain permission of the Employer detailing the socket to which the appliances
may be connected.

The Employer will not grant permission to connect until he is satisfied that

(a) The appliance is in good condition and is fitted with a suitable plug.

(b) The appliance is fitted with a suitable cable having two earth conductors, one of
which shall be an earthed metal sheath surrounding the cores.

15.03.00 No electric cable in use by the other Contractor/ Employer will be disturbed without
permission. No weight of any description will be imposed on any such cable and
ladder or similar equipment will rest against or be attached to it.

15.04.00 No repair work shall be carried out on any live equipment. The equipment must be
declared safe by the Employer and a permit to work issued before any work is carried
out.

15.05.00 The Contractor shall employ the necessary number of qualified, full time electricians
to maintain his temporary electrical installation.

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 7 OF 40

16.00.00 REMOVAL OF MATERIAL

No material brought to the Site shall be removed from the Site by the Contractor
and/or his Sub-Contractors without the prior written approval of the Employer.

17.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES

The provisions of the clause entitled Inspection, Testing and Inspection Certificates
given in Part - C of the Technical Specification, shall also be applicable to the
erection portion of the Works. The Employer shall have the right to re-inspect any
equipment though previously inspected and approved by him at the Contractors
works, before and after the same are erected at Site. If by the above inspection, the
Employer rejects any equipment, the Contractor shall make good for such rejections
either by replacement or modification/ repairs as may be necessary to the
satisfaction of the Employer. Such replacements will also include the replacements or
re-execution of such of those works of other Contractors and/or agencies, which
might have got damaged or affected by the replacements or re-work done to the
Contractors work.

18.00.00 ACCESS TO SITE AND WORKS ON SITE

18.01.00 Suitable access to site and permission to work at the Site shall be accorded to the
Contractor by the Employer in reasonable time.

18.02.00 In the execution of the Works, no person other than the Contractor or his duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do work
on the Site, except by the special permission, in writing by the Employer or his
representative.

19.00.00 CONTRACTORS SITE OFFICE ESTABLISHMENT

The Contractor shall establish a Office at the Site and keep posted an authorised
representative for the purpose of the Contract. Any written order or instruction of the
Employer or his duly authorised representative shall be communicated to the said
authorised resident representative of the Contractor and the same shall be deemed
to have been communicated to the Contractor at his legal address.

20.00.00 CO-OPERATION WITH OTHER CONTRACTORS

20.01.00 The Contractor shall co-operate with all other Contractors or tradesmen of the
Employer, who may be performing other works on behalf of the Employer and the
workmen who may be employed by the Employer and doing work in the vicinity of the
works under the Contract. The Contractor shall also arrange to perform his work as
to minimise, to the maximum extent possible, interference with the work of other
Contracts and their workmen. Any injury or damage that may be sustained by the
employees of the other Contractors and the Employer, due to the Contractors work
shall promptly be made good at his own expense. The Employer shall determine the
resolution of any difference or conflict that may arise between the Contractor and
other Contractors or between the Contractor and the workmen of the Employer in
regard to their work. If the work of the Contractor is delayed because of the any acts

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 8 OF 40

of omission of another Contractor, the Contractor shall have no claim against the
Employer on that account other than an extension of time for completing his works.
Employer shall have full access to visit the contractors site at any time for inspection
and surveillance checks.

20.02.00 The Employer shall be notified promptly by the Contractor of any defects in the other
Contractors works that could affect the Contractors Works. The Employer shall
determine the corrective measures if any, required to rectify this situation after
inspection of the works and such decisions by the Employer shall be binding on the
Contractor.

21.00.00 DISCIPLINE OF WORKMEN

The Contractor shall adhere to the disciplinary procedure set by the Employer in
respect of his employees and workmen at Site. The Employer shall be at liberty to
object to the presence of any representative or employee of the Contractor at the
Site, if in the opinion of the Employer such employee has mis-conducted himself or is
incompetent, negligent or otherwise undesirable then the Contractor shall remove
such a person objected to and provide in his place a competent replacement.

22.00.00 CONTRACTORS FIELD OPERATION

22.01.00 The Contractor shall keep the Employer informed in advance regarding his field
activity plans and schedules for carrying out each part of the works. Any review of
such plan or schedule or method of work by the Employer shall not relieve the
Contractor of any of his responsibilities towards the field activities. Such reviews
shall also not be considered as an assumption of any risk or liability by the Employer
or any of his representatives and no claim of the Contractor will be entertained
because of the failure or inefficiency of any such plan or schedule or method of work
reviewed. The Contractor shall be solely responsible for the safety, adequacy and
efficiency of plant and equipment and his erection methods.

22.02.00 The Contractor shall have the complete responsibility for the conditions of the Work-
Site including the safety of all persons employed by him or his Sub-Contractor and all
the properties under his custody during the performance of the work. This
requirement shall apply continuously till the completion of the Contract and shall not
be limited to normal working hours. The construction review by the Employer is not
intended to include review of Contractors safety measures in, on or near the Work-
Site, and their adequacy or otherwise.

23.00.00 PHOTOGRAPHS AND PROGRESS REPORT

23.01.00 The Contractor shall furnish three (3) prints each to the Employer of progress
photographs of the work done at Site. Photographs shall be taken as and when indi-
cated by the Employer or his representative. Photographs shall be adequate in size
and number to indicate various stages of erection. Each photograph shall contain
the date, the name of the Contractor and the title of the photograph.

23.02.00 The above photographs shall accompany the monthly progress report detailing out
the progress achieved on all erection activities as compared to the schedules. The
report shall also indicate the reasons for the variance between the scheduled and

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 9 OF 40

actual progress and the action proposed for corrective measures, wherever
necessary.
23.03.00 The Contractor shall submit the progress of work in video cassettes (2 copies)
quarterly highlighting the progress and constraints at site.
24.00.00 MAN-POWER REPORT
24.01.00 The Contractor shall submit to the Employer, on the first day of every month, a man
hour schedule for the month, detailing the man hours scheduled for the month, skill-
wise and area-wise.
24.02.00 The Contractor shall also submit to the Employer on the first day of every month, a
man power report of the previous month detailing the number of persons scheduled
to have been employed and actually employed, skill- wise and the areas of
employment of such labour.
25.00.00 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it is finally
taken over by the Employer. No claim will be entertained by the Employer or the
representative of the Employer for any damage or loss to the Contractors works and
the Contractor shall be responsible for complete restoration of the damaged works to
original conditions to comply with the specification and drawings. Should any such
damage to the Contractors Works occur because of other party not being under his
supervision or control, the Contractor shall make his claim directly with the party
concerned. If disagreement or conflict or dispute develops between the Contractor
and the other party or parties concerned regarding the responsibility for damage to
the Contractors Works the same shall be resolved as per the provisions of the as
specified at clause no 20.00.00- of this chapter entitled Co-operation with other
Contractors. The Contractor shall not cause any delay in the repair of such
damaged Works because of any delay in the resolution of such disputes. The
Contractor shall proceed to repair the Work immediately and no cause thereof will be
assigned pending resolution of such disputes.
26.00.00 EMPLOYMENT OF LABOUR
26.01.00 In addition to all local laws and regulations pertaining to the employment of labour to
be complied with by the Contractor pursuant to GCC, the Contractor will be expected
to employ on the work only his regular skilled employees with experience of the
particular work. No female labour shall be employed after darkness. No person below
the age of eighteen years shall be employed.
26.02.00 All travelling expenses including provisions of all necessary transport to and from
Site, lodging allowances and other payments to the Contractors employees shall be
the sole responsibility of the Contractor.
26.03.00 The hours of work on the Site shall be decided by the Employer and the Contractor
shall adhere to it. Working hours will normally be eight (8) hours per day - Monday
through Saturday.

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26.04.00 Contractors employees shall wear identification badges while on work at Site.
26.05.00 In case the Employer becomes liable to pay any wages or dues to the labour or any
Government agency under any of the provisions of the Minimum Wages Act,
Workmen Compensation Act, Contact Labour Regulation Abolition Act or any other
law due to act of omission of the Contractor, the Employer may make such payments
and shall recover the same from the Contractors Bills.
27.00.00 FACILITIES TO BE PROVIDED BY THE EMPLOYER
27.01.00 Space
The Contractor shall advise the Employer within thirty (30) days from the date of
acceptance of the Notification of Award about his exact requirement of space for his
office, storage area, pre-assembly and fabrication areas, labour and staff colony
area, toilets, etc. The above requirement shall be reviewed by the Employer and
space as decided by Employer will be allotted to the Contractor for construction of
his temporary structures/ facilities like office, storage sheds, pre-assembly and
fabrication areas, toilets, etc. for Contractor's as well as his Sub-Contractors use.
Land for staff and labour colony shall not be provided by the owner and bidder has to
make his own arrangement for the same at his own cost.
27.02.00 Electricity
The Contractor shall submit to the Employer within thirty (30) days from the date of
acceptance of the Notification of Award, his electrical power requirements, if any, to
allow the planning of the same by the Employer. The Contractor shall be provided
with free supply of electricity for the purposes of the Contract, only at two locations in
the Employer's Site and at 415V voltage level. The Contractor shall make his own
further distribution arrangement. All temporary wiring must comply with local
regulations and will be subject to Employer's inspection and approval before
connection to supply. The free supply of power will not be provided for the use in the
labour and staff colony. Power supply for labour and staff colony shall be provided at
one point and the Contractor shall be charged at rates prevalent at the site.
27.03.00 Water
Contractor shall make all arrangements himself for the supply of construction water
as well as potable water for labour and other personnel at the worksite/colony.
27.04.00 Communication
The Employer will extend the telephone facilities, if available at Site, for purposes of
Contract. The Contractor shall be charged at actuals for such facilities.
28.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
28.01.00 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an authorized
representative for the purpose of the contract, pursuant to GCC.

28.02.00 Tools, tackles and scaffoldings

The Contractor shall provide all the construction equipments, tools, tackles and
scaffoldings required for pre-assembly, installation, testing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He shall

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submit a list of all such materials to the Employer before the commencement of pre-
assembly at Site. These tools and tackles shall not be removed from the Site without
the written permission of the Employer. The Contractor shall arrange Dozer, Hydra,
Cranes, Trailer, etc. for the purpose of fabrication, erection and commissioning.
28.03.00 Testing Equipment and Facilities:
The contractor shall provide the necessary testing, equipment and facilities.
28.04.00 Site laboratory for civil works:
Contractor shall provide and maintain a site laboratory for the testing of construction
material under the direction and general supervision of employer.
28.05.00 First-aid
28.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. Enough number of Contractors
personnel shall be trained in administering first-aid.

28.05.02 The Employer will provide the Contractor, in case of any emergency, the services of
an ambulance for transportation to the nearest hospital.

28.06.00 Cleanliness

28.06.01 The Contractor shall be responsible for keeping the entire area allotted to him clean
and free from rubbish, debris etc. during the period of Contract. The Contractor shall
employ enough number of special personnel to thoroughly clean his work-area at
least once in a day. All such rubbish and scrap material shall be stacked or disposed
in a place to be identified by the Employer. Materials and stores shall be so arranged
to permit easy cleaning of the area. In areas where equipment might drip oil and
cause damage to the floor surface, a suitable protective cover of a flame resistant, oil
proof sheet shall be provided to protect the floor from such damage.

28.06.02 Similarly the labour colony, the offices and the residential areas of the Contractors
employees and workmen shall be kept clean and neat to the entire satisfaction of the
Employer. Proper sanitary arrangements shall be provided by the Contractor, in the
work-areas, office and residential areas of the Contractor.

29.00.00 LINES AND GRADES

All the Works shall be performed to the lines, grades and elevations indicated on the
drawings. The Contractor shall be responsible to locate and layout the Works.
Basic horizontal and vertical control points will be established and marked by the
Employer at Site at suitable points. These points shall be used as datum for the
works under the Contract. The Contractor shall inform the Employer well in advance
of the times and places at which he wishes to do work in the area allotted to him so
that suitable datum points may be established and checked by the Employer to
enable the Contractor to proceed with his works. Any work done without being
properly located may be removed and/or dismantled by the Employer at Contractors
expense.

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30.00.00 FIRE PROTECTION

30.01.00 The work procedures that are to be used during the erection shall be those which
minimise fire hazards to the extent practicable. Combustible materials, combustible
waste and rubbish shall be collected and removed from the Site at least once each
day. Fuels, oils and volatile or flammable materials shall be stored away from the
construction and equipment and materials storage areas in safe containers.
Untreated canvas, paper, plastic or other flammable flexible materials shall not at all
be used at Site for any other purpose unless otherwise specified. If any such
materials are received with the equipment at the Site, the same shall be removed
and replaced with acceptable material before moving into the construction or storage
area.

30.02.00 Similarly corrugated paper fabricated cartons etc. will not be permitted in the
construction area either for storage or for handling of materials. All such materials
used shall be of water proof and flame resistant type. All the other materials such as
working drawings, plans etc. which are combustible but are essential for the works to
be executed shall be protected against combustion resulting from welding sparks,
cutting flames and other similar fire sources.

30.03.00 All the Contractors supervisory personnel and sufficient number of workers shall be
trained for fire-fighting and shall be assigned specific fire protection duties. Enough of
such trained personnel must be available at the Site during the entire period of the
Contract.

30.04.00 The Contractor shall provide enough fire protection equipment of the types and
number for the warehouses, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all time.

31.00.00 SECURITY

The Contractor shall have total responsibility for all equipment and materials in his
custody stores, loose, semi-assembled and/or erected by him at Site. The Contractor
shall make suitable security arrangements including employment of security
personnel to ensure the protection of all materials, equipment and works from theft,
fire, pilferage and any other damages and loss. All materials of the Contractor shall
enter and leave the Employer Site only with the written permission of the Employer in
the prescribed manner.

32.00.00 CONTRACTORS AREA LIMITS

The Employer will mark-out the boundary limits of access roads, parking spaces,
storage and construction areas for the Contractor and the Contractor shall not
trespass the areas not so marked out for him. The Contractor shall be responsible to
ensure that none of his personnel move out of the areas marked out for his
operations. In case of such a need for the Contactors personnel to work out of the
areas marked out for him the same shall be done only with the written permission of
the Employer.

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33.00.00 CONTRACTORS CO-OPERATION WITH THE EMPLOYER

In case where the performance of the erection work by the Contractor affects the
operation of the system facilities of the Employer, such erection work of the
Contractor shall be scheduled to be performed only in the manner stipulated by the
Employer and the same shall be acceptable at all times to the Contractor. The
Employer may impose such restrictions on the facilities provided to the Contractor
such as electricity, etc. as he may think fit in the interest of the Employer and the
Contractor shall strictly adhere to such restrictions and co-operate with the Employer.
It will be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and operation
of the equipment systems which are erected by him. The Contractor shall also be
responsible for flushing and initial filling of all the oil and lubricants required for the
equipment furnished and installed by him, so as to make such equipment ready for
operation. The Contractor shall be responsible for supplying such flushing oil and
other lubricants unless otherwise specified elsewhere in documents and
specifications.

34.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES

34.01.00 General

34.01.01 The Contractor upon completion of installation of equipments and systems shall
conduct pre-commissioning and commissioning activities, to make the
equipment/systems ready for safe, reliable and efficient operation on sustained basis.
All pre-commissioning/commissioning activities considered essential for such
readiness of the equipment/systems including those mutually agreed and included in
the Contractors quality assurance programme as well as those indicated in clauses
elsewhere in the technical specifications shall be performed by the contractor.

34.01.02 The pre-commissioning and commissioning activities including Guarantee tests,
checks and trial operations of the equipment/systems furnished and installed by the
contractor shall be the responsibility of the Contractor as detailed in relevant clauses
in Technical Specification. The Contractor shall provide, in addition, test instruments,
calibrating devices etc. and labour required for successful performance of these
operations. If it is anticipated that the above test may prolong for a long time, the
Contractors workmen required for the above test shall always be present at site
during such operations.

34.01.03 The following activities shall be carried out by the contractor, 18 month prior to
schedule date of commissioning of the equipment/systems installed by him.

(a.) The contractor shall furnish the organization chart of his operation and
commissioning engineers for the acceptance of employer. Adequate number of
operation and commissioning engineers shall be deployed by the contractor to
effectively meet the requirement of round the clock operation in shifts also, till
the plant is taken over by the employer.

(b.) The contractor shall submit the bio-data containing the details of experience of
his operation and commissioning engineers for the acceptance of employer.

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(c.) The contractor shall furnish the deployment schedule of his operation and
commissioning engineers for the acceptance of the employer.

(1.) Apart from above, contractor shall ensure deployment of sufficient
skilled/semi-skilled/unskilled manpower during pre-commissioning and
commissioning activities.

34.01.04 It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial
operation of the equipment/systems which are installed by him.

34.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils and
lubricants required for the equipment furnished and installed by him so as to make
such equipment ready for operation. The Contractor shall be responsible for
supplying such flushing oil and other lubricants unless otherwise specified elsewhere
in these specifications and documents.

34.02.00 Commissioning Documentation

34.02.01 The contractor shall submit the commissioning documentation, comprising of
Standard checklists, pre-commissioning procedures, testing schedules,
commissioning schedules and commissioning networks for various
equipment/systems covered under the contract, for the approval of employer.

34.02.02 Standard checklist, as the name suggests, shall be a fairly general documents,
containing the list of all checks required to be carried out for similar and repetitive
type of equipment to ensure consistent and thorough checking. An indicative list of
such equipment is enclosed as Annexure I.

34.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system Commissioning schedule is a
document envisaged for commissioning of a system the testing/Commissioning
schedule shall have a standard format in order to maintain consistency of
presentation, content and reporting. A brief write up on the contents of the Testing
Schedule/Commissioning Schedule is enclosed as Annexure-II.

34.02.04 The contractor shall submit the list of commissioning documentation to be submitted
by him, alongwith their submission schedule for various equipment/systems covered
under the contract, with in 6(six) month from the date of award of contract, for the
acceptance of employer.

34.02.05 The Contractor shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of employer, at least 18
months before the scheduled date of commissioning of the equipment/systems.

34.03.00 Commissioning Activities

34.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall initiate
commissioning of facilities. During commissioning the Contractor shall carry out
system checking and reliability trials on various parts of the facilities.

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34.03.02 Contractor shall carry out the checks/tests at site to prove to the Employer that each
equipment of the supply complies with requirements stipulated and is installed in
accordance with requirements specified.

34.03.03 Before the plant is put into initial operation the Contractor shall be required to
conduct test to demonstrate to the Employer that each item of the plant is capable of
correctly performing the functions for which it was specified and its performance,
parameters etc. are as per the specified/approved values. These tests may be
conducted concurrently with those required under commissioning sequence.

34.03.04 Other tests shall be conducted, if required by the Employer, to establish that the plant
equipment are in accordance with requirements of the specifications.

34.03.05 The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including
all electrical equipment/systems not specifically brought out above but are within the
scope of work and facilities being supplied and installed by the Contractor and follow
the guidelines indicated above or elsewhere in these technical specifications(Section-
VI)

34.04.00 Initial Operation

Upon completion of system checking/Tests as above and as a part of commissioning
of facilities, complete plant/facilities shall be put on initial operation as stipulated in
General Technical Requirements.

35.00.00 MATERIALS HANDLING AND STORAGE

35.01.00 All the equipments furnished under the Contract and arriving at Site shall be promptly
received, unloaded and transported and stored in the storage spaces by the
Contractor.

35.02.00 Contractor shall be responsible for examining all the shipment and notify the
Employer immediately of any damage, shortage, discrepancy etc. for the purpose of
Employer's information only. The Contractor shall submit to the Employer every
week a report detailing all the receipts during the week. However, the Contractor
shall be solely responsible for any shortages or damage in transit, handling and / or
in storage and erection of the equipment at Site. Any demurrage, wharfage and other
such charges claimed by the transporters, railways etc. shall be to the account of the
Contractor.

35.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the list
of all equipment received by him for the purpose of erection and keep such record
open for the inspection of the Employer.

35.04.00 All equipment shall be handled very carefully to prevent any damage or loss. No bare
wire ropes, slings, etc. shall be used for unloading and/or handling of the equipment
without the specific written permission of the Employer. The equipment stored shall
be properly protected to prevent damage either to the equipment or to the floor where
they are stored. The equipment from the store shall be moved to the actual location
at the appropriate time so as to avoid damage of such equipment at Site.

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35.05.00 All electrical panels, controls gear, motors and such other devices shall be properly
dried by heating before they are installed and energised. Motor bearings, slip rings,
commutators and other exposed parts shall be protected against moisture ingress
and corrosion during storage and periodically inspected. Heavy rotating parts in
assembled conditions shall be periodically rotated to prevent corrosion due to
prolonged storage.

35.06.00 All the electrical equipment such as motors, etc. shall be tested for insulation
resistance at least once in three months from the date of receipt till the date of
commissioning and a record of such measured insulation values maintained by the
Contractor. Such records shall be open for inspection by the Employer.

35.07.00 The Contractor shall ensure that all the packing materials and protection devices
used for the various equipments during transit and storage are removed before the
equipment are installed.

35.08.00 The consumables and other supplies likely to deteriorate due to storage must be
thoroughly protected and stored in a suitable manner to prevent damage or dete-
rioration in quality by storage.

