Co-Gen Bid

Doc No.
Date
Assign No.
Date
: GDP/EPC-BID/09-10/030, R1
: June 8, 2009
: GPD/SDE/HPCL/08-09/045
: September 12, 2008
ENGINEERING, PROCUREMENT & CONSTRUCTION

(EPC) BID DOCUMENT
20 MW Cogeneration Power Plant

Village Lauriya, District West Champaran, Bihar
Technical Basis And Specifications

Prepared For
Hindustan Petroleum Corporation Ltd. (HPCL)

(A Govt. of India Enterprise)
Petroleum House, 17, Jamshedji Tata Road,
Mumbai 400 022
Prepared By
MITCON Consultancy Services Ltd. (MITCON)

Kubera Chambers, Shivajinagar
Pune - 411 005
June, 2009
Doc No.
Date
Assign No.
Date
: GDP/EPC-BID/09-10/030, R1
: June 8, 2009
: GPD/SDE/HPCL/08-09/045
: September 12, 2008
EPC BID DOCUMENT

20 MW Cogeneration Power Plant
Village Lauriya, District West Champaran, Bihar
TABLE OF CONTENTS
Chapter
Chapter No.
No.
DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS,
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
PERFORMANCE GUARANTEE
Design Basis
Scope Of Work
Terminal Points
Building Dimensions
TECHNICAL SPECIFICATIONS FOR MECHANICAL &
ELECTRICAL EQUIPMENTS, INSTRUMENTATION &
CONTROL AND ERECTION AND COMMISSIONING
Steam Generator &Auxiliaries
Steam Turbine Generator & Auxiliaries
EOT Crane & Hoists
Water Treatment Plant
Air Compressor & Air Dryer
Fuel And Ash Handling System
Cooling Tower & Auxiliaries
Fire Fighting System
Piping & Fittings
Painting
Electrical Evacuation System
Cabling
DCS Based Instrumentation And Control
Uninterrupted Power Supply
Erection & Commissioning
Page
No.
1 - 175
1
172
174
175
176 463
176
221
281
292
300
303
314
322
326
333
335
385
397
437
444
TABLE OF CONTENTS (contd..)

Chapter
No.
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
Chapter No.
Page No.
CIVIL WORKS
Major Civil Works
Design Data
System Description & Specifications
Design Criteria
Foundations
Machine Foundations
General Design Considerations
Design Of Miscellaneous Items
Architectural Concepts And Design
Construction
464 - 486
464
465
465
466
467
467
471
475
477
480
487 - 512
4.1
4.2
4.3
APPROVED LIST OF VENDORS, LIST OF SPARES AND

LIST OF DRAWINGS / DOCUMENTS
Approved List Of Vendors
List Of Spares
List Of Drawings & Documents
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
DATA SHEETS
Steam Generator & Auxiliaries
Steam Turbine Generator & Auxiliaries
Water Treatment Plant
Cooling Tower
Fuel & Ash Handling
EOT Crane
Electrical Evacuation
DCS
Building Dimensions
Performance Guarantee Data Sheet
Technical Deviations
513 - 552
513
516
519
522
523
531
533
549
550
550
552
487
493
501
TABLE OF CONTENTS (contd..)

LIST OF APPENDICES
APPENDIX
APPENDICES
NO.
I
SITE LOCATION MAP
II
PROXIMATE & ULTIMATE ANALYSIS OF BIOMASS FUELS
III
TYPICAL TG HALL LAYOUT
IV
PROPOSED MASTER PLAN DEMARCATING COGEN

AREA AND PROVIDING SCHEMATIC OF FUEL
HANDLING SYSTEM
TYPICAL SCHEMATIC PLANT STEAM SYSTEM
VI
TYPICAL SCHEMATIC FOR HP HEATER
VII
TYPICAL SCHEMATICS COOLING WATER SYSTEM
VIII
TYPICAL SCHEMATICS PLANT WATER SYSTEM
IX
TYPICAL BOM, FIRE FIGHTING
TYPICAL SCHEMATICS SYSTEM CONFIGURATION,

PLANT DCS
TYPICAL SINGLE LINE DIAGRAM, ELECTRICAL
XI
EVACUATION & DISTRIBUTION SYSTEM

XII
PIPING MATERIAL SPECIFICATIONS
XIII
CODES & STANDARDS
XIV
TYPICAL PAINTING SUMMARY
XV
ELECTRICAL SYSTEM REQUIREMENTS FOR MOTOR

SELECTION
XVI
RAW WATER ANALYSIS
XVII
HEAT & MASS BALANCE DIAGRAM
XVIII
TERMS & CONDITIONS FOR ERECTION &

COMMISSIONING
CHAPTER 1
DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS

AND PERFORMANCE GUARANTEE
1.1
DESIGN BASIS
1.1.1
General
The cogen power plant will have installed capacity of 20 MW and will
Employ 110 kg/cm2 and 540C configurations. Bagasse generated from
cane crushing, excluding handling losses and bagacillo requirements will
be available for operation of the high-pressure boiler during season of 130
days. Saved bagasse, cane trash, rice husk will be used during the offseason period of about 170 days.
The auxiliary steam consumption for the cogen power plant will be for
soot blowing and other auxiliary consumptions like Steam Jet Air Ejector
(SJAE) & Gland Steam Condenser (GSC) at high pressure, for twin type
HP heater at medium pressure and for de-aerator at low pressure. The
auxiliary power consumption for the power plant should be about 8.5% of
generation during season and 9% of generation during off-season periods.
The process steam required for sugar @ 22% on cane or 32.08 TPH during
season, 20 TPH for ethanol plant during season & 10.25 TPH during offseason will be provided from the cogen power plant. Also, power
requirement of 2.92 MW for sugar process during season & 0.15 MW
during off-season, 1 MW during season & 0.9 MW during off-season
periods for ethanol plant & 0.15 MW both during season and off season
periods for the colony will be provided from the cogen power plant.
Technical EPC Bid Document for Cogen Power Plant at Lauriya, Dist. West Champaran, Bihar
The brief design parameters for the cogen power plant will be as follows:
Boiler capacity, TPH
: 1 x 100
Pressure, kg/cm2
: 110.00
Temperature, C
: 540
Turbine capacity, MW
: 20.00
Turbine type
: Bleed
cum
double
extraction cum condensing
Season operation, days
: 130
Off season operation, days
: 170
Fuels used for season operation
: Mill bagasse
Fuels used for off season operation
: Saved bagasse, Cane Trash,

Biomass
Boiler efficiency, %
- On bagasse / bio-mass / cane : 70.00, 2
trash
: 210
Feed water temperature, C
Captive power consumption, % of : 8.5 during season & 9

generation
during off-season
1.1.2
Key performance parameters

The key performance parameters for the cogen power plant are given
below:
Sr.
No.
1
2
3
Description
Value
Steam Generator efficiency, %
: 702 on bagasse / biomass

/ cane trash
kg : 2.65
Steam to Fuel Ratio,

bagasse / kg
Average Steam to Power
Ratio, kg / kW
: 5.08
Season
: 3.80
Off-Season
Auxiliary
Power
consumption, MW (%)
:
Season
: 1.70 (8.5)
Off-Season
1.80 (9)
Note: The estimated HMBD is provided in Appendix XVII. However, the

Tenderer can optimise the same to maximise power generation at
the required steam flows to process.
1.1.3
Ambient Conditions
Plant Elevation above Mean Sea Level (MSL)
: 71 meters
Temperatures:
(a)
Maximum Temperature
: 46 Deg. C
(b)
Minimum Temperature
: 5 Deg. C
(c)
Plant Design Temperature
: 36 Deg. C
(Performance design)
(d)
Plant Design Wet Bulb Temperature
: 27.0 Deg. C
(e)
Plant Design Temperature for Electrical : 50 Deg. C
Equipment
Precipitation:
(a)
Average Annual Rainfall
Wind:
(a)
Wind Direction
(b)
Design Wind Velocity
: 1422 mm
: South - West (May Sept)
North - East (Oct - Apr)
: As per IS 875
Seismic Coefficient
: As per IS: 1893-2002
Seismic Zone
: Zone 4
: 20 ton/m at 2 m
from NGL
* Tenderer will need to carry out required trial pits and other tests to
affirm the SBC and other required soil characteristics
Soil Bearing Capacity*
1.1.4
Fuels
a)
Design & Guarantee Fuels

During sugar season, the principle fuel will be bagasse and the
steam generator will be designed for 100% MCR on bagasse.
During sugar off-season, the boiler will operate on stored /
procured bagasse and other biomass.
The estimated fuel balance will be as follows :
Value
Season
Off
season
Crushing rate, TCH
146
Bagasse generation at 34% on cane, 49.58
TPH
Bagacillo / handling loss at 1.0% on 1.46
cane, TPH
Bagasse available as fuel at 33% on 48.13
cane, TPH
Biogas available from distillery 2.08
2.08
(equivalent to bagasse), TPH
Total equivalent bagasse available, 50.21
0.00
TPH (MT)
(156655)
Bagasse consumed by cogen boiler, 37.74
26.60
TPH (MT)
(117748)
Bagasse saved / available for off 12.47
9.54
season operation, TPH (MT)
(38904)
(38904)
Biomass
requirement,
equivalent 17.43
bagasse, TPH (MT)
(71114)
Sr. Item
No.
1.
2.
3.
4.
5.
6.
6.
7.
8.
The following will be the analysis and the Gross Calorific Value
(GCV) of the design fuel (Bagasse).
Ultimate Analysis:
Carbon
Hydrogen
Oxygen
Moisture
Ash
GCV with 50% moisture
:
:
:
:
:
:
23.5%
3.25%
21.75%
50%
1.5%
2270 Kcal/Kg
The Following gives the Ash Analysis for Bagasse:

SiO2
:
50-60%
Al2O3
:
10-13%
Fe2O3
:
10-12%
CaO
:
3-5%
MgO
:
3-4%
TiO2
:
2-4%
P2O5
:
1-2%
Na2O
:
0.5-1.5%
K2O
:
4.5-6.0%
SO3
:
Nil
b)
Other Fuels
The Cogeneration plant will also be designed to operate with other
fuels like sugarcane trash, rice husk and maize cobs in combination
with bagasse. The operation of the plant during the seasonal
operation will be basically with bagasse and during off season with
saved bagasse and biomass. However during off season bio-mass
fuel sugarcane trash, rice husk and maize cobs are envisaged to be
used depending upon the availability.
Ultimate and Proximate analysis of the other fuels like sugarcane
trash, , rice husk and maize cobs are given in Appendix II
1.1.5
Plant Design Criteria

The estimated cogen plant design criteria is as follows :
Sr. No.
1.
2.
Item
Cane crushing, TCH
Bagasse generation, % cane (TPH)
3.
Bagacillo / handling loss,% cane (TPH)
4.
Bagasse available for boiler, % cane (TPH)
5.
Bio-gas available from distillery as fuel

(equivalent bagasse)
Total equivalent bagasse available for boiler,
TPH
Steam generation, TPH (@ 2.65kg steam / kg
bagasse
Steam consumption, TPH
HP steam @ 110 & 25 kg/cm2
- Gland Steam Condenser & Steam Jet Air
Ejector (SJAE)
- HP heater I
MP steam @ 8 kg/cm2
- Ethanol process
- HP heater II
- De-superheating water addition
- Total MP steam
LP steam @ 2.5 kg/cm2
- Sugar process @ 22% on cane
- De-aerator
- Total LP steam
Condensing steam @ 0.1 kg/cm2
Total steam consumption
Power generation, MW (@ 5.08 kg/kW avg.)
Power consumption, MW
- Sugar process @ 20 kWh/TCH
6.
7.
8.
8.1
8.2
8.3
8.4
8.5
9.
10.
Value
146
34.00
(49.58)
1.0
(1.46)
48.13
(98.60)
2.08
50.21
100.00
1.00
7.00
20.00
8.00
(0.56)
27.44
32.08
4.60
(0.73)
35.95
28.61
100.00
19.69
2.92
Sr. No.
17.
18.
19.
20
Item
- Ethanol
- Cogen auxiliaries
- Colony
- Total
Power export, MW (14-15)
Power export, MUs
Off Season Operation
Steam generation, TPH
Steam consumption, TPH
HP steam @ 110 kg/cm2 for GSC
HP steam @ 25 kg/cm2 for HP Heater I
MP steam @ 8 kg/cm2
- HP heater II
- Ethanol Plant
- Net MP steam
LP steam @ 2.5 kg/cm2
- De-aerator
- Total LP steam
Condensing steam @ 0.1 kg/cm2
Total steam consumption
Power generation, MW (@ 3.80 kg/KW avg.)
Power consumption, MW
- Colony & Sugar Complex
- Ethanol Plant
- Cogen auxiliaries
- Total
Power export, MW
Power export, MUs
Total power export, MUs
Boiler size & configuration
21
Turbine size & configuration
11.
12.
13.
14.
14.1
14.2
14.3
14.4
14.5
15.
16.
Value
1.00
1.70
0.15
5.77
13.92
43.43
76.00
0.76
5.32
6.08
10.25
(0.33)
16.00
5.70
(0.11)
5.59
48.33
76.00
20.00
0.30
0.90
1.80
3.00
17.00
69.36
112.79
1x110TPH
110kg/cm2,
5400C
1x20 MW
105kg/ cm2,
5350C
1.1.6
Main Plant And Equipments

1.1.6.1
Steam Generator & Auxiliaries

The steam generating system for the Cogeneration plant will
consist of one bagasse and biomass fired boiler with a Maximum
Continuous Rating (MCR) of 110 TPH. The outlet steam parameters
of the boiler shall be 110 kg/cm2 and 540 deg C. The tolerance on
the super-heater outlet temperature shall be a + 5 Deg. C. The
combustion system of the boiler shall be travelling grate with
spreader stoker. The boiler efficiency, firing 100 % bagasse, shall
be a minimum of 70 % on the GCV basis. The flue gas
temperature leaving the boiler to stack shall be chosen such that
maximum economically possible efficiency is achieved but the
temperature shall be sufficiently higher than the dew point
considering the fuel characteristics. However, at 100% MCR the
same shall not be higher than 140 deg C. An ESP is envisaged to
control outlet emission to 100 mg/Nm3.
1.1.6.2
Turbo-generator & Auxiliaries

Triple extraction cum condensing steam turbine generator &
auxiliaries is envisaged. The high pressure bleed will be at about
25 kg/cm, medium pressure bleed at 8 kg/cm and low pressure
controlled extraction at 2.5 kg/cm will cater to the sugar mill
process needs and cogeneration power plant auxiliaries. Balance of
steam will be passed through condenser to generate the rated
capacity. Feed water will be de-aerated in a pressurized de-aerator
and further heated in HP heaters.
The Turbo - Generator and the Auxiliary Equipment covered under
this specification shall be designed to achieve maximum power
generation as per normal steam flow rates from the triple extraction
cum condensing set.
Part of the generated power will be supplied to the sugar factory

complex and the rest will be exported to the grid, after stepping up
the voltage to EHV and transporting the power through
transmission lines to the nearby sub-station of the BSEB. The
extractions from the turbine provide the sources for the medium
and low pressure steam for the use in the sugar complex & power
plant auxiliaries.
The turbo alternator shall be designed taking into consideration all
possible electrical parameters affecting the choice of the machine,
assuring stable and reliable operation in a rural network. Tenderer
shall offer his standard micro-processor based controls and
instrumentation system with panels etc, for the start up, shut down
and operation with all standard features.
Basic Design Parameters for the design:
Water
Cooled
Condenser
Operating Pressure (ata)
Temperature rise for cooling
water (Deg. C)
Power Factor (lagging)
Generation Voltage (kV)
Ambient
Temperature
for
Electrical Equipment Design
(Deg. C)
Parallel operation with grid
Grid Voltage
Duty Requirements
System Frequency
Turbine Type
Inlet Steam Parameters
- Pressure (Kg/Sq. Cm(a))
- Temperature (C)
- Flow (Kg/Hr)
0.1 (in off-season)

8
0.8
11.0, 3 phase
50
Required with BSEB grid

132 kV, 3 phase
Continuous 8000 hours
50 + 5%
Triple
Extraction
cum
Condensing
105
535
99000 in season & 75250 in
off-season
Extraction parameters, No of
Extractions, Steam Flow
3 extractions at 25 kg/cm,
8 kg/cm and at 2.5
kg/cm. Bleed at about 25
kg/cm is only for HP
heater no. 2. Bleed at 8
kg/cm is for HP heater
no.1 and to supply 20 TPH
to ethanol in season.
Extraction at 2.5 kg/cm is
for deaerator and supply of
32 TPH steam to sugar
process
in
season.
Appendix XVII provides
the HBD
The turbo-generator system should be designed in such a way that

the TG set does not trip during the Grid load- throw off condition,
when the plant is operating at 100% rated capacity.
The prime mover control system shall be selected and programmed
to satisfy the following conditions under parallel mode of operation
with the grid:
a.
Load set point shall remain unaffected for the variation

of frequency between 47.5 Hz and 52.5 Hz.
b.
The turbine inlet steam pressure shall be maintained at

the set value by controlling the power export to the grid.
The Turbine extraction which provides the Medium Pressure

Process Steam shall be selected such that the pressure at the
battery limit will be maintained between the turbine inlet steam
flows of 60% to 100% of the MCR flow. This is required mainly
from the point of view of energy efficiency, where in even under
less than the capacity crushing of the sugar plant, the MP process
steam is taken through the turbine instead of taking the steam
through the PRDS.
10
1.1.6.3
Fuel & Ash Handling

The project will have common bagasse and biomass handling
systems. The bagasse handling system will take-off the mill
bagasse from the take-off point in the sugar mill to the boiler,
return the excess bagasse to the yard and supply bagasse from the
yard to the boiler. Other biomass will be mixed in the bagasse
storage yard.
All ash will be mechanically handled and conveyed to ash silos and
will be transported from the site by trucks / trolleys.
The fuel & ash handling system covered under this specification
shall be designed to achieve the following objectives.
2
3
4
5
Bagasse from sugar mill elevator & yard,

biomass from the yard
Ash from Boiler bed, Economiser, ESP Hoppers
of Boiler & Bagasse from yard & mill
Ash from furnace through submerged ash
conveyor will be normally wet when it is
discharged on to the belt.
Bulk Density
Bagasse : 150 Kg/ Cu M
Bagasse Ash: 180 Kg/ Cu. M
Material
180 Deg. C for the fly ash and
Temperature
40 Deg .C for the bagasse
Nature of Ash
The ash collected will Contain un-burnt carbon
Material
Particles & also occasionally un-burnt Bagasse
Bagasse Ash analysis (% )
SiO2
50 - 60
Al2O3
10 - 13
Fe2O3
10 - 12
CaO
3 -5
MgO
3 -4
TiO2
2 -4
P2 O5
1 -2
Na2O
0.5 -1.5
K2O
4.5 - 6.0
Material
Handled
11
1.1.6.4
Cooling Tower & Pumps

A closed circuit cooling water system to provide cooling water for
condenser and power plant auxiliaries will be constructed. Pumps
and piping circuits will be provided for auxiliary cooling.
The cooling tower to be designed for continuous duty. The design
of the tower shall be as per the enclosed specification and Data
Sheet.
The equipment offered shall be capable of cooling the rated
capacity of water through the specified range at the design wet
bulb temperature.
The specified design wet bulb temperature of 27.50C includes the
necessary recirculation allowance. Hence, Tenderer shall design his
cooling tower based on this design wet bulb temperature without
considering further recirculation allowance.
While arriving at the air flow through the tower, due consideration
shall be given to heat carried away by evaporation and enthalpy
correction of altitudes. Tenderer shall furnish detailed heat balance
calculation in support of the air flow through the tower. Tenderer
shall also furnish the basis of the enthalpy values indicated.
The motor rating of the cooling tower fans shall be at least 125% of
the fan power requirement at the motor output shaft to take care of
any changes in tower loading or fan performance at a later date,
Tenderer shall furnish calculations for arriving at the motor rating.
1.1.6.5
Water Treatment System

Raw water will be drawn by the Tenderer from the delivery header
of the raw water transfer pumps at the ground water reservoir.
Appendix IV provides the plant layout. Tenderer will also provide
borewells at locations provided by the Owner / Consultant and
connect the same to the day reservoir before the water treatment
plant. The total capacity of the borewells should be 3000 m3/day
Schematic of plant water system is given in Appendix VIII
12
Primary package consists of the treatment plant consisting of alum,

polyelectrolyte, sodium hypo chlorite, and lime dosing systems,
clarifloculator with bridge or tube settler, flash mixer, raw water
pumps, auxiliary equipments for clarifier / tube settler, clarifier
sludge pipes, related sludge discharge pumps, clarified water
pumps etc., sampling devices, plant instrumentation, metering /
measuring devices, pressure gauges, basket strainers, all piping etc.
Secondary system comprises of Multi grade Filters, Activated
Carbon Filters, Filter Water pumps, Chlorine dosing and acid
dosing, anti-scalant dosing systems, SMBS system related tanks and
pumps, ultra-filtration unit, DM plant, Degasser, Degasser Tank,
Blowers, degassed water pumps, mixed bed units, related acid and
alkali dosing tanks, ejectors, morpholine dosing systems, all
auxiliaries, including pumps and piping. Plant instrumentation
including pH, conductivity meters, flow metering devices and
totalliser.
Basis for Design
Source of water
Sikharana River. In case of exigencies,

borewell water will be required to be used
for process and boiler. Hence the water
treatment plant should be designed
accordingly.
Total outflow of DM plant : 1000 m/day, OBR
water
Pre-treatment plant : 1250 m/day. OBR
No. of Regeneration One per stream
per day
1.1.6.6
Compressed Air System

Two (2) instrument air compressors will supply the requirement of
compressed air for instruments and the control systems of the
proposed cogeneration plant with one (1) working and the other
standby. Each of the compressors shall be of 7 kg/cm pressure.
The air compressor shall be provided with accessories like
Intercooler, after cooler, Moisture separators, Air driers, Air
receivers and control panel.
13
The air compressor shall be oil free two (2) stage reciprocating nonlubricating type with belt drive. The design of the reciprocating
compressor will be opposed piston dynamically balanced
according to the standard.
The heat exchangers (inter and after coolers) shall be designed as
per TEMA-C and coolers shall be mounted horizontally. The
cooling water flow shall be through tubes and the tubes shall be of
copper. The internal surfaces of the cooler shall be galvanized. The
coolers shall be fitted with moisture separators and all necessary
accessories.
The air drier unit shall comprise of 2 x 100% absorber towers with
one of the towers in operation and the other one in regeneration
mode. The towers shall be fabricated from SA 515Gr. 70 or IS:2002
material and filled with alumina. The air drier shall be provided
with sequence timer for automatic change over valves. He entire
drying system shall be skid mounted.
The air receiver capacity shall be fabricated from SA 515 Gr. 70 or
IS:2002 material. The internal surface shall be galvanized. The air
receiver shall be fitted with all accessories including safety valves,
moisture separators etc.
The control system of pressure switches, solenoid valves, regulators
for automatic loading of compressors shall be mounted on a local
control panel.
All air piping shall be internally galvanized.
The service air requirement of the Cogeneration plant, being very
low will also be met by the instrument air compressors. However
the service air will be directly tapped off from the air receiver by
passing the dryer units.
14
The compressors are to be opposed, belt pulley driven, nonlubricating type reciprocating air compressors complete with drive
guards, AC electric motors, LPBS, air receiver, intercooler, after
cooler, moisture separators, air dryer, moisture traps, all
interconnecting pipe work & fittings, control panel, etc. The heat
exchangers shall be designed as per TEMA-C and coolers shall be
mounted horizontally. The air receiver shall be fabricated from SA
515 Gr. 70 or IS : 2002 material. The internal surface shall be
galvanised.
Control air will be supplied to boiler and its auxiliaries, turbo
generator and its auxiliaries and common plant auxiliaries like
water treatment plant, fuel handling plant, ash, pump house etc.
Compressed air will meet the requirements as stated below :
Capacity
: 200 m3/hr or higher as per plant

needs
Nos.:
: 2 nos. (1 operating & 1 standby)
Pressure at receiver outlet : 7 kg/cm2 (g)

Dew point temperature at
Atmospheric conditions : (-) 400C
Particulate material size (max.)
: 1 micron
Contaminants
: No corrosive, hazardous, toxic

Or flammable material
Oil Content
: 100% Oil Free
It is proposed to interconnect the service air system with the

instrument air system before the instrument air dryers. A nonreturn valve and a manual isolating valve will be provided in this
line so that instrument air cannot be supplied to the service air
system.
15
1.1.6.7
Tanks & Vessels

The tanks shall be designed, manufactured and tested in
accordance with the requirements of the ASME Boiler and
Pressure vessel Code Section VIII. Other equivalent standards are
also acceptable. All vessels for steam application shall be designed
for full vacuum.
The cogeneration plant tanks will have storage capacities as
required by design of the systems. Tanks will be of the closed top
type. Tanks will be fabricated in accordance with guidelines
established by API or AWWA, as determined by the service. A
corrosion allowance of 3 mm shall be provided.
Overflow connections and lines shall be provided where required
and will be at least one pipe size larger than the largest input line
or combination of inputs that can discharge simultaneously.
Maintenance drain connections shall be provided of an adequate
size to facilitate drainage of tanks is within a reasonable time.
Manholes where provided on tanks and pressure vessels shall be of
size NB 500. The manhole covers shall be provided with davits.
Ladders and cleanout doors will be provided on large tanks. DM
water tank shall be internally lined with natural rubber or painted
with three coats of Epoxy Coating. DM water and make up water
tank shall be provided with interconnection platforms and
staircase.
The saddles and reinforcement pads welded on to the vessels and
tanks shall be of the same material as that of the vessel/tank shell
or head. Insulated vessels shall be provided with insulation cleats
for applying the insulation.
16
1.1.6.8
Piping
All cogeneration plant piping will be as per applicable IBR / IS
standards. All piping will be aesthetically and neatly laid on pipe
racks with approved colour coding. The cogeneration plant piping
will inter-alia include raw water intake, water treatment plant,
cooling water circulation, auxiliary cooling water circulation, plant
service water, plant potable water, plant sanitation, compressed air
ring, drain piping, treated effluent piping, steam piping from boiler
to turbine, steam piping from HP line via PRDSH stations to LP &
MP headers, HP / MP / LP steam piping to all cogeneration
auxiliaries, steam piping from LP & MP headers to sugar plant
headers.
HP piping to be sized for highest safety valve pressure at 110%
MCR with maximum pr. drop of 2 kg/cm for the entire piping.
The pipeline will be duly approved by IBR by the Tenderer on the
buyers behalf. Standard fittings like expansion loops, stream traps,
supports etc. are to be provided. The line should be insulated to
suit weather conditions and preferably of LRB mattress with
multilayer mineral wool and aluminium cladding (22 g), to achieve
skin temperature of not higher than 65C. Stress analysis for the HP
piping to be submitted by the Tenderer along with IBR approved
steam pipe drawing.
All piping required for effectively connecting the steam generator
with the steam, feed water, and other systems shall be provided.
The piping provided shall be complete in all respects including
valves, fittings, supports etc. as required. Necessary supporting
materials, towers and trestles to support and anchor the pipelines
at regular intervals shall be supplied. Suitable expansion loops and
hangers shall be provided wherever necessary.
Suitable expansion loops restraints and anchors shall be provided
so as to ensure compliance with the applicable codes and to limit
the stress and reactions to within the allowable values.
17
a) The flow velocities in pipes shall be limited to the following

values:
Super-heated Steam.
30-60m/sec depending on pipe size
Saturated Steam.
20 to 35 m/sec
Cooling Water.
Up to 3 m/sec
b) Drains at all low points and vents at all high point shall be
provided.
c) Al local instruments shall be located on pipelines so as to
render them observable from the nearest available platform.
d) Oil drains shall be sized to run no more than half full when
flowing at a velocity of 0.3 m / sec, and shall be arranged to
ensure good drainage.
Material Of Fabrication Of Equipments And Piping Wherever
Applicable
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
Clarifloculator
Inlet well
Alum Dosing Tank
NaOCl dosing tank
Polymer Dosing Tank
Lime Dosing Tank
Mixing channels
Clarifier
Clarified water storage tank
Multi grade filter
ACF
Acid Measuring Tank
Caustic Measuring Tank
Anti Scalant Tank
Fast Flush Tank
Backwash Tank
Degasser Tower
Degassed Water Tank
Rotating Bridge Type

RCC
HDPE / FRP / MSRL
HDPE / FRP / MSRL
HDPE / FRP / MSRL
HDPE / FRP / MSRL
RCC (Through flow pipe)
RCC
RCC
MSEP
MSEP
HDPE / MSRL
MS / MSRL
HDPE
HDPE
HDPE / FRP
MSRL
MSRL
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
1.1.6.9
Degassed Blower
Degassed water pumps
MB Unit
ETP Pump
Acid and Caustic Lye Pumps
Neutralisation pit
SS 316 internals
SS 316
MSRL
SS 316
PP
RCC with acid proof tile
lining
Softener
MSEP
Brine Preparation Tank
RCC Bitumen
Brine Dosing Tank
MSEP / Bitumen
Sludge Sump
RCC
Sludge Pumps
SS 304
DM water piping
MSRL
Soft water piping
MS
UFRO Unit
SS / PVC / MSRR
Effluent / Sludge Slurry
PVC
DM water tank
MSRL
Soft water tank
MSEP
Filtered water storage tank
MSEP
All dosing pumps
SS 316 internals
Raw water pumps
CI
Filtered water and clarified CI with SS 316 internals
water pumps
Insulation
High grade insulation materials suitable for out door Steam
generators shall be supplied with LRB mattress with mineral wool
of multilayer with aluminium cladding, water proof lagging and
protected from rain water, wind and Dust etc. for the exposed
portion of the steam and mud drums, steam generator furnaces,
integral pipe work from the feed pumps to the steam generators,
steam & exhaust piping, hot air & gas dusting, condensates pipes,
valves having high temperature fluids & hot water / condensates
feed water tank, de-aerated water tanks, and other steam generator
accessories to be provided.
19
Glass wool materials is used should confirm to I.S. 3690 - 1974 type
2 mineral wool shall confirm to I.S. 5696 - 1970. The thickness
should be to suit the diameter and temperature of pipes. The wire
mesh should be of galvanized wire and lugs/pins used should be
galvanized.
1.1.6.10 Fire Fighting System
Fire fighting scheme meeting TAC recommendations and ensuring
plant & personal safety will be constructed.
Pressurized fire hydrant system will consist of a pipe network and
hydrants positioned around the station in sufficient numbers and
so located that all buildings and risks are readily protected.
Necessary number of loops will be formed around various risks.
The loops will be interconnected for better reliability of the system.
To isolate a portion of the ring main because of damage/repair,
suitable nos. of valves will be provided.
The hydrant network will be sized and analysed to ensure that
about 3.5 kg/cm2 pressure is available at the hydraulically remotest
point in the system with the hydrant pump discharging at rated
head and capacity. The velocity in the hydrant main will not
exceed 2 m/sec.
The fire alarm system shall consist of smoke detectors, heat
detectors, fire alarm panel, hooter, manual call point etc. The
detectors shall be located in all the electrical panel rooms, control
room and battery room. The manual call point and hooters shall be
located throughout the entire TG building. The detectors will sense
the fire automatically and will generate fire alarm through Fire
alarm panel.
The portable fire extinguishers shall consists of dry chemical
powder type, carbon-di-oxide type, foam type fire extinguishers.
The extinguishers shall be located strategically inside the TG
building.
20
Raw water will be will be taken from the raw water pumps header
at ground water reservoir to the fire water reservoir in the cogen
plant. Raw water will be used for fire fighting. Typical BOM for
fire fighting is provided in Appendix IX
1.1.6.11 Crane for the Turbo-generator Building
An Electrically operated overhead travelling (EOT) crane with
the main hook lifting capacity suitable for maintenance
requirement of turbo-generator and an auxiliary hook lifting
capacity of 5 Tons shall be provided to facilitate maintenance of the
Turbo-generators and their auxiliaries. The crane travel will cover
the entire length of the Turbo-generator building.
The crane shall be electrically operated, bridge type and shall be
designed and equipped for indoor operation complete with all
accessories. The crane bridge shall consist of bridge girders each
one carrying a rail on which a wheeled trolley is to run. The bridge
trucks and trolley frames shall be fabricated from structural steel.
Access walkways with safe hand railing are required along the full
span length on either side of the bridge girders.
Bridge and trolley trucks shall be of cast steel or fabricated structural steel sections. Wheel trucks of cast or welded construction
shall be stress relieved as per accepted standards. Spring buffers
shall be provided on the trolley and bridge structural frames at
suitable places to absorb the shock of impact without transferring
to the structural frame.
1.1.6.12 Electrical System
The power generated will be evacuated to the sugar mill at the
given terminal points. All the cogeneration power plant auxiliaries
will operate on the power supplied from the cogeneration power
plant. Balance of power generated after meeting the sugar and
auxiliary load will be exported to the grid after stepping up to 132
kV. DG set will be provided for emergency power. All other power
sources including DC power, UPS, control power, lighting, etc. will
be derived from the cogeneration panels. Required earthing will be
provided to ensure safety.
21
Proposed synchronous alternator shall be of 20 MW rating with

generation at 11 kV. Surplus power, after meeting the cogeneration
plant auxiliary requirement and power requirement of the sugar
plant, shall be exported to the grid through 11/132 kV,
ONAN/ONAF, generator transformer. The generator transformer
shall be suitable for exporting the maximum power at 132 kV,
without any limitation in the plant operation and power export.
All equipment shall be designed to withstand the maximum
fault levels provided in this tender document. The successful
tenderer shall carry out complete system study for the electrical
systems to ascertain the selection of fault levels of the switchgears
are within limit, power (active and reactive) flow, system losses
and power factor at various MCCs, voltage level in various level of
voltage, motor starting analysis and stability study of the plant
with BSEB grid.
Power system shall be designed so as to export the entire power
from cogeneration plant (total generation less auxiliary power
consumption), when the sugar plant is not in operation.
Following lighting sources are considered,
Plant areas
HPMV Lamp in Industrial type High Bay

fixtures or in integrated Well Glass
luminaries, Industrial type Fl. Lamp
fixtures with Vitreous enamelled reflectors
Electrical Room
Mirror Optic Fl. Lamps or CFL
Outdoor Lighting in transformer yard HPMV flood light fittings

Battery operated Critical Lighting provided at strategic
locations such as stair cases, control rooms and escape routes in
the plant area - CFL lamps
22
Earthing arrangement in 132 KV switchyards shall be strictly as per

the statutory regulations. The earthing shall include:
a. Provision of earth electrodes for LAs, switchyard equipments
body earthing, T.G. set Alternator , D.G. set Alternator
Neutral and Body earthing, Transformer neutral earthing,
earthing of structures etc.
b. Provision of earth mat as per IEEE 80.
c. Provision of lightning conductor over 33KV switchyard.
d. Provision of earthing grid conductor as per fault level
considered.
e. Chimney Lightning protection and Lightning protection of
other buildings
The switchgear shall be free floor standing, totally enclosed, dust
and vermin proof with draw out type circuit breakers. Vertical
units shall be assembled to form a continuous line Up of uniform
height and depth
The panel structure shall house the components contributing to the
major weight of the equipment such as circuit breaker, main
horizontal bus bars and other components are adequately
supported without deformation or loss of alignment during transit
or during operation.
Each unit of the switchgear shall have necessary internal sheet
metal barrier to form separate
compartments for buses,
instruments, relays, cable connections etc.
Adequate barriers shall permit personnel work safely within an
empty compartment with the bus bars energised. Checking and
removal of components shall be possible without disturbing the
feeder.
All auxiliary equipment shall be easily accessible to facilitate their
operation and maintenance. It shall be possible to set all relays and
measuring instruments without de-energising the switchgear.
23
All doors and opening shall be fitted with dust excluding neoprene
gaskets with fasteners designed to ensure proper compression of
the gaskets.
When covers are provided in place of doors, generous overlap shall
be assured between sheet steel surfaces with closely spaced
fasteners to preclude the entry of dust.
The panels shall have a rear cable chamber housing the cable and
connections. The design shall ensure generous availability of space
for easy installation and maintenance.
System Fault Level
a)
:
:
:
:
40 kA for 1 Sec. for 132kV system

40 kA for 1 Sec. for 11kV system
50 kA for 1 Sec. for 415V System
9 kA for 1 Sec. for Lighting Circuits
Power Supply:

132 kV + 10%, 50Hz + 5 %, 3 Phase for Grid Connection

11 kV + 10%, 50Hz + 5 %, 3 Phase for Generation and Power
Supply to 11KV Eqpts.
415 V + 10% , 50Hz + 5 % , TPN for plant load operating at
415V supply
Control Voltage 110V AC, 50Hz for MCCs and PCCs
Power Supply for Space Heaters, Plug Sockets, Lighting : 230
V,50 Hz, 1Ph.
Power Supply for Tripping and Closing Circuits of Circuit
breakers : 110 V, D.C.
24
b)
Power Distribution :
a)
b)
c)
d)
c)
Power will be generated at 11KV, 3Ph, 50Hz with Steam