35.09.00 All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flameproof covering material wherever applicable.

35.10.00 If the materials belonging to the Contractor are stored in areas other than those
earmarked for him, the Employer will have the right to get it moved to the area
earmarked for the Contractor at the Contractors cost.

35.11.00 The Contractor shall be responsible for making suitable indoor storage facilities to
store all equipment which require indoor storage. Normally, all the electrical
equipments such as motors, control gear, exciters and consumables like electrodes,
lubricants etc. shall be stored in the closed storage space. The Employer, in addition,
may direct the Contractor to move certain other materials, which in his opinion will
require indoor storage, to indoor storage areas which the Contractor shall strictly
comply with.

36.00.00 CONSTRUCTION MANAGEMENT

36.01.00 The field activities of the Contractors working at Site, will be coordinated by the
Employer and the Employer decision shall be final in resolving any disputes or
conflicts between the Contractor and other Contractors and tradesmen of the
Employer regarding scheduling and coordination of work. Such decision by the
Employer shall not be a cause for extra compensation or extension of time for the
Contractor.

36.02.00 The Employer shall hold weekly meetings of all the Contractors working at Site, at a
time and place to be designated by the Employer. The Contractor shall attend such
meetings and take notes of discussions during the meeting and the decisions of the
Employer and shall strictly adhere to those decisions in performing his Works. In
addition to the above weekly meeting, the Employer may call for other meeting either
with individual Contractors or with selected number of Contractors and in such a case
the Contractor if called, will also attend such meetings.

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36.03.00 Time is the essence of the Contract and the Contractor shall be responsible for
performance of his works in accordance with the specified construction schedule. If
at any time, the Contractor is falling behind the schedule, he shall take necessary
action to make good for such delays by increasing his work force or by working
overtime or otherwise accelerate the progress of the work to comply with the
schedule and shall communicate such actions in writing to the Employer, satisfying
that his action will compensate for the delay. The Contractor shall not be allowed any
extra compensation for such action.

36.04.00 The Employer shall however not be responsible for provision of additional labour
and/or materials or supply or any other services to the Contractor except for the co-
ordination work between various Contractors as set out earlier.

37.00.00 FIELD OFFICE RECORDS

The Contractor shall maintain at his Site Office up-to- date copies of all drawings,
specifications and other Contract Documents and any other supplementary data
complete with all the latest revisions thereto. The Contractor shall also maintain in
addition the continuous record of all changes to the above Contract Documents,
drawings, specifications, supplementary data, etc. effected at the field and on
completion of his total assignment under the Contract shall incorporate all such
changes on the drawings and other Engineering data to indicate as installed
conditions of the equipment furnished and erected under the Contract. Such
drawings and Engineering data shall be submitted to the Employer in required
number of copies.

38.00.00 CONTRACTORS MATERIALS BROUGHT ON TO SITE

38.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,
including construction equipment, tools and tackles for the purpose of the Works
under intimation to the Employer. All such goods shall, from the time of their being
brought vest in the Employer, but may be used for the purpose of the Works only and
shall not on any account be removed or taken away by the Contractor without the
written permission of the Employer. The Contractor shall nevertheless be solely
liable and responsible for any loss or destruction thereof and damage thereto.

38.02.00 The Employer shall have a lien on such goods for any sum or sums which may at
any time be due or owing to him by the Contractor, under, in respect of or by reasons
of the Contract. After giving a fifteen (15) days notice in writing of his intention to do
so, the Employer shall be at liberty to sell and dispose off any such goods, in such
manner as he shall think fit including public auction or private treaty and to apply the
proceeds in or towards the satisfaction of such sum or sums due as aforesaid.

38.03.00 After the completion of the Works, the Contractor shall remove from the Site under
the direction of the Employer the materials such as construction equipment, erection
tools and tackles, scaffolding etc. with the written permission of the Employer. If the
Contractor fails to remove such materials, within fifteen (15) days of issue of a notice
by the Employer to do so then the Employer shall have the liberty to dispose off such
materials as detailed under as specified at clause no 38.02.00- of this chapter and
credit the proceeds thereto to the account of the Contractor.

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39.00.00 PROTECTION OF PROPERTY AND CONTRACTORS LIABILITY

39.01.00 The Contractor shall be responsible for any damage resulting from his operations. He
shall also be responsible for protection of all persons including members of public
and employees of the Employer and the employees of other Contractors and Sub-
Contractors and all public and private property including structures, building, other
plants and equipments and utilities either above or below the ground.

39.02.00 The Contractor will ensure provision of necessary safety equipment such as barriers,
sign - boards, warning lights and alarms, etc. to provide adequate protection to
persons and property. The Contractor shall be responsible to give reasonable notice
to the Employer and the Employers of public or private property and utilities when
such property and utilities are likely to get damaged or injured during the
performance of his Works and shall make all necessary arrangements with such
Employers, related to removal and/or replacement or protection of such property and
utilities.

40.00.00 PAINTING

All exposed metal parts of the equipment including pipings, structure railings, etc.
wherever applicable, after installation unless otherwise surface protected, shall be
first painted with at least two coats of suitable primer which matches the shop primer
paint used, after thoroughly cleaning all such parts of all dirt, rust, scales, greases,
oils and other foreign materials by wire brushing, scraping or sand blasting and the
same being inspected and approved by the Employer for painting. Afterwards, the
above parts shall be finished painted with three coats of allowed resin machinery
enamel paints. The minimum thickness of paint film shall not be less than 100
microns. The quality of the finish paint shall be as per the standards of Bureau of
Indian Standards (BIS) or equivalent and to be of the colour as approved by the
Employer.

41.00.00 INSURANCE

41.01.00 In addition to the conditions covered under the Clause entitled Insurance in Section
General Conditions of Contract (GCC), the following provisions will also apply to the
portion of works to be done beyond the Contractors own or his Sub-Contractors
manufacturing Works.

41.02.00 Workmens Compensation Insurance

This insurance shall protect the Contractor against all claims applicable under the
Workmens Compensation Act, 1948 (Government of India). This policy shall also
cover the Contractor against claims for injury, disability disease or death of his or his
Sub-Contractors employees, which for any reason are not covered under the
Workmens Compensation Act, 1948. The liabilities shall not be less than the
following:

Workmen's Compensation - As per Statutory Provisions

Employee's Liability - As per Statutory Provisions

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41.03.00 Comprehensive Automobile Insurance

This insurance shall be in such a form to protect the Contractor against all claims for
injuries, disability, disease and death to members of public including the Employers
men and damage to the property of other arising from the use of motor vehicles
during on or off the Site operations, irrespective of the Ownership of such vehicles.
The liability covered shall be as herein indicated :

Fatal Injury : Rs.100,000 each person

: Rs.200,000 each occurrence

Property Damage : Rs.100,000 each occurrence

41.04.00 Comprehensive General Liability Insurance

41.04.01 The insurance shall protect the Contractor against all claims arising from injuries,
disabilities, disease or death of members of public or damage to property of others,
due to any act or omission on the part of the Contractor, his agents, his employees,
his representatives and Sub-Contractors or from riots, strikes and civil commotion.
This insurance shall also cover all the liabilities of the Contractor arising out of the
Clause entitled Defence of Suits in Section General Conditions of Contract (GCC).

41.04.02 The hazards to be covered will pertain to all the Works and areas where the
Contractor, his Sub-Contractors, his agents and his employees have to perform work
pursuant to the Contract.

41.05.00 The above are only illustrative list of insurance covers normally required and it will be
the responsibility of the Contractor to maintain all necessary insurance coverage to
the extent both in time and amount to take care of all his liabilities either direct or
indirect, in pursuance of the Contract.

42.00.00 UNFAVOURABLE WORKING CONDITIONS

The Contractor shall confine all his field operations to those works which can be
performed without subjecting the equipment and materials to adverse effects during
inclement weather conditions, like monsoon, storms, etc. and during other
unfavourable construction conditions. No field activities shall be performed by the
Contractor under conditions which might adversely affect the quality and efficiency
thereof, unless special precautions or measures are taken by the Contractor in a
proper and satisfactory manner in the performance of such Works and with the
concurrence of the Employer. Such unfavourable construction conditions will in no
way relieve the Contractor of his responsibility to perform the Works as per the
schedule.

43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS

The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc.
which he may come across during the course of performance of his Works either
during excavation or elsewhere, are properly protected and handed over to the
Employer. Similarly the Contractor shall ensure that the bench marks, reference

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points, etc., which are marked either with the help of Employer or by the Employer
shall not be disturbed in any way during the performance of his Works. If, any work is
to be preformed which disturb such reference, the same shall be done only after
these are transferred to other suitable locations under the direction of the Employer.
The Contractor shall provide all necessary materials and assistance for such
relocation of reference points etc.

44.00.00 WORK & SAFETY REGULATIONS

44.01.00 The Contractor shall ensure proper safety of all the workmen, materials, plant and
equipments belonging to him or to Employer or to others, working at the Site. The
Contractor shall also be responsible for provision of all safety notices and safety
equipment required both by the relevant legislation and the Employer as he may
deem necessary.

44.02.00 The Contractor will notify well in advance to the Employer of his intention to bring to
the Site any container filled with liquid or gaseous fuel or explosive or petroleum
substance or such chemicals which may involve hazards. The Employer shall have
the right to prescribe the conditions, under which such container is to be stored,
handled and used during the performance of the works and the Contractor shall
strictly adhere to and comply with such instructions. The Employer shall have the
right at his sole discretion to inspect any such container or such construction
plant/equipment for which material in the container is required to be used and if in his
opinion, its use is not safe, he may forbid its use. No claim due to such prohibition
shall be entertained by the Employer and the Employer shall not entertain any claim
of the Contractor towards additional safety provisions/conditions to be provided
for/constructed as per the Employer's instructions.

Further, any such decision of the Employer shall not, in any way, absolve the
Contractor of his responsibilities and in case, use of such a container or entry thereof
into the Site area is forbidden by the Employer, the Contractor shall use alternative
methods with the approval of the Employer without any cost implication to the
Employer or extension of work schedule.

44.03.00 Where it is necessary to provide and/or store petroleum products or petroleum
mixtures and explosives, the Contractor shall be responsible for carrying-out such
provision and/or storage in accordance with the rules and regulations laid down in
Petroleum Act 1934, Explosives Act, 1948, and Petroleum and Carbide of Calcium
Manual published by the Chief Inspector of Explosives of India. All such storage shall
have prior approval of the Employer. In case, any approvals are necessary from the
Chief Inspector (Explosives) or any statutory authorities, the Contractor shall be
responsible for obtaining the same.

44.04.00 All equipment used in construction and erection by Contractor shall meet
Indian/International Standards and where such standards do not exist, the Contractor
shall ensure these to be absolutely safe. All equipments shall be strictly operated and
maintained by the Contractor in accordance with manufacturers operation Manual
and safety instructions and as per Guidelines/Rules of Employer in this regard.

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44.05.00 Periodical Examinations and all tests for all lifting/ hoisting equipment & tackles shall
be carried-out in accordance with the relevant provisions of Factories Act 1948,
Indian Electricity Act 1910 and associated Laws/Rules in force from time to time. A
register of such examinations and tests shall be properly maintained by the
Contractor and will be promptly produced as and when desired by Employer or by the
person authorised by him.

44.06.00 The Contractor shall be fully responsible for the safe storage of his and his Sub-
Contractors radioactive sources in accordance with BARC/DAE (Bhabha Atomic
Research Centre/ Department of Atomic Energy, Govt. of India) Rules and other
applicable provisions. All precautionary measures stipulated by BARC/DAE in
connection with use, storage and handling of such material will be taken by
Contractor.

44.07.00 The Contractor shall provide suitable safety equipment of prescribed standard to all
employees and workmen according to the need, as may be directed by Employer
who will also have right to examine these safety equipments to determine their
suitability, reliability, acceptability and adaptability.

44.08.00 Where explosives are to be used, the same shall be used under the direct control
and supervision of an expert, experienced, qualified and competent person strictly in
accordance with the Code of Practices/Rules framed under Indian Explosives Act
pertaining to handling, storage and use of explosives.

44.09.00 The Contractor shall provide safe working conditions to all workmen and employees
at the Site including safe means of access, railings, stairs, ladders, scaffoldings etc.
The scaffoldings shall be erected under the control and supervision of an
experienced and competent person. For erection, good and standard quality of
material only shall be used by the Contractor.

44.10.00 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to the Employer or other Contractors under any circumstances,
whatsoever, unless expressly permitted in writing by the Employer to handle such
fuses, wiring or electrical equipment.

44.11.00 Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other Contactor or Employer, he shall:

(a.) Satisfy the Employer that the appliance is in good working condition:

(b.) Inform the Employer of the maximum current rating, voltage and phases of the
appliances;

(c.) Obtain permission of the Employer detailing the sockets to which the
appliances may be connected.

44.12.00 The Employer will not grant permission to connect until he is satisfied that;

(a.) The appliance is in good condition and is fitted with suitable plug;

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(b.) The appliance is fitted with a suitable cable having two earth conductors, one of
which shall be an earthed metal sheath surrounding the cores.

44.13.00 No electric cable in use by the Contractor/Employer will be disturbed without prior
permission. No weight of any description will be imposed on any cable and no ladder
or similar equipment will rest against or attached to it.

44.14.00 No repair work shall be carried out on any live equipment. The equipment must be
declared safe by the Employer and a permit to work shall be issued by the Employer
before any repair work is carried out by the Contractor. While working on electric
lines/equipments whether live or dead, suitable type and sufficient quantity of tools
will have to be provided by Contractor to electricians/workmen/officers.

44.15.00 The Contractors shall employ necessary number of qualified, full time Electricians/
Electrical Supervisors to maintain his temporary electrical installations.

44.16.00 The Contractor employing more than 250 workmen whether temporary, casual,
probationer, regular or permanent or on contract, shall employ atleast one full time
officer exclusively as Safety Officer to supervise safety aspects of the equipments
and workmen, who will coordinate with the Employer Safety Officer. In case of work
being carried out through sub-Contractors, the Sub- Contractors workmen/
employees will also be considered as the Contractors employees/workmen for the
above purpose.

The name and address of such Safety Officer of Contractor will be promptly informed
in writing to Employer with a copy to Safety Officer-Incharge before he starts work or
immediately after any change of the incumbent is made during currency of the
Contract.

44.17.00 In case any accident occurs during the construction/ erection or other associated
activities undertaken by the Contractor thereby causing any minor or major or fatal
injury to his employees due to any reason, whatsoever, it shall be the responsibility of
the Contractor to promptly inform the same to the Employer in prescribed form and
also to all the authorities envisaged under the applicable laws.

44.18.00 The Employer shall have the right at his sole discretion to stop the work, if in his
opinion the work is being carried out in such a way that it may cause accidents and
endanger the safety of the persons and/or property, and/or equipments. In such
cases, the Contractor shall be informed in writing about the nature of hazards and
possible injury/accident and he shall comply to remove shortcomings promptly. The
Contractor after stopping the specific work can, if felt necessary appeal against the
order of stoppage of work to the Employer within 3 days of such stoppage of work
and decision of the Employer in this respect shall be conclusive and binding on the
Contractor.

44.19.00 The Contractor shall not be entitled for any damages/ compensation for stoppage of
work due to safety reasons as provided in para 44.18.00 and the period of such
stoppage of work will not be taken as an extension of time for completion of the
facilities and will not be the ground for waiver of levy of liquidated damages.

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44.20.00 The Contractor shall follow and comply with all Safety Rules of the Employer,
relevant provisions of applicable laws pertaining to the safety of workmen, employees
plant and equipment as may be prescribed from time to time without any demur,
protest or contest or reservation. In case of any inconformity between statutory
requirement and Safety Rules of the Employer referred above, the later shall be
binding on the Contractor unless the statutory provisions are more stringent.

44.21.00 If the Contractor fails in providing safe working environment as per the Employer's
Safety Rules or continues the work even after being instructed to stop work by the
Employer Manager as provided 44.18.00, the Contractor shall promptly pay to the
Employer, on demand by the Employer compensation at the rate of Rs. 5,000/- per
day or part thereof till the instructions are complied with and so certified by the
Employer. However, in case of accident taking place causing injury, to any individual,
the provisions contained in paragraph 44.22.00 shall also apply in addition to
compensation mentioned in this paragraph.

44.22.00 If the Contractor does not take all safety precautions and/or fails to comply with the
Safety Rules as prescribed by the Employer or under the applicable law for the safety
of the equipment and plant and for the safety of personnel and the Contractor does
not prevent hazardous conditions which cause injury to his own employees or
employees of other Contractors, or the Employer's employees or any other person
who are at Site or adjacent thereto, the Contractor shall be responsible for payment
of compensation to Employer as per the following schedule:-

1 Fatal injury or accident These
are causing death applicable
Rs. 1,00,000/-

2 Major injuries or accident
causing 25% or more
permanent disablement to
workmen or employee
Rs. 20,000/-
These are
applicable for
death/ injury to any
person
whomsoever.

Permanent disablement shall have same meaning as indicated in Workmens
Compensation Act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the relevant provisions of
the Workmens Compensation Act and rules framed thereunder or any other
applicable laws as applicable from time to time. In case the Employer is made to pay
such Compensation then the Contractor is liable to reimburse the Employer such
amount in addition to the compensation indicated above.

44.23.00 If the Contractor observes all the Safety Rules and Codes, Statutory Laws and Rules
during the currency of Contract awarded by the Employer and no accident occurs
then the Employer may consider the performance of the Contractor and award
suitable ACCIDENT FREE SAFETY MERITORIOUS AWARD as per scheme as
may be announced separately from time to time.

45.00.00 FOREIGN PERSONNEL

45.01.00 The Contractor shall submit to the Employer data on all personnel he proposes to
bring into India from abroad for the performance of the Works under the Contract, at
least sixty (60) days prior to their departure to India. Such data will include for each

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person the name, his present address, his assignment and responsibility in
connection with the works, and a short resume of his qualification, experience etc. in
relation to the work to be performed by him.

45.02.00 Any person unsuitable and unacceptable to the Employer shall not be brought to
India. Any person brought to India, if found unsuitable or unacceptable by the
Employer, the Contractor shall within a reasonable time make alternate
arrangements for providing a suitable replacement and repatriation of such
unsuitable personnel.

45.03.00 No person brought to India for the purposes of the works shall be repatriated without
the consent of the Employer in writing, based on a written request from the
Contractor for such repatriation giving reasons for such an action to the Employer.
The Employer may give permission for such repatriation provided he is satisfied that
the progress of work will not suffer due to such repatriation.

45.04.00 The cost of passports, visas and all other travel expenses to and from India, incurred
by the Contractor shall be to his account. The Employer will not provide any
residential accommodation and/or furniture for any of the Contractors personnel
including foreign personnel and Contractor shall make his own arrangements for
such facilities in the area allotted at Site, to him by the Employer for that purpose.

45.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws, rules
and regulations and shall not in any way interfere with Indian political and religious
affairs and shall conform to any other rules and regulations which the Government of
India and the Employer may establish from time to time, on them. The Contractors
expatriate personnel shall work and live in close co-operation and coordination with
their co-workers and the community and shall not engage themselves in any other
employment neither part-time or full-time nor shall they take part in any local politics.

45.06.00 The Employer shall assist the Contractor, to the extent possible, in obtaining
necessary permits to travel to India and back, by issue of necessary certificates and
other information needed by the Government agencies.

46.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES

46.01.00 The surfaces of foundations shall be dressed to bring the top surface of the
foundations to the required level, prior to placement of equipment/equipment bases
on the foundations.

46.02.00 All the equipment/ equipment bases, shall be grouted and finished as per these
specifications unless otherwise recommended by the equipment manufacturer.

46.03.00 The concrete foundation surfaces shall be properly prepared by chipping, grinding as
required to bring the top of such foundation to the required level, to provide the
necessary roughness for bondage and to assure enough bearing strength.

46.04.00 Grout

The grout shall be high strength grout with crushing strength one grade higher then
the foundation concrete. Minimum crushing strength shall be 30N/mm
2
unless higher

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strength requirements is specified by the equipment supplier or the grout
manufacturers. The grout shall be chloride - free, cement based, free flowing, non-
metallic grout.

The Grout shall have good flowability even at very low water/ grout powder ratio.

The Grout shall have characteristics of controlled expansion to be able to occupy its
original volume to fill the voids and to compensate for shrinkage. Grout shall be of
pre-mix variety so that only water needs to be added before use.

The mixing of the Grout shall conform to the recommendations of the manufacturer of
the Grout.

46.05.00 Placing of Grout

46.05.01 After the base has been prepared, its alignment and level has been checked and
approved and before actually placing the grout, a low dam shall be set around the
base at a distance that will permit pouring and manipulation of the grout. The height
of such dam shall be at least 25mm above the bottom of the base. Suitable size and
number of chains shall be introduced under the base before placing the grout, so that
such chains can be moved back & forth to push the grout into every part of the space
under the base.

46.05.02 The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides to make the grout move in a solid mass under the
base and out in the opposite side. Pouring shall be continued until the entire space
below the base is thoroughly filled and the grout stands at least 25 mm higher all
around than the bottom of the base. Enough care should be taken to avoid any air or
water pockets beneath the bases.

46.05.03 In addition to the above, recommendations of Grout manufacturer shall also be
followed.

46.06.00 Finishing of the Edges of the Grout

The poured grout should be allowed to stand undisturbed until it is well set.
Immediately thereafter, the dam shall be removed and grout which extends beyond
the edges of the structural or equipment base plates shall be cut off, flushed and
removed. The edges of the grout shall then be pointed and finished with 1:2 cement
mortar pressed firmly to bond with the body of the grout and smoothened with a tool
to present a smooth vertical surface. The work shall be done in a clean and scientific
manner and the adjacent floor spaces, exposed edges of the foundations, and
structural steel and equipment base plates shall be thoroughly cleaned of any
spillage of the grout.

46.07.00 Checking of Equipment After Grouting

After the grout is set and cured, the Contractor shall check and verify the alignment
of equipments, alignment of shafts of rotating machinery, the slopes of all bearing
pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as
applicable and the like items to ensure that no displacement had taken place

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during grouting. The values recorded prior to grouting shall be used during such post
grouting check- up and verifications. Such pre and post grout records of alignment
details shall be maintained by the Contractor in a manner acceptable to the
Employer.

47.00.00 SHAFT ALIGNMENTS

All the shafts of rotating equipment shall be properly aligned to those of the matching
equipments to as perfect an accuracy as practicable. The equipment shall be free
from excessive vibration so as to avoid overheating of bearings or other conditions
which may tend to shorten the life of the equipment. The vibration level of rotating
equipments measured at bearing housing shall not exceed forty (40) microns and
shall conform to VDI 2056.All bearings, shafts and other rotating parts shall be thor-
oughly cleaned and suitably lubricated before starting.

48.00.00 DOWELLING

All the motors and other equipment shall be suitably doweled after alignment of
shafts with tapered machined dowels as per the direction of the Employer.

49.00.00 CHECK OUT OF CONTROL SYSTEMS

After completion of wiring, cabling furnished under separate specification and laid
and terminated by the Employer, the Contractor shall check out the operation of all
control systems for the equipment furnished and installed under these specifications
and documents.

50.00.00 COMMISSIONING SPARES

50.01.00 It will be the responsibility of the Contractor to provide all commissioning spares
including consumable spares required for initial operation till the Completion of
Facilities. The Contractor shall furnish a list of all commissioning spares within 60
days from the date of Notification of Award and such list shall be reviewed by the
Employer and mutually agreed to. However. such review and agreement will not
absolve the Contractor of his responsibilities to supply all commissioning spares so
that initial operation do not suffer for want of commissioning spares. All
commissioning spares shall be deemed to be included in the scope of the Contract at
no extra cost to the Employer.

50.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to
the schedule date of commencement of initial operation of the respective equipment
and utilised as and when required. The unutilised spares and replaced parts, if any,
at the end of successful completion of guarantee tests shall be the property of the
Contractor and he will be allowed to take these parts back at his own cost with the
permission of Employer.

51.00.00 CABLING

51.01.00 All cables shall be supported by conduits or cable tray run in air or in cable channels.
These shall be installed in exposed runs parallel or perpendicular to dominant
surfaces with right angle turn made of symmetrical bends or fittings. When cables

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are run on cable trays, they shall be clamped at a minimum intervals of 2000mm or
otherwise as directed by the Employer.

51.02.00 Each cable, whether power or control, shall be provided with a metallic or plastic tag
of an approved type, bearing a cable reference number indicated in the cable and
conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at
both ends of the cable adjacent to the terminations. Cable routing is to be done in
such a way that cables are accessible for any maintenance and for easy
identification.

51.03.00 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC
insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the
cable. Installation of other cables like high voltage, coaxial, screened, compensating,
mineral insulated shall be in accordance with the cable manufacturers
recommendations. Wherever cables cross roads and water, oil, sewage or gaslines,
special care should be taken for the protection of the cables in designing the cable
channels.

51.04.00 In each cable run some extra length shall be kept at a suitable point to enable one or
two straight through joints to be made, should the cable develop fault at a later date.

51.05.00 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to the Employers approval. Multicore control cable jackets
shall be removed as required to train and terminate the conductors. The cable jacket
shall be left on the cable, as far as possible, to the point of the first conductor branch.
The insulated conductors from which the jacket is removed shall be neatly twined in
bundles and terminated. The bundles shall be firmly but not tightly tied utilising
plastic or nylon ties or specifically treated fungus protected cord made for this
purpose. Control cable conductor insulation shall be securely and evenly cut.

51.06.00 The connectors for control cables shall be covered with a transparent insulating
sleeve so as to prevent accidental contact with ground or adjacent terminals and
shall preferably terminate in Elmex terminals and washers. The insulating sleeve
shall be fire resistant and shall be long enough to over pass the conductor insulation.
All control cables shall be fanned out and connection made to terminal blocks and
test equipment for proper operation before cables are corded together.

52.00.00 EQUIPMENT DELIVERY AND ERECTION


(a.) This part covers Contractor's responsibilities for packing, shipping, ware-
housing and the installation of all equipment and materials furnished and
installed under this specification.

(b.) The Contractor shall submit for Employer's approval draft manual for
Equipment Delivery and Erection (EDE Manual) covering detailed instructions,
write up, technical data, drawings, check-lists, documentation formats for all
activities after equipment manufacture upto installation of equipment. This
manual shall cover general instructions for all equipment and specific

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instructions for individual equipment wherever required and shall include at
least the following :

(1.) Instructions for packing, shipping, receiving handling, ware-housing and
storage.

(2.) Instructions for location and installation of equipment furnished by this
specification.

(3.) Installation drawings for field mounted equipment, panels, cubicles and
other equipment covered under this specification.

(4.) Instruction relating installation of piping/ tubing, support and routing
drawings of impulse pipes/signal tubes and tube/cable trays.

(5.) Check lists and quality assurance hold points.

(6.) Format for all related documentation.

(c.) The EDE Manual shall conform to the requirements of this specification, all
applicable codes and standards, recommendations of equipment manufacturers
and accepted good engineering practices and shall be subject to Employer
approval during detailed engineering.

(d.) The Contractor shall ensure that all work under this part shall be performed as
per the requirements of this specification, Employer approved EDE Manual and
drawing/documents approved by the Employer during detailed engg.

52.02.00 Crating

(a.) All equipment and materials shall be suitably coated, wrapped, or covered and
boxed or crated for moist humid tropical shipment and to prevent damage or
deterioration during handling and storage at the site.

(b.) Equipment shall be packed with suitable desiccants, sealed in water proof
vapour-proof wrapping and packed in lumber of plywood enclosures, suitably
braced, tied and skidded. Lumber enclosures shall be solid, not slatted.

(c.) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to
provide the required surface area and activated prior to placing in the
packaging. Calcium sulphate desiccants shall be of a chemical nature to absorb
moisture. In any case, the desiccant shall not be of a type that will absorb
enough moisture to go into solution. Desiccants shall be packed in porous
containers, strong enough to withstand handling encountered during normal
shipment. Enough desiccant shall be used for the volumes enclosed in
wrapping.

(d.) Review by the Employer of the Contractor's proposed packaging methods shall
not relieve the Contractor of responsibility for damage or deterioration to the
equipment and materials specified.

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(e.) All accessory items shall be shipped with the equipment. ; Boxes and crates
containing accessory items shall be marked so that they are identified with the
main equipment. The contents of each box and crates shall be indicated by
markings on the exterior.

(f.) All boxes, crates, cases bundles, loose pieces, etc. shall be marked
consecutively from No.1 upward throughout all shipments from a given port to
completion of the order without repeating the same number.

(g.) An itemized list of contents shall be enclosed inside each case and one other
copy securely fastened to the outside of the case in a tin or light weight sheet
metal envelope or pocket. The lists shall be plainly marked and placed in
accessible locations to facilitate receipt and inspection. The packing list shall
indicate whether shipment is partial or complete and shall incorporate the
following information on each container, etc., according to its individual shipping
number :

1. Export case markings

2. Case number

3. Gross weight and net weight in Kilograms

4. Dimensions in centimeters

5. Complete description of material

(h.) Packaging or shipping units shall be designed within the limitations of unloading
facilities and the equipment which will be used for transport. Complications
involved with ocean shipment and the limitations of ports, railways and roads
shall be considered. It shall be the Contractor's responsibility to investigate
these limitations and to provide suitable packaging to permit safe handling
during transit and at the job site.

(i.) Electrical equipment, control and instrumentation shall be protected against
moisture and water damage. All external gasket surfaces and flange faces,
couplings, motor pump shafts, bearing and like items shall be thoroughly
cleaned and coated with rust preventive compound as specified above and
protected with suitable wood, metal or other substantial type covering to ensure
their full protection.

(j.) Equipment having antifriction or sleeve bearings shall be protected by weather
tight enclosures.

(k.) Coated surfaces shall be protected against impact, abrasion, discolouration and
other damage. Surfaces which are damaged shall be repaired.

(l.) All exposed threaded parts shall be greased and protected with metallic or
other substantial type protectors. All female threaded openings shall be closed
with forged steel plugs. All pipings, tubing, and conduit equipment and other

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equipment openings shall be sealed with metallic or other rough usage covers
and tapped to seal the interior of the equipment piping, tubing, or conduit.

(m.) Provisions shall be made to ensure that water does not enter any equipment
during shipment or in storage at the plant site.

(n.) Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Contractor's expense.

(o.) While packaging the material, care shall be taken for the limitation from the
point of view of availability of railway wagon sizes in India.

52.03.00 Factory Assembly

(a.) Instrument enclosures shall be supplied and erected completely in the factory
with instrument, air supply and blow down piping with necessary valves, fittings,
etc. and also all electrical wiring between the instruments and the enclosure
terminal blocks. Control panel and cubicles shall also be fully wired in the
factory. Control panel mounted equipments are to be dismounted from the
panels before shipment and individually packed for shipment. Electronic control
modules of the plug-in type are to be removed from equipment racks after
factory checkout are individually packed for shipment. Other equipment shall be
fully assembled at the factory, except for necessary shipping splits in panels.

(b.) All separately packaged accessories items and parts shall be shipped with the
equipment. Containers for separately packaged items shall be marked so that
they are identified with the main equipment. An itemized packing slip,
indicating what is in that carton only, shall be attached to the outside and inside
of each container used for packing.

A master packing slip covering all accessories items for a given piece of equipment
which are shipped in separate containers, shall be attached to one container.

52.04.00 Equipment Installation

(a.) General Requirements

The Contractor shall furnish all construction materials, tools and equipment
and shall perform all work required for complete installation of all control and
instrument equipment furnished under this specification.

Contractor shall prepare detailed installation drawings for each equipment
furnished under this specification for Employers approval. Installation of all
equipment/systems furnished by this specification shall be as per Employer's
approval.

Erection procedures not specified herein shall be in accordance with the
recommendations of the equipment manufacturers. The procedures shall be
acceptable to the Employer.

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The Contractor shall coordinate his work with other suppliers where their
instruments and devices are to be installed under specifications.

(b.) Installation Materials

All materials required for installation, testing and commissioning of the
equipment shall be furnished by the Contractor.

(c.) Regulatory Requirements

All installation procedures shall confirm with the accepted good engineering
practice and with all applicable governmental laws, regulations and codes.

(d.) Cleaning

All equipment shall be cleaned of all sand, dirt and other foreign materials
immediately after removal from storage and before the equipment is brought
inside the power plant building or to other installation sites. All piping and
tubes shall be air blown.

(e.) Equipment Assembly

Equipment installed under these specifications shall be assembled if shipped
unassembled. The equipment shall be dismantled and reassembled as
required to perform the installation and commissioning work described in
these specifications.

(f.) Equipment Setting

Field mounted instruments and accessories shall be bracket or sub panel
mounted on the nearest suitable firm steel work or masonry. The brackets,
stands, supports and other miscellaneous hardware required for mounting
instruments and accessories such as receiver gauge, air set, valve manifold,
purge-meter etc. shall be furnished and installed. No field mounted
instruments shall be installed such that it depends for support or rigidity on
the impulse piping or on electrical connection to it.

Indicating type field mounted instruments shall be installed in such a way that
centre of indicating dial shall be about 1600-1800mm from operating floor
level. Non-indicating type field instruments shall be installed such that
operating handle of manifold block / isolating cock comes within 1600 mm
from operating floor level.

All free standing instrumentation cabinets and panels shall be located within
the construction tolerances of +/- 3 mm of the location dimensions indicated
on the Employer's plant arrangement drawings.

(g.) Free-Standing Equipment

Free-standing Cabinets shall be attached to the floor, concrete equipment
bases or supporting steel as indicated on the manufacturer's drawings and

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CONDITIONS OF
CONTRACT
PAGE 32 OF 40

the Employer's Plant Arrangement Drawings. The cabinets shall be shimmed
for proper alignment before bolting them to the floor. Adjacent enclosures
shall be shimmed to maintain mutually level appearance before they are
attached to floor. Vibration dampening mounts shall be installed between
supporting structures and panels when specified.

(h.) Non-free Standing Equipment

Non-free standing local enclosures and cabinets shall be mounted in
accessible locations on columns, walls, or stands in locations as indicated on
the Employer's Plant Arrangement Drawings. Bracket and stands shall be
fabricated as required to install the local enclosures and cabinets in a
workman like manner.

Rough edges and welds on all fabricated supports shall be ground smooth.
The supports shall be finished with two coats of primer and two coats of paint
as specified in this part.

(i.) Equipment Location

All individual items of equipment not located in cabinets or on panels and
racks are located approximately according to the floor elevation and the
nearest building column designated by the Employer.

Solenoid valves not located in enclosures or mounted on valves shall be
mounted in easily accessible protected locations near the components with
which they are associated.
All brackets, stands, supports and other miscellaneous hardware required for
mounting devices shall be furnished and installed.

Thermometers shall be installed in the process lines and ducts as required
and adjusted for ease in reading.

Permanent temperature wells on the main steam, hot reheat and cold reheat
piping shall not be installed until steam blowing has been completed.
Temporary temperature wells shall be installed in the main and reheat steam
piping during steam blow and discarded after completion.

Any required adapting hardware such as pipe bushings, nipples, drilled caps
and the like shall be provided for complete installation of control devices into
process connections.

For location of C&I related equipment/devices, the requirement specified
elsewhere in the technical specification may be referred.

(j.) Installation of Field Mounted Instruments and Devices

The Contractor shall submit installation drawings for all field mounted
equipment furnished under this specification for Employer's approval. These
drawings shall meet the requirements of this specification, installation
drawings, applicable codes and standards and recommendations of

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 33 OF 40

manufacturers of instruments/devices. All installation work under this
specification shall be strictly as per installation drawings approved by the
Employer during detailed engineering stage.

In addition to above relevant Portion as specified elsewhere in technical
specification may be referred.

(k.) Piping Connections

All equipment having piping connections shall be levelled, aligned and
wedged in place but shall not be grouted or bolted prior to the initial fitting and
alignment of connecting piping. All equipment shall, however, be grouted or
bolted to its foundation prior to final bolting or welding of the connection
piping.

All flanged joints shall be checked and retightened after approximately 10
days of operation at normal operating temperature.

(l.) Equipment Checkout

All equipment shall be cleaned after installation. Equipment subject to
pressure differentials shall be checked for leakage.

After erection, all equipment having moving parts, having electrical apparatus,
or subject to pressure differentials shall be trial-operated.

(m.) Defects

All defects in erection shall be corrected to the satisfaction of the Employer
and the Project Manager. The dismantling and reassembly of Contractor
furnished equipment to remove defective parts, replace parts, or make
adjustments shall be included as a part of the work under these
specifications.

The removal of control and instrument equipment in order to allow bench
calibration, if required, and the re-installation of the said equipment after
calibration shall also be included as a part of the work under these
specifications.

(n.) Equipment Protection

All equipment to be erected under these specifications shall be protected from
damage of any kind from the time of contract award until commissioning of
each unit.

The equipment shall be protected during storage as described herein.

Equipment shall be protected from weld spatter during construction.

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 34 OF 40

Suitable guards shall be provided for protection of personnel on all exposed
rotating or moving machine parts. All such guards with necessary spares and
accessories shall be designed for easy removal and maintenance.

Equipment having glass components such as gauges, or equipment having
other easily breakable components, shall be protected during the construction
period with plywood enclosures or other suitable means. Broken, stolen, or
lost components shall be replaced by the Contractor.

Machine finished surfaces, polished surfaces, or other bare metal surfaces
which are not to be painted, such as machinery shafts and couplings shall be
provided temporary protection during storage and constructional periods by a
coating of a suitable non- drying, oily type, rust preventive compound.

53.00.00 WELDING - SPECIAL REQUIREMENTS

If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed under separate
specifications, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.

54.00.00 DEVIATIONS DISPOSITIONING:

Any deviation to the contract and employer approved documents shall be properly
recorded in the format prescribed by NTPC. Al the deviations shall be bought to the
knowledge of employers representative for suitable dispositioning.

55.00.00 NON-DESTRUCTIVE TESTING ( NDT):

The contractor shall record results of NDTs carried out at site in the format
acceptable to employer. All the radiographs & its report duly signed & correlated to
the job shall be handed over to the employer. Sensitivity of all the test equipment
shall be compatible to the job & acceptance norms agreed.

56.00.00 TESTING EQUIPMENT & FACILITIES:

Contractor shall provide the testing equipment and facilities necessary to carry out
tests & inspections.

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 35 OF 40

ANNEXURE-I

STANDARD CHECKLIST (TYPICAL)

Commissioning/Testing Essential pre-requisite

Sl. No. DESCRIPTION

(a.) Mechanical

VALVES

(i.) Manually operated valve

(ii.) Electrically operated valve

(iii.) Pneumatically actuated valve

(iv.) Hydraulically actuated valve

(v.) Safety valve

(vi.) Butterfly valve(electrically operated)

(vii.) Butterfly valve (manually operated)

(viii.) Butterfly valve(four way-electrical)

(ix.) Non-return valve (including hydraulic/pneumatic FCNRVS)

(x.) Relief valve

(xi.) Differential pressure regulating valve

(xii.) Float operated valves

Pumps

(xiii.) Pump Low Pressure Centrifugal (Motor Driven)

(xiv.) Pump up to 350 HP (260 Kw)

(xv.) Pump Sump Installation

(xvi.) Gear Pump/Screw Pump

PIPE WORK SYSTEM

(xvii.) Water services

(xviii.) Oil Resistant Fluid System

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 36 OF 40

(xix.) Air services (compressor)

(xx.) High pressure services

(xxi.) Constant load support

(xxii.) Spring supports

(xxiii.) Hangers and other supports

STRAINER AND FILTER

(xxiv.) Strainer/Filter Basket Type

Heat Exchanger (Scoop Coupling)

(xxv.) Heat exchanger (general)

(xxvi.) Heat Exchanger-Oil/Water

FANS AND COMPRESSORS

(xxvii.) Fans-Non-pressure Lubricated

(xxviii.) Fans-Axial flow pressure Lubricated

(xxix.) Compressors-General

GATES
(xxx.) Manually operated gate

(xxxi.) Electrically operated gate

Duct Work

(xxxii.) Ventilation ducting

(xxxiii.) Expansion Joints

(xxxiv.) Observations & Access Door

HOISTS AND ELEVATORS

(xxxv.) Electric Hoist / Elevator

(xxxvi.) Travel Support Structure For Hoists / Elevator

(xxxvii.) Long travel & cross traverse motion of hoists

(xxxviii.) Main aux. Hoist motion

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 37 OF 40

POWER TRANMISSION

(xxxix.) Power transmission gear box

(xl.) Bearing

(xli.) Fluid Couplings

(b.) Electrical

D.C. Motor

HV squirrel cage induction motor

415 V squirrel cage induction motor

Motor operated actuators

HT Switchgears

LT Switchgears/MCC

Standard Checklists for all types of relays used in Switchgears Protection
System

PT Carriage and Cubicles

Cable/Bus Duct/Bus Bars

Contractor Module

Switch fuse module

Master Panel of Lube Oil Panel

Feeder panel of lube oil panel

Space heater and cable module

HT Circuit Breaker

415 V Circuit Breaker

Power cable

Auxiliary cable

D.C. cable

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 38 OF 40

Explosion Proof Electrical Equipment

Junction box

Control transformer module

Soot blower sequence panel

Brush gear assembly

Aux. Control and relay panel desk

Indicating instrument
Recording instrument

Integrating instrument

Level switch (float actuated)

Level switch (electrode type)

Level Switch Displaced actuated)

Level Indicator (Float/Pulley Type)

Local temperature indicators including test procedure

Resistance Thermometer Element including Test Procedure

Thermocouple element and connecting cable

Thermocouple and Resistance Thermometer Convertor/Transmitter including
Test Procedures.

Temperature Switch/Thermostat including test procedures

Cold Junction Boxes

Pressure and Vacuum Gauge

Pressure And Vacuum Switch Including Test Procedure

Differential Pressure Transmitter including test procedure

Differential Pressure switch including test procedure.