Turbine. Power will be
stepped up to 132KV for Grid Connection and
Evacuation to BSEB.
11kV Power Supply will be given to Sugar Plant
Switchboard. Further downstream power distribution will
be done in Sugar Plant.
11kV/433V distribution transformers are provided to cater
power to 415V rated equipments in plant.
230 V Single phase power supply shall be derived through
Phase & Neutral for single phase power consumer.
Design Criteria In Equipments / Power Distribution :
All Busbars shall be Air insulated and of Aluminium. Busbar

size shall be selected based on Temperature limit of 85 C at
Busbar for the rated current.
Power Cables (HV & LV) shall be XLPE armoured
ALUMINIUM conductors above and including 6 sq. mm.
size. Power cables including and less than 4
sq. mm.
shall be copper conductor.
Squirrel Cage Motors up to 15 KW shall have automatic
DOL Starter suitable for operating from MCC, DCS
and PB Station near Motors.
Motor rating above 15 KW up to 200KW shall be with
Automatic Star Delta - Starter suitable for operating
from MCC, DCS and PB Station near Motors.
Motor rating above 200KW shall be operated with Soft
Starter suitable for operating from starter, DCS and PB
Station near Motors. Starter Shall have bypass contactor
with AC3 rating.
VFD shall be provided as per the functional requirement.
Following spare feeders shall be considered in Power
Distribution
o In 11KV Switchboard - 1 No. Transformer feeder
25
o Panels in other areas including PCC / MCC / DB 1 No. of Each Rating

MCC shall be floor mounted self supporting, dust and
vermin proof , fixed type construction.
Power Control Center (PCC) shall have Switch Disconnector
Fuse up to 630A and above 800A these shall have Manually
operated Draw Out (MDO) type ACB.ON indication shall
be provided on outgoing feeders.
Motor Control Center (MCC) shall have Switch Disconnector
Fuse unit, Contactor and Bimetallic Over Load (O/L) relay
for starters. Starters on MCCs shall have ON & TRIP
indication. The selection of switchgear components shall
be
minimum with one stage higher than Type II co
ordination as per IS 13947
Motor protection shall be provided in ACVF Drives & Soft
Starters, as inbuilt protection functions.
Rating of Switchboard incomer ACB/SDF shall be 1.2 times
the operating load current.Protection & Indication
Flameproof equipments such as Push Button Stations,
junction boxes, Lighting Switches, L lighting Fixtures etc
shall be considered with hazardous area classification in
Ethanol plant.
Push Button Station with Shrouded type actuator for
ON push button, Lockable Mushroom type actuator for
OFF Push button with Aluminum die cast enclosure
shall be provided. Push Button Station for Motors above
15KW rating shall be provided with suppressed scale
Ammeter. Push Button Station for VFD shall have Speed
Setting Potentiometer and speed indicator in addition to
Push Buttons and Ammeter
26
d)
Power And Distribution Transformer
The following criteria shall be applicable for the sizing of

Transformer
1)
Total Connected Load shall be calculated based on Motor
List.
2)
Operating Load shall be calculated excluding Standby Loads
and equipment for maintenance such as Crane.
3)
Load Factors shall be considered on Operating Loads
according to Load Factor to consider shall be as below:
Motor Loads with DOL / S/D Starter / Soft Starters : 0.85
Motor Loads with VFDs 0.75
Lighting Loads : 1.0
Utility Plug Sockets : 0.5
Cranes, winches etc. : 0.1
4)
Average Power Factor 0.8 shall be considered to arrive at
KVA.
5)
Equipment Efficiency shall be considered 90% as average.
6)
On such Calculated load + 20% Margin shall be considered.
7)
If necessary percentage impedance shall be increased more
than the impedance indicated in IS to limit 415 V side Fault
Level to 50KA for 1 sec.
e)
Power Factor Improvement

01)
02)
Plant PF shall be required to improve above 0.95

This is achieved by providing:
Capacitors across HV Motors as per recommendation of
manufacturer.
Provide Automatic Power Correction Panel with required
no. of APP type capacitor banks in 415V PCC in Cogen
Plant.
27
03)
f)
To determine number of capacitors following consideration

be given
Operating KW & Average operating P.F.
Drive with VFD shall maintain P.F. above 0.95. These loads
shall not to be considered for deciding capacitor rating.
LV Power Control Centre (PCC)

The following points shall be considered while designing and
selection of components.
I)
TYPE OF FEEDERS:
Incomers
: D.O. 3-Pole ACB
Emergency Power Supply
: D.O. 4-Pole ACB
Feeder
Outgoing Feeders
: SDF up to 630 A
: MDO Type ACB Above
800A
II)
BUSBARS
Color Coded Sleeved

Aluminum
Bus bar Size shall be selected
as per following norms:
Continuous current carrying
capacity as per the Rated
Current of Incomer
Temperature Rise Limit
Short Circuit Withstand
Capacity
28
g)
Motor Control Centre (MCC) :

The following points shall be considered while designing &
selecting components.
I)
Incomer Feeder
- MDO ACB above 800 A up to 2000

A
Fixed Switch Fuse Disconnector up
to 630 A
II)
Outgoing Starter
Feeder
Feeders shall be comprising of:

Switch Fuse Disconnector
Contactors
Thermal Overload Relay
Timer in case of Star Delta Starters
Push Buttons
Indicating Lamps
III)
IV)
Bus bar
Control Logic
Above 125A rating

Plant shall be capable of operation
from MCC, DCS located at Central
Control Room or locally from Push
Button Station near motor.
02) It will be possible to start the Motor
locally through enable command from
PLC.
03) P.F. and KW parameter of Incomer
shall be communicated to PLC.
05) ON/ OFF Status of the Motor shall
be communicated to PLC.
V)
Provision of
Spare feeders
In MCC total 10% spare feeders shall be

provided, depending on feeder ratings
in MCC following feeders shall be
provided.
29
h)
LV Bus Ducting
Bus duct up to 3200A shall be CRCA enclosure with color coded
sleeved Aluminum bus bar. Short circuit rating shall be 50KA, 1
sec.
i)
Battery And Battery Charger

01) BATTERY:
02) BATTARY
CHARGER
03) DCDB
j)
1) VRLA Maintenance Free

2) Capacity shall be determined by total
operating load and 20% margin.
3) AH shall be determined for 8 hour
backup time.
1) Float and Float cum Boost with 20%
capacity
Built in with Battery charger panel with
Incomer as MCCB & Outgoing as MCB.
Grounding / Earthing System) & Lightening Protection

01) Earthing shall be done according to IS 3043 1987.
02) Earthing shall be carried out by G.I. Strips & Wires. Earth
Electrodes shall be G.I. Plate type & Pipe type as per requirement.
However, Transformer Neutral will be connected to G.I. Earth
Electrode through Copper Strip.
03) Total Resistance of Earthing system shall be Less than one ohm.
04) Plant shall be protected against lightning according to IS 23091989.
30
k)
Cables
The following consideration shall be given for Cable Sizing and
Selection on Nominal Current Capacity
Ambient Temperature in Air/Ground
Continuous Load Current
Short Circuit Withstand Capacity
Voltage Drop at the Starting of Motor limited to 15% & 5%
at Steady state up to motor terminals.
Deration Factor due to type of Laying & Grouping.
Generally Power and Control cables shall be stranded.
XLPE insulated cables upto & including 4 sq.mm shall be
with stranded copper conductors. Cables of 6 sq.mm &
above size shall be with Al. conductor
Generally Cable trays shall be prefabricated Hot Dip Galvanized
Iron. Cable Trays shall be run in Vertical formation as far as
possible.
HV & LV Power Cables shall have separating distance of 300mm.
Separating distance between Power and Control cable shall be
300mm. Instrument cables & screened shall run on perforated
cable tray having 300 mm separating distance of 300 mm.
The Lux Level in various indoor areas shall be as per IS. In plant
areas, the lighting shall be provided as per functional requirement.
HPMV Well Glass with integral control gear box fittings (IP55)
shall be provided in plant areas. Industrial FL. Lamp fittings will
be provided in sub station and other indoor areas. Mirror Optic
fixtures shall be provided in CCR. In outdoor areas HPSV Lamp
fixtures (IP 55) shall be provided.
The lighting shall be catered by Main Lighting DB. LDB & SLDB
connected by Al. conductor cables. The Emergency power supply
from 415V DG set will be made available to lighting transformer in
case of failure of power
31
1.1.6.13 Instrumentation & Control System

The entire plant will be controlled by a centralized DCS with high
redundancy level with inputs and controls of all loops, analyzers,
control valves, motorized valves, motors, etc.
The integration of all the inputs / signals for continuous
monitoring, operation, data logging, data analysis, alarms, safety
interlocks, annunciations etc. will be achieved through the DCS.
The DCS will include the DCS control station, related licensed
software & hardware, instrument & control cabling from the
marshalling cabinet receiving signals from junction boxes of all
cogeneration equipment, all MCCs and software links with Turbovisory panel, Woodward Governor and turbine temperature
scanner.
The entire cogeneration plant will be smoothly started, normally
operated, provided with necessary interlocks & emergency trips,
monitored, controlled and smooth shut down from the DCS. The
DCS to have required software or compatibility to internet.
Basic Control Design should be as below:
a.
Generator, gearbox, turbine bearing temperature monitoring
shall be through the temperature scanner.
b.
Critical AI/AO/DI/DO signals will be redundant while
non-critical & DAS points will be non-redundant. All
controllers for critical controls will be redundant. The field
inputs for critical inputs will be1/2 logics. 25% of the I/Os
to be considered as critical.
c.
Sequence of event recorder will be provided
d.
Required Annunciation windows shall be included
e.
25% spare I/Os to be considered.
f.
TG governing will be by Woodward 505E. However the
critical parameters will be monitored by providing serial
Modus Interface
32
g.
All I/Os will be potential free
Plant communication shall be provided with Telephone system,

Public Address System and Walkie-talkies
1.1.6.14 In-Plant Communication System
The cogeneration power plant will have an EPBAX system with
intercoms at all operating locations, admin building and security
points. The EPBAX will have expandability and junction box to be
interconnected to the EPBAX systems of the sugar, ethanol and
non-plant buildings. The system will have minimum 20 extensions.
The Tenderer will provide a wireless handheld walkie talkie system
of Motorola / Philips make for intercommunication of all plant
personnel with minimum of 15 instruments. The required battery,
battery charger, centralized transmission system, etc. to be
included. The system will have a frequency which will not disturb
any other public or radio system. The tenderer will be responsible
for obtaining the in-principle and operating license and the
frequency allocation. Statutory fees, if any, will be paid by the
Owner
1.1.6.15 Civil & Structural
a)
Construction Specification For Rough Grading

This specification covers furnishing all labour, materials and
equipment, and performing the necessary work to complete
the clearing, grubbing and excavating, filling, rough
grading, consolidation and compacting
i
Clearing And Grubbing :Within the battery limits, all shrubs, stumps,
vegetation and jungle, including roots, shall be
removed and burned except as directed by the Owner
/ Architect.
33
ii
Excavation :Excavation will include earth, weathered rock and

hard rock. Whenever finishing grade is referred to, it
shall mean to elevations indicated on the drawings
plus or minus thirty millimeters. For descriptive
purposes, excavation shall be classified as follows :excavation
shall
be
defined
as
Earth
unconsolidated, or consolidated material which
can be broken with a pick.
Weathered rock shall be defined as consolidated
or cemented material which can be broken with a
pointed pry bar or pick.
Hard rock shall be defined as competent
consolidated material with few fractures that
cannot be broken with a pointed pry bar and must
be blasted.
Ditch or channel excavation shall be defined as
that excavation between the invert of the channel
and the point at which the channel side slope
intersects natural or finish grade, whichever is
lower
iii
Filling :Filling shall consist of performing all operations

necessary to place the fill to the line and grade. Filling
shall be placed in layers that are not over 150 mm
thick before compaction, then watered and
compacted as hereinafter specified.
34
In platforms for structures, roadbeds, the top 150mm

shall not contain lumps or rock of 60mm size or
larger. When filling is to be placed against hillsides or
existing fill, the material consists of large rock
material or hard lumps which cannot be readily
broken, such material shall be well distributed
throughout the fill, and sufficient earth or other fine
material as it is deposited, so as to fill the interstices
and produce a dense compact fill.
iv
Watering :Watering for compacting backfill material and water

required for laying dust caused by grading operations
shall be applied as directed by the Owner. The water
shall be applied so as to obtain the optimum moisture
content for compaction. The application of water will
be by a distributor equipped with a spray system that
will ensure a uniform application of water. At the
direction of the Owner, water may be applied to the
excavation area from which the fill is obtained.
Compaction :All fill shall be compacted by road rollers, tamping

rollers, or by tamping, as specified herein.
All areas within the bench area of buildings marked,
compaction of all roads, shall be compacted by
tamping rollers and / or road rollers. The layer
excluding the top layer shall be compacted by not less
than four passes with the tamping roller. Before the
last layer is placed the road roller shall make one pass
over the area. The last layer shall then be placed and
compacted with the road roller by making not less
than four passes. The balance of the fill may be
compacted by using air operated or hand rammers, as
directed by the Owner.
35
Tamping rollers shall be a metal drum surrounded

with metal studs with tamping feet projecting not less
than 160mm from the surface of the drum. The
tamper feet shall be arranged in rows spaced not less
than 150mm, nor more than 300mm on centre. The
load on each foot shall not be less than 250 pounds
per square inch (17.58 kg/sq.cm.). The load per foot
will be determined by dividing the roller weight by
the cross-sectional area of one row of feet across the
roller.
Road roller shall be three wheeled and weight not less
than 12 tonnes and shall produce a compression on
the rear wheel of not less than 325 pounds per liner
inch (60 kg per liner cm) of wheel width.
Rammers shall have a base area of at least 28 square
inches (182 sq. cm.).
vi
Weed Killer :All roadway base shall be treated with a commercial

weed killer applied according to the manufacturers
recommendations.
vii
Civil Works Requirements

Scope of Work
The scope of permanent works includes the
construction of all earthworks associated with
site levelling and embankments, mass and
reinforced concrete foundations to machinery
and buildings incorporating all holding down
bolts and all site roads, hard-standing and
drainage for the structures
36
Materials
Materials used in the works shall be new and as
per approved list or relevant IS standards. The
Owners Representative shall have the right to
reject any material that is damaged or has
deteriorated and such materials shall be
removed from site immediately.
Branded materials shall be handled, stored and
used, and processes shall be carried out strictly
in accordance with the manufacturer's
instructions and recommendations.
The Owners Representative may require the
Tenderer to obtain at his own expense a
certificate in respect of any material stating that
it is in accordance with the relevant Indian
Standard Specification.
Elevations and Benchmarks
Except where otherwise specified, all elevations
will be in meters above mean sea level with an
accuracy of two decimals. The data for all levels
will be based on Benchmarks. The Tenderer, on
his own responsibility, shall ensure that the
Works are constructed in relation to this data.
Benchmarks and other points of reference in the
vicinity of the Site may be indicated on the
Drawings.
37
viii
Demolition And Site Clearance

Removal of Termite Hills
All termite hills shall be demolished and the
surplus material removed to tip. The cavity
formed by the removal of the termite hill shall
be treated with the solution specified below in
"TERMITE PROOFING" and then filled with
approved material in the specified manner for
in-filling trenches.
Termite Proofing
Termite Proofing shall be undertaken over the
whole area of the buildings and aprons and shall
consist of the application of a solution of 5 parts
pentachlorophenol and 95 parts of furnace oil
(by weight) well mixed together and applied by
means of watering cans with fish tail spouts at a
rate of 5 liters per m2. Before treatment the
surface must be cleared of all rubbish and in
particular scrap timber. The treatment shall be
on the ground after removal of the top soil
and/or soft layer before making up levels.
Site Clearance
The site of the works shall be cleared of all trees,
bushes and vegetation. Trees and bushes shall
be uprooted and raked into windrows and
burnt. Holes left by stumps and roots shall be
filled with suitable material and compacted as
specified.
38
Mature trees required to be preserved for

landscaping purposes will be indicated and
marked by the Owners Representative before
site clearance commences. The Tenderer shall
take all necessary precautions to protect such
trees from damage during all phases of the
works.
ix
Earthworks
The excavation and fillings shall be carried out in
such manner and order as the Owners
Representative may direct.
The following definitions of the earthworks materials
shall apply to this tender in which reference is made
to the defined materials:
'Top Soil' shall mean the top layer of soil
containing more than 5% by weight of organic
matter.
'Unsuitable material' shall mean other than
suitable material and shall include:
(i)
material from swamps, marshes or bogs;
(ii)
peat, logs,
material;
(iii)
material susceptible to spontaneous

combustion;
(iv)
clay of liquid limit exceeding 80 and/or

plasticity index exceeding 55;
stumps
and
perishable
39
'Rock' shall mean material which in the opinion of

the Owners Representative requires the use of
wedges, pneumatic tools or blasting to enable the
excavation to be completed, but specifically
excludes isolated volumes of rock or other hard
material of up to one cubic meter in content.
Rippable soft rock' shall mean material which, in
the opinion of the Owners Representative,
requires the use of tractor drawn tines to break up
the material. These rocks will, in general, be
weathered sandstones and other sedimentary
rocks.
'Ordinary ground' shall mean material which in
the opinion of the Owners Representative can be
excavated by normal excavation machinery.
b)
Construction Specification For Structural Excavation And

Fine Grade
The work covered by this specification includes furnishing
all labour, materials, equipment and performing the
operations necessary to complete the excavation and filling
required, for all buildings; structures and foundations and
the fine grading.
i
Excavation:The Tenderer shall perform all excavation required

for the various structures and foundations. All
excavation shall be to line and grade required for the
proper installation and removal of the forms and to
facilitate the construction. Excavation for all
foundations shall be carried one meter below the floor
slab for interior footing or one meter below the
finished grade for wall footings and exterior footings.
40
ii
Back- Filling :After all below grade work has been completed and
all debris has been removed, the excavated area shall
be backfilled. The backfilled material shall be the
excavated material and it shall be placed in 150 mm
layers.
iii
Compaction :All backfill areas shall be well watered and well

compacted by ramming as directed by the Owner.
iv
Shoring And Bracing :The Tenderer shall furnish and install all shoring,
bracing and sheeting as required to adequately
support the excavation and to provide safety for the
personnel. This shoring shall be removed as the
backfilling takes place.
Fine Grade :The Tenderer shall furnish and install the sand or
gravel sub grade below the floor slabs. This sub grade
shall be levelled and compacted. Exterior fine grade
will include cutting, filling and compacting.
vi
Earthworks
Where the excavation reveals a combination of
suitable and unsuitable materials the Tenderer shall,
unless
otherwise
agreed
by
the
Owners
Representative, carry out the excavation in such a
manner that suitable materials are excavated
separately for use in the Works without
contamination by the unsuitable materials.
41
The Tenderer shall dispose of excavated materials in

such a manner and, at such time, as instructions
provided by the Owner
vii
Limits Of Excavation
The excavation shall be carried out to the required
lines, levels, widths and depths.
Before commencing any excavation the Tenderer
must satisfy himself as to the accuracy of the levels
shown and bring to the notice of the Owners
Representative any discrepancies.
Excavations shall be suitably trimmed and leveled
before oversite concrete is placed. In locations where
the material is subject to softening, a bottom layer of
soil approximately 75 mm thick shall be left in and
removed immediately before the placing of concrete.
In the event of over-excavation, the area shall be filled
with selected excavated material or Grade 10
concrete.
viii
Protection Of Excavations
The faces of excavations shall be retained with
sheeting, timbering, strutting and shoring as
necessary to protect the workmen and to prevent
damage to adjacent services and structures.
If, in the opinion of the Owners Representative,
sufficient support of the excavation is not being
provided and the work is dangerous to workmen or
property or to permanent work, the Owners
Representative may suspend operations until
sufficient timbering or sheeting is provided.
42
The Tenderer must take every precaution against

slips or falls and should any occur he shall remove
the surplus as required by the Owners
Representative.
All necessary temporary drains and culverts shall be
constructed to keep the site free of water. Trenches
and excavations shall be kept free of surface water by
pumping or other means.
ix
Approval Of Bottoms Of Excavation