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 39 OF 40

Flow Indicator (variable area)
Orifice plate

Tachometer

Vibration measurement

Digital indicator

Moving coil indicator including test procedure

Recorder including test procedure

Electrical auto manual control station

Push button module

Alarm annunciator equipment including test procedure

Test procedure for electronic Modules of DDCMIS

Note: The items which are not part of this specification may not be considered as not
applicable.

CLAUSE NO.


SECTION-VI, PART-D
BID DOC NO.:CS-0260-156-2(R)
ERECTION
CONDITIONS OF
CONTRACT
PAGE 40 OF 40

ANNEXURE-II

BRIEF WIRE UP ON THE CONTENTS OF TESTING SCHEDULE /
COMMISSIONING SCHEDULE

Testing Schedules should be designed to ensure that the plant area, equipment or
apparatus are tested and commissioned and will operate as per the employers
specifications and good engineering practices.

Testing Schedule/Commissioning Schedule is required to be of a standard format in
order to maintain consistency of presentation, content and reporting.

Testing Schedule/Commissioning Schedule should contain the following sections to
make the document a self contained one:

(a.) Plant Details/Design data

(b.) Testing Objective/Proposals

(c.) STATE OF THE PLANT

Erection Status with respect to Mech. Elect

AVAILABILITY OF THE SERVICES REQUIRED

SAFETY REQUIREMENTS AS PER MANUFACTURERS

(d.) Test method including completion/acceptance criteria

(e.) RESULTS

(f.) APPENDIX

TESTING PROGRAMME

Mech/ElectPlant item completing list

List of Drawing/documents required for carrying out the testing.

SECTION-VI
PART-E

PART - E

LIST OF TENDER DRAWINGS

CLAUSE NO.

SECTION VI, PART-B
BID DOC. NO.: CS-0260-156-2(R)
PART-E
Page
1 of 1

-----------------------------------------------------------------------------------------------------------------
S.NO. DRG. NO. TITLE
-----------------------------------------------------------------------------------------------------------------

A MECHANICAL

1. 0260-156-POM-A-001 General Plant Layout In plant Coal Handling
system

2. 0260-156-POM-A-002 Coal Flow Diagram

3. 0260-156-POM-A-003 GA of crusher house (CH).

4. 0260-156-POM-A-004 GA of Conveyor 1A/1B, 2, 3, 4 and Transfer point
TP-1, TP-2, TP-3, TP-4

5. 0260-156-POM-A-005 GA of existing JNT-50

6. 0260-156-POM-A-006 GA of Conveyor 6A/6B, 7A/7B and Drive House

7. 0260-156-POM-A-007 GA of Conveyor 9A/9B to 14A/14B and Transfer
point TP-6 to TP-12

8. 0260-156-POM-A-008 GA stacker, reclaimer and yard conveyor
16A /16B

9. 0260-156-POM-A-009 GA of Conveyor 15A/15B, 17A/17B & 8A/8B and
Transfer point TP-13, TP-14, TP-15, TP-16 and
TP-5

10. 0260-156-POM-A-010 Single Line Diagram for DS, SW, CW and potable
water system

11. 0260-156-POM-A-011 General Notes

B ELECTRICAL

1. 0260-156-POE-A-001 In Plant Coal Handling System- Single Line
(3 Sheets) Diagram

2. 0260-156-POE-A-002 In Plant Coal Handling - Typical PLC
configuration for each Stacker and Reclaimer

C CIVIL

1. 0260-156-POC-A-001 GA & Details of Stacker and Reclaimer

2. 0260-156-POC-A-002 Typical Architectural Details
(4 Sheets)
SCALE:
I-IOR-1: 1000
VER-1: 100
NTECL-PROPOSED EXTERNAL COAL CONVEYOR CORRIDOR.
CROSS SECTlON @ 25m lNTERVAL
Cross Scctien 0 1225 WOm
0
Qor Ss t t t a B 4525.m &om Seciim o 4 5 7 5 . m
, , . . . . I
Cross Section 0 6603 MXlm Cross Scclim 0 4625.DD[Xn
- .-
Cross Section 0 46S0000m
Crws Sectlon @ 4bM).DD(m
( FOR TENDER PURPOSE ONLY 1
I
I I\ITPC-TAMILNADU ENERGY COMPANY LTD.
I
( A JOINT VENTURE COMPANY BETWEEN NTPC AND TNEB )
1 I I
Cross Section 0 SODO 00(m PROJECT
NTECL POWER PROJECT (3x500MW)
(VALLUR THERMAL POWER PROJECT-3~500MW)
f TCE
IN PLANT COAL HANDLING SYSTEM PACKAGE
I 1 I I I r- I 1 I I ' 1 \~
I SIZE 1 SCALE f ORG.NO. I REV.
B RELEASED FOR TENDER
I ' 8 I 7 I 6 I 5 1
bv\*
'I
.... ~ L - ~ ~ - - - . .. . .. . -.- ---- .- -- .. .-.-"-- - - . - - - ... - -~ . - . ..- - .- - -- -- - - ~ - - - . ~ . . - . . ~ . . .. . .--. .. . . . - - . _-- _ _ . . - - _" __ CAD FILE NAME : 0260- 156-POM-A-001 B-SH2.dwg ~ ~ -~ - - - ~- -
R N .
b@
DESCRlPTiON
L
DRAWN
.,qo6
DESIGN
GENERAL PLANT LAYOUT
CHKD.
I CLEARED I E BY
I C" ~ APPDI DAT E
- - - - . --
--
- - . . . - .
0260-156-POMA-001 ( S H E E T ~ O F ~ )
-
A
LEGEND
BELT CONVEYOR
I 0s I BELT SCALE I
I
t
CSu I COAL SAMPLING UNIT
MAGNFTIC SEPARATOR
(IN LINE)
( MD 1 METAL DETECTOR I
I W V I VENTILATION I
ROD GATE
RACK & PINION GATE
I ma I CRUSHER
I 8 sM
SUSPENDED MAGNET
1
I BF I BELT FEEDER I
UNIT #l
-INTERNAL
STAIRCASE
PLAN VIEW SHOWING CRUSHER LAYOUT
SAND BED
(W
4 COLUMN q COLUMN
NOTES:
1. ALL DIMENSIONS ARE IN mm AND LEVELS ARE IN METERS.
2. ALL L M L S ARE MARKED w.r.t. EL. 0.00 WHICH CORRESPONDS TO RL 4.6 M
3. PLATFORMS/HANDLING ARRANGEMENT FOR SERVICING, INSTALLATION AND EASY
REPLACEMENT SHALL BE PROVlDED BY BIDDER.
4 ADEQUATE VENTILATION. NO. OFF LOWERS, WiNOOWS ETC. SHALL BE PROVIDED FOR PROPER
5 COAL SAMPLER I S NOT SHOWN IN DETAIL IN CRUSHER HOUSE FOR CLARITY. THlS
SHALL BE PROVlDED BY BIDDER. ALL ADDITIONAL ACCESS PLATFORMS FOR CSU
EQUIPMENT TO BE PROWDED BY BIDDER.
6 HANDLING C~USHEPS ARRANGEMENT ~ ~ T F C D ~ I ! ! ~ Y S FOR 4 SERVICING, T T U ~ c?pT: INSTALlATlON ly - ~ l l r u c o AND EASY 4rrlPr REPLACEMENT - . OF
- l uC J ~ A ~ L 2E
PROVIDED BY THE BIDDER, THESE ARE NOT SHOWN IN TENDER DRG FOR CL ARI ~.
7 FOR ALL OTHER NOTES REFER DRG.NO. 0260- 156-POM-A-011.
8. THlS DRG. SHALL BE READ IN CONJUNCTION WlTH OTHER TENDER DRGS.
9. PROPER SLOPE SHALL BE PROVlDED ON CONCRETE FLOOR TOWARDS DOWN
COMMERS FOR RUN OFF WASHING.
10. ALL FLOOR OPENING IN CRUSHER HOUSES/TPIS SHALL HAVE lOOmm HIGH CURB
ALL AROUND THE OPENING FOR FLOOR WASHING.
1 1 . CRUSHER FOUNDATION SHALL BE SUPPORTED ON R.C.C. DECK WHICH I N W B
RESTING ON SUITABLE VlBRATION ISOlATORS WITH SPRINGS AND VlSCO DAMPERS
SUPPORTED ON STEEL BEAMS {NTEGRATED WITH MAIN BUILDING FRAME WORK.
12. CRUSHER SUPPORTING H.C.C. DECK SHALL BE ISOLATED FROM M A I ~ BUILDI~G -
-
FLOOR BY PROMDING AN AIR GAP IN BETWEEN WHlCH SHALL BE SUITABLY
COVERED.
13. COASTING TIME Of CONVEYOR 6A/6B SHALL BE SELECTED IN SUCH A WAY THAT
CHUTE ABOVE FEEDER WILL NOT RE FULL MORE THAN 50%UNDER ANY OPERATING
CONDITION, FURTHER THE CHUTE SHALL BE CAREFULLY DESIGNED WITH MIN. OF
INCLINED FACES AND SHARP CORNERS AS FAR AS POSSIBLE TO PREVENT THE
TENDENCY OF COAL BUILD-UP.
14. ONE (1) NO. RACK & PINION ELEVATOR SHALL BE PROVIDED TO SERVlCE VARIOUS
FLOORS OF THE CRUSHER HOUSE INCLUDING ANY OTHER FLOOR REQD. BY BIDDER
FOR HIS EQUIPMENT ACCESS/MAINTENANCE.
15. FOR MONORAiLS PROJECTING OUT OF BUILDING, SLIDING TYPE DOORS SHALL BE
PROVIDED.
16. SEPERATE PERSONNEL ENTRY AND EQUIPMENT HANDLING ACCESS POINTS SHALL BE
PROVlDEO AT GROUND FLOOR.
17. CRUSHER HOUSE HEIGHT AND BUl l Ol NG OIMENSIONS ARE INDICATIVE. BIOOER TO
SELECT SIZES AND HEIGHT NOT LESS THAN THOSE MErJTlONED IN TENDER DRGS. IF
DURlNG DETAILED ENGG. ANY lNCREASE IN SIZES/HEICHTS ARE REQUIRED BY
SUCCESSFUL BIDDER FOR HIS EQUIPMENT THE SAME SHALL BE PROVIDED WITHOUT
ANY COMMERCIAL IMPLICATION TO EMPLOYER.
18. ACCESS PLATFORMS (NOT SHOWN IN TENDER DRGS.) REQUIRED FOR ATTENDING
CHUTES SHALL BE PROVIDED. ADEQUATE DUST PROOF MANHOLES SHALL BE
PROMDED FOR ROUTINE INSPECTION IN ALL CHUTES (FROM EACH ACCESS FLOOR).
19. GTU Df3AIC AS SHOWN 1s APPLICABLE FOR ALL CONVEYORS OF THlS PACKAGE
EXCEPT FOR ONES SPECIFICALLY MENTIONED Of DIFFERENT ARRANGEMENT.
INTERMEDIATE ACCESS PLATFORMS AT 4.OM INTERVAL SHALL BE PROVIDED FOR
G.T.U. PULLEY ACCESS. SUITABLE ACCESS LADDER SHALL ALSO BE PROVIDED FROM
GROUND TO ALL PUT F ORE. SIMILAR DETAILS SHALL ALSO BE APPLICABLE FOR
SINGLE CONVEYORS.
20. THE CRUSHER MOUSE SHALL BE PROVIDED WITH 2 NOS. EXTERNAL STAWCASE AND
ONE NO. INTERNAL STAIRCASE. ALL THE STAIRCASES ARE NOT SHOWN IN THIS DRG.
FOR CLARITY.
ELEVATION OF CONV. 7Al7B --
DRIVE HOUSE(DH)
1380.5N1185.OE
CROSS
NOTES :
- -
i _ ? R GENEPAL IJCjTES REFEF; CIPG i _ - , - . = F a - - , , . - . - - u - - - . - +.-
< , - - --" . I HIS DRAWII\JG SHALL RE REAL 1 1 1 I. . ' , _ ' , I . - ' - -
TFI.4DER DRGS
ELEVATION OF CONV. 6A16B
RECLAIMER MACHINE STACKER MACHINE
1 BUCKET
I WHEEL
COAL\ HEAP
12000
-I-
70000~ 1
I PlLE LENGTH
BC( SECTIONAL ELEVATION OF YARD CONVEYOR-16B -- -
RECLAIMER MACHINE STACKER MACHINE
h BUCKET
I WHEEL
I
-
I
.- COAL HEAP
PlLE LENGTH
u-
SECTIONAL ELEVATION OF YARD CONVEYOR-I 6A
SECTION B-B
NOTES :
18. DUST & DEBRIS DISPOSAL CHdTE OF I MXI M SlZE 6MM THK. MILD STEEL PLATE SHALL BE PROVIDED UPTO GROUND FLOOR FROM EACH FLOOR
OF CRUSHEP fiOUSE AND ALL TRANSFER POINTS (INCLUDING MAIN PLANT TPs).
ALL DIMENSIONS ARE IN mm AND LEVELS ARE IN METRES UNLESS NOTED OTHERWISE.
THE SCOPE OF WORK COVERED UNDER THIS CONTRACT INCLUDES EXCAVATION & FILLING/BACK FILLING WITH EITHER EXCAVATED MATERIALS OR
SPECIALLY SELECTED MATERIALS AS DIRECTED BY THE EMPLOYER. THE EXCAVATED MATERIAL SHALL BE NEATLY STACKED AT PLACE DIRECTED BY
THE EMPLOYER. SOME OF THESE EXCAVATED MATERIALS MAY BE REQUIRED TO BE BROUGHT BACK FOR BACKFILLING/FILLING PURPOSE AS
DIRECTED BY THE EMPLOYER. THE SCOPE OF THIS CONTRACT ALSO INCLUDES THE FINAL DlSPOSAL OF REMAINING EXCAVATED AND STACKED
M.4TERIALS AT A DISTANCE UPTO 5 KMS BEYOND POWER PLANT BOUNDARY AS DIRECTED BY THE ENGINEER.
TYPICAL DETAILS FOR GTU TOWER AS SHOWN IN TEqDER DRAWING IS APPLICABLE FOR ALL CONVEYORS INTERMEDIATE ACCESS PLATFORMS AT
4M INTERVAL SHALL BE PROVIDED FOR GTU PULLE', ACCESS. SUITABLE ACCESS LADDERS SHALL ALSC BE PROVIDED FROM GROUND TO ALL
PLATFORMS. SIMILAR DETAIL SHALL ALSO BE APPLICABLE FOR SINGLE CONVEYORS ALSO,
ACCESS PLATFORMS AND LADDER/STAIRS (NOT SHOWN IN TENDER DUG) AS REQUIRED FOR ACCESS/SERVICING CHUES, EQUIPMENT ETC. SHALi
BE PROVIDED BY THE CONTRACTOR.
WELDED WlRE FABRIC OF MINIMUM 1.6MM THICK WlRE (CONFORMINGTO 15-4948) & HAVING 12mm X 30 mm MESH SlZE SHALL BE FIXED TO
FRAMES FOR WINDOWS TO BE PROVIDED IN BOTH SIDES OF CONVEYOR GALLERY AS SPECIFIED.
ALL CHUTES SHALL BE PROVIDED WITH ADEQUATE CJST PROOF MANHOLES HINGED INSPECTION DOORS SHALL ALSO BE PROVIDED AT ALL
FLOORS OF BUILDING? FOR ROUTINE INSPECTION IN ALL CHUTES.
WHEREVER COLOUR WASHING OVER PLASTERED SURFACE IS SPECIFIED, THE NUMBER OF COATS TO BE APPLIED SHALL BE MINIMUM THREE OR
M3RC.
TRESTLE LOCATION AAD N P E SHALL BE AS PER TE.:H. SPECIFICATION.
SEPARATE PERSONNEL ENTRY AND EQUIPMENT HANC LING ACCESS POINTS SHALL BE PROVIDED ON GROUND FLOOR OF ALL TPs.
MINIMUM 20MM DIAMETER M.S. RUNGS SHALL BE PROVIDED I N UDDERS. FOR HEIGHT OF 10M & ABOVE, CAGE LADDERS SHALL BE PROVIDED.
LADDERS SHALL BE MINIMUM 450mm WIDE. THIS DRG. IS TO BE READ IN CONJUNCTION WITH C N E R TENDER DRGS.
E. ALL DIMENSIONS & RELATIVE ELEVATIONS OF VARIOUS TRANSFER POINTS, STRUCTURES AND OTHER BUILDINGS AS SHOWN IN VARIOUS TENDER
DRGS. ARE MINIMUM ACCEPTABLE TO THE EMPLOYER, CONTRACTOR SHALL SELECT SIZES OF VARIOUS TRANSFER
POINTS, STRUCTURES AND OTHER BUILDINGS TO SUIT EQUIPMENT SELECTED/HANDLING REQUIREMENT BY HIM AND THE SAME SHALL IN ANYC ASE
25. ACCESS PLATFORMS WlTH LADDERS ABOVE RCC FLO )R SHALL BE PROVIDED WHEREVER BOTTOM OF EQUIPMENT/PULLEY/DRIVE ETC. EXCEEDS
1.2M. CARE SHALL BE TAKEN TO PROVIDE PROPER ACCESS TO ALL CHUTES, HOISTS (AT PARKING PLACE), CONVEYOR DRIVES, PULLEYS
ETC.
SHALL NOT BE LESS THAN SIZES INDICATED IN VARIOUS TENDER DRGS. NO COMMERCIAL IMPLICATIONS SHALL BE ENTERTAINED FOR INCREASE IN
BUILDING SIZES DURING DETAILED ENGG. ON ACCOUNT OF EQUIPMENT SELECTED BY CONTRACTOR.
26. IN ADDITION TO CLEARANCES SHOWN 1N INDIVIDUAL )RG. TRESTLES SHALL HAVE TO CLEAR ALL FAClLlTlFS SHOWN IN GENERAL LAYOUT.
I
7 PLINTH LEVEL OF ALL BUILDINGS & STRUCTURES SHALL BE 500mm ABOVE THE ADJACENT GROUND LEVEL. ALL FLOOR LEVEL, ROOF LEVELS
ETC., PROPOSED IN THE TENDER DRAWINGS ARE WITH RESPECT TO THIS PLINTH LEVEL.
27. THE NO. & MONORAIL HOISTING SYSTEMS SHALL A L W BE DECIDED CONSIDERING THE MOVEMENT OF THE EQUIPMENT BEING LIFTED OVER/BOTH
SIDES OF OTHER EQUIPMENTS WITHOUT REMOVING THE LATTER. THE NECESSARY LEVELS OF FLOOR IN VARiOUS BUILDINGS SHALL BE DECIDEC
CONSIDERING THE ABOVE REQUIREMENT.
6. ADEQUATE N3. OF MONO RAILS SHALL BE PROVIDED WITH ELECTRIC HOISTS TO FACILITATE MAINTENANCE OF ALL COAL HANDLING EQUIPMENTS
28 EXTERNAL FIRE ESCAPE STAIRCASE ALONGWITH INTERr.IAL STAIRCASE SHALL BE PROVIDED FOR ALL MCC/CONTROL ROOMS & CRUSHER HOUSE.
INCLUSIVE OF GTU/TAIL PULLEYS, FG ETC. THE LOCATION AND NO. OF MONO RAILS WITH ELECTRIC HOISTS ARE NOT SHOWlv IN DRGS. FOR THE CRUSHER HOUSE SHALL BE PROVIDED WITH TWO (2) EXTERNAL AND ONE NO, INTERNAL STAIRCASES (MINIMUM).
I
CLARITY, HOWEVER, THESE SHALL BE FlNALlSED DURING DEAILED ENGG. AND THE SAME IS SUBJECT TO EMPLOYER'S APPROVAL. MONORAIL WlTH
CHAIN PULLEY BLOCKS AS REQUIRED SHALL ALSO BE PROVIDED. SIZES OF MONORAILS AND CAPACITY OF CHAIN P U L N BLOCK SHALL BE 29 ALL TRANSFER HOUSES SHALL BE PROVIDED WITH E)TERNAL STAIRCASES. FOR ALL BUILDINGS THE STAIRCASES SHALL BE EXTENDED UPTO ROOF
FlNkLlSED DURING DETAILED ENGG. AND THE SAME IS SUBJECT TO EMPLOYER'S APPROVAL. TOP. PROPER ROOF HOOD TO BE PROVIDED FOR PkOTECTION FROM SUN/RAIN.
I
1 C TECHNICAL SPECIFICATION REQUIREMENTS SHOWN IN TENDER DRGS. ARE NOT EXHAUSTIVE.
I
1
1
I
I
1 ' . ALL CONVEYORS SHALL BE PROVIDED WlTH ALL ACCESSOREIS SUCH AS PULL CHORDS, BELT SWAY & ZERO SPEED SWITCHES, BELT SCRAPPER
UKITS ETC AS PER TECH SPECS. THESE ARE NOT SHOWN IN TENDER DRAWINGS FOR CLARIN.
9 THE WiDTH OF GALLERIES & TUNNELS INDICATED I N THE DRGS. IS MINIMUM REQUIRED. BIDDER MAY INCREASE THE WIDTH BASED ON HIS EQPT.
30 ALL BEND PULLEYS, TAIL PULLEYS, FIXED TRIPPER PJLLEYS ETC. SHALL BE PROVIDED WlTH SUITABLE PKOTECTiON GUARD.
SlZE KEEPING CLEAR WALKWAY DIMENSIONS AS SPECIFIED WlTt-iOUT ANY COST IMPLICATION TO NTPC.
.I 31 MINIMUM lOOMM HIGH CURB SHALL BE PROVIDED AROUND ALL FLOOR OPENINGS IN CHP BUILDING.
I
I
12. FOR CLARIN VARIOUS DETAILS SHOWN IN ONE VIEW HAVE NOT BEEN DUPLICATED IN ALL THE VIEWS.
I
13 FLOOR DRAIN, DOWN COMERS AND CONNECTION UPTO COAL SLURRY SmL l NG TANK, EXTERNAL VERTICAL SHAFT ETC. FOR VARIOUS BUILDINGS
HAVE NOT BEEN SHOWN IN THE TENDER DRAWINGS FOR CLARIN. THESE SHALL BE PROVIDED BY THE CONTRACTOR AS SPECIFIED IN THE
SPEC1FICATION.
14 FENCING WIT1 LOCAKABLE GATES SHALL BE PROVIDED AROUND ALL GTU TOWERS GRAVITY TAKEUP WEIGHT. FURTHER SAND BED OF 600 mm
DEPTH SHALL BE PROVlDED AT GROUND LEVEL TO TAKE THE IMPACT OF FALLING TAKE UP WEIGHT IN CASE OF BELT SNAPPING. AREA IN STONE
i
PICKING ZONE SHALL ALSO BE BARRICATED WITH SUITABLE APPROACH & ACCESS.
I ' 5 ALL SEWER LINES COMING OUT FROM RESPECTIVE BUILDINGS SHALL BE CONNECTED TO THE EMPLOYER'S SEWER LINE. IN CASE THE
EMPLOYER'S SEWER LINE IS MORE THAN 25M AWAY FROM THE OUTER EDGE OF THE BUILDING, THE SAME SHALL BE TERMINATED THERE WITHIN
Ir\lSPECTIOt\ CHAMPER OF SUFFICIENT SlZE AT THE TERMINATION POINT.
16 TRAMP IROK CHUTE OF Mll'i. I MX l M SlZE (6mm THICK US) OR AS SPECIFIED IN THE TECH. SPECIFICATIONS SHALL BE PROVIDED TO RECEIVE
TRAMP METAL FROM ILMS AND DROP IT UPTO GROUND LEVEL. ONE NO. TROLLEY OF ADEQUATE CAPACITY SHALL BE PROVIDED IN THAT BUILDING.
THE TRAMP IROR CHUTE ANGLE SHALL BE 50' MIN. FROM HORIZONTAL AND SHALL BE ROUTED INSIDE BUILDING UPTO GROUND. SUITABLE POKE
D03RS SHALL BE PROVIDED IN THE TRAMP CHUTE AT EACH FLOOR FOR ATENDING TO ENTRAPPED TRAMP WIRES, PIECE ETC.
/ FOR TENDER PURPOSE ONLY I
I
17. FOF MOWORAIL PROJECTING OLIT OF Bl l i i Dl NG STEEL FRAME DOORS, PREFERABLY SLIDING NPE OR OTHERWISE OPENABLE INSIDE SHALL BE
PROVIDED. OPENABLE DOORS SHALL PREFERABLY BE COMPARTMENTALISED. MONORAIL COMING Ot'T OF BUILDING' SHALL BE PROJECTED BY
CLEAR MIN. 3. ON OUTSIDE THE SHEETING. I NTPC-TAMILNADU ENERGY COMPANY LTD. I
I
( A JOINT VENTURE COMPANY OF NTPC AND TNEB )
! I
PROJECT
i NTECL POWER PROJECT (3X500MW)
(VALLUR THERMAL POWER PROJECT-3X500MW)
TITL IN PLANT COAL HANDLING SYSTEM PACKAGE
A. RELEASED FOR TENDER
GENERAL NOTES
*b@=+
- -
\L o,>t~'
SlZt SCALE DRC.NO. R N .
C I M
E C&l
REV. DESCRIPTION DRAWN DESIGN CHKD APPD DATE A.
0260-156-POM -A- 01 1 A
CLEARED BY
CAD FILE NAME : 0260-156-POM-A-011.dwo
TO BE DISCONTINUEDAT
DOZERENTRYLOCATIONS /'
1 COAL HEAP
PRECASTRCC
COVER(TYP) 1
PRECASTCOVER , 'w
CRUSHEDCOAL HEAP
TO BEDISCONTINUEDAT
DOZERENTRY LOCATIONS
::;EST RCC
/A
1 RCC - GRADINGBY OWNER
PROVIDEDTHROUGHOUT
DEPTHVARIES
WALL To
THE LENGTHOF STOCKPILE ~ ~ T H K . PCC 1:4:8
WITHOPENINGS(750x250a3250 c/c
75THK. PCC 1 :4:8
AT FGL)
RCCTRENCH800WIDE&
700 DEEP( NP) I
SECTION SHOWING STACKER RECLAIMER
FOUNDATION & DRAINAGE ARRANGEMENT
(TYPICAL)
SHEETING RAL 9002
AS/SPECS (NP)
I r
FIXED POLYCORBONATE SHHET
AS/SPECS (VP)
FLOOR FINISH
77
FLOOR FINISH
2
AS/SPECS (TYP)
FLOOR FINISH
\7
AS/SPECS (TYP)
SHEETING RAL 5012
AS/SPECS (NP)
TYPICAL PLAN OF CRUSHER HOUSE
AS/SPECS (TYP)
STEEL LOUVERED WINDOW AS/SPECS.(TYP)
FLOOR FINISH
Q
ALL DIMENSIONS ARE IN MM AND LEVELS ARE IN METRES.
TYPlCAL 750 MM WIDE PLINTH PROTECTION SHALL BE PROVIDED
ALLROUND THE BUILDING AS PER TECHNICAL SPECIFICATIONS.
ALL PAINTING, FLOORING AND ALLIED WORKS, INTERNAL AND
EXTERNAL FINISHES ETC. SHALL BE AS PER TECHNICAL SPECIFICATIONS.
THIS DRAWING SHALL BE READ IN CONJUNCTION WITH SCHEDULE OF
ITEMS AND TECHNICAL SPECIFICATIONS.
THIS DRAWING IS FOR TENDER PURPOSE ONLY.
3
-
A
lYPlCAL ARCHITECTlJRAL DETAILS AS SHOWN IN THE
DRAWING ARE INDICATIVE ONLY AND FOR TENDER
PURPOSE ONLY.
THE ELEVATION HEIGHT. NUMBER OF BAYS, NUMBER
OF FLOORS, Sl ZE OF BUILDING, NO. OF STAIRCASES,
NO. OF ROLLING StiUTTERS, OPENING FOR CONVEYORS,
ETC. IS SHOWN IN THE DRAWING ARE INDICATIVE ONLY
AND FOR TENDER PURPOSE ONLY.
CAD FILE NAME
TYPICAL WA T I O N OF CRIJSHER HOUSE
.
a
THE WORKS SHALL BE CARRIED OUT AS PER THE
RELEASED FOR CONSTRUCTION DRAWINGS DURING
DETAIL ENGINEERING STAGE. TYPICAL DETAIL OF GUTTER
A
RN. NO.
12
1
NTPC-TAMILNADU ENERGY COMPANY LTD.
( A JOINT VENTURE COMPANY EN rlTPc AND TNEB )
1
PROJECT
NTPC-TAMIL NADU ENERGY COMPANY LTD. POWER PROJECT
(3 X 500 MW)
IN PLANT COAL HANDLING SYSTEM PACKAGE
CRUSHER HOUSE
TYPICAL ARCHITECTURAL DETAILS
RELEASED FOR TENDER PURPOSE ONLY
D E S C R I P T I O N
SlZE
A1
SCALE
NTS
rn
M
DRAWN ORG. NO.
0260- 156-POC-A-OM
(SHEET - 1 OF 4)
REV. NO
A
CLEARED BY
E C
DESIGN CHKD.
C&l
11.12.07
DATE
,
ARCH.
APPD
15 MM GROOVE IN PLASTER
100 MM TH. PARtjPET ,
TERRACING AS/' PEC. , ,
LAID TO SLOPE
R. W. GUTFR
ROUND C.I. GRA iNG
100 0 R W.P.
DOWN Ci;MER
HALF
TYPICAL GUTTER DETAIL
TYPICAL ELEVATION OF MCC ROOM
I
I
SW. GF/. & MCC
I
I
I
I HT..
o l o Ill 0 I @ /Ill
RPICAL AIICHITECTURAL DETAILS AS SHOWN IN THE
DRAWING ARE INDICATIVE ONLY AND FOR TENDER
PURPOSE ONLY.
THE ELEVCTION HEIGHT, NUMBER OF BAYS, NUMBER
OF FLOORS, SIZE OF BUILDING, NO. OF STAIRCASES ETC.
IS SHOWN IN THE DRAWING ARE INDICATIVE ONLY
AND FOR TENDER PURPOSE ONLY.
THE WORKS SHALL BE CARRIED OUT AS PER THE
RELEASLO FOR CONSTRUCTION DRAWINGS DURING
DETAIL ENGINEERING STAGE.
TYPICAL PLAN OF MCC ROOM
A
(2) MOWLE TYPE 'DCa SHALL BE PROVI MD VI TH AUXILIARY SWITCH VI TH PNO+BNC CONTACTS
(3) MODULE TYPE '5' SKbLL H A M VDLTHETER Vl T H SELECTOR .SVITCH. INSTANTANEOOS UNDER V O L T G ~ ' RELAY (27).
INSTANTANEOUS OVER VOLTAGE RELAY (59). EARTH LEAKAGE RELAY. I NDl CATl f f i LAMP. CDNTRDL FUSES b NEUTRAL LINK.
a BOOST CHARGING SHALL BE CARRIED OUT VI TH THf BATTERY DISCONNECTED FROM
I TS DCDB. PROVlSl&i FOR A KEY HfCHANICAL INTERLOCK S W L BE MADE I N THE
TRICKLC/BOOST SELECTOR S V I T M TO ENSURE ?HAT THIS ISOLATIOH I S ACHI EMD
BEFORE BOOST CHARGING HAY COHHENCL
I PROVISION FOR A K E I INTERLCCK SHALL BE UADE I N THE .TIE SVI TCH TO ENSURE THAT
THE TI E I S CLOSED BEFORE THE SECTION I S ISDLATED FROH I T S BATTERY AND CHARGER.
(4) 4 M1S 3 2 1 F ~ D E R < ~ O A TOTAL LOAD) ON 2BDV K D B I N HCC-IA SHALL BE PROVIDED FOR EMPLOYER'S US; .
(5) 4 NOS 16A FEEDfR(2OA TOTAL LOAD) ON 2BOV DCFB I N HCC-IB SHALL BE PROVIDEb FOR EUPLOYER'S USE-
EARIN i - ur CMIH r u r
i
RCLAY <see-11 =LAY <ac - l l l
1,
!I
!.I
;I
.
j;
NOTES-
f t
(1) WOULR-E TYPE -HD SHALL HAVE KEY lNTERLOCK Vl TH NODULE T WE be ON BOTH SECTIONS FOR TENDER PURPOSE ONLY
I N SUCH A WAY THAT VHEN S V I T M ' HV I S I N OPEN CONDITION THE KEY SHALL BE TRAPPED, A
i
ON CLOSING mnULE ma THE KEY SHALL x RELEASED. nouuLE T w E *nc' CAN m y BE OPENED
1 ON l NMRTl NG THE ABOVE KEY I N ANY O M DF THE SECTION.
(2) HODmE TYPE 'DC' SHALL BE PROVIDED V l l H AUX~L~ARY SVITCH Vl TH 2NO+2NC CONTACTS.
(3) HODULE TYPE 'So SHALL HAVE VOLTMETER WITH SELECTOR SVI TM, INSTANTANEOUS UNDER VOLTAGE RELAY (27).
INSTANTAMWS OVER VOLTAGE RELAY (59). EARTH LEAKAGE RELAY. INDICATING L mP. CONTRK FUSES b MUTRAL LINK. -
= BOOST CHARGING SWILL BE CARRIED OUT Vl TH THE BATTERY DISCONPKCTED FROM
I TS DCDB. PROVlSlON FOR A KEY NECHANlCAL INTERLOM ' MALL BE UADE I N THE
TRICKLE/BOOST SELECTOR S V l T M TO ENSURE THAT THIS ISOLATION I S AFHIEVED
BEFORE ~ ~ ODST CHARGl S UAY COMMENCE:
I PROVISION FOR A KEY INTERLOCK W L L BE WOE I N T M TI E SVl TCH TO ENSURE THAT
THE TI E I S CLOSED BEFORE THE SECTlDN I S ISOLATED FRDN I TS BATTERY AND CHARGER.
* "m. -
"0 ~~ u 0 2 6 0 - 1 5 6 - P OE - A- 0 0 1 B
(4) 2 NOS J ~ A FEEDER(BOA TOTAL L mn ) DN'IIOV DCDB IN MCC-ID SHALL BE PROVIDED FOR EHPLOYER'S USE
m a 7 SH. 3 OF 3
VALLUR-I 10"-C-CHP-INTLmNlLD1C
. .
-- . . -- - --- ---- . "-. . .--,. &- --. . . - -- - - --.- _. --
MCC .ROOM .
. _. _. _. - . _. - . - . - . - . - . - . - . - . - . - . - .
OPERATOR CABIN
r.-.-.-.-.--. 1
OPERATING PR~GRAMMING PRINTER I HMI GRAPHICAL DlSPlAY UNIT/ I
! 'OPERATOR CONTROL TERMINAL WITH'
. .
..
1 .
.
' 1
f l.
A .
1 1.
. I PC BASED WORK STATION A4 SIZE
/ \
I r GRAPHICAL USER INTERFACE
, I
I . '
I
I
/ H I * .. ,\ I
I
- I
!
I .
* I
PLC PROCESSOR-:!
KBD
7 -
- I
. . I .
. I
INCEFENDENT DUAL DATA COMMU I(:ATION LIEIK ON ETHERNET
*
I
PLC PROCESSOR-1
I
.
. I
I
4 C
I
- .I
I -
I
: .I
! ; I
L .-.-.-.-.-, __I
:I
-
*-
-INK !- * .
. 1. j l . .
3
-
INDEPENDENT
I
DUAL I/O COMMUNIC,ATION
4
H
I
b r
. -
. -
I
I -
. . -
I ' . .
. .
I -
I
. _
. . I I
. i
1/0 RACK
I I
B
L. - . - . - . - . - . - . - . - . L. - . - . - . - : - . - . - . - j.-
FOR EACH STACKER MACHINE AND RECLAIMER MACHINE
, . FOR TENDER* PURPOSE ONLY
. .
. .
NOTES; - -
- MC-TMUXDU XNKRGY COYPW im.
( r a n wMMYOm~ n e I y I )
1. PLC PROCESSORS-1 C2 SHALL BE I N HARDWARE AS WELC AS
SOFTWARE BASED REDUNDANCY CONFIGURATION.
VALLUR-INTERNAL-CHP-SLD-DWC
m.
m
- -
DIJC*rrm
--&a;YLn
- ~ l f f - ~ ~ m w o r c a ~ ~ ~ m p r m a ~ a a r r c r
(amaon)
INnzNAL COAL ImiDmo BYSPgl
.TYPICAL PtC CON?lGUIUTlON
=
4 m rn m', ,
, . Y
lUClDw
I I
SH. 1 OF 1 -
I
IUU m m
oeao-iae-POE-A-oor