The Tenderer shall report to the Owners
Representative, at least 24 hours before concreting is
required, when suitable bottoms to the excavations
have been reached. Any further work executed
before the excavations have been inspected and
approved shall, if required by the Owners
Representative, be removed and new work
substituted after the excavations have been approved,
at the Tenderer's expense.
Infilling Of Channels, Trenches And Pipes

When no longer required, all temporary channels,
trenches or pipes which it may have been necessary to
construct in or under the permanent work shall be
filled with suitable material, approved by the
Owners Representative. Infilling shall be performed
in layers not exceeding 300 mm thick and each layer
thoroughly compacted to the satisfaction of the
Owners Representative.
43
xi
Blasting
The Tenderer shall store explosives, if required, in a
store or magazine provided with separate
compartments for detonators. Explosives shall be
handled by experienced and competent shot firers.
The Tenderer shall ensure that there is no
unauthorized issue or improper use of explosives
brought on the Site.
Explosives shall be used in the quantities and manner
recommended by manufacturers.
The written
permission of the Owners Representative shall be
obtained for each location or series of locations where
the Tenderer wishes to use explosives.
xii
Filling By Embankments
Suitable material arising from excavations shall be
used where possible for filling on the Site, unless
otherwise specified or required by the Owners
Representative.
Where insufficient suitable material is available from
excavations approved suitable material from borrow
areas may be used.
Borrow areas within the Site will be those areas
specifically designated as such by the Owners
Representative.
Sand for filling, in making up levels, etc. shall be
naturally occurring sand, or sand prepared by
crushing natural stone.
44
The compaction achieved in filling will be measured

by the following tests, carried out in accordance with
Indian Standards 'Methods of Testing Soil for Civil
Engineering Purposes'.
Density-Moisture Tests
Density Tests
The moisture content of the fill materials shall be

adjusted as necessary to achieve the required
compaction.
The minimum relative compaction to be achieved in
the compacted areas shall be 100% of maximum dry
density as measured above. Any material which,
after repeated compaction, does not achieve this
figure will be removed.
Filling in areas on which no roads, structures or
services are to be constructed shall be spread in layers
not thicker than 100 mm and subjected to as much
traffic as possible during construction.
At the end of each day, the surface shall not be left
with areas that can retain water and, if necessary,
ditches shall be cut to ensure that this object is
attained.
When the state of the weather is such that, in the
opinion of the Owners Representative, it would
adversely affect the placing of compacted fill, all such
work shall be stopped.
All filling material, whether placed and/or
compacted or awaiting placing and/or compaction
which, in the opinion of the Owners Representative,
does not comply with the specification or has been
damaged by weather or in any other way.
45
xiii
Frequency Of Compaction Test

Each layer shall be compacted satisfactorily before
proceeding with the next layer, with a maximum
thickness of 200 mm per layer.
xiv
Surplus Excavated Material

The disposal of excavated material shall be carried
out as required by the Owners Representative.
All surplus excavated material, where so required,
shall be removed and transported to a tip.
The location of such tip will be specifically designated
by the Owners Representative, within the overall Site
or without.
xv
Hard Core
Hard core shall be sound approved uniformly graded
stone of maximum size 150 mm.
xvi
Clay For Lining

Clay used for impervious lining shall be excavated
from borrow pits on site as required by the Owners
Representative. The location of borrow pits will be
determined by the Owners Representative on site
during the progress of work. The maximum haul
distance from borrow pits to areas requiring lining
shall not exceed 4,000 meters.
46
xvii
Compaction Of Clay For Lining

Materials for impervious linings shall be deposited in
uniform layers, not exceeding 150 mm. The material
shall be compacted so that it is homogeneous and free
from lenses, pockets, streaks or other imperfections.
Each layer shall be compacted using a 'sheepsfoot'
roller of sufficient weight for proper compaction, by
hand or power tampers or by other means and
equipment approved by the Owners Representative.
The dry density of the soil fraction in the compacted
material shall not be less than 95 per cent of the
laboratory standard maximum soil density (dry) as
determined by Test as specified.
If the water content is less than that required for
optimum compaction, water shall be added either at
the site of excavation or at site of compaction as
necessary.
If the water content is more than that required for
optimum compaction the material shall be rejected for
use or compaction shall be delayed until such time as
the material has dried out to the optimum water
content.
xviii
Stone Pitching
Stone pitching shall be of sound, durable, crushed
rock or natural stone as approved by the Owners
Representative and shall be uniformly sized between
100 mm minimum dimension to 150 mm maximum
dimension.
47
The stone shall be hand placed in a single layer and

bedded on a uniform surface of approved excavated
material to give a uniform finished surface with
maximum opening between contiguous stones of
25 mm.
Stone pitching shall be pointed with a mortar of 3
parts sand to 1 part cement.
xix
Rip-Rap
Rip-rap shall be of sound, durable, crushed rock or
natural stone as approved by the Owners
Representative and shall be uniformly sized at 200
mm nominal maximum dimension.
The stone shall be placed and spread to produce the
minimum finished thickness with a uniform finished
surface.
xx
Seeding
The ground shall first be rotovated to a depth of 300
mm, leveled and raked free of stones. Prior to
sowing, the ground shall be well watered and seed
then spread at the rate of 1 kilogram per 20 square
meters. Seed will be covered by raking and the
ground consolidated with a light roller.
The area will be watered daily by the Tenderer until

the site has been accepted by the Owners
Representative.
48
c)
Construction Specification For Concrete

operations necessary to complete the concrete work. The
Tenderer has to prepare the working drawing alongwith the
bar bending schedule in detail alongwith the form drawings
from the R.C.C. drawing and shall get approved the same,
prior taking up the actual work activities at site.
i
Applicable Publications :All work shall be in accordance with the latest

revision of the Indian Standard except where
specifically noted otherwise : Plain and Reinforced Concrete
Cement
Aggregates
Structural Safety
Testing of Concrete
Sampling
Compaction
Rapid Hardening Cement
Admixtures
ii
I.S. 456
I.S. 269
I.S. 383
I.S. 875
I.S. 516
I.S. 1199
I.S. 2505
I.S. 8041
I.S. 9103
I.S. 2506
I.S. 2645
Materials : Cement
Cement shall be ordinary portland cement
conforming to I.S.269. All cement used in exposed
concrete faces of the structure shall be of the same
manufacturer.
All cement shall be suitably
protected from exposure to moisture until used.
Special cement, if any, shall be used only after the
approval of the Owner/Architect.
49
Coarse Aggregate
Coarse Aggregate shall consist of approved sound
crushed rock or gravel. It shall be free of organic
matter or other deleterious material. Adequate
supplies of coarse aggregate shall be stockpiled
sufficiently in advance of construction to permit
sampling and testing before use.
Fine Aggregate
Fine Aggregate shall consist of approved natural
sand, or crushed stone screenings combination of
both;and shall be hard and durable. It shall be
free of organic matter or other deleterious
material. Adequate supplies of aggregate shall be
stockpiled sufficiently in advance of construction
to permit sampling and testing before use.
Water
Water shall be clean, fresh and free from organic
or deleterious matter in solution or in suspension,
and shall be added in such amount that may not
impair the strength of concrete as specified.
Water, for mixing concrete, shall be supplied by
the Owner, if available at site, otherwise Tenderer
has to make his own arrangement for the
construction water requirement. For all purpose,
the Tenderer shall arrange his own supply, storage
and necessary pumping and conveyance system.
Forms
Forms shall be of wood or metal, approved by the
Owner/Architect.
50
Admixtures
The use of admixtures is encouraged where a
sound technical reason justifies it, but with the
approval of the Architect/Owner.
Water stops
Water stops may be either rubber or copper.
Copper water stops shall be 24 guage material.
Expansion joint filler
Expansion joint filler material shall consist of
formed strips of a durable resilient compound.
Where
stiffness is lacking in proformed
expansion joint filler, the strips shall be encased in
saturated felt, asphalt impregnated cotton
webbing or other satisfactory material.
Any
material used for encasement shall be firmly
sealed to the body of the joint filler and shall not
become detached there-from after immersion in
water for a period of 48 hours. Expansion joint
filler material shall be manufactured in a
workman-like manner and when 10 percent or
more of any lot or shipment is of non-uniform or
improper construction, the entire lot or shipment
may be rejected.
iii
Concrete Design Mix And Strength :Unless otherwise noted on the drawings, all concrete
shall be proportioned so as to obtain a twenty eight
(28) days cube compressive design strength of 200
kg/cm2 at preliminary test. The grade of concrete
shall be M:15 (1:2:4 approximately) / M:20 (1:11/2:3)
or as specified. The design mix shall be prepared by
an established testing laboratory and submitted by
51
the Tenderer to the Architect / Owner for approval

before use.
iv
Grading Of Aggregates :Aggregate shall be furnished in primary sizes

specified herein and shall be stored in separate
batching. bins and batched as required to confirm to
the combined grading requirements.
The
proportioning of the fine and coarse aggregate may
be varied as directed by the Engineer to produce a
workable mixture.
The maximum size of aggregate shall be controlled by
the purpose for which the concrete is intended and in
accordance with the following table.
Location
Maximum Size
Coarse Aggregate
Massive Foundations
2 inch (63mm)
Typical Foundations
1 inch (38mm)
Columns, Beams and Girders
1 inch (25mm)
Walls 8 inch (200mm) and thicker
1 inch (38mm)
Walls 6 inch (150mm) and thinner inch (18mm)
Slab at grade thicker than 4 inch 1 inch (25mm)
(100mm)
Slab at grade 4 inch (100mm) thick inch (18mm
Structural slabs
inch (18mm)
52
The grading of aggregates shall be as follows :

SIEVES Primary
2 Inch
3
100
2
90-100
2
35-100
1
0-15
1
0-10
0-5
3/8
No.4
No.8
No.16
No.30
No.50
No.100
No.200
v
Aggregate Size
1 Inch
Inch
100
95-100
55-85
35-70
10-30
0-5
100
90-100
20-55
0-10
0-5
PERCENTAGE PASSING SIEVES

Combined Aggregate Sizes
Fine
2 max
1 max
max
100
95-100
80-85
100
65-85
95-100
50-75
50-80
100
45-65
45-75
90-100
100
35-55
35-60
60-80
95-100 30-45
30-45
40-60
80-85
20-35
20-35
30-45
50-85
15-30
15-30
20-35
25-60
10-15
10-15
10-25
10-30
5-10
5-10
5-15
2-10
0-3
0-3
0-5
0-2
0-2
0-2
0-2
Storage Of Aggregates :Aggregates shall be stored or stockpiled in such a

manner that separation of coarse and fine particles of
each size will be avoided and also that various sizes
will not become intermixed before proportioning.
Aggregate in storage shall be adequately protected
from dust or other foreign matter and all aggregates,
which have become coated with dust or foreign
material to such an extent as the Engineer may
determine, has impaired the quality of the aggregates,
shall be washed or rejected as the Engineer may
decide
In placing materials in storage or moving them from
storage to the mixer, any method which may cause
segregation, degradation, or combining of materials
of different grading, shall be discontinued and the
materials so handled shall be reprocessed.
53
vi
Mixing Of Concrete : Machine Mixing :

All concrete shall be mixed in batch mixers of
approved type except where hand mixing is
specifically approved by the Engineer. The
capacity of the mixer shall be considered to be
rated capacity as given in the manufacturer's
catalogue, provided that a quantity equal to the
rated capacity can be thoroughly mixed in the
prescribed time period and further, provided there
is no loss of ingredients during the mixing. Each
batch shall be mixed not less than two minutes
after all the ingredients are in the mixer and until
the mass is uniform and homogeneous. The mixer
shall be completely discharged before being
recharged. The peripheral speed of the concrete
mixer drum shall be approximately 60 m/minute.
Hand Mixing :
Where specifically approved by the Engineer,
hand mixed concrete may be made in batches of
not more than one cement bag and shall be mixed
in a watertight mixing boat placed in a level
position. The coarse aggregate shall be placed in
the boat and the fine aggregate shall be sprayed on
this layer, the two layers together not being more
than 300 mm in depth. On this mixture shall be
placed the cement and the whole mass turned not
less than two times dry; then the whole mass shall
be sprinkled with sufficient water evenly
distributed, and again turned not less than three
times or until uniform consistency is obtained.
54
vii
Amount Of Water And Slump Tests :The amount of water added at the mixer shall be in
accordance with the design mix and shall be
regulated in accordance with the free water in the
aggregates and the requirements for workability
within the limits of slump test forth. The amount of
water, including the free-water in the aggregates,
shall not exceed 25 litres per sack of Cement. The
equipment for measuring and supplying the water to
the mixer shall be so constructed and arranged that
the amount of water to be added to the mixture can
be measured positively, and the predetermined
quantity of water required can be discharged rapidly
in one operation. The equipment shall be so designed
that water from the source of supply cannot enter the
measuring tank while the water is being discharged
from the measuring tank into the mixer.
Location Of Concrete
Slump
Heavy sections & foundations 2-3 inches
(50mm to 75mm)
Thin sections 8" and under.
3 inches (75mm)
Slabs at grade
3-4 inches
(75mm to 100mm)
Structural slabs.
3 inches (75mm)
All slumps are to be plus or minus 12mm. Slump test
shall use the procedure of I.S.- 456. Slump test will be
made by the Tenderer in presence of the
Engineer/Architect.
55
viii
Form : The forms shall be smooth, true to line and grade

and of sufficient strength to resist any appreciable
springing out of shape during the placing of
concrete. All dirt, chips, saw dust, tie wire, or
other foreign matter shall be removed from the
forms before any concrete is placed therein. Before
concrete is deposited in the forms, all inside
surfaces of the forms shall be coated with an
approved form oil. The form oil shall be of high
penetrating quality leaving no film on the surface
of the forms that can be absorbed by the concrete.
All sharp corners above grade shall be chamfered
with 1"x1" (25mm x 25mm) triangular fillets. The
fillets or chamfer strips shall be surfaced on all
sides.
Forms shall be of sufficient strength to carry the
lean weight of the concrete as a liquid without any
deflection. Forms for beams, girders and slabs
shall be cambered such amount as may be
directed.
Form ties shall be approved form clamps or bolts
to fasten the forms. The use of twisted wire-loops
to hold the forms in placing during concreting will
not be allowed. Bolts or clamps shall be positive in
action and shall be of sufficient strength to prevent
spreading out of the forms. They shall be of such
type that can be entirely removed or cut back
25mm below the concrete surface. All forms for
side of members shall be constructed with stiff
wales at right angle to the studs and all form
clamps shall extend through and fasten such
wales.
56
Plans of false work and centering shall be

submitted to the Owner/Architect two weeks in
advance of the time, the Tenderer begins
construction of the false work. All false work and
centering shall be designed and constructed to
provide the necessary rigidity and to support the
loads. All false work shall be adequately braced.
The forms and false work shall not be removed or
released before the concrete has obtained
sufficient strength to support itself, but in no case
less than the following time, shall the forms
remain in place:--------------------------------------------------------------------LOCATIONS.
TIME
--------------------------------------------------------------------Sides of footing
24 hours
Mass footings
3 days
Columns
3 days
Walls
5 days
Sides of beams or girders
5 days
Soffits of beams or girders
21 days
Structural slabs
14 days
--------------------------------------------------------------------At time of low temperature or other adverse
conditions, the Owner may increase the setting time
to 28 days.
Removal of forms shall be in such a manner as to not
damage the concrete. Centering shall be removed
uniformly and gradually starting at the middle of a
span and working towards the support.
57
ix
Concrete Coverage Of Reinforcing :The concrete coverage of reinforcing steel shall be as

follows, except, as specifically noted otherwise on the
drawing.
---------------------------------------------------------------------------LOCATION
COVERAGE
---------------------------------------------------------------------------Footing poured against earth
3 inches (75mm)
Footing poured against forms
2 inches (50mm)
Formed concrete against earth
2 inches (50mm)
Columns
2 inches (50mm)
Beams and Girders :Bottom of beams
Sides of beams
Tops of beams
2 inches (50mm)
2 inches (50mm)
1 inches (38mm)
Structural Slabs :Bottom

1 inch (25mm)
Tops
1 inch (25mm)
-----------------------------------------------------------------------------x
Waterstops :Waterstops shall be accurately located and secured

against displacement during the placing of concrete.
For rubber water stops, all field splices shall be fullvulcanised, shall be bevelled at 45 degree or flatter.
All finished splices shall have a tensile strength of not
less than 50 percent of the un-spliced material. For
copper water stops, all splices be lapped 25 mm and
soldered each side of the joint to form a smooth
watertight joint.
58
xi
Expansion Joint Filler :Expansion joint filler shall be placed true to line and
grade and shall be placed full depth of slab or width
of wall. It shall be securely held in place by cementing
to the oldest concrete, at the joint, with a bitumastic
cement. The ends will be butted tight.
Expansion Joints In Buildings
Where shown, expansion joints shall be formed
between the concrete faces, or between concrete
and brick work or blockwork, by means of
incorporating in the formwork an approved
impregnated fibre-board filler.
The exposed edges of expansion joints shall be
sealed. Filler boards shall be adequately wired
into adjoining concrete to prevent their falling out
when the joint opens.
In-situ ground floor slabs on hardcore shall be cast
in bays but not exceeding 140 mm in area. The
layout of construction joints in the slab shall be
approved in advance. The mesh reinforcement
shall be so arranged that no laps shall occur along
the joints.
xii
Placing Concrete : Before placing concrete, all form work, reinforcing

embedded items, end etc. will be checked for
completeness and location. Concrete shall be
placed only upon the issue of an approved pour
slip from Engineer-In-Charge/Architect.
59
Concrete shall be transported to the forms and

shall be placed at location without segregation of
its ingredients and before it has taken its initial set.
Concrete shall be placed as nearly as possible in its
final position. In walls, concrete shall be placed in
horizontal layers, between pour joints of such
depth that it may be adequately vibrated. Before
concrete is placed in beams, girders, or caps of
beams, columns, the concrete in the column shall
have been in place at-least two hours.
With the exception of sidewalk, curbs, gutters and
concrete placed on a slope at grade, all concrete
shall be compacted with high speed internal
vibrators of a type and size approved by the
Owner. The number of vibrators employed shall
be adequate to consolidate incoming concrete
within 15 minutes after it is deposited in place. In
all pours there shall be at least one vibrator as
standby in addition to those required for
consolidation of the concrete. The location,
application and duration of vibrating shall be
sufficient to secure a minimum consolidation of
the concrete. free of voids and a proper texture to
exposed surfaces.
No concrete will be allowed to fall from a height
of more than two meters without the use of
adjustable length pipes or "Elephant-Trunks".
The use of chutes in conveying or placing concrete
will be allowed only at the discretion of the Owner
and when used shall be laid on such.
No concrete shall be placed when the ambient
temperature is 95 degree F (35 Degree Centigrade)
and rising, nor when the ambient temperatures is
below 50 degree F (10 Degree Centigrade) and
Falling.
60
Transportation Of Concrete
The concrete shall be discharged from the mixer
and transported to the Works by means that shall
be approved by the Owners Representative and
which shall prevent adulteration, segregation or
loss of ingredients, and ensure that the concrete is
of the required workability at the point and time
of placing.
Mixed concrete shall not be modified by the
addition of extra water or cement or otherwise, in
order to facilitate handling or for any other
purpose. Additives to improve workability may
be added only with prior approval.
When the concrete will be carried in purpose
made agitators, operating continuously, or truck
mixers, the concrete shall be compacted and in its
final position within 2 hours of the introduction of
cement to the aggregates, unless a longer time is
agreed by the Owners Representative. The time
of such introduction shall be recorded on the
delivery note together with the weight of the
constituents of each mix.
When truck mixed concrete is used, water shall be
added under supervision either at the site or at the
central batching plant as agreed by the Owners
Representative, but in no circumstances shall
water be added in transit.
61
Unless otherwise agreed by the Owners

Representative, truck mixer units and their mixing
and discharge performance shall comply with the
requirements of Indian Standards. Mixing shall
continue for the number and rate of revolutions
recommended in accordance with Indian
Standards or, in the absence of the manufacturer's
instructions, mixing shall continue for not less
than 100 revolutions at a rate of not less than 7
revolutions per minute.
xiii
Bonding : Construction joints shall only be located where

shown on the drawings or on the Tenderer's
approved pouring schedule.
Joints at stoppage of work shall be horizontal in
walls and columns and in general be at the tops
and bottoms of sections or stories. After the pour
is completed to the construction joints, and before
the concrete has taken its permanent set. the entire
surface of the joint shall be thoroughly cleaned of
laitance. Clean aggregate shall be exposed by wire
brushing and washing with water. The joint shall
be level across the section. Sloping joints will not
be permitted.
Before placing new concrete against a construction
joint in a wall, beam, girder or structural slabs, the
joint shall be wetted and splashed with sandpaste.
62
xiv
Finishing :Concrete in slabs shall be thoroughly tamped and

struck to grade by a strike-board operating between
the headers or screeds. It shall then be floated to a
smooth surface and trowelled to raise the fines to the
surface. When the concrete is firm enough to support
the weight of a man, without marking the slab, it shall
again be steel trowelled to a hard dense surface.
Topping layers or dashing cement on the surface will
not be allowed.
Non-slip finish for slabs such as at ramps, shall be
made by brushing the surface with a stiff bristle
broom after the first steel trowelling and in lieu of the
second step trowel operated.
xv
Curing :All concrete shall be kept wet by the continuous

application of water, for a period of seven days.
Walls, beams, girders and columns may be cured by
wetting the forms. In the event the forms are
removed, burlap shall be used to cover the surface,
and this shall be kept continuously wet.
Slabs shall be cured by applying water from a nozzle
that automizes the flow so that a mist and not a spray
is formed, until the slab is covered by the curing
medium. The moisture shall not be applied under
pressure directly upon the concrete and shall not be
allowed to accumulate on the surface in a quantity
sufficient to cause a flow or to wash the surface. After
the surface is sufficiently hard not to mark it, shall be
covered with at least a 50 mm depth of sand or earth
blanket. This blanket shall be continuously watered
and kept saturated for a period of seven days.
63
xvi
Repairs And Patching :As soon as the forms are removed from vertical
surfaces all fines and projections shall be removed.
All rock pockets from bolt holes and other voids shall
be filled and patched. The voids shall be thoroughly
cleaned, dashed with water and then filled with a
mixture composed of one part cement and two parts
sand by volume, and sufficient, water to make a
homogenous mixture. Care shall be exercised to
completely fill the void, and to obtain a perfect bond
with the concrete. Where in the opinion of the Owner
the work cannot be adequately repaired, that section
shall be removed and replaced at the Tenderer's
expense.
xvii
Test Cubes :From each pour of 25 cubic meters or as per the

direction of the Owner, cubes shall be taken. The first
cube shall be broken at the age of seven days and
should indicate approximately 70% of the design
strength. The second cube shall be broken at the age
of 28 days and should indicate the design strength,
specified. If the second cube indicates the design
strength, third cube shall be disposed off. If the
second cube does not indicate the design strength the
third cube shall be tested. If the average strength of
the second and third cubes indicate a strength of 90%
of the design strength, the concrete shall be assumed
to meet this specification.
If the average strength of the second and third cube
does not reach 90% of the design strength, the
concrete shall be declared defective and shall be
removed and replaced at the Tenderer's expense.
64
Before removal of the concrete under the conditions

of the preceding paragraph, the Tenderer may elect,
at his own expense, to core the section. If the section
in question is eight inches (200mm) or more in
thickness, two cores shall be taken, and sawed in half
to give four sample cores. If the section is less than
eight inches (200mm) four cores shall be taken. If the
average compressive strength of the cores, adjusted
for high ratio, indicate the compressive strength of the
section equals 90% of the design strength, the
questioned section shall then be judged to comply
with these specifications and if it does not indicate an
average strength of 90% of the design strength, the
Tenderer shall then remove the defective concrete and
replace it at his own expense.
Cube shall be taken in accordance with Appendix "E"
of I.S. 456 except that in all cases, rodding must be
done and vibration will not be permitted.
The cost of taking and breaking the cubes shall be
borne by the Tenderer.
xviii
Drypack :Dry pack shall be composed of one part cement, one

and one-half parts sand and sufficient water to make
a stiff paste.
Dry pack shall be placed by ramming into position
with a metal ram.
Curing of dry pack shall be by covering with burlap
and keeping the burlap continuously wet for 7 days.
65
xix
Grout :Plastic grout shall be composed of one part cement

and one-and-one half part of sand to which shall be
added 4.75 imperial gallons (22 litres) of water per
sack of cement.
Flowable grout shall be composed of one part cement,
one-and-one-half parts sand to which shall be added
4.75 imperial gallons (22 litres) of water per sack of
cement.
Curing of grout shall be by covering with burlap and
keeping the burlap continuously wet for three days.
xx
Non-Shrink Grout :Plastic non-shrink grout shall be composed of one

part portland cement, one part sand and one part
Embeco or Cico no.3 or equivalent approved to which
shall be added 3.9 imperial gallons (18 litres) of water
per sack of cement.
Flowable non-shrink grout shall be composed of one
part portland cement, one part sand and one part
Embeco or Cico or equivalent approved to which
shall be added 4.25 imperial gallons (20 litres) of
water per sack of cement.
No more non-shrink grout shall be mixed than can be
placed in 20 minutes. Retempering of non-shrink
grout shall not be permitted.
Curing of non-shrink grout shall be by covering with
burlap and keeping burlap continuously wet for three
days.
66
Commercial non-shrink grout as marketed by various

manufacturers can be allowed, after the approval to
the same from the Architect / Owner, and shall be
used as per the manufacturers instructions and
specifications.
Concrete shall not be placed in standing or running
water unless so specified or approved.
xxi
Concrete Lining For Canals

The sub grade of the canal profile shall be thoroughly
wetted before placement of concrete.
xxii
Construction Joints
Concreting shall be carried out continuously up to
construction joints.
When work has to be resumed on a surface which has
set, the whole surface shall be thoroughly roughened.
It shall be cleaned of all loose and foreign matter and
laitance, washed with water and all free water
removed immediately before placing the fresh
concrete, which shall be well compacted against the
joint.
xxiii
Special Measures For Hot Weather Working

Mixing - In hot weather suitable means shall be
provided to shield the aggregate stockpiles from
the direct rays of the sun or to cool the aggregates
by spraying with water and to insulate the
mixing-water tank and pipelines to ensure that the
temperature of the concrete when deposited shall
not exceed 32oC (90oF).
67
Placing - In hot dry weather suitable means shall

be provided to avoid premature stiffening of
concrete placed in contact with hot dry surfaces.
Where necessary the surfaces, including
reinforcement, against which concrete is to be
placed shall be shielded from the direct rays of the
sun and shall be sprayed with water to prevent
excessive absorption by the surfaces of water from
the fresh concrete.
Curing - As per para xv above
xxiv
Building In Pipes, Bolts, Etc.

Pipes and pipe specials through concrete walls and
floors shall as far as possible be positioned and built
in during construction. They shall be true to line and
level. The Tenderer shall take particular care to
ensure that fully compacted concrete is in contact
with the pipe at all points.
Where it is impracticable to cast pipes and specials in
the concrete, box holes shall be formed in the
shuttering. The box shall have six or eight sides,
depending on the pipe diameter, and shall be no
larger in size than will give adequate clearance for the
subsequent positioning and grouting in of the pipe.
The sides of the hole shall be provided with a tapered
central annual recess to provide a positive key. The
box hole shall be stripped with the main shuttering
and the concrete surface thoroughly cleaned and
roughened.
When the pipe is later fixed, the hole shall be
re-shuttered and filled with approved expanding
grouting material.
68
Holding down bolts shall be fitted with expanded

metal cones, positioned and built in during
construction. The bolts shall be fixed in the precise
position using an approved expanding grouting
material.
xxv
Precast Concrete
Precast concrete - general
Precast concrete shall be cast in properly made
strong moulds to form shapes required. For work
described as "fairface" the mould shall be lined
with sheet metal or other approved material.
Surfaces against which insitu concrete mortar or
grout is to be placed, shall be prepared as soon as
possible after casting by spraying with a fine
water spray or brushing with a stiff brush, just
sufficient to remove the other mortar skins and
expose the large aggregate without disturbing it.
Lifting links, pockets or sockets that may be
considered necessary for erection shall be
subjected to prior approval and shall be so
constructed and positioned as to be invisible after
construction is complete.
Precast concrete shall be concrete Class 25 as
described and shall be thoroughly compacted by
vibration in the moulds and shall not be removed
from them until seven days after placing the
concrete. The sides may be removed after three
days provided that the moulds are such that the
sides are easily removable without damaging the
concrete.
69
The precast work shall be cast under sheds and

shall remain there for seven days in the moulds
and a further seven days after removal from the
moulds. During the whole of this period the
concrete shall be shielded by sacking or other
approved material kept wet. It shall then be
removed from the sheds and stacked in the open
for at least seven days to season.
Precast work shall be cast in lengths convenient
for handling unless otherwise required. The
precast units shall have adequate strength to resist
overstressing and damage during handling and
erection. Care shall be taken to ensure that the
units are not chipped or damaged.
Testing of precast concrete units
Load testing to destruction shall be carried out in
1% of all precast units. Units for routine testing
shall be taken at random and those units
destroyed shall be immediately replaced.
Erection of precast units
Precast units shall be hoisted and placed in proper
position in such a way as to avoid overstressing or
damaging the units or causing damage to
previously erected structure. Where shown, the
units shall be laid on a thin bed of cement in order
to even out irregularities of supporting members.
Steps necessary, such as taping of joints shall be
taken to prevent escape of grout which lead to
staining of brick and block works and exposed
concrete surfaces when the insitu topping is laid.
Precast members shall be held rigidly in position
during placing of insitu concrete.
70
Holes in precast units

Examine architectural, structural and services
drawings to determine dimension and location of
holes.
Permission to form holes in precast units after
casting shall not normally be given, but in
exceptional cases where the structural soundness
of the perforated unit and its visual acceptability is
satisfactory such permission may be given in
writing.
Marking
Precast units shall be clearly marked after casting
or demolding, showing the identification of the
unit and, if necessary, erection instructions. The
marking is to be such as to be invisible after
erection.
Samples
Samples of precast units, before fabrication in bulk
specimen samples of the precast units shall be
submitted for approval, with which further
deliveries or casting shall be compared for
uniformity of color and finish.
d)
Construction Specification For Reinforcing Steel

all labour, material and equipment and performing the
operation necessary to complete the reinforcing work for
concrete and masonry. If demanded by the Owner, the
Tenderer shall produce manufacturer's test certificate for
steel procured and proposed to be put in the work.
71
Applicable Publication :All work shall be in accordance with the latest

revision of the standards except where specifically
noted otherwise.
Tor steel
I.S.
1786
Reinforcing steel
I.S.
432
Welded steel wire Fabric A. S. T. M. A. 185, I.S. 1566
Fixing of Reinforcement I.S.
2502
ii
Materials :Reinforcing shall be made from new billet steel

conforming to I.S. 432, of tested quality, No re-rolled
material shall be allowed.
Welded steel wire fabric shall conform to A.S.T.M.A.
185 or I.S. 1566.
Reinforcing tie wire shall be annealed wire of 14 or 16
gauge.
Cold work deformed bars conforming to I.S. 1786 and
hot rolled variety conforming to I.S. 1139.
iii
Steel Lists And Placing Diagrams :Two copies of all reinforcing lists and placing
diagrams shall be furnished to the Owner before any
fabrication of reinforcing is done. The list and
diagram will be reviewed for design only and one
corrected or approved copy will be returned to the
Tenderer.
iv
Cleaning :Reinforcing steel, before being placed in the forms,

shall be thoroughly cleaned of scale and rust, mortar,
oil, dirt or coatings of any character that would
72
destroy or reduce bond, and it shall be maintained in

this condition untill the concrete is placed.
73
Bending :Reinforcing steel shall not be bent or straightened in a

manner that will injure the material. Bars with bends
or kinks not shown on the drawings shall not be used.
Bends for stirrups and ties shall be made around a pin
having a diameter of not less than two times the
thickness of the bar. Bends for other bars, shall be
made around a pin having a diameter larger than 25
mm where the pin shall not be less than eight times
the bar diameter. All bars shall be bent cold.
vi
Placing :Reinforcing steel shall be accurately placed and

secured and shall be supported by chair, spacers, or
hangers. Reinforcing steel shall be securely held in
position by wiring at inter-sections with annealed
wire of 14 or 16 gauge. Placing bars on fresh concrete
as the work progresses and adjusting bars during the
placing of concrete will not be permitted.
The minimum clear distance between parallel bars,
except in columns, shall be either the diameter of the
bar, 25 mm or one and one third times the maximum
coarse aggregate whichever is greater.
Cover of concrete over reinforcing steel shall be as
specified in this tender document
All dowels shall be accurately placed with a lap
length of 40 bar diameter extending across the joints.
Vertical reinforcing for masonry shall be held in place
with a frame like device until the masonry is in place.
Horizontal reinforcing may be placed as the masonry
progresses.
74
Welded steel - fabric shall be rolled flat before placing

concrete. Wire fabric shall be positioned and held
against vertical or horizontal movement by devices. If
during placing it is found that the mesh is being
displaced, the Tenderer shall provide means of
pulling mesh into the proper position while the
concrete is being placed. Polythene covers or suitable
covers available in the market shall be used.
Splices in reinforcement in slabs, beams, girders, shall
not be made, at points of maximum stress. Splices
where permitted shall be lapped a sufficient length so
as to develop the bar in bond but not less than 40 bar
diameter. In such splices the bars shall be wired
together.
Splices in reinforcement in columns where change in
column cross section occurs shall be spliced in a
region where lateral support is afforded. Where offset, the slope of the inclined portion of the bars shall
not be more than one in six, and in tied columns the
ties shall be spaced at 75mm on centre for a distance
of 30 cms. below the actual point of offset.
Splices in welded steel wire fabric shall be by lapping
one mesh length.
The test reports of the various lots supplied at site, as
directed by the Engineer at site, shall be obtained
from time to time, after getting the sample tested
from the approved laboratory as directed by the
Owner, at the cost of the Tenderer.
e)
Construction Specification For Structural Steel

operations necessary to complete the structural steel work
75
The Tenderer has to prepare the shop drawing from the

structural drawing and the shop drawing shall be got
approved prior taking up the Fabrication work from the
Architect / Owner.
i

revision of the Indian Standards except where
specifically noted otherwise.
Structural Steel
Structural Safety
Structural Safety
ii
I.S. 800, I.S. 226

I.S. 806 & 1161
I.S. 875
Materials :All materials shall be new and tested quality,

Necessary test certificate from manufactures, from
whom materials are procured shall conform to the
following : Structural steel shall conform to I.S. 226 and shall
be of tested quality.
Rivets shall conform to I.S. 1148.
Welding electrodes shall conform to I.S. 814
Electrodes for general welding shall be I.S. Code
M 317443.
Low Hydrogen Electrodes shall be I.S. Code M
615499. All low Hydrogen electrodes shall be
delivered in hermetically sealed containers until
used and after the containers are opened, shall be
maintained at a minimum moisture-content in an
oven.
76
All bolts and nuts shall conform to I.S. 1608.