SECTION-VI
PART-F

PART - F

LIST OF MANDATORY SPARES

CLAUSE NO. LIST OF MANDATORY SPARES

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
1 of 22

S.N. ITEM QUANTITY Unit
1 Mechanical

A) IDLERS
1 i) 35
o
Troughing idlers complete with
base frame and mounting brackets
etc.
200 nos
ii) Rolls for (i) above 300 nos.
2 i) Troughing idlers complete with
base frame & mounting brackets
etc. (for belt feeder).
20 nos.
ii) Rolls for (i) above 30 nos. of each type
3 i) 35
0
impact idlers complete with
mounting brackets and base frame
etc.
100 nos.
ii) Rolls for (i) above 300 nos.
4 35
0
troughing training idler
complete with base frame and
brackets etc. (if used)
20 % of total installed quantity
5 Transition idler complete as in (1)
above
5 nos.
6 Flat return idlers complete with
mounting brackets etc.
100 nos.
7 Flat return idlers complete with
mounting brackets etc.(for belt
feeders)
10 nos.
8 Flat return trainer complete with
mounting brackets etc.
10 nos.
9 Belt cleaning spiral rubber disc
return idler complete with mounting
brackets etc.
10 nos.
10 i) Two roll 10
o
troughing return idler
assy
40 nos.
ii) Rolls for (I) above 40 nos.
11 SS idlers 2 sets of each type
B) CONVEYOR GEAR BOXES
(including, boom conveyor, belt
feeders & intermediate conveyor
of S/R)

i) Input shafts with pinion 1 set of each type and rating
ii) Oil seals 2 sets of each type and rating

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
2 of 22

iii) Bearings 1 set of each type and rating
iv) Hold back device 2 nos. of each type and rating
v) Cooling fan with cover 2 nos.of each type and rating
vi) Complete gear box assy with hold
back device
1 set of each type and rating
(for population upto 10
Nos)
2 sets of each type and rating
(for population more than
10 Nos)
C) CONVEYOR DRIVE AND
CONVEYOR BELT

a) Gear Coupling/ other type of
coupling

i) All types of drive couplings
including gear Coupling
2 nos. of each type
ii) Bolts for gear coupling 2 sets of each size
iii) Seal kit for gear coupling (o-ring) 2 sets of each type
b) Fluid Coupling
I) Fluid Coupling complete 1 no. of each type and size
Nos)
(for population more than
10 Nos)
ii) Multi Disc assembly (for fluid
coupling)
4 nos each type and size
iii) Resilient Drive plate assy. 1 no. of each type and size
iv) Bearings 1 no. of each type and size
v) Seal kit for fluid coupling 2 sets of each size
vi) Fusible plug 10 nos. of each size
vii) Complete actuator and engaging
assembly (including motor, gear
box etc.)
1 set of each type
viii) Oil Cooler assembly (if applicable) 1 set of each type
ix) Oil pump-motor set (if applicable) 1 set of each type
x) Water pump motor (individual or
group)
1 set of each type
xi) Oil filters 5 sets of each type
xii) Oil/Cooler valves (if applicable) 2 nos. of each type


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
3 of 22

c) Belting
Conveyor Belt
i) Main Conveyors one drum length of 200 m of
each type, size and rating
ii) Boom conveyor, belt feeder &
bunker seal belt
two complete length of each
type, size and rating
d) Brakes
i) Brakes 1 no of each size & type
ii) Brake shoes 2 sets of each size

D)
PULLEYS
i) Pulleys complete with shaft
excluding bearing & plummer
blocks (complete with lagging)
1 no. of each type and size in
pulley drum and shaft
dia.(for population upto 10
Nos)
pulley drum and shaft
dia.(for population more
than 10 Nos)
ii) Plummer Block complete with
bearings & sleeves
2 no. each type and size
iii) SS Pulleys complete with shaft
excluding bearing & plummer
blocks (complete with lagging)
pulley drum and shaft dia.
E)
BELT CLEANERS AND SKIRT
BOARD

i) Modular segments for belt cleaner 5 %of total population of each
type & size

ii) Modular segments for skirt board 5 %of total population of each
type & size

iiI) Skirt Rubber 5 %of total population of each
type & size

iv) Complete belt cleaner (internal /
external )
2 %of total population of each
type & size
F)
IN-LINE MAGNETIC
SEPARATORS

i) Cleated conveyor belt 1 set
ii) Motor, gear box drive assy.
complete
1 set
iii) Pulleys with plummer block &
bearings
1 set of each size & type
iv) Sheaves 1 no. of each size & type

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
4 of 22

v) V-belts 2 no. of each size & type
G)
COAL SAMPLER
i) Plummer block 1 no. of each type and size
ii) Hammers 1 set of each type and size
iii) Liner plate 1 set
iv) Cutter lip 1 no.
v) Cutter seal 1 no.
vi) V-belts (for crusher) 1 sets
vii) Hammer pins 1 sets of each type and size
viii) Pulley 1 no. of each type and size
ix) Conveyor belt 1.2 times length of each type
and rating
x) Gear box assembly for conveyor 1 no. of each type and rating
xi) Gear box drive assy, for primary
and secondary samplers
1 set of each type and rating
xii) Solenoid valves with coils 2 set of each type
xiii) Hydraulic pump with motor and
coupling
1 set of each type
xiv) Hydraulic motor 1 set of each type
xv) Hydraulic cylinder 1 set of each type
xvi) Cylinder sealing kit 2 set of each type
xvii) Set of hoses 2 set of each type
xviii) Coupling with grid for primary
sampler
2 sets
xix) Screw conveyor gear box assembly 1 set
H) COAL CRUSHER (Ring
Granulators)

i) Plummer Block assembly complete
including bearing, lock nut, lock
washer etc.(DE+NDE)
2 Sets
ii) Shaft seal 4 sets
iii) Hammer sets