Washers shall conform to I.S. 226.
Structural Tubes shall be yst 22 grade finished
welded and tested quality with minimum wall
thickness of 3.25 mm unless otherwise mentioned
and shall conform to I.S. 806 and I.S. 1161
Paint
Shop coat shall be one coat Red lead and oil or
Zinc chromate Noble Chrome Prime or equal,
GHD shall confirm to I.S. 2074
Field coat except as noted shall be two coats of
Noble Iron coat or equal.
Acid Resistant paints shall be Noble chlorcote or
equal.
iii
Fabrication And Shop Assembly :Before being fabricated or worked in any manner, all
material shall be straightened, by method which do
not damage the steel, and all rust and scale shall be
removed. After working, all twists or bends shall be
removed before parts are assembled.
All members and section shall be closely fitted and
finished true to line.
Joints between columns and base or cap plates shall
have the contact faces milled to a true surface and
shall be rigidly held in position while fastening
together.
All necessary accessories such as fixtures, fittings,
connections, shall confirm to the relevant
specifications of I.S. 730
77
iv
Welding :All welding shall be done by the Electric Arc welding

process, and shall confirm to I.S. 816.
Riveting :All riveted members shall be accurately held in place

during the riveting operation. All rivets shall be
properly heated and when driven shall completely fill
the hole. Drifting of unfare holes will not be
permitted.
vi
Bolting :All bolted members shall be accurately held in place

during the bolting operation. Drifting of unfair holes
will not be permitted. On sloped connections bevel
washer shall be used to ensure satisfactory bearing
under bolt heads and nuts.
vii
Erection :All members shall be erected plumb, square and true

to the line and grade and in the precise position as
indicated. Temporary guys, shores and bracings shall
be installed where necessary and shall be capable of
sustaining all loads which occur during erection.
Temporary guys, shores and bracings shall remain in
place as long as necessary to safeguard the structure.
As erection progresses, the work shall be bolted up as
required to maintain the structure in proper position
during erection and to sustain all loads during
erection. After the structure is properly aligned,
plumbed and levelled, all field connections shall be
made.
78
Each column base plate shall be accurately set with

proper alignment and shall be plumbed at the proper
height. The base plate shall be held accurately in
position with either levelling nuts or steel shims.
Except as specifically called for, levelling plates will
not be permitted.
The erection of all members shall be carried out in
proper sequence with the work of other trades, and
shall be anchored to other materials in conformance
with the details.
viii
Painting :After fabrication all steel shall be thoroughly cleaned

of scale, grease, oil, dirt or other foreign matter and all
surfaces, except those to be embedded in concrete or
masonry, shall be given a shop coat of the specified
primer to a dried thickness of 0.06 mm. The paint
shall not be applied until all surfaces to be covered
are clean and thoroughly dry. It shall be worked into
all joints and angles and shall cover all surfaces. This
coat shall be completely dry before being loaded for
delivery.
After erection, all field connections, and abrasions
shall be cleaned and given a touch-up coat of primer
and the either work shall be left in a neat and
acceptable condition to receive the field coat of paint.
After the touch-up coat is thoroughly dry and all
surfaces are clean, the field coats shall be applied to
all surface not encased in concrete or masonry. Each
field coat shall have a dried coat thickness of 0.05mm.
Colours of field coat will be selected from standard
Manufacturer's colours, and shall be approved by the
Architect.
79
ix
Fencing
Materials
Materials for fencing and gates shall conform to
the following requirements:
(a)
Chain link intermediate and straining T

posts shall conform to the requirements of
I.S.
(b)
Gate posts and frames shall conform to the

Indian Standards.
(c)
Bracing bars shall

requirements of I.S.
conform
to
the
(d) Concrete for fencing and gate posts shall be

Grade 10 concrete as described in this
tender document.
Fencing shall be galvanized steel with a
thickness of 2.5 mm. The mesh shall be diamond
shaped with 50 x 50 mm opening to the center of
wires.
Fence posts and strainers shall be 35 x 35 x 3 mm
mild steel Tee profiles .
Fence bracing shall be 12 mm mild steel
reinforcing bars.
Gates shall be RHS expanded metal
Tying wires for chain-link fencing shall be 2 mm
thick mild galvanized steel wires.
80
Fabrication
Fence posts, strainers, gate posts and gates shall be
fabricated in accordance with the applicable codes.
Welding for gates and posts and bracings to fence
posts shall be in accordance with the requirements
in Structural Steel.
Welded joints on gates and gate posts shall be
neatly made, filed smooth and left clean.
Gate and gate posts shall be primed at shop and
painted after installation as specified in
Anti-Corrosion Measures.
Installation
Intermediate, strainer and gate posts shall be fully
embedded in concrete.
Chain link fences shall be securely tied to fence
posts bracings using tie wires. The holes in the
posts for tying shall be spaced at a maximum
distance of 100 mm.
Bracing bars shall be securely welded to posts and
strainers.
Fence posts, strainers and bracings shall receive
one coat of primer preceding the installation of
chain link fence.
81
Execution
Inspection:
The Owners Representative shall examine the
areas and conditions under which miscellaneous
metal items are to be installed and notify the
Tenderer in writing of conditions detrimental to
the proper and timely completion of the work. Do
not proceed with the work until unsatisfactory
conditions have been corrected in a manner
acceptance to the Owners Representative.
Preparation:
Furnish setting drawings, diagrams, templates,
instructions and directions for the installation of
anchorages, such as concrete inserts, anchor bolts
and miscellaneous items having integral anchors,
which are to be embedded in concrete or masonry
construction. Coordinate the delivery of such
items to the project site.
Installation:
(i)
Fastening To In-Place Construction: provide

anchorage devices and fasteners for securing
miscellaneous metal items to in-place
construction; including, threaded fasteners
for concrete and masonry inserts, toggle
bolts, through-bolts, lag bolts, wood screws
and other connector as required.
82
(ii)
Cutting, Fitting And Placement: perform

cutting, drilling and fitting required for the
installation of the miscellaneous metal items.
Set the work accurately in location, alignment
and elevation, plumb, level, true and free of
rack, measured from established lines and
levels. Provide temporary bracing or anchors
in formwork for items which are to be built
into
concrete,
masonry
or
similar
construction.
(iii) Fit Exposed Connections accurately together

to form tight hairline joints.
Weld
connections which are not to be left as
exposed joints, but cannot be shop welded
because of shipping size limitations. Grind
joints smooth and touch-up shop paint coat.
Do not weld, cut or abrade the surfaces of
exterior units which have been hot-dip
galvanized after fabrication, and are intended
for bolted or screwed field connections.
(iv) Field Welding: Comply with BS.4870, 4871,
4872, 5135 for the procedures of manual
shielded metal-arc welding, the appearance
and quality of welds made, and the methods
used in correcting welding work.
(v)
Touch-Up Painting:
Immediately after
erection,
clean
fields
welds,
bolted
connections, and abraded areas of the shop
paint, and paint all exposed areas with the
same material as used for shop painting.
Apply by brush or spray to provide a
minimum dry film thickness of 0.05 mm.
83
Metallic Coatings
Parts to be galvanized shall be properly prepared
and galvanized in accordance with I.S. Safeguards
against possible embrittlement of steel products
shall be in accordance with I.S. Galvanized
surfaces shall be supplied free from damage.
Repair of Paint Film
The Tenderer shall provide paint of compatible
material and colour to repair any shop paint film
which has been damaged during transit.
If the base metal has deteriorated due to the
damaged protective coat, the affected area and the
immediate surrounding area for a distance of 50
mm shall be cleaned and repainted in accordance
with the original specification.
Sufficient paint for the repair of shop coating shall
be delivered in containers sealed by the
manufacturer and the capacity of the containers
for single pack paints shall not exceed 5 liters.
xi
Testing and Inspection

Testing
The Owner may appoint a testing consulting
laboratory to carry out testing and inspection as
required by the Owners Representative to ensure
conformance with the design and specifications.
The Tenderer shall assist the testing laboratory by
making access to fabrication facilities and erected
sections.
84
Shop welding shall be tested by the Owners

Representative's inspector at the factory at the
Owners Representative's option. If testing is
required by the Owners Representative no item
shall leave the shop until approved by the testing
laboratory.
Inspection or Test Failure
In the event of failure of the product or any part to
fully meet any inspection or test requirements
specified herein, the Tenderer shall notify the
Owners Representative should he wish to repair
and/or use such product or part. At the discretion
of the Owners Representative, suitable repairs
and re-inspection and retesting may be carried
out.
If the repairs, including redesign, are likely to
affect the results of the tests or work previously
completed, appropriate re-inspection and retesting
shall be conducted.
Test Reports
Within thirty days of completion of each and
every test required, as proof of compliance with
the Specification and/or each and every specified
test, including commissioning tests, the Tenderer
shall submit to the Owners Representative 6
signed copies of a report covering such tests.
The test records for materials shall identify the
component parts in which the materials are to be
used and the certificate shall be prepared in such a
way that it can be easily determined if the
applicable Specification or standard has been
complied with.
85
Field Testing
The Owner reserves the right to make any
laboratory and/or field tests to determine whether
or not any item supplied meets the requirements
of this Specification.
xii
Structural Steel
Requirements
and
Miscellaneous
Structural
Materials
(i)
Structural steel for buildings, including

rolled shapes bars and plates shall comply
with the requirements of I.S.
(ii) Nuts and bolts I.S. regular series hexagon
head and nuts.
(iii) Shear connectors shall be of sizes and
welding in accordance with I.S. codes.
(iv) Shop painting shall be of red lead iron
oxide linseed oil primer.
Cutting, Sawing and Drilling

Plates and sections shall be true to form.
Stiffeners, plates and the like shall be ground to fit
the profile of the member. Sections to be cut to
'exact' lengths shall be accurately cold sawn or
machined. Preparation of edges by flame cutting
shall, wherever practicable, be done by machine.
Cold sawn, machine-cut and flame-cut edges shall
be cleaned free of burrs and slag and left as
smooth and regular as those produced by edge
planning.
86
Check Plate
Check plate flooring shall be 'Durbar' non-slip
raised pattern or other equal approved.
Individual plates shall be cut and fitted so that the
pattern on adjacent panels matches in all
directions.
Unless otherwise stated, the plate shall be 8 mm
thick on plain and shall be fastened to the
steelwork by 10 mm counter-sunk set screws at a
pitch not exceeding 500 mm centers.
Kicking strips not less than 100 mm high shall be
provided at the edges of all platforms and doors.
Steel Grating
Steel grating 40 mm thick, of a non-slip all welded
type shall be supplied and supported.
Crane Rails
Joints shall be staggered on opposite sides.
Manufacture in accordance with I.S. for Crane
Rails.
Galvanized Steel Railings
40 mm inside diameter standard steel pipe
handrail. Brackets not to exceed 1.5 m on centre.
All joints and corners to be smooth. Bends in
hand railing shall be carefully formed to give
satisfactory continuity of curvature and alignment
and rails shall be jointed with a flush scarf joint
held together by means of a tapered pin or other
approved joint.
87
Steel Stairs
The treads and landings of stairways shall be
check plate or similar. The treads shall have
double nosing bar to emphasize the leading edge
of the tread, or other equal approved. All treads
in a flight shall match one with another and also
with the line pattern of the landings and, where
possible, with the floors served by the stairs.
Unless otherwise specified the widths of landings
shall be 1,000 mm and the width between staircase
stringers 760 mm minimum. The inclination of
stair stringers to the horizontal shall not exceed
42 degrees. Kicking strips not less than 100 mm
high shall be provided at the edges of all landings.
Insulated Roof Cladding
Steel roof cladding shall conform with the
structural steel layout. Insulated roof cladding
shall be 0.5 mm minimum thick with a "U" value
of 0.10 (minimum). All roof cladding material
shall be hot dip galvanized.
Steel Cladding
Steel sheet cladding shall conform with the
structural steel layout, 0.5 mm thick. All sheeting
material shall be hot dip galvanized unless
otherwise specified.
Chain Link Netting
The chain link netting surrounding the
fermentation section of the ethanol plant shall be
hot dip, galvanized and supplied in sections to
facilitate removal.
88
Holding Down Bolts

Bolts shall be I.S. regular series hexagon head and
nuts.
Ventilators
The ventilators shall be 26 gauge galvanizing steel
mounted ridge and of the gravity type.
Ventilators shall not permit entry of insects or
birds into the building.
Metal Ladders
Ladders shall be as detailed with single rungs,
shouldered at each end, and inserted into
prepared holes in the stringers and welded. The
pitch of additional rungs to bridge the gap
between the top rung of ladders and edges of
platforms shall not exceed 57 mm. The stringers
shall open out at the top of the ladder to allow
adequate room for the user to turn to face the
ladder when descending and the stringers shall
extend a minimum of 1,060 mm above the level of
the platform. Where necessary the stringers shall
be bent over to form a continuous connection with
the platform hand railing and at the same height
as the top rail. Ladders shall be provided with
safety hoops. Stringers shall be attached to the
adjacent structure by suitable cleats which shall be
firmly attached to the stringers and the supporting
structure and be sufficiently close together to
make the ladder rigid throughout its length.
89
The cleats shall be of sufficient length to give the

required clearance at the back of the ladder. The
top rung of a ladder shall be at the same level as
the floor or edge of the platform unless the
flooring of the platform has been extended to form
the top rung and there shall be no obstructions
above this level.
Metal Flashing
The metal flashing shall be of 26 gauge galvanized
steel and formed to the required profile.
Light Panels (Translucent Sheets) :Translucent sheeting shall comply with I.S. and
shall be continuous and of thermosetting polyester
synthetic resin.
The sheeting shall be coated to prevent attack by
ultra violet light. Light transmission shall be at
least 75%.
It shall be graded AA when tested to I.S. and shall
have a Class 1 surface spread of flame.
Louvers
Louvers shall be of galvanized steel designed as
an integral part of the cladding system. They shall
be fixed type louvers.
Gutters
The gutters shall be fabricated of 26-gauge
galvanized steel designed with a contour fitting
the general configuration of the buildings.
90
Downspouts
The downspouts shall be of 26-gauge galvanized
or as specified.
Bearing Splices
Fastening of bearing splices of compression
members shall be done after the abutting surfaces
have been brought completely into contact.
Bearing surfaces and surfaces that will be in
permanent contact shall be clean prior to final
assembly of members.
Bolted Joints
All bolted connections shall be in accordance with
I.S.
Structural steel bolts, nuts, studs and washers
shall comply with I.S.
High strength friction grip bolts shall comply with
I.S. and shall be used in accordance with I.S.
Lining and Plumbing Tolerances
The tolerances within which the final position of
the steelwork will be accepted shall be as follows:
Permissible Deviation
Linear Dimension (in plan):
Up to and including 8 m +/- 10 mm
Over 8 m up to and including 15 m - 15 mm
Over 15 m up to and including 25 m 20 mm
Over 25 m 20 mm
91
Plumb:
In 30 m height +/- 15 mm
Levels:
Plumb distance between designed and actual

level of the base of the first column to be
erected +/- 5 mm

level of any beam at its junction with a
column (in any 30 m length) +/- 15 mm

levels of the upper and lower surfaces
of
two or more beams meeting at a column +/5 mm
Qualification and Testing of Welders

The Tenderer shall satisfy the Owners
Representative that welding operators are suitable
for the work upon which they will be employed.
Welders shall provide evidence to the satisfaction
of the Owners Representative that they are
capable of passing the tests as specified in I.S.
Crane Runways
Crane runways shall be erected complete with all
columns, girders, beams, bracing, crane rails,
crane stops, and other required components as
indicated. The gauge, alignment and elevation of
crane rails shall be accurate to a tolerance of plus
or minus 3 mm. Crane rails joints shall be
staggered with respect to each other on opposite
sides of the runway and shall not coincide with
the crane girder joints. The top of the crane rails
shall be flush at all joints.
92
Non-Destructive Testing of Welds

Weld quality and correct standards shall be in
accordance with I.S, as modified herein. The
Tenderer shall furnish facilities for performing the
tests, including power and utilities, at no
additional cost to the Owner at the expense of the
Tenderer.
(i)
Radiographic testing shall be in

accordance with I.S. The welder or
welding operator's identification mark
shall be stamped on the steel as
specified so that full and complete
identity and history of the welding
operation will be known.
(ii)
Correction of Defective Welds. Weld

areas containing defects exceeding the
standards of acceptance in the above
I.S., revealed by radiography shall be
repaired under the direction of the
Owners Representative, and additional
radiographs of the repaired areas shall
be made at the Tenderer's expense, 100
percent radiographic inspection of that
welder's work will be required at the
Tenderer's expense.
(iii)
Ultrasonic Inspection. Technique and

standards of acceptance shall be in
accordance with I.S.
(iv)
Magnetic Particle Inspection methods

shall be in accordance with I.S.
(v)
Liquid Penetrant Inspection methods

shall be in accordance with I.S.
93
f)
Construction Specification For Masonry Construction

operations necessary to complete the masonry work
i

Cement
Sand
Lime
Stone
Brick
Concrete Block
ii
I.S.
I.S.
I.S.
I.S.
I.S.
I.S.
269
383
712
1127
1077
2185
I.S.
1725
Material : Cement :Cement Shall be ordinary portland Cement

conforming to I.S. 269. All cement used shall be
suitably protected from exposure to moisture until
used.
Sand
Sand shall consist of approved natural sand,
manufactured sand or a combination of both and
shall be hard and durable. It shall be free from
organic matter or other deleterious material.
Adequate supplies of sand shall be stockpiled
sufficiently in advance of construction to permit
sampling and testing before use. Sand shall
conform to the following sieve analysis.
94
Sieve
Percentage Passing
10mm
100
No. 4 (4760 Micron
95-100
No. 8 (2380 Micron)
80-100
No. 16 (1190 Micron )
50- 85
No. 30 ( 590 Micron)
25-60
No. 50 (297 Micron)
10-30
No. 100 (149 Micron)
2-10
With not more than 45% retained between any
two consecutive sieves. The fineness modulus
shall be between 2.25 and 2.75
Stone :Stone shall be natural stone and shall be sound,
clean, hard, durable and free from seams or other
imperfections, and free from skins form. No
weathered stones will be accepted.
Brick :Brick shall be hard burned clay bricks and at the
time of laying shall have a rate of absorption of
not more than 4.60 gms. of water per square cm. of
surface submerged to 3 mm. of water for one
minute.
iii
Mortar And Grout : Mortar :Mortar shall be composed of one part cement, one
part lime putty, four and one-half parts sand, and
sufficient water to make a plastic mix or as
specified on drawing and schedule of quantity.
95
Grout :Grout shall be composed of one part cement, two

part sand, and sufficient water to allow the grout
to flow into all joints and interstices of the
masonry.
Grout compressive strength shall be not less than
70.3 kg per square cm. at seven days nor less than
104.61 kg. per square cm. at twenty-eight days.
Mixing :Mixing shall be done either in a mechanical mixer
or in a mixing pot. The sand, cement and water
shall be placed in the mixer, in that order, for each
batch of mortar or grout and shall be mixed for a
period of at least two minutes, and the mixing
continued as long as need to secure a uniform
mass, but in no case less than two minutes.
Equipment for mixing and handling shall be
approved. Retempering of mortar shall be done
only by adding water into basic made with
mortar, and the mortar carefully worked into it.
Retempering by dashing water over the mortar
will not be permitted. Any mortar or grout unused
within one hour after the initial mixing shall be
removed from the work. Mortor shall be mixed
and maintained while being used to a slump of
5.08 cm. & 1.27 cm. to 10 cm. using a truncated
cone 100mm or 50mm, 150mm high, and grout
should have a slump of 12.7cm. to & 1.27 cm.
Mortar compressive strength shall be not less than
52 kg. per square cm. at seven days nor less than
105 kg. per squrae cm. at twenty-eight days.
96
iv
Stone Construction: Wetting of stones :