10 sets or 750 Nos whichever
is more (1 set means
hammers required for one
crusher)

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
5 of 22

iv) Rotor assembly complete
consisting of rotor shaft & keys,
End discs, Centre discs, distance
rings, suspension bars, disc
clamping nuts and shaft extension
etc. but without hammers, bearings
and pillow blocks
1 set
v) Cage bars, if applicable 4 Set
vi) Breaker plates 4 Sets
vii) Crusher frame Liners 2 Sets
viii) Suspension bars 4 Set
ix) Kick-off plate 4 Set
x) Screen plate upper & lower 4 no. each
xi) Tramp iron pick up plate 2 no. each
xii) Fluid coupling
a) Fluid coupling complete 1 set
b) Bearings 2 set
c) Seal kit (sealing rings) 2 sets
d) Fusible plugs 8 nos.
e) Oil pump motor set (if applicable) 1 set of each type
f) Water pump motor set (if
applicable)
1 set of each type
g) Oil filter 3 sets
h) Complete actuator and engaging
assembly (including motor, gear
box etc.)
1 set
I) Cooler assembly (if applicable) 1 no.
j) Oil / Water valves 2 nos. of each type
k) Gear Coupling of crusher drive
along with bolts and sealing kit.
2 sets
l) Multi Disc assembly (for fluid
coupling)
m) Resilient Drive plate assy 2 sets of each type and rating
n) One complete hydraulic door
operating mechanism for one
crusher including hydraulic
cylinders, hoses, valves, hydraulic
pump, panels, limit switches

1 set

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
6 of 22

I) VIBRATING SCREENING
FEEDER

i) Bearings 2 no. of each type & size

ii) Seals 2 no. of each size

iii) Liners 1 set

iv) Screen plates 10 Sets

v) Unbalanced shafts/ weights/ blocks 1 set of each type and rating
and direction

vi) Sheaves 1 set of each type and rating
and direction

vii) Hoses (if applicable) 2 set

viii) Drive unit assembly (including
electric motor, hydraulic pump,
hydraulic motor, flexible shaft, gear
box, as applicable)
1 set

ix) Base springs, rubber pads 2 sets. of each type & size

x) Any other type of springs 2 sets. of each type & size

xi) V belts

4 sets. of each type & size

xii) Plummer Blocks 2 sets of each type & size
J) ELECTRIC HOISTS
i) Brake linings 2 sets of each type
ii) Rope guide & rope tightner 1 no. of each type
iii) Limit switch 2 nos. of each type & size
iv) Gear box/gear set 2 sets of each type
v) Motor/geared motor 1 no of each type & rating
vi) Drum bearing 1 set of each type & rating
K) FLAP GATES (INCLUDING THAT
OF TRIPPERS)

i) Limit switch 8 nos. of each type & rating
ii) Actuator (complete with motor, gear
box, limit switches etc.)
2 nos. of each type & rating
iii) Oil seals of Actuator 2 nos. of each type & rating
iv) Flap gate shaft 1 nos. of each type & rating
v) Pressure nut

12 nos. of each type & size
L) RACK & PINION GATE
i) Limit switch 2 no. of each type & size
ii) Rollers with bearings 2 no. of each size

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
7 of 22

iii) Motor gear box assembly 1 set of each type
iv) Actuator (complete with motor, gear
box, limit switches etc.)
1 nos of each type & rating
M) SUMP PUMP (If applicable)
i) Complete pump assembly with
pump, motor, coupling base etc
1 set
ii) Impeller with key & nut 2 set of each size & type
iii) Oil seal 2 nos. of each size
iv) Coupling bolt with bushes 2 set of each type
v) Pump shaft 2 no. of each size
vi) Shaft sleeve 2 sets of each size
vii) Bearing bush 2 sets of each size
viii) Set of bearings 2 sets
N) DUST SUPRESSION & SERVICE
WATER SYSTEM

a) Pump impeller with key & nut 1 set of each type & size
b) Pump Shaft 1 no of each type & size
c) Bearings 1 sets each type & size
d) Wearing rings 2 sets of each type & size
e) shaft sleeve 2 sets of each type & size
f) Bushings 2 sets of each type & size
g) Coupling bolts & nuts (with bushes) 1 sets each type & size
h) Spray nozzles 50 nos. of each type & size
i) Solenoid valves 5 % of each type and size
j) Globe valve / plug valves 10 % of each type and size
k) Gate valve 2 nos. of each size
l) Strainers 1 no. of each type
m) Pressure regulating station 2 sets of each type & size
n) Water and air hoses 2 sets of each type & size
o) Pressure gauges 2 sets of each type & size
p) Null
q) Compressors
i) Air filter element 8 Nos.
ii) Oil filter 6 Nos.
iii) Discharge check valve 3 Nos.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
8 of 22

iv) Inlet valve assembly 2 Nos.
v) Oil pump parts (including
distance ring, eccentric ring,
pump element, pin, key, O-ring
2 sets
vi) Electronic regulator 3 Sets
O) VENTILATION SYSTEM
i) V-Belt 1 set of each type
ii) Pre-filter element of pressurizing
fans
2 sets of each type
iii) Foundation Rubber pads 1 sets of each type & size
iv) Bearings 1 sets of each type & size
v) Plummer Blocks 1 set of each type & size
P) TRAVELLING TRIPPER
i) Complete drive assembly including
gear box, coupling, brake etc.
1 sets of each type & size
ii) Null
iii) Bearings for gear box 2 sets
iv) Drive axle with wheels, plummer
blocks, bearings etc.
1 set
v) Oil seals of gear box 2 nos. of each size
vi) Non-drive axle with wheels
plummer blocks, bearings etc.
1 set of each type
vii) Flap gate actuator with motor, gear
box, position / thrust switches
1 set of each type
viii) Chain assembly with sprockets 1 set of each type & size
ix) Festoon Roller assembly for flexible
cable
4 Nos
x) Pulleys and plummer block
bearings
2 nos of each type and size

Q)

STACKERS
(Including boom conveyor)

1 Fluid coupling (complete) 1 no. of each type, size and
rating
2 Fluid coupling spares
i) Fusible plug 4 sets for each type of
coupling
ii) Oil seals 4 sets for each type of
coupling
iii) Bearings 2 set of each type

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
9 of 22

3 couplings consisting input and
output halves (for travel drive)
1 no. of each type and rating
4 Bearings excluding slewing
bearings
5 Hydraulic pump for luffing, slewing,
with electric motor, coupling, valves
etc.
1 set of each type, size and
rating
6 Hydraulic cylinder assembly
including those of boom luffing,
operator cabin, skirt board along
with solenoid valves, distributors
etc. mounted on cylinder
2 sets of each type, size and
rating
7 Hydraulic motor for slewing 2 Set of each type and rating
8 Repair kit for hydraulic cylinder
including oil seals etc.
2 set for each type of cylinder
9 Grease pump 1 no. of each type, size and
rating
10 Null
11 Solenoid valves 2 nos. of each type
12 Slew gear Box 1 No. of each type, size and
rating
13 Out put Shaft after slewing gear
box for slewing operation (with key)
1 no
14 Carbon brushes for current
collector of cable reeling drum
2 sets for each drum
15 Plummer blocks and bearings of
(CRD)
1 set of each type
16 Traverse drive assembly consisting
of reducer, couplings, brake assy.
etc.
1 no. of each type and
direction
17 Brake shoes 4 sets for each type of brake
18 Complete carriage wheel assembly
(Each set comprising of 1 wheel + 1
axle + 2 bearing + 2 locking assly)
1 sets
19 Drive assembly of cable reel drive
consisting of motor, gear box,
coupling, brake etc.
rating
20 Chain & chain sprockets 1 set of each type, size
21 Cable guide assembly 1 set of each type, size
22 Various plummer block used in
Stacker
1 no. of each type & size
23 Plummer block with bearing for
cable reel drums
1 set of each type
24 Rail clamp assembly 1 set of each type

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
10 of 22

25 Seal kit for thrustor assembly 1 set of each type
26 Thrustor cylinder assembly 1 set of each type
27 Filter element (1 No. Pressure Filter
+ 1 No. Return Filter)
5 sets
28 Hydraulic Hoses 2 sets

R)

RECLAIMERS
(Including boom conveyor)

1 Fluid coupling (complete) 1 no. of each type, size and
rating
2 Fluid coupling spares
i) Fusible plug 4 sets for each type of
coupling
ii) Oil seals 4 sets for each type of
coupling
iii) Bearings 2 set of each type
3 couplings consisting input and
output halves (for travel drive)
4 Bearings excluding slewing
bearings
1 no.of each type and rating
5 Hydraulic pump for luffing, slewing,
bucket wheel drive with electric
motor, coupling, valves etc.
rating
6 Hydraulic cylinder assembly
including those of boom luffing,
operator cabin, skirt board along
with solenoid valves, distributors
etc. mounted on cylinder
2 sets of each type, size and
rating
7 Hydraulic motor for slewing, bucket
wheel
2 Set of each type and rating
8 Repair kit for hydraulic cylinder
including oil seals etc.
2 set for each type of cylinder
9 Grease pump 1 no. of each type, size and
rating
10 Null
11 Solenoid valves 2 nos. of each type
12 Slew gear Box 1 nos of each type, size and
rating
13 Out put Shaft after slewing gear
box for slewing operation (with key)
1 no
14 Gear Box of bucket wheel 1 nos of each type and size
15 i) Carbon brushes for current
collector of cable reeling drum
2 sets for each drum

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
11 of 22

16 ii) Plummer blocks and bearings of
(CRD)

1 set of each type
17 Traverse drive assembly consisting
of reducer, couplings, brake assy.
etc.
1 no. of each type and
direction
18 Brake shoes 4 sets for each type of brake
19 Complete carriage wheel assembly
(Each set comprising of 1 wheel + 1
axle + 2 bearing + 2 locking assly)
1 sets
20 Complete bucket with liners, pins,
wedges
1 bucket
21 Drive assembly of cable reel drive
consisting of motor, gear box,
coupling, brake etc.
rating
22 Chain & chain sprockets 1 set of each type, size
23 Cable guide assembly 1 set of each type, size
24 Plummer block for bucket wheel
drive
25 Various plummer block used in
reclaimer
26 Plummer block with bearing for
cable reel drums
1 set of each type
27 Rail clamp assembly 1 set of each type
28 Seal kit for thrustor assembly 1 set of each type
29 Thrustor cylinder assembly 1 set of each type
30 Filter element (1 No. Pressure Filter
+ 1 No. Return Filter)
5 sets
31 Hydraulic Hoses 2 sets
S) ELEVATOR
a. Brake
1. Tool to brake 1 No.
2. Fan 1 No.
3. Magnet coil with housing pads 2 Nos.
4. Brake pads 6 Nos.
5. Adjusting sleeve 2 Nos.
6. Fixed brake disc 2 Nos.


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
12 of 22

b. Worm Gear
1. Worm gear 1 no.
2. 'O' ring 2 nos. of each type
3. Sealing ring 2 nos. of each type
c. Door Front
1. Bearing 2 Nos.
2. Roller 3 Nos.
3. Bushing 2 Nos.
d. Limit Cams
1. Sensor 1 No
2. Switch 2 Nos.
3. Switch arm 2 Nos.
e. CAD
1. Guide roller 50 % of the total ones installed
each type or minimum 1 no.
whichever is higher
2. Switch 1 no.
f. Sliding Door
1. Rollers 4 nos. of each type
g. Machinery
1. Guide roller 2 nos.
2. Pinion 1 no.
3. Rubber inserts 6 nos.
4. Grove ring 6 nos.
5. Brake motor 1 no.
h. Cable trolley
1. Ball bearing 2 nos. of each type
T) DUST EXTRACTION SYSTEM
1 Fan Motor 1 nos. of each type & rating
2 Plummer Blocks 2 sets. of each type
3 Bearing of fans & motor 1 sets of each type
4 Pulley 2 nos of each type
5 Belts 2 sets. of each size
6 Null
7 Null

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
13 of 22

8 Null
9 Motor terminal blocks with studs for
all motors
1 set of each rating and type
of motor
10 Spray nozzle 10 nos of each type
11 Solenoid valve with coil 2 nos of each type
II "ELECTRICAL"
A) CONVEYORS
(including Boom
Conveyor/intermediate conveyor of
stacker reclaimers/belt feeders)

1 Drive Motor (LT and HT) 1 no. of each type & rating
nos.)
(for population more 10
Nos)
2 Belt Sway Switches 5 % of each type
3 Pull cord switches 15 % of each type
4 Zero speed switches 15 % of each type
5 Chute Block switches 15 % of each type
6 Position switches for trippers 10 % of each type
7 Sensor/probe for zero speed switch 20 %(min. 1 no)of each type
and speed range
8 Micro/limit switch of pull cord
switch, belt sway switches, chute
block switches
20 %(min. 1 no)of each type
9 Motor terminal block with studs for
all motors
1 set. of each type and rating
of motor
B) CRUSHING EQUIPMENT
1 Motor of crusher 1 No.
2 Set of pressure, temperature flow
switches, zero speed/under speed
switches, limit switches etc.)
2 nos. of each type and rating
all motors
1 set. of each rating and type
of motor


SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
14 of 22

C) MAGNETIC SEPARATORS
1 Rectifier with surge absorber 1 set
2 Rectifier transformer 1 no.
3 Auxiliary and power relays 2 nos. of each type
4 Control transformers 1 no. of each type
5 Ammeter 2 nos. of each type
6 Under current relay 1 no. of each type
7 Isolating switch 1 no. of each type
all motors
of motor
D) COAL SAMPLER
1 Motors 1 no. of each type
2 Set of various limit switches 2 nos. of each type
3 Zero speed switch 1 no. of each type
4 Solenoid valves with coils 2 nos. of each type and size
all motors
of motor
E) TRAVELLING TRIPPER
1 Drive motor 1 no.
2 Brake assembly for traverse drive
complete
2 sets
3 Set of limit switches 2 nos. of each type
4 Cable tension switches with lead 2 sets of each type
5 Infra red anti-collision device 1 set
6 Any other type of motor (flap gate
motor)
1 no of each type and rating
all motors
of motor
8 Festoon roller assembly 2 sets
F) METAL DETECTOR
1 Cards 1 set complete
2 Relays 2 nos. of each type
3 Coils of metal detector 2 sets
4 Cables for search coils 1 set
G) BELT WEIGHER
1 Set of cards 2 nos. of each type

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
15 of 22

2 Load Cells 2 nos. of each type
3 Display Unit 2 nos. of each type
4 Speed sensor 1 nos. of each type
5 Cables for load cells & speed
sensor
2 sets
6 Transducer, if applicable 2 nos. of each type
H) STACKERS
1 Motor (other than those covered in
A)(1) above)
2 Proximity detectors 5 % of total population min 1
no
3 Level switches 5 % of total population min 1
no
4 Rotation digit emitters (Flashing
Beacon)
5 % of total population min 1
no
5 Limit Switch 5 % of total population min 1
no
6 Pressure switch 5 % of total population min 1
no
7 Temperature switch 5 % of total population min 1
no
8 Cable tension switches with loads 2 sets. of each type
9 Flow switches 2 nos. of each type
10 Flexible Trailing cable (power &
control)
1 length of each size & rating
LT drive of Stacker
11 Transducers of thyristor/VVF/VFD
pane
2 nos. of each type
12 Complete converter and inverter
unit consisting of Thyristors of
thyristor/Main control Transistor
(main current carrying components)
1 Set of each type
13 Potentiometers of thyristor /
equivalent panel
10 Nos. of each type
14 Set of cards of thyristor/Power
Board Gate Drive Board
2 Sets complete
15 All type of electronics modules 10 % or 1 no(whichever is
more)of each type and
model
16 Input and out put chokes 1 set
all motors
of motor

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
16 of 22

18 Coupling relays 10 Nos. of each type
Slew Drive
panel
2 nos. of each type
1 Set of each type
equivalent panel
10 Nos. each type
2 Sets complete
model
24 Input and output chokes 1 set
all motors
of motor
I) RECLAIMERS
1 Motor (other than those covered in
A)(1) above)
2 Proximity detectors 5 % of total population min 1
no
3 Level switches 5 % of total population min 1
no
4 Rotation digit emitters (Flashing
Beacon)
5 % of total population min 1
no
5 Limit Switch 5 % of total population min 1
no
6 Pressure switch 5 % of total population min 1
no
7 Temperature switch 5 % of total population min 1
no
8 Cable tension switches with loads 2 sets. of each type
9 Flow switches 2 nos. of each type
10 Flexible Trailing cable (power &
control)
1 length of each size & rating
LT drive of Reclaimer
pane
2 nos. of each type
1 Set of each type

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
17 of 22

equivalent panel
10 Nos. of each type
2 Sets complete
model
16 Input and out put chokes 1 set
all motors
of motor
Slew Drive
panel
2 nos. of each type
1 Set of each type
equivalent panel
10 Nos. each type
2 Sets complete
model
24 Input and output chokes 1 set
all motors
of motor
J) AUXILIARY TRANSFORMERS
(DRY)

i) HT Bushing 3 nos. of each type & rating
ii) LT Bushing 3 nos. of each type & rating
iii) Neutral bushing 1 no. of each type & rating
iv) Neutral CT 1 no. of each type & rating
v) Winding temp. indicator with alarm
& trip contacts
1 no. of each type
K) HT LOAD BREAK SWITCH AND
JUNCTION BOX

i) Trip coil 1 no.
ii) Support Insulators

1 set.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
18 of 22

L) BUS DUCT
i) Support insulators 3 no. for each type & rating
ii) Flexible terminal connectors for
switchgear end with fasteners.
1 set of each rating
iii) Flexible terminal contactors for
transformer end with fasteners.
1 set of each type
iv) Enclosure expansion bellows(if
applicable)
1 set of each type
M) L.T. SWITCHGEAR / MCCs,/
DISTRIBUTION BOARDS

a) Circuit Breaker Components
i) Spring charging motor 4 no. of each type
ii) Primary disconnect (power) 1 no. of each type
iii) Auxiliary contact set 2 set of each type / rating of
breaker
iv) Limit switch 5 nos. of each type
v) Arc chutes for each rating 2 sets
vi) Moving contacts of each rating 1 sets
vii) Fixed contact of each rating 2 sets
viii) Arcing contact of each type 2 sets
ix) Closing coils for each type 10 nos.
x) Tripping coils for each type 10 nos.
xi) Closing & tripping springs 5 nos. of each type
xii) Releases 2 nos. of each type
xiii) Carbon brushes for spring charging
motor
5 sets of each type
xiv) Over current devices 1 no of each type and rating
xv) All type of protection/aux/relays,
timers
xvi) Coupling relays 10 nos of each type and rating
b) LT panel components
i) Auxiliary contactor 2 nos of each type and rating
ii) Coupling relays without base 10 nos of each type and rating
iii) Bi-metallic overload relay 2 nos of each type and rating
iv) Overload relay reset chord
complete
10 nos of each type
v) Switch fuse unit 5 nos of each type and rating
vi) Control fuse base with carrier 20 nos

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
19 of 22

vii) LT module incoming male/female
power contacts
viii) LT module outgoing male/female
power contacts
ix) Moving/detachable control
disconnects contacts of each rating
x) Power fuse base with carrier 3 sets(9nos)of each type and
rating
c) Instrument Transformer
I) Current Transformer 3 nos of each type & rating
ii) Voltage Transformer 1 nos of each type & rating
d) Control supply transformer 1 nos of each type & rating

e) Meters
i) Ammeters 2 nos of each type & range
ii) Voltmeters 1 nos of each type & range
f) Relays (Protection, aux, coupling
relay and timers)
1 nos of each type
g) Contactors
I) Contactors and aux. Contactors
(complete)
ii) Coil for the Contactors and aux.
Contactors
iii) Main Contacts sets for power.
Contactors
h) Control, isolating & selector
switches
i) Push button of Various colours 2 nos of each type & rating
N) CONTROL PANEL
(Main control desk,
Stacker/Reclaimer control desk &
local control panels of metal
detector, magnetic separator, coal
sampling system, belt weigher,
hoists, dust suppression system,
sump pumps, fluid couplings etc.)

i) Control supply transformers 1 no. of each type & rating
ii) Relays and timer 1 no. of each type & rating
iii) Contactors 1 no. of each type & rating
iv) Ammeters 1 no. of each type & rating
v) Voltmeters 1 no. of each type & rating

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
20 of 22

vi) LEDs 5 nos. of each type & rating
vii) Control switches 1 no. of each type
viii) Selector switches 1 no. of each type
ix) Push button (complete with contact
elements)
1 no. of each type & colour
x) Auxiliary contactors and bimetallic
overload relay set for panel
1 complete set
xi) Control fuse base with carrier
complete set for panel
1 complete set
xii) Any special meter 1 no. of each type
xiii) Bi-metallic overload relay 2 complete sets
Note Spares already covered under
respective equipment spares shall
not be duplicated under control
panel spares.

O) PLC (STACKER / RECLAIMER )
i) PLC cards (Processor, memory and
all cards other than I/O cards)
1 no. of each type
ii) Stabiliser 1 no. of each type
iii) Power pack 1 no. of each type
iv) I/O cards 2 nos. of each type & rating
v) Fuses & Fused terminals 10 nos. of each type & rating
vi) Set of cards for UPS 1 set
vii) Modems 1 no. of each type
viii) Optical fibre cable 10 %
P) VIBRATION MONITORING
SYSTEM

i) Vibration pick up 2 Nos of each type
ii) Pick up cable 1 length of each type
iii) Vibration monitor module and other
cards
1 no. of each type
iv) Power supply 1 no. of each type
v) Relays 2 nos. of each type
Q) DUST SUPRESSION & SERVICE
WATER SYSTEM

i) Electric motor 1 nos. of each type & rating

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
21 of 22

ii) Flow switches 2 nos. of each type
iii) Pressure switches 2 nos. of each type
iv) Level switch 2 nos. of each type
R) SUMP PUMP (If applicable)
i) Level switch 1 set of each type
S) VENTILATION SYSTEM
i) Electric motor 1 nos. of each type & rating
T) ELEVATORS
i) Contactors 4 nos. of each type
ii) Auxiliary Transformer, control
transformer
iii) Relays 4 nos. of each type & rating
iv) Resistor 6 nos. of each type & rating
v) Switch 1 no. of each type
vi) Rectifier 10 nos.
vii) Limit switch 4 nos. of each type
viii) Battery Charger 1 no. of each type
ix) Tone frequency transmitter 1 set of each type
x) Tone frequency receiver 1 Set of each type
U) VIBRATING SCREENING
FEEDER

i) Motor terminal block with studs for
all motors
1 set of each rating and type
of motor
ii) Cards of variable frequency drive of
vibrating screening feeders
1 set

Note :
1. Unless stated otherwise a set means items or sub-items required for each type/size
range of the assembly/ sub-assembly, required for replacement in one main equipment.It
is further intended that the assembly/ sub-assembly which have different orientation( like
left hand or right hand, top or bottom), different direction of rotation or morrior image
positioning or any other reasons which result in maintaining two different sets of the
spares to be used for the subject assembly/ sub-assembly, these shall be considered as
different types of assembly/ sub-assembly.
2. Wherever quantity has been specified as percentage (%), the quantity of mandatory
spares to be provided by contractor shall be the specified percentage (%) of the total
population of the plant. In case the quality so calculated happens to be a fraction, the
same shall be rounded off to next higher whole number.

SECTION VI, PART-B
BID DOC NO.: CS-0260-156-2(R)
PART - F
MANDATORY SPARES

Page
22 of 22

3. Whenever the quantities have been indicated for each type, size, thickness, material,
radius, range etc., these shall cover all the items supplied and installed and the breakup
for these shall be furnished in the bid.
4. In case spares indicated in the list are not applicable to the particular design offered by the
bidder, the bidder should offer spares applicable to offered design with quantities generally
in line with the approach followed in the above list.
5. Price of each and every item is to be given separately.
6. If some spares are common among stackers and reclaimers; or among other equipments;
or being repeated, maximum number of the same mentioned at one place are to be
considered for the bid.



SECTION VII, ATTACHMENT-12

TECHNICAL DATA SHEETS
FOR



SECTION VII, ATTACHMENT-12

FOR


This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred,
reproduced or otherwise used for purposes other than that for which it is specifically issued.

CONTENTS

NTECL Power Project (3x 500 MW)
(Vallur TPP 3 x 500MW)
IN PLANT COAL HANDLING
SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
CONTENTS
Page
1 of 1

SECTION DESCRIPTION

SECTION A TECHNICAL INFORMATION AND DATA TO BE SUBMITTED
WITH THE PROPOSAL

SECTION B TECHNICAL INFORMATION AND DATA TO BE UBMITTED
AFTER AWARD OF CONTRACT

ATTACHMENT 12 TO SECTION -VII

SECTI ON - A
TECHNICAL INFORMATION AND DATA
TO BE SUBMITTED WITH THE PROPOSAL

Clause No.

TECHNICAL INFORMATION AND DATA TO BE SUBMITTED
WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
1 of 40

SECTION A

TECHNICAL INFORMATION

1.0 The Bidder shall furnish complete technical literature supported by Manufacturer's
catalogues/leaflets, general arrangement schematics, layout etc. for complete coal
handling plant including the following:

1.01 General Plan, showing layout of the proposed conveyor system.

1.02 Coal Flow Diagram

1.03 Sectional Elevation drawings of all conveyors with chutework.

1.04 General Arrangement Drawings of all Coal Handling Plant Buildings with the
housed equipment.

1.05 General Arrangement drawings for all major mechanical & electrical equipments
showing constructional features and space requirement for operation and
maintenance of the equipment.

1.06 Descriptions and write-up of the control systems.

1.07 Details of instrumentation such as speed monitoring system,
pressure/Flow/Temperature sensors/switches, levels sensor/switches, and other
switch devices such as belt sway switches, pull cord switches etc.

1.08 Electrical single line diagrams, typical control schematic.

GA drgs and typical foundation plan for all major electrical equipt. eg. control
panels, 3.3 KV, 415 V motors, switchgear/MCC, transformers etc. showing
constructional features and space requirement for their operation and
maintenance.

1.09 Descriptive literature of all major electrical equipment (viz. circuit breaker, Air
break switches, contactors, Thermal over load relays with single phasing
preventor, fuses, Relays and Releases, Instrument Transformers, Control
Transformers, Cable trays fitting & accessories, cable termination and jointing kits
etc.), instruments panels etc, supplied along with catologues.

1.10 The drawings and information related to the civil, structural and architectural work
to be executed under this contract:

a) Preliminary general arrangement and architectural drawings indicating the
conceptual design, grade of concrete and steel used, thickness of concrete
structural members, steel sections, and typical architectural details etc.

b) All assumptions made and loading taken for the design (Including
equipment loads) shall be clearly indicated.
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
2 of 40

c) The capacity, type, length, diameter & reinforcement details of piles.
Typical design calculations justifying the capacity of pile assumed shall be
furnished along with the bid.

d) A broad outline of steel erection scheme.

e) Names of manufacturers for all bought out items like doors, windows,
louvers, rolling shutters, fixtures and fittings, paints etc. Manufacturers
catalogues for all hardware and fixtures shall also be supplied.

2.0 The Bidder shall enclose with his proposal a list of items of non-Indian origin.

3.0 Bidder to fill up all the data in the data requirement while submitting the bid. For
the Transfer points, which are in others Scope & where the bidder shall install his
conveyor/equipment, Load data for design of such TPs shall be furnished to the
Employer.

4.0 Bidder shall indicate proposed makes of all the items/equipments pertaining to the
Coal Handling Plant Package and shall Annex with the document separately.
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
3 of 40

TECHNICAL DATA

I. COAL HANDLING EQUIPMENT, DUST CONTROL & MISC SYSTEMS,
VENTILATION SYSTEM
Bidder to fill separate sheets for separate items/equipment.

1.00.00 BELT CONVEYOR SYSTEM Conveyor nos.

1.01.00 Conveyor Capacity, MTPH

a) Rated (Guaranteed)
b) Design

1.02.00 Belt width, mm

1.03.00 Belt speed, m/sec

1.04.00 Length, centre to centre,
meter

1.05.00 Lift, meter

1.06.00 Max. angle of inclination

1.07.00 Type of take-up

1.08.00 Conveyor belting

1.08.01 Type of fabric / chord

1.08.02 a) Belt Rating

- Nylon Nylon

- Steel Cord

b) Cover thickness Synthetic belting Steel cord belting

- Top (mm)
- Bottom (mm)

1.08.03 Code/Standard to which the
beltings conforms to

1.09.00 Angle of wrap, over
drive pulley, degrees

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
4 of 40

1.10.00 Drive Pulleys diameter

1.11.00 Tail and Take-up pulleys diameter

1.12.00 Bend and snub pulleys diameter

1.13.00 Discharge Pulley diameter

1.14.00 Troughing idlers

1.14.01 a) Shell dia., mm

b) Shell thickness, mm

1.15.00 Return Idlers



1.15.02 Troughing angle, degrees

1.16.00 Self aligning return
idlers



1.17.00 Rubber disc type Impact
idlers



1.17.02 Rubber disc dia (OD), mm

1.18.00 Self cleaning type
rubber disc. return idlers

1.18.01 Shell dia., mm

1.18.02 Diameter of rubber disc

1.18.03 No. of self cleaning idlers
for each conveyor

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
5 of 40

1.19.00 Conveyor Galleries

1.19.01 Gallery Cross-section

a) Width, mm

b) Clear headroom
inside gallery from
walkway level, mm

1.20.00 Drive Equipment for
Belt Conveyor system

a) Motor speed, RPM

b) Drive pulley speed, RPM

1.20.01 Reduction gears

a) Type

b) Nominal rating, kw

Mechanical

Thermal

c) Method of lubrication

1.20.02 Fluid Couplings

a) Type

b) Rating, kw

1.20.03 Brakes

a) Type

b) Rating

1.20.04 Flexible couplings

a) Type

b) Rating

1.20.05 Drive motors
a) Motor nameplate rating,
KW at 50 deg.C Ambient
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
6 of 40

2.00.00 CHUTES & HOPPERS

2.01.00 Chutes & hoppers
construction details

2.01.01 Material of chute plate

2.01.02 Two Trolleys provided for each
ILMS reject chute Yes/No

2.02.00 Skirt board side plate material

2.03.00 Flap Gates plate material

2.03.01 Type of actuator

3.00.00 COAL CRUSHERS

3.01.00 a) Name of Ring granulator type
Coal crusher Supplier/manufacturer

b) Experience & Details Plant 1 Plant 2

(i) Details of Installation
(address & year of
Commissioning)

(ii) Quantity & Capacity
of Coal Crusher

(iii) Application
(power plant /mines etc.)

(iv) Coal crusher parameters

- Input lump size of coal
- Output product size
- Rated crusher capacity
- Crusher RPM,

(v) Certificate from client Yes/No Yes/No
Enclosed

3.02.00 Numbers & Type offered

3.03.00 Name of Manufacturer

3.04.00 Guaranteed capacity, MTPH

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
7 of 40

3.05.00 Crusher (ring granulator)

(i) Model No.

(ii) Rotor dia x Rotor length (mm)

(iii) Rotor speed, rpm

3.05.01 size of crusher inlet
opening, mmmm (inside)

3.05.02 Guaranteed output
coal size, mm

3.05.03 Weights in kg.

a) Crusher rotor with hammers

b) Complete crusher

3.05.04 Drive Chain Arrangement

a) Motor

i) Rating (at 50
o
C temp.)

ii) speed, rpm

b) Hydraulic scoop fluid
coupling rating

c) Flexible couplings

i) Type

3.05.05 Material of construction

a) Ring Hammers

i) Material

ii) Hardness, BHN

b) Rotor Shaft

c) Suspension bars

d) Cage bars

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
8 of 40

e) Side screen plates

f) Rotor discs

g) Breaker plate

i) Material

ii) Hardness, BHN

iii) Plate thickness, mm

h) Liners

i) Material

ii) Thickness, mm

4.00.00 VIBRATING SCREENING FEEDERS

4.01.00 a) Name of Vibrating Screening
Feeder Supplier/manufacturer


(address & year of
Commissioning)

of vibrating screening
feeder

(iii) Application

(iv) VSF parameters

- VSF capacity
- Deck size (L x B)
- Vibrator type
- Coal lump feed size
- Screen size

Enclosed

4.02.00 Numbers & Type offered

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
9 of 40

4.04.00 Guaranteed capacity, MTPH

4.05.00 Solid Deck (Pan) size
(mm x mm)

4.06.00 Screening Area (mm x mm)

4.07.00 Inclination of deck

4.08.00 Vibrator

a) Type of drive

b) Type of vibrator

c) Range of feed
rate adjustment

4.09.00 Perforated Deck

a) Material

4.10.00 Solid Deck

a) Material of solid plate
of the deck

b) Liners on the solid
plate provided ? Yes/No

c) Material of liners

4.11.00 Supporting Springs

a) Type

b) Material of springs

4.12.00 Drive Motors

a) Motor name plate rating,

5.00.00 TRAVELLING TRIPPERS

5.01.00 Nos. provided


Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
10 of 40

5.01.03 Travel per tripper, m

5.01.04 a) Max. conveyor angle
over tripper, deg.

b) Radius of concave
curvature, mtr.

5.01.05 Rails, kg/m

5.01.06 Travel speed, m/min.

5.01.07 Travel Motors

a) Nos. provided

b) Motor rating, KW
at 50 deg.C Ambient

5.01.08 Tripper pulley

a) Dia, mm

b) Thickness of lagging

5.01.09 Rail clamps

a) Type

b) Location

6.00.00 BELT WEIGHING SCALES Conveyor Boom Conveyors


6.02.00 Measuring capacity

a) Max. MTPH

b) Min. MTPH

6.03.00 Location

6.04.00 Accuracy (%)

a) at maximum load

b) at minimum load

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
11 of 40

6.05.00 Rate Indicators

a) Type

b) No. of rate indicators
provided per weigher

c) Location

6.06.00 Totaliser

a) Type

7.00.00 IN-LINE MAGNETIC SEPARATORS


7.02.00 Location

7.03.00 Strength, in gauss at
400 mm distance

7.04.00 Magnet

a) Type

b) Material of magnet
core

c) Material of coil

d) Class of insulation

e) KW rating at 50 deg.C
Ambient

7.05.00 Self-Cleaning Belt

a) Belt width, mm

b) Belt specification

c) Belt speed, m/sec

d) Drive motor name plate
rating, KW at 50 deg.C
Ambient

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
12 of 40

7.06.00 Type of handling arrangement for

a) Height adjustment

b) Cross travel

8.00.00 COAL HANDLING PLANT BUILDINGS

8.01.00 Transfer points/Crusher house

8.01.01 Cladding

a) Material

b) Thickness

8.01.02 Identify Structures where
piling is envisaged

1. TP

2. Conveyor galleries

3. Control Bldgs.

4. Stacker and reclaimer foundation

5. Any other structure

8.01.03 Piles (if applicable):

a) Type:

b) Method of boring

b) Dia/ Capacity

8.01.04 No. of staircases provided

a) For TP

b) For Crusher house

c) For Main Control Room building

d) For MCC

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
13 of 40

8.02.00 Control/MCC Rooms

8.02.01 Locations

9.00.00 COAL SAMPLING UNIT

9.01.00 a) Name of Coal sampler
Supplier/manufacturer


(address & year of
Commissioning)

Of Coal samplers

(iii) Application

(iv) Coal sampler parameters

- Lump size of coal
- Suitable for belt width,
- belt capacity (TPH)

Enclosed

9.02.00 Standard /Code to which the For uncrushed For Crushed
sampling system conforms Coal Coal

9.03.00 a) Location

b) Make

c) Model No.

d) Catalogue/Technical
literature furnished ? Yes/No

10.00.00 ELEVATORS

10.01.00 Salient Particulars

i) Load Carrying
Capacity (kg)

ii) Location
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
14 of 40

iii) Type of elevator

iv) Speed (M/Min.)

10.02.00 Location of the Drive Unit

11.00.00 DUST CONTROL & MISC.
SYSTEMS

11.01.00 Sea Water Dust
Suppression System Coal stockyard

11.01.01 DS-system/zone

11.01.02 Pump house / Tanks Location

11.03.00 Dry fog system for Transfer Point & crusher house

i) Spray Bar Assembly

a) No. of spray bar assemblies per transfer point

b) Material of spray bar assemblies

c) No. of nozzles per assembly

d) Type of nozzles with flow ratings (Air/water)

ii) Pressure Regulating Units

a) No. of PRUs

b) Type of regulation

c) Regulation ranges

iii) Flow Activation Stations

a) No. of Flow Activation Stations

b) Type

iv) Compressor with accessories
a) Make
b) Model
c) Type
d) Capacity

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
15 of 40

12.00.00 METAL DETECTORS


12.01.00 Nos. provided

12.02.00 Location

12.03.00 Type

13.00.00 VENTILATION & AIR
CONDITIONING

13.01.00 Type of Ventilation Type

13.01.01 Area Description Location

13.01.02 Fans

a) Type

b) Numbers provided

- Supply

- Exhaust

13.01.04 Filters

a) Type

13.02.00 Pressurized Ventilation

13.02.01 Area Description - Location

13.02.02 Type of Ventilation System

13.02.03 Fans

a) Type

b) Numbers provided

- Supply

- Exhaust

13.02.05 Filters

a) Type
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
16 of 40

13.03.00 Air Conditioning System Main S & R S & R
Control Machine Machine
Room Operator MCC
Cabins Rooms
13.03.01 PAC Units

a) Location

b) Nos. provided

c) Capacity of each
unit (TR)

13.03.03 Compressor

a) Type

b) Nos. per PAC unit

c) Capacity, TR each

14.00.00 DUST EXTRACTION SSYTEM IN
CRUSHER HOUSE AT VSF FLOOR

a) Type of DE System

b) Dust Collection method

c) Dust disposal arrangement
upto Coal Settling Pond Yes/No

15.00.00 STACKERS AND RECLAIMERS
(Furnish applicable data separately) Stackers Reclaimers
15.01.00 Numbers furnished

15.02.00 Type

15.03.00 Stacking capacity, MTPH

a) Guaranteed

b) Design

15.04.00 Reclaiming capacity, MTPH

a) Guaranteed

b) Peak

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
17 of 40

15.05.00 Boom length, m

15.06.00 Stockpile configuration

a) Height of stock piles,
m

b) Width of stockpile
base on either side
of yard conveyor, m

c) Effective length of
each Coal pile, mtr.

15.07.00 Maximum safe wind
velocity, KMPH

a) Under operating condition

b) Under non operating
condition

15.08.00 Rail Track

a) Gauge, mm

b) Size of rails, kg/m

c) Max. wheel load, MT

d) Gross travel length, mtr.

e) Over travel limit switches

Nos per machine

Type

f) Rail clamps

Type

Numbers

Location

Method of
Operation

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
18 of 40

15.09.00 Travel Mechanism

15.09.01 Travel speed, m/min

a) Maximum speed

b) Minimum speed

c) Control for continuous
variation in speed provided Yes/No

15.09.02 Travel Carriage

a) Type of Equalising Arrangement

b) No. of wheels

Driven

Non-driven

c) Type of wheels

d) Drive arrangement

15.10.00 Bucket wheel

15.10.01 Diameter of bucket wheel, mm

15.10.02 Bucket Details

a) Number of buckets

b) Bucket wheel speed, RPM

c) Type of buckets

d) Water fill Capacity of each
bucket, (excluding ring
volume), litres

e) Total volume of ring
for complete bucket
wheel, litres

f) Peak reclaim capacity
MTPH

g) Bucket teeth replaceable? Yes/No

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
19 of 40

15.10.03 Bucket wheel drive

a) Bucket wheel speed, rpm

b) Drive arrangement

c) Gear box

i) Type
ii) KW rating
Mechanical

Thermal

iii) Method of lubrication

d) Fluid coupling, KW rating

e) Flexible coupling

i) Type

f) Brakes

Type

Make

g) Overload protection

15.10.04 Method of lubrication arrangement
provided for Bucket wheel

15.11.00 Boom Conveyor - Data to be
filled up in conveyor section
at sl. no. 1.00.00

15.11.01 Boom Luffing

a) Angle of inclination, deg.

i) Above horizontal

ii) Below horizontal

b) Method of hoisting/ lowering

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
20 of 40

c) Speed of hoisting/
lowering in m/min. at
bucket wheel centre

Maximum speed

Minimum speed

Steps of speeds

d) No. of luffing cylinders

15.12.00 Slewing Mechanism

15.12.01 Maximum slew angle, deg.

15.12.02 Slewing speed, rad/min

a) Maximum

b) Minimum

c) Control for continuous
variation in speed provided Yes/No

15.12.03 Slew Drive

a) Type

b) No. of drive pinions

c) Brakes

Type

Make

15.12.04 Slew bearing type

15.12.05 Type of lubrication arrangement
provided for slew drive

15.13.00 Operator's cabin

15.13.01 Construction

15.13.02 Location

15.13.03 Levelling mechanism

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
21 of 40

15.14.00 Tripper

15.14.01 Walkways with handrailings

a) Provided on both sides ? Yes/No

b) Width of walkways, mm

15.14.02 Radius of concave curve, m

15.14.03 Hold down pulley provided ? Yes/No

15.14.04 Maximum angle of inclination, deg.

15.15.00 Self-lubricating bearings

15.15.01 Whether provided at all
angular movement points
(hinge points)? Yes/No

15.16.00 Cables & Cable Reeling Drums

15.16.01 Location of CRDs with respect
to Rail Tracks (inside/outside)

15.17.00 Electrical room /MCC room

a) Construction

b) Location
-------------------------------------------------------------
15.18.00 Drive Motors Long Slew Bucket Boom Boom
Travel Drive wheel Conv. hoist
Drive Drive Drive Drive
-------------------------------------------------------------
15.18.01 Tentative motor rating,

16.00.00 MAKES OF EQUIPMENT
16.01.00 Bakes & clamps
16.02.00 EOT & HOT Hoists
16.03.00 Belting
16.04.00 Couplings
- Fluid Compling
- Flexible Compling
- Scoop Compling
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
22 of 40

16.05.00 Vibrating Screening Feeder
16.06.00 Crusher
16.07.00 ILMS / Magnets
16.08.00 Metal Detectors
16.09.00 Coal Sampling System
16.10.00 Elevator
16.11.00 Stacker & Reclaimer
16.12.00 Pumps DS/SW/CW/PW
16.13.00 Fans
16.14.00 PAC
17.00.00 Sub-QR data for Design agency for
4000 TPH belt conveyor system.