All stones shall be thoroughly wetted before
placing in position.
Laying of stones :
The walls shall be carried up truly plumb. Every
stone shall be carefully fitted to the adjacent
stones, so as to form neat and close joints, stone
may be laid at random without being brought up
to any level courses except at plinth, window sills,
bond beams and roof level. The bond shall be
obtained by filling in closely the adjacent stones
and by using two bond stones for every 1 Sq.
meter of wall surface and staggered. Through
bond stone shall run right through thickness of
wall. The stone shall be laid on its natural quarry
bed.
Face stone shall extend and bond well into the
backing. These shall be arranged to break joints as
much as possible, and to avoid long vertical joints.
Their heights shall not be greater than the breadth
at the face or the depth inwards.
The hearting or interior filling of the wall face
shall consist of rubble stone not less than 13 cm in
any direction. The hearting will be laid nearly
level with facing and backing except that at about
one meter intervals, vertical "Plumbs" projecting
about 15 to 20 cm. shall be firmly embedded to
form a bond between successive courses. The use
of chips shall be restricted to the filling of
interstices between the adjacent stones in hearting
97
and these shall not exceed 15% of the quantity of

stone masonry. Selected stones roughly squared
to line shall be placed at all wall angles, corners
and ends. Flat or stratified stones shall be laid in a
horizontal and not on edge.
Joints in face of the wall shall be not less than
12mm. nor more than 25mm. in thickness. Interior
spaces between stones shall be filled with mortar.
No voids will be permitted in any part of the wall.
Pointing :
Within 24 hours after construction, the joints on all
exposed wall faces shall be racked clear of loose
mortar, to a depth of not less than 20mm and
pointed with the mortar specified, so that all joints
are recessed a minimum of 6mm.
Curing :
All masonry shall be kept continuously damp for a
period of seven days after laying by either fog
spraying or by covering all surfaces with burlap
and wetting this burlap.
v
Brick Construction :All bricks shall be wetted thoroughly so that at the

time of laying, the bricks will have a residual rate of
absorption of between 5 and 15 per cent.
Laying of Brick :
All Bricks shall be laid true to line and grade, level
and plumb in a full bed joint, with a full shoved
head joint set in English bond. Furrowing of
mortar will not be allowed.
98
Horizontal concrete surfaces which are to receive

brick work shall be damp, clean and free of
laitance. In reinforced grouted masonry, the
vertical reinforcing shall be in place before the
masonry work begins. The first course on each
side of the wall shall be laid and then 40mm. of
grout shall be placed between the bricks.
The bricks shall then be laid so that not more than
three bricks in height are laid on one side of the
wall before one course is laid on the opposite and
the grout space is then filled. This procedure shall
be followed throughout so that at no time is one
way more than three bricks high than the other,
and at no time is the top of the grout more than
40mm. below the top of the brick in the lower
whythe. Mortar shall not project into grout space
on head or bed joints.
Grout shall be placed as the work progresses and
shall be poured from the inside face of wall. Grout
shall be well puddled with a stick, slicing with a
trowel will not be permitted.
Tooling of joints :
Except for walls to be plastered, all joints shall be
tooled with a round tool of 2mm. diameter in such
a way as to squeeze the mortar into the joints and
fill all pinholes in the mortar. Joints in wall to be
plastered shall be struck flush.
Curing :
Curing shall be as specified in this tender
document
99
vi
Cleaning :On the completion of the masonry work, all surfaces

which are to be exposed in the final condition are to
be cleaned, removing all mortar, grout and stains
from the exposed faces.
vii
Masonry To Be Plastered :
All surfaces to be plastered shall be thoroughly wet
down 48 hours and then again 24 hours before
plastering operation begins. The surface must be
clean and free from dirt, oil, paint, or other material
which may reduce bond.
viii
Masonry To Be Painted :All surfaces to be painted shall be thoroughly dry and

in no case paint be applied until two months have
elapsed after the completion of masonry or two
months after the monsoon season.
ix
Cleaning-Up :At the completion of the masonry work, the Tenderer

shall remove all scaffolding, equipment, debris and
surplus material from the site and dispose of all
debris as directed.
Brickwork And Masonry

Concrete Block Walls
Concrete block walls shall be built with new
hollow concrete blocks laid and bonded with
mortar
100
All units shall be laid with full mortar coverage of

the face shells in both horizontal and vertical
joints. Units shall be lapped in successive vertical
courses.
Wall surfaces shall be plumb and straight. Wall
thickness shall be as shown on the Drawings.
Concrete blocks shall comply with I.S. Class A.
They shall be obtained from an approved supplier
or may be manufactured on Site. Samples shall be
submitted to the Owners Representative and his
approval must be obtained before any blocks are
delivered or used in the construction of the Works.
For blocks manufactured on Site, the Tenderer
shall prepare a design mix using the materials
available to him to give a minimum average
compressive strength of 2.8 N/mm2 on gross area
after 28 days from casting. A minimum of six
blocks shall be prepared from this mix for testing.
Samples of blocks from each subsequent batch
(minimum number six) shall be submitted to the
Owners Representative for testing to ensure that
the prescribed standards are maintained and
when blocks are manufactured on Site, the
Tenderer shall mark each day's output with the
date of manufacture for identification.
Materials for the blocks shall not contain any
impurities which will affect the strength for
durability of the blocks or the durability and
appearance of any applied finishes.
101
Blocks shall be uniform in texture, shape and size,

with sharp arises and free from any cracks or
defects. Curing shall be carried out for at least
seven days under moist coverings.
All
manufacture and curing shall take place on a
suitable smooth concrete floor and only machines
of approved design may be used for manufacture.
The surface characteristics of the blocks shall be
such that a good key for rendering or plastering, is
provided where required.
Portland cement shall conform with the latest
specifications of the Indian Standard I.S.
Sand shall comply with I.S.
Lime shall be hydrated lime and shall comply
with I.S.
Water shall be as that specified in this tender
document
Block walls shall have concrete tie columns at
corners, ends of free standing walls, at sides of
wall openings exceeding two meters and at two
meters on centres.
Tie columns shall be 200 mm wide by 300 mm
long, reinforced with four vertical bars 14 mm
diameter and ties 8 mm diameter spaced 300 mm
on centres.
Block walls shall be capped at top of wall with a
tie beam and reinforced with intermediate tie
beams vertically spaced two meters on centres.
Concrete tie beams shall be 200 mm wide by 300
mm high reinforced with four bars 16 mm
diameter (two top and two bottom).
102
Blocks shall be properly stacked on level hard

standing and be adequately protected from
inclement weather.
Cements and limes shall be stored in dry,
watertight sheds or stores and in such a manner to
enable them to be used in rotation, in order of
delivery.
Sands shall be stored separately, according to
type, on clean, dry, hard standing and
protected from contamination.
xi
Damp Proof Courses

Damp-proofing for horizontal application shall be
hessian based bituminous felt conforming to I.S.
Damp-proofing for vertical application shall be high
melting point bitumen of approved manufacture.
xii
Mastic Pointing
Joints and surfaces to receive mastic shall be properly
cleaned and primed as required and the mastics
mixed and applied strictly in accordance with the
manufacturer's instructions.
xiii
Movement Joints
Movement or expansion joints are to be provided
only if shown or specified on the drawings and shall
be plumb, continuous open vertical joints 10 mm
wide, the centre of each joint plugged with either
expanded polystyrene or soft board and the faces of
the joint subsequently sealed with a bitumastic
sealant approved by the Owners Representative.
103
xiv
Protection Of Finished Walls

The Tenderer shall ensure that all finished walling
will not be damaged by subsequent operations.
The Tenderer shall protect newly or partially erected
walling from drying out too rapidly by the sun's heat.
In particular, the Tenderer shall, as necessary,
dependent upon the climatic conditions, keep all
newly erected walling well-watered for at least three
days.
xv
Stone Dressing
Stone shall be roughly hewn to manageable sizes,
more or less prismatic in shape. The least dimension
shall be not less than 100 mm.
In addition, stone for exposed masonry shall be fair
chisel dressed on the exposed face and shall measure
450 mm +/- 70 mm in the longest direction.
Paving stones shall be random shapes and sizes.
Maximum sizes shall not exceed 600 mm and
minimum sizes shall not be less than 200 mm
measured on the face. Fill-in stones shall be sized as
required. Paving stones shall be 100 +/- 20 mm thick.
xvi
Stone Paving
Stone paving blocks shall be laid on 100 mm thick
tamped sand bedded or on concrete, to levels, falls
and patterns.
Joints shall be cleaned to a depth approximately equal
to the thickness of the paving stones and
subsequently filled with cement mortar, the joints
shall be finished flush with the stone surface.
104
PERMISSIBLE TOLERANCES FOR VARIOUS TYPES OF FINISH
Type of Structure
Buried concrete in
foundations,
Culverts, retaining
wall
Exposed concrete
in columns, piers,
retaining walls,
abutments
Type of Irregularity
Departure from alignment
and grade as shown on
the approved drawings
Tolerances (mm) in Finish Type

F1
F2
F3
U1
U2
+/-15
+/-15
-
U3
-
Variations in crosssectional dimensions

Abrupt
Gradual
+15
-8
+/-15
+/-15
+/-15
+/-15
Departure from alignment

and grade as shown on
the approved drawings
+/-15
+/-15
Variations in crosssectional dimensions

Abrupt
Gradual
+15
-8
+/-8
+/-15
+15
-8
+/-4
+/-8
g)
+/-8 +/-8
+/-8 +/-4
+/-8 +/-4
Construction Specification For Plastering And Pointing

The work covered by the specification includes furnishing
all labour, materials, equipments and performing
the
operations necessary to complete the plastering and pointing
works.
i

Cement
I.S.
269
Sand for plaster
I.S.
1542
Building Lime
I.S.
712
Structural Safety
I.S.
875
105
ii
Material :Cement shall be ordinary Portland Cement

confirming to I.S. 269. All cement shall be suitably
protected from exposure to moisture until used.
Sand shall consist of approved natural sand,
manufactured sand, or a combination of both and
shall be hard, clean and durable. It shall be free of
organic or other deterious material and conform to
I.S. 1542 class A.
Building Lime shall conform to I.S. 712 class A.
Water shall be supplied by the Tenderer.
iii
Mixing:Material which has partially set shall not be

retempered or used. The mixer or mixing box shall be
thoroughly cleaned of all set or hardened material,
before materials for a new batch are loaded.
Machine Mixing :The sand and Cement shall be placed in the mixer
dry and thoroughly mixed; then the water shall be
added to obtain the proper consistency and the
entire mass shall be mixed for five minutes after
all ingredients are in the mixer. The entire mixer
shall then be emptied before being recharged.
106
Hand Mixing :Hand mixing shall be done in a water tight mixing

boat placed on the level. The dry sand and cement
shall be placed in the boat and turned twice. The
water shall then be added and the entire mass
hoed into the water and well mixed for 10 minutes
or until the entire mass is homogeneous. The
mixing boat shall be completely emptied before a
new batch is mixed.
iv
Plaster Mixed :Plaster over exterior concrete shall be single coat or

12mm. thickness and shall be composed of one part
cement, four parts plaster sand, or as noted in the
schedule of quantity.
Plaster over exterior masonry shall be two coats with
the first coat of 15mm. thickness and shall be
composed of one part cement, three parts plaster
sand. The second or finished coat shall be 10mm thick
and shall be composed of one part cement, three parts
plaster sand, and finished as noted in the schedule of
quantity.
Plaster over interior masonary shall be two coats with
the first coat of 5mm. thickness and shall be
composed of one part cement and three parts plaster
sand. The second or finishing coat shall be 10mm.
thick composed of one part cement, three parts
plaster sand, and finished as noted in the schedule of
quantity.
Plaster backing for glazed ceramic tile shall be of
15mm.thickness and shall be composed of one parts
of cement and two parts plaster sand, or as specified.
107
Cement punning shall be applied over a first coat of

the same proportions as the first coat of paragraph 5.4
and shall be not over 3mm. thick and shall be
composed of one part cement, one part ground sand,
or as specified.
Suspended ceilings shall be of three coats over metal
lath. The first coat shall be 10mm. in thickness and
shall be composed of one part cement, three parts
plaster sand. The second coat shall be as same as the
first coat. and finish coat shall be not over 3mm. in
thickness and shall be composed of one part Lime
putty and one part ground sand, or as specified.
Raised pointing shall be 18mm. high and 12mm. wide
and be composed of one part cement and three parts
sand.
Deep sunk pointing shall be 30mm. deep and full
stone joint wide and be composed of one part cement
and three parts sand or as specified.
v
Surface Preparation :All surfaces to receive plaster shall be cleaned of all

loose material and dirt with a clean bristle brush.
Concrete surfaces shall be sufficiently roughened to
provide a proper bond. If in the opinion of the
Owner, the surface is not sufficiently rough, it shall be
roughed by hacking or hammering.
Stone and brick masonry surfaces shall have the
mortar joints raked about 15mm. provide proper key
for raised pointing and 30mm. for deep sunk
pointing.
108
vi
Application :First coat of two and three coat work shall be applied
with sufficient material and pressure to form good
full keys or good bond. This coat shall be applied to
cover well and to fill out to the grounds. It shall be
placed to a true plane with rod and darby and left
rough.
Second coat of three coat work shall be applied upto
screeds, well rodded, screeded and floated with
angles true, straight and plump and just slack of
grounds.
Finish coat shall be applied after under coat is dry. It
shall be applied so that all surfaces are straight true,
plumb, even and flush with all grounds, corners,
angles and wall intersections shall be straight, sharp
and true.
All coats of plaster shall be damp cured for two days
and then be allowed to dry before an additional coat
is applied. The previously applied plaster shall be
uniformly redampened before additional coats are
applied.
When ballies have been inserted in the walls, when
they are removed, the hole shall be filled and
uniformly patched with plaster conforming with
balance of the wall. As far as possible the scaffold for
walls shall be free from wall but shall be selfsupporting, sound and safe for erection Loading.
109
vii
Clean-Up :Upon completion of the work in a space, the Tenderer

shall remove all rubbish, debris, scaffolds, and
surplus material, and leave the area or space, broom
clean.
h)
Construction Specification For Painting

The work covered under this agreement includes furnishing
all labour, material, equipment and performing the
operation necessary to complete the painting work.
i
Preparation Of Surfaces :All spaces shall be broom clean before painting is

started and all surface shall be clean, dry, free from
foreign materials, and in the opinion of the Owner,
ready to receive the painting.
All wood surface shall be lightly sanded and dusted
before priming and between each coat.
All surface shall be primed in accordance with the
instructions of the manufacturer of the covering
material.
Surfaces to receive white wash, colour wash and
distemper, shall be properly wet before the work
begins.
All concrete and plaster surface shall be spackled to
fill all cracks and holes, it shall then be primed with
an alkali Resistant primer.
Metal surfaces shall have all grease removed with
benzine, remove rust spots and defective paint down
to bare metal and touch-up with metal primer.
110
ii
Protection :The Tenderer shall remove all electric plates, surface

hardware and other accessories before painting and
replace when painting is completing.
iii
Workmanship :All work shall be done by first class skilled mechanics

in a workmanlike manner. All material shall be
evenly applied so as to be free from runs, sags, or
other defects. All coats shall be thoroughly brushed
out so as to show a minimum of brush marks except
enamel which shall be flowed on.
All coats shall be thoroughly dry before succeeding
coat is applied with minimum of twenty four hours
between coats except for white wash, colour wash,
and distemper .
All finishes shall be uniform as to colour and texture.
iv
Clean-Up :The Tenderer shall remove all paint spills, splashes,

or spattered, on all fixtures, fittings or other materials
including cleaning of paint off all glass.
i)
Construction Specification For Roofing, Damp-Proofing

And Water Proofing
all labour, material, equipment and performing the
operations necessary to complete the roofing and dampproofing
111

specifically noted otherwise:Specification for Bitumen Felts
Code of Practice for Laying damp
proof coursing
Code of Practice for water proofing
roofs with Bitumen Felts
Specification for the Blown type
Bitumen
ii
I.S. 1322
I.S. 1609
I.S. 1346
I.S. 702
Materials :Roofing felts shall be Hessian base Self-Finished Felt

type three grade one.
Damp proofing Felts shall be Hessian base selffinished felt type three grade two.
Flashing felts shall be fiber base self-finished felt two
grade two.
Laying of damp proof course in floor including the
primer, bitumen binder and bitumen felts.
iii
Surface Preparation :Roof Surfaces shall be clean, dry and have had all
cracks repaired by being cut in a 'V' Section, cleaned
and filled with cement grout as specified in this
tender document. All brackets, cants, angle fillers,
chases for flashing felts shall be in place before
roofing operation begins.
112
Walls to be damp proofed, shall be clean, dry and

have all cracks filled as specified in this tender
document. All sharp corners shall be eased with
cement mortar fillets.
iv
Application For Roofing :After the surface has been prepared as specified in
this tender document, the entire roof surface shall be
primed.
The Bitumen bonding material shall be heated to the
proper temperature and maintained to that
temperature until applied.
The felts shall be laid so as to be free of wrinkles,
buckles and so that pronounced ridges are not formed
at laps.
The mopping of the Bitumen bonding material
between piles of the felts shall be uniformly applied
to cover the entire surface so that at no place will felt
touch felt.
Gravel shall be dry and in no case be less than 75
degree F (24 Degree Centigrade) when applied.
On the roof, the layers shall be lapped over each ridge
from alternate sides in alternate layers.
Application Of Damp Proofing :After the surface has been prepared as specified in
this tender document, the entire surface which is to
receive damp proofing shall be primed.
The excavation shall be maintained in a dry condition
until the work is complete.
113
The Bitumen bonding material shall be heated to the

proper temperature and maintained to that
temperature until applied.
The felts shall be cut to the proper length, cleaned and
then brushed into the bonding material so as to be
free of wrinkles, buckles and so that pronounced
ridges are not formed at laps.
The mopping of the Bitumen bonding material
between piles of the felts shall be uniformly applied
to cover the entire surface, so that at no place will felt
touch felt.
The second layer shall break joint midway between
the joints of the layer below.
vi
Application Of Bitumen Layer :Primer shall be bituminous solution of suitable

viscosity to be applied to the wall or floor surface to
assist adhesion of the binding material.
Bitumen binder shall conform to I.S. 702. The
penetration of Bitumen shall be limited to 40 when
tested in accordance with I.S. 1203.
The exposed surface shall be thoroughly cleaned.
Bitumen shall then be applied at the rate of 2 Kg per
Sqm. at a temperature of not less than 121 degrees C.
(250 Degrees F.) evenly throughout, and allowed to
set before laying the top flooring.
114
vii
Cement Water Proofing Compound :Cement water proofing compound shall be as per I.S.
2645.
The Cement water proofing compound shall be CICO
products as manufactured by the Structural Water
Proofing Co. Pvt. Ltd. Calcutta or approved equal.
The application shall be 2 % or 3 % of CICO cement
water proofing compound or equivalent by weight of
cement as specified by the Manufacturer's
instructions and specifications.
viii
Clean-Up :All surplus material, scraps, scaffolding shall be

removed from the site at the completion of the work.
All Bitumen smeared on surfaces other than those to
be covered, shall be removed and the surface restored
to its previous condition.
j)
Construction Specification For Miscellaneous Architectural