17.01.00 Name & Address of the design agency

17.02.00 Name & Address of the Plant for which
design of 2000 TPH conveyor system
was undertaken:

17.03.00 Scope of the main Contract :

17.04.00 Scope of design assignment :

17.05.00 Start date of Contract :

End date of Contract :

17.06.00 Duration of design assignment:

17.07.00 Software used for design:

17.08.00 Design review by

a) Owner (give details)

a) Consultant (give details)

18.00.00 Sub-QR data for design agency for civil work & structural works.

18.01.00 Design agency for civil works:
18.01.01 Name & address the design agency for civil design
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
23 of 40

18.01.02 Name & address of the plant for which design of civil works

18.01.03 Scope of civil works

18.01.04 Software used for civil design :

18.01.05 Scope of the integrated bulk material handling
contract for which design of civil works was under taken

a) Start date :

b) Completion date:

18.01.06 Duration of the assignment



b) Consultant (give details)

18.02.00 Design agency for structural works:

18.02.01 Name & address the design agency for Structural design

18.02.02 Name & address of the plant for which design of Structural works

18.02.03 Scope of Structural works

18.02.04 Software used for Structural design :

18.02.05 Scope of the integrated bulk material handling
contract for which design of Structural works was under taken

a) Start date :

b) Completion date:

18.02.06 Duration of the assignment



b) Consultant (give details)
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
24 of 40

II. COAL HANDLING ELECTRICAL EQUIPMENTS

1.00.00 Information and drawings to be submitted alongwith the following :

The following information and drawings of the proposed equipment shall be
submitted in required number of copies by the Bidder alongwith his proposal.

1.01.00 Complete technical literature supported by catalogues for all the equipments and
accessories covered in his scope of supply.

1.02.00 Instruction manuals for all the equipments covered in the Bidder's scope of supply.

1.03.00 Technical data sheets (guaranteed technical particulars) of the equipment offered.

2.00.00 Information and drawings to be submitted after the awared of the contract.

2.01.00 Contractor shall submit all the drawings, data documents, manuals, catalogues
etc. as per the requirements given under applicable sections of the specifications.

2.02.00 Drawings showing adequate details of equipment/panels and accessories offered
and typical drawings of major schemes offered.

2.03.00 Contractor shall also submit the technical data sheets (Guaranteed Technical
Particulars) of all the equipments being supplied.

2.04.00 Type test and routine test reports for all the equipments and accessories covered
under Bidder scope of supply.

3.00.00 Check list for Information and drawings to be submitted with the bid (This
checklist must be attached to the data sheet).

3.01.00 Complete technical literature Yes/No
supported by catalogue for
all the equipments and
accessories enclosed

3.02.00 Instruction manuals for all Yes/No
the equipments enclosed

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
25 of 40

MOTORS
(To be filled in for each
type & rating)

1.00.00 Manufacture & country of origin .............................. ............................

2.00.00 Equipment .............................. ............................

3.00.00 (a) Motor type (Squirrel cage/ .............................. ............................
slipring/DC etc.)
(b) Type of duty .............................. ............................

4.00.00 Frame size & type designation .............................. ............................

5.00.00 Application standard to which .............................. ............................
motor confirms

6.00.00 Stator winding insulation

(a) Class & Type .............................. ............................

(b) Tropicalized .............................. ............................

(c) Temperature rise .............................. ............................
over specified
ambient of 50
o
C

9.00.00 Power factor at rated .............................. ............................
load

10.00.00 Starting current at

100% voltage .............................. ............................

85% voltage .............................. ............................

11.00.00 Torques (kg-meter) at

(a) Starting .............................. ............................

(b) Pull - up .............................. ............................

(c) Pull - out .............................. ............................

12.00.00 Type of enclosure and .............................. ............................
method of cooling

13.00.00 Degree of protection .............................. ............................

14.00.00 Rated voltage and frequency .............................. ............................
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
26 of 40

15.00.00 Rated speed .............................. ............................

16.00.00 Type of terminal box for .............................. ............................
stator leads

17.00.00 Bearing type

(i) DE .............................. ............................

(ii) NDE .............................. ............................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
27 of 40

LT SWITCHGEAR

(Bidder to furnish following data
for each type and class of switch-
gear separately)

1.00.00 SWITCHGEAR & MCC

a) General

i) Manufacturer's Name .............................................

ii) Type designation .............................................

iii) Country of origin .............................................

b) Rated voltage .............................................

c) Symmetrical short circuit .............................................
withstand current at rated
voltage of switchgear/
MCC cubicle

d) Peak short circuit withstand .............................................
current

e) Degree of protection
as per IS:13947

i) Breaker/MCC cubicles .............................................

ii) Busbar chamber .............................................

f) Shrouding arrangement in cable Yes/No
alley provided or not

g) Earth busbar size & material .............................................

2.00.00 POWER BUSBARS & INSULATORS

a) Material & applicable standards .............................................

b) Temperature rise over design .............................................
ambient temperature for con-
tinuous current rating deg.C

c) One Second current rating (kA) .............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
28 of 40

3.00.00 CONTROL SUPPLY TRANSFORMERS

a) Make .............................................

b) Type .............................................

c) Material & class of insulation .............................................

4.00.00 CIRCUIT BREAKER

a) Manufacturer's name and country .............................................
of manufacturer

b) Rated Voltage .............................................

c) Rated operating duty .............................................

d) Design ambient temperature .............................................

e) Rated symmetrical breaking .............................................
current

f) Rated peak making current .............................................

g) Rated short time rating .............................................
(for 1 sec.)

h) Power operating mechanism .............................................

i) Spring charging motor details

i) Type .............................................

ii) Rated voltage .............................................

iii) Class of insulation .............................................

j) Emergency Manual charging Yes/No
facility provided

k) Telescopic trolley

i) Make .............................................

ii) Type designation .............................................

iii) Dimensions .............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
29 of 40

5.00.00 AIR BREAK SWITCHES
(The following details shall be
furnished for each type & rating)

a) Make .............................................

b) Type .............................................

c) Applicable standards .............................................

6.00.00 CONTROL / SELECTOR SWITCH

a) Make .............................................

b) Type Designation .............................................

c) Voltage grade .............................................

7.00.00 CONTACTOR
furnished for each type & rating)

a) Make .............................................

b) Type & applicable standards .............................................

c) Rated voltage of main and .............................................
auxliary contacts

d) Rated voltage of coils .............................................

8.00.00 CURRENT TRANSFORMER
provided for each type & rating)

a) Make .............................................

b) Applicable standards .............................................

c) Class & Type of insulation .............................................

9.00.00 VOLTAGE TRANSFORMERS

a) Make .............................................

b) Ratio .............................................

c) Class & Type of insulation .............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
30 of 40

10.00.00 RELAYS
furnished for each type & appli-
cations including coupling relay)

a) Make .............................................

b) Type .............................................

c) Application .............................................

11.00.00 415V NON SEGREGATED BUSDUCTS

a) Manufacturer's name & address .............................................

b) Type of busduct .............................................

c) Material of busbars .............................................

d) Rated voltage (volts) .............................................

e) Short circuit current ratings .............................................
& duration (kA/Sec.)

f) Temperature rise over the ambient
temperature

i) Busbars .............................................

ii) Enclosures .............................................

g) One minute power frequency .............................................
withstand voltage (kV)

h) Clearance (mm)

i) Phase to Phase .............................................

ii) Phase to earth .............................................

i) Material and thickness of Busduct .............................................
enclosure

12.00.00 LIGHTING AND WELDING TRANSFORMERS

a) Make .............................................

b) Voltage ratio .............................................

c) KVA Rating .............................................
Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
31 of 40

POWER CONTROL AND TRAILING CABLES
(Use separate sheet for each type and size of cables)

1.01.00 Make & Type .............................................

1.02.00 Country of Manufacturer ..............................................

1.03.00 Type & Designation ..............................................

1.04.00 Applicable standard ..............................................

1.05.00 Rated voltage ..............................................

1.06.00 Conductor ..............................................

a) Material ..............................................

b) Nominal cross section area ..............................................
in sq.mm

c) Shape of conductor ..............................................

1.07.00 Insulation

a) Material ..............................................

b) Nominal thickness (in mm) ..............................................

c) Type of curing (for XLPE) ..............................................

1.08.00 Type of Inner sheath ..............................................

1.09.00 Armour material ..............................................

1.10.00 Outer sheath material ..............................................

1.11.00 Over all dia cable (in mm) ..............................................

1.12.00 Guarantee value of minimum ..............................................
oxygen index of outer sheath

1.13.00 Maximum acid-gas generation ..............................................
by weight (%) of outer sheath
1.14.00 Average light transmission ..............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
32 of 40

ILLUMINATION SYSTEM

1.00.00 Lighting distribution board

a) Make ..............................................

b) Applicable standard ..............................................

c) Type of construction ..............................................

d) Degree of protection ..............................................

2.00.00 Lighting Panel

a) Make ..............................................


c) Enclosure ..............................................

3.00.00 Lighting fixtures & Accessories

a) Make of lighting fixture & ..............................................
accessories

4.00.00 Receptacles/Sockets

a) Make ..............................................

b) Type ..............................................


a) Make ..............................................

b) Type ..............................................

c) Material ..............................................

6.00.00 Terminal Blocks

a) Make ..............................................

b) Type ..............................................

c) Rating ..............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
33 of 40

7.00.00 Rigid Steel Conduits/Fittings
& Accessories

a) Make ..............................................

b) Material ..............................................

c) Applicable Standard ..............................................

8.00.00 Hume Pipes

a) Make ..............................................

b) Applicable Standard ..............................................

9.00.00 Flexible steel conduit

a) Make ..............................................


10.00.00 Lighting Wires

a) Make ..............................................
c) Voltage grade ..............................................
d) Size ..............................................
e) Conductor material ..............................................
f) Insulation ..............................................
11.00.00 Lighting Poles

a) Make ..............................................
c) Type ..............................................
d) Pole height ..............................................
12.00.00 Lighting Masts

a) Make ..............................................
b) type ..............................................
c) Overall height ..............................................
d) Applicable standard ..............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
34 of 40

CABLING, EARTHING AND LIGHTNING PROTECTION
CABLE SUPPORT SYSTEM

1.00.00 Cable, Trays, Tray Covers
& Accessories

1.01.00 Make ..............................................

1.02.00 Type of cable tray ..............................................

1.03.00 Type of cable support system ..............................................


2.00.00 Conduit Pipes & Accessories

2.01.00 Make ..............................................

2.02.00 Material ..............................................

2.03.00 Applicable Standard ..............................................


3.01.00 Make ..............................................

3.02.00 Material ..............................................


4.00.00 Cable Glands

4.01.00 Make ..............................................

4.02.00 Material ..............................................


5.0.00 Cable Jointing / Termination Kits

5.01.00 Make ..............................................

5.02.00 Type of system

a) Termination ..............................................

b) Joints ..............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
35 of 40

6.00.00 Cable Lugs & Terminals

6.01.00 Make ..............................................


7.00.00 Earthing System

a) Buried earthmat

i) Material & size ..............................................

ii) Applicable standard ..............................................
for the system

b) Equipment earthing

i) Material ..............................................

ii) Size ..............................................

iii) Applicable standard ..............................................

8.00.00 Lightning Protection System

i) Applicable standard ..............................................

ii) Size & material for Air ..............................................
termination and down
conductor

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
36 of 40

TRANSFORMER
(Dry Type transformer)

1.00.00 Manufacture ..............................................

2.00.00 Service

3.00.00 Type / Designation ..............................................

4.00.00 Rated Voltage

a) HV winding (KV) ..............................................

b) LV winding (KV) ..............................................

5.00.00 Type of Cooling ..............................................

6.00.00 Class of insulation ..............................................

7.00.00 Type of insulation ..............................................

8.00.00 Tap changing equipment

A) No. of Steps ..............................................

9.00.00 Guaranteed positive sequence
impedence at 75 deg.C with
100% rating

a) Principal tap ..............................................

b) Maximum tap ..............................................

c) Minimum tap ..............................................

10.00.00 Temperature rise over an ambient

A) Windings (by resistance measure- ..............................................
mend method) (deg.C)

11.00.00 Withstand time for three phase ..............................................
short circuit at terminals (sec.)

12.00.00 Bushings

a) Manufacturer ..............................................

b) Type ..............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
37 of 40

c) Rating ..............................................

13.00.00 Insulation level

a) Separate source power
frequency voltage withstand

i) HV winding (KV rms) ..............................................

ii) LV winding (rms) ..............................................

b) Induced over voltage withstand

i) HV winding (KV rms) ..............................................

ii) LV winding (rms) ..............................................

c) Full wave lightning impulse
withstand

i) HV winding (KVp) ..............................................

14.00.00 Over excitation withstand time ..............................................
(sec.) and %over excitation
continuous and short time

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
38 of 40

CONTROL DESK/CONTROL PANELS/PLC

1.00.00 Meter & Instruments

a) Manufacturer ................................................

b) Type and designation ................................................

c) Catalogue attached ................................................

2.00.00 Push Buttons

a) Manufacturer ................................................



3.00.00 Panels

a) Manufacturer ................................................



4.00.00 Control Panel Details

a) Make of control panel

b) Antivibration pad provided (Yes/No)

c) Panel IP protection

5.00.00 PLC System
a) Make of the PLC system

b) Description of list and diagonstic
features of PLC system

c) Field interrogation voltage level
i) For input

ii) For output

d) Hot standby provided Yes/No

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
39 of 40

6.00.00 Vibration Monitoring System

a) Type .............................................

b) Make .............................................

c) Country of manufacturer .............................................

d) Power supply .............................................

Clause No.

WITH THE PROPOSAL

BIDDERS NAME :

SYSTEM
BID DOCUMENT NO. :
CS-0260-156-2(R)
TECHNICAL DATA
SHEETS
ATTACHMENT 12,
SECTION -VII
SECTION A
Page
40 of 40

H.T. LOAD BREAK SWTICH AND JUNCTION BOX

1.00.00 H.T. Load Break Switch

a) Make .............................................

b) Type .............................................

c) Whether shunt trip coil provided .............................................

d) Type of insulators .............................................

2.00.00 H.T. Junction Box

a) Make .............................................

b) Type .............................................

d) Type of insulators

ATTACHMENT 12 TO SECTION -VII

SECTI ON - B
TECHNICAL INFORMATION AND
DATA TO BE SUBMITTED
AFTER AWARD OF CONTRACT

Clause No.

TECHNICAL INFORMATION AND DATA TO BE
SUBMITTED AFTER AWARD OF CONTRACT

BIDDERS NAME :

NTPCTAMIL NADU ENERGY CO LTD.
BID DOCUMENT
NO.:CS-0260-156-2(R)
ATTACHMENT 12 TO
SECTION -VII
SECTION B
Page
1 of 3

SECTION - B


GENERAL

1.00.00 After award of contract, the contractor shall submit drawings, data sheets, design
calculations/criteria, write up on operation, control interlock protection, type test
procedure, guarantee test procedure and erection/O&M manuals as per agreed
engineering information flow schedule finalised on the basis of standard master
list of drawings/data sheets/documents.

2.00.00 The formats for data sheets of equipments shall be furnished to successful bidder
during preaward discussion which shall be followed while submitting equipment
data sheets for approval during detailed engineering stage.

3.00.00 General arrangement drawings for track hopper, transfer houses, tunnel
conveyors, overground conveyors, overhead conveyors, control rooms, crushers
house, bunkerbays, dust control/ventilation equipment etc. shall be accompanied
by load data details along-with basis and embedded part details/anchor bolt
schedule.

4.00.00 Fabrication drawings of conveyor technological structures, chutes/hoppers, paddle
feeders and trippers shall be submitted for reference.

5.00.00 Bidder shall furnish reports on shop tests, type test alongwith test certificates,
protocols.

6.00.00 Bidder shall furnish GA and cross sectional drawing, bill of material, performance
characteristics and material specification as applicable for all equipment.

7.00.00 Bidder shall furnish selection calculations for all drives, gearboxes, couplings,
brakes etc. for all equipments.

8.00.00 Bidder shall furnish field testing, precommissioning and commissioning procedure
for each equipment and system.

9.00.00 Bidder shall furnish performance and guarantee test procedures.

10.00.00 Bidder shall furnish to the Employer the design calculations selection criteria for
models of all major equipment.

11.00.00 Bidder shall furnish operation and maintenance instruction manual which shall
interalia include :

Clause No.


BIDDERS NAME :

BID DOCUMENT
NO.:CS-0260-156-2(R)
ATTACHMENT 12 TO
SECTION -VII
SECTION B
Page
2 of 3

(a) Instruction for initial operation.

(b) Instruction for operation, maintenance and repair.

(c) Recommended inspection points and periods of inspection.

(d) Safety and other warning notices and cautions for operation and
maintenance.

(e) List of spare parts, material specification, ordering information for all
replaceable parts etc.

12.00.00 The following informations shall be submitted for review/approval of Employer
after award of contract with regard to civil and structural works involved in this
package.

(a) Design calculations and computations and design drawings for approval.

(b) Loading drawings setting out clearly and concisely the various loads taken
into consideration for design including equipment loads.

(c) Sequence of pile driving, if piles are required.

(d) Civil and structural drawings showing arrangement, reinforcement details,
architectural details, floor details, finishing works, door and windows
including their fixing details, rail fixing arrangement, drainage etc.

(e) With in 30 days of receipt of approval/comments on design drawings from
Employer, the final working drawings including bar bending schedules shall
be submitted to Employer for reference. Inserts and anchorage as required
shall be shown.

(f) The bidder shall also prepare and submit structural steel fabrication
drawings for reference of Employer.

13.00.00 The infomations to be submitted for review/approval of Employer after award of
contract in connection with Electrical/works covered under this package shall
interalia include :

(a) GA drgs of control/MCC/SWGR rooms.

(b) All equipment GAs with cross section, bill of materials, performance
characteristics and material specifications.

(c) General layout/details of cable trenches, trestles risers etc.

Clause No.


BIDDERS NAME :

BID DOCUMENT
NO.:CS-0260-156-2(R)
ATTACHMENT 12 TO
SECTION -VII
SECTION B
Page
3 of 3

(d) Earthing & lighting layouts with earthing & lighting conductor size
calculations.

(e) Detail drawings of cable boxes, cable termination for various motors,
switchgears, MCC etc.

(f) Interlock schematics.

(g) Terminal arrangements and inter connection diagrams for different control
panels, switch-boards, MCC etc.

(h) Cable schedules/selection.

(i) Voltage drop calculations during starting and normal operation.

(j) Fault level calculations on HT/LT (415V) switchgear.

(k) List of drives, kw, frame size, full load current etc.

(l) Transformer size calculations.

(m) Details of 3.3 KV, 415V AC and 220V DC and other loads with single line
diagrams.

(n) Lighting design critieria, lighting layouts with BOQ.

14.00.00 The informations sought out in the data sheets enlcosed hereinafter in this section
shall be furnished by contractor in format specified by typing out answers to the
questionnaire at the appropriate place allotted.

15.00.00 Electrical

15.01.00 The formats of the data sheets of various electrical equipment required to the
bidder after award to contract.

Technical Specifications of CHP NTPC 3x500 MW

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Technical Specifications of CHP NTPC 3x500 MW

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NTPC TAMIL NADU ENERGY COMPANY LTD.

(A Joint Venture Company of NTPC and TNEB)

Cement consumption at batching plant shall also

Applicable if steel is procured by Contractor

a minimum of three specimen shall be tested for

These tests shall also be carried out, in case of

ii Acceptance of installation of materials for

Efflorescence shall be checked at each source.

Test on Bricks(Fly Ash Based) IF FLYASH BRICKS ARE USED

Mfr.s T.C. shall be correlated with the

Mfr.s T.C. shall be correlated with the

1)FQP for structural steel shall also be

17.5 Check for the installation, alignments,

18.2 Earthing Mat (Grounding System)

ii Weld sizes & length Visual/Tape B Visual/

ii Acceptance of installation of Insulations

21.2 Execution of treatment

Correlated MTC shall be verified.

*To be approved by CQA

If required suitable stiffners shall

1.03.02 Post Weld Heat Treatment

Sl. No Characteristics / instruments Class# of

5.01.03 iii). Dye Penetration Test -

Test on production test coupons

Wherever RT is not feasible UT to

In case of failure of any welds in

6.00 FOUNDATION CHECKS

6.02 Foundation Bolts and

7.00 PRE-ASSEMBLY CHECKS

7.04 Control assembly check at shop Theodolite, Tape,

8.02 Tightening of bolts/ Torque

8.03 Acceptance of erected structure Theodolite, Tape,

9.00 PAINTING SYSTEM

10.02 Contact surfaces before bolting

10.05 Acceptance of installed bolts - B Physical Each bolt SR

10% DPT after back gauging, 5%spot

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