Items
operations necessary to complete the Architectural finishes.
i

Plain cement tiles
I.S. 1443, 1237
Marble Mosaic Tiles
I.S. 1237
Glazed Tiles
I.S. 777
Plywood for general purpose
I.S. 303
Veneered Decorative plywood
I.S. 1328
Sheet glass for Glazing
I.S. 1761
115
ii
Materials :Terrazzo Aggregate shall be well graded from onehalf inch and down, of a colour to be selected.
Terrazzo tiles shall be 12" x 12" x 3/4" thick, colour to
be selected.
Glazed tile shall be of size and colour to be
determined complying with I.S. 777
Marble mosaic tiles shall be as per I.S. 1237
Veneered decorative plywood shall be 1/4" (6mm)
thick and four feet by eight feet sheets, complying to
I.S. 132, with a Indian Teak face ply.
Glass shall be of the best quality, free from bubbles,
scratches or imperfections of any kind. Glass for
windows shall be clear Twenty-one ounces per square
foot, except for toilet rooms which shall have an
opaque glass. Glazed door shall be 1/4" (6mm) plate.
Plain Cement Tiles shall be as per I.S. 1443 and 1237
iii
Application Of Terrazzo :The Concrete slab shall be cleaned of all dirt and
foreign matter and the underbed 1 & 1/2" (40mm)
thick composed of one part cement and four parts
sand, shall be placed to a level 5/8" (15mm) below
finished floor elevation.
The Division strips of 1/8" x 1" (3mm x 25mm) brass
shall be installed while the underbed is still semiplastic but in no case over four feet (1200mm) centers
each way, with the top of the strip at the elevation of
the finish floor.
116
The topping mix composed of one part "colorcrete" to

two parts marble granules shall be mixed just with
sufficient water to make a workable mix.
Place topping mix into spaces between strips and
tamp to a compact mass and until super-fluous
cement and water are extracted, then hand trowel to
an even surface flush with top of strips. The finished
surface shall show a minimum of 70% marble
granules. The surface is to be kept moist during these
operation and shall be cured at least six days.
Terrazzo base shall be applied to a backing coat of
cement, sand, mortar and the base shall be set 1/4" (
6mm) beyond the face of the finished wall above.
After the surface has set hard, the surfacing of the
floor shall be polished with machine or hand rubbing
with coarse carborundum grit stones. Next, a light
grouting of colorcrete shall be rubbed over the surface
to fill all voids.
The surface shall have the final grouting removed
with a final carborundum grit 72 hours after final
grouting, the surface shall be washed with clean
water.
iv
Application Of Terrazzo Tiles :The concrete slab shall be cleaned of all dirt and
foreign matter and the underbed 1 & 1/4" (30mm)
sand and shall be placed to a level 3/4" (20mm) below
finished door elevation.
The tile shall be embedded in the underbed with a
1/4" (6mm) joint space on all sides.
After the tile has been set the joints shall be filled with
colorcrete.
117
After the joints have been filled, all surplus colorcrete

shall be wiped off, and the surface cured for six days.
After the surface has cured, it shall be washed with
clean water.
v
Application Of Concrete Hardner :The concrete surface shall be swept and washed with
clean water to remove all dirt and foreign matter. All
cracks shall be filled with admixture of cement and
water.
Surface shall be well mixed with equal quantity of
water immediately before using.
The diluted mixture shall be evenly sprinkled on the
surface with a fine spray in a generous quantity but
without leaving actual pools on the surface.
Twenty-four hours later the surface shall be cleaned if
necessary and a second coat, similar to the first shall
be applied.
CICO surface hardener or CICO hard seal liquid
concrete hardener or equivalent approved, shall be
used as specified as per the instructions of
manufacturer.
vi
Application Of Shahabad Flooring :The slab stones specified in the item shall be got
approved by the Owner. At its thinnest part, no stone
shall be thinner than minimum specified. The stone
shall be hard, sound, durable, resistance to wear.
118
Uniformity of size shall be maintained and shall have

plain surface. They shall have, even, natural surfaces
free from broken flakes on the top and shall be
chiselled on edges to half its depth, true and square to
ensure uniform width of joint. The surfaces and the
edges of the slab shall be straight.
Cement mortar or lime mortar for the bedding and
cement mortar for pointing shall be of the proportion
as specified in the item.
The base as specified shall be laid and compacted to a
true plain surface below the level of the finished floor
to the extent of the thickness of the slabs and mortar
bedding.
The surface to receive shahabad slabs shall be cleaned
off all dirt and foreign matter. Underbed of 20mm
sand or as specified in item shall be placed to a level.
The required slope shall be given to the bed.
Before laying, the slabs shall be thoroughly wetted
with clean water. Cement grout of honey like
consistency shall be spread on the mortar bed over
the area which could be covered with the slabs within
half an hour. The specified type of stone slabs shall
be laid on the neat cement float and shall be evenly
and firmly bedded with the help of wooden mallet
tapped gently till there is no hollow sound from the
slabs. The joint shall be 6mm to 10mm thick and filled
solidly with mortar for full depth and shall be struck
smooth but there shall be no smearing of mortar over
the slabs. All surplus grout shall be wiped off. The
joints shall be of uniform thickness and straight lines
to give continuous parallel long joints with cross
joints at right angles. Diamond pattern paving slabs
shall be square and laid with triangular shaped slabs
to make up the edges. In plain pattern, stones on each
course shall break joint with those in the next.
119
The joints shall be pointed with cement mortar of the

proportion mentioned in the item.
The flooring shall be kept well wetted with damp
sand or water for 14 days.
It shall be kept
undisturbed for at least seven days.
After the surface has cured, it shall be washed with
clean water.
vii
Application Of Indian Patent Stone :The coarse aggregate shall be carefully selected,
sufficiently tough and hard stone pieces broken in a
manner that will provide particles of approximately
cubical shape affording good interlocking. The
maximum size of the coarse aggregate shall be 12mm.
The fine aggregate shall consist of properly graded
sand.
The proportion of mix shall be M 150 (1:2:4). The least
amount of water that will produce a workable mix
and will allow finishing without excessive trowelling
shall be used.
The sub grade for the concrete floor shall be of
sufficient thickness and properly executed as per
specifications. The sub grade shall be at proper levels
and slope, well compacted and cured. The top
surface shall be kept slightly rough.
The surface of the sub grade shall be cleaned of all
loose materials and moistened immediately before
laying the concrete floor. The concrete flooring shall
be laid in alternate bays not exceeding 6 Sq.m. The
edge of each panel into which the floor is divided
shall be supported by flat bars of steel or wood duly
oiled to prevent stickings. The bars shall be removed
before filling in the adjoining panels.
120
The concrete shall be laid immediately after mixing.

The formation of voids or honey comb pockets shall
be prevented. Compacting and levelling shall be
carried out with a heavy straight edge. The floating
shall be followed by steel trowelling after the concrete
has hardened sufficiently to prevent excess of fine
material from working to the surface. The finish shall
be brought to a smooth and even surface free from
defects and blemishes and tested with straight edges.
After the concrete has sufficiently dried, the rendering
with a thin coat of 1:1 cement mortar with fine sand
and uniform float shall be carried out. Approved
colour pigment confirming to I.S.459 shall be added to
cement mortar to give the required colour and shade
to the flooring. When the cement mortar rendering is
sufficiently stiff, lines shall be marked on it with
strings or by any device to give the appearance as
specified.
After the concrete in the bays has set, the joints of the
panels shall be filled with cement cream or with
suitable bitumestic compounds.
Vertical edges shall be neatly marked on the surface
of the concrete with appointed trowel after filling the
joints.
When rendering is somewhat stiff, neat cement of
approved colour cement mixed with the required
shade of approved pigment may be sprinkled on the
surface and rubbed lightly to give smooth cement
coloured surface. Surface shall be protected from
direct sun when it is green.
Curing shall start on the next day after finishing and
shall be continued for 14 days.
121
Even the small strips of I.P.S. in between shahabad

stone flooring panels, shall be carried out in the same
manner as specified above.
viii
Application Of Glazed Tile : The surface to receive glazed ceramic tile shall be
clean and free from foreign materials. Before the
setting bed is spread, the surface shall be thoroughly
moistened with clean fresh water. All excess water
shall be removed.
For floors the setting bed shall be composed of one
part cement and four parts sand.
For walls, if the scratch or backing coat is not
sufficiently even and true, a plumb coat composed of
one part cement, 1/2 part lime putty and four parts
sand shall be applied to true the surface.
For floors, the cement mortar shall be applied over
the setting bed until the surface is absolutely true and
smooth and even in plane as to drainage. The entire
surface shall be sprinkled with cement and the tiles
placed, with 1/8" (3mm) joints, and beaten into the
mortar until true to line and even. As soon as the
cement mortar beds have set sufficiently, the tiled
surface shall be washed, and the joints between the
tiles pointed with a cream consistency mixture of one
part white portland cement and one part white sand.
For vertical surfaces, the tile shall be buttered with the
setting mortar and tamped into place, with 1/8"
(3mm) joints and brought to a plumb and true surface
flush with other tile. The back of each tile shall be
covered with mortar to make a even and level bed.
All joints shall be plumb and true and the joining
strings or wedges shall be removed before pointing.
122
Clean-up :
After the tile joints have been pointed, all the tile
surfaces shall be wiped clean. After the joints
have set, all tile surfaces shall be washed with
clean water.
ix
Application Of Thermofriz :The sheets of Thermofriz shall be unbroken and be set

with full sheets in the field with any irregularities
taken up in the border.
The sheets shall be face nailed with nails 1 1/2"
(40mm) long set 1/2" (12 mm) from the edge of the
sheet. All joints shall be tight butt joints.
After all sheets are in place, the joints shall be covered
with wood battens 1/4"x2" (6mmx50mm) which shall
be attached through the joint of the Thermofriz with
counter sunk screws 2" (50mm) long. The joints of
the battens shall be tight, smooth and square.
Clean-up :
At the completion of installation, all excess
materials and debris shall be removed from the
site.
Installation Of Teak Decorative Panelling :The surface to receive the teak panelling shall be true
to line and grade and all backing walls shall be dry.
The panelling shall be applied to the ceiling first
starting in the middle of the space with full sheets and
working to the walls where irregularities shall be
taken up.
123
The wall panelling shall begin in the middle of wall

surface with a full width sheet and irregularities shall
be taken up at the corners.
All sheets shall be blind nailed with finishing nails 1
& 1/4" (32mm) long. Where blind nailing cannot be
done, the nails shall be set 1/8" (3mm) and the hole
filled with a putty coloured to match the panel.
All panel surfaces shall be fine sanded and then
finished with three applications of a dull finish wax.
Clean-up :
At the completion of the panelling work, all debris
shall be removed from the site.
All rebates not primed shall be painted black before
the installation of glass.
All glass panes shall have 1/6" (4mm) clearance all
around the pane.
All glass shall be back puttied so as to fill the void
between the glass and the rebate.
Putting shall be carefully done so that putty runs in
neat straight lines parallel with the inside of the
mounting or rebate, corners shall be carefully made
and excess putty removed.
Glass Breakage :The Tenderer shall be responsible for all glass
broken because of faulty setting and shall replace
same at his own expense.
124
Cleaning :
At the completion of the construction, the
Tenderer shall remove all dirt, stains, paint, excess
putty and any other foreign materials and clean
and polish all glass.
xi
Application Of Plain Cement And Marble Mosaic

Tiles :The cement slab or bed shall be cleaned of all dirt and
foreign matters.
The tiles shall be as per I.S. 1237 of specified cement
colour, patterns, marble chips, designs, thickness and
size as directed for marble mosaic and as per I.S. 1443
for plain cement tiles.
Fixing, polishing & cleaning shall be done entirely as
per I.S. 1443. Polishing shall be done by machine to a
smooth & plane surface.
The item includes cleaning the base and laying mortar
and levelling, providing and laying the tiles in neat
cement floor on the bedding mortar, filling the joints
of tiles with neat cement or colour cement slurry,
curing, all labour, materials, use of tools &
Equipments for carrying out the items as specified.
The amount of water while preparing the mortar for
bedding shall be minimum as to give sufficient
plasticity for laying, and free from hard lumps, evenly
and smoothy spread over the base to proper level or
slope. The thickness of bedding shall be not less than
12mm or more than 25mm in any place. The tiles
shall be laid on the mortar bedding when it is still
plastic but turned sufficient stiff to offer the firm
cushioning.
125
The tiles shall be soaked in water for at least 2 hrs.

before laying. Neat cement grout of honey like
consistancy shall be spread over the bedding mortar
to cover the area which can be tiled within half an
hour.
Each tile shall be pressed & gently tapped with
wooden mallet till it is properly bedded in & in level
with the adjoining tiles. The edges of tiles shall be in
straight lines and as clean as possible. The joints shall
be grounded with white cement slurry. The joint
between tiles shall not exceed 1.5 mm (about 1/16")
wide. The flooring shall be cured and allowed to
mature undisturbed for 14 days.
The surplus cement grout shall be cleaned off and
remove before set or after every days fixing, works,
machine polishing shall be carried out as per the
instruction of the Architect and the flooring shall be
got cleared up and washed with water and kept ready
for occupation.
xii
Application Of Frc Composites (Tapecrete) Floor

Toppings :Prior to installation, all surfaces must be properly
cleaned, free of foreign matter and thoroughly
wetted.
Depression, if any, shall be filled and levelled using
Tapecrete Fillers.
Tapecrete Membranes shall be applied in the required
number of Fabric layers of 3 mm, 6 mm thickness as
specified. Each layer of Fabric in the membrane shall
provide a uniform thickness of about 1.5mm (1/16").
Topping shall be applied by the skill labour by way of
trowelling, spraying and by other approved
mechanized means.
126
Tapecrete system is cured by air drying. The system

shall be applied with air temperatures above 7 degree
C (45degree F). During the First 12-Hours of curing it
must be protected from abrasion, rain, and other
adverse conditions. No traffic shall be allowed on a
standard Tapecrete surface within 48 hours after
installation.
The flooring shall be open for surface traffic after 7 to
10 days.
For 8mm thickness Tapecrete Topping, material
required for one cu.m is cement 650kg/Cum, Polymer
P151-338kg./m3 and fine silica sand 1300 kg/m3
while for 6mm thickness cement 512 kg/m3, P151-266
kg/m3, coarse silica sand 768 kg/m3 and fine silica
sand - 768 kg/m3.
xiii
Carpentry And Joinery

Introduction
This tender describes the materials and
workmanship required for the construction of
wood roof framing, wood cabinets, doors, door
frames, wood trim and miscellaneous other items
to be constructed of wood.
References
Reference to relevant Indian Standards shall be
made.
127
Samples
Samples, measuring 300 x 300 mm, of each type of
panelling, of each type of solid wood, chipboard
or plywood and of laminated plastic shall be
submitted in duplicate for approval.
Samples, measuring 300 mm in length, of each
type of trim and moulding shall be submitted in
duplicate for approval.
Quality Control
Certificates of treatment from vacuum/pressure
impregnation plant shall be submitted for
preservative treated timber.
Preservative treated timber shall be branded so
that it is distinguishable from non-treated timber.
Product Data
Product data shall be submitted for approval for
the following
(i) Wood preservative treatment process
(ii) Preservative for use on cut surfaces of
vacuum pressure impregnated timber.
(iii) Preservative for use on timber to be
encased in masonry.
Product Delivery And Storage
Timber shall be protected from rain and dampness
and shall be packaged as far as practicable, to
prevent moisture absorption, contamination by
dirt, oil, grease or other harmful materials, and to
prevent damage or loss during transport and
storage.
128
Transport
and
storage
requirements
as
recommended by the preservative treatment plant
shall be strictly adhered to.
Timber and assembled woodwork shall be stored
off the ground in weatherproof enclosures, timber
shall be open stacked.
Packaged materials shall be clearly labeled with
manufacturer's name.
Contents, quality and
quantity shall be clearly marked on packages.
Protection
Installed cabinet work, trim and other joinery shall
be protected in a manner and until such time as
directed.
Shop Drawings
Shop drawings of built in cabinets, counters,
closets, shelves and benches shall be submitted for
approval. Shop drawings shall show general
arrangement, details of construction, jointing,
fastening, finishing, other related details, wood
species and descriptions of other materials used.
Materials
Timber shall be hard and soft woods in
accordance with their definition as given by
Indian Standards.
129
Unless otherwise specified or shown on Drawings,

timber shall be used as follows:
(i)
Carpentry work Trusses, purlins, ceiling battens

Fascia and barge boards and skirting
Wedges, studs, backings and blocks
(ii)
Joinery work - cabinets, counters,

closets, shelves and benches - to be
determined
Glue for treated timber shall be of resin type.

Plywood shall conform to the requirements I.S.
and shall be first grade plywood.
Chipboard shall conform to the requirements of
I.S. The board shall be weatherproof and bonded
with synthetic resin.
Laminated plastic sheeting shall be 1.6 mm thick.
The colour and pattern shall be subject to
approval.
Nails, screws, bolts, spikes, fasteners, brackets,
supports, guides, stops and holders shall be of
size, material and finish consistent with the
function.
Nails shall comply with the
requirements of I.S.
Closet, cabinet and counter hardware shall be
chromium plated brass.
130
Door hinges shall be forged iron, regular type with

removable threaded pivot. The handle shall be
chromium plated brass level handle and the locks
shall be Yale type.
Fabrication And Manufacture - General
Timber shall be well seasoned, sawn square and in
straight lengths and shall be free of dirt.
Timber shall be inspected as it arrives and any
timber not approved shall be removed forthwith.
Timber shall be dried to a moisture content of not
more than 20% prior to preservative treatment.
Timber shall be cut, machined, planed, notched
and bored prior to preservative treatment as far as
practicable. Where cross-cutting, notching or
boring or treated timber cannot be avoided, the
exposed surface shall be "brush-treated" with
approved type and grain preservative.
Timber shall be pressure impregnated with the
approved preservative at a pressure of not less
than 1 MPa and in accordance with the chemical
manufacturer's instructions.
After pressure treatment timber shall be reduced
to a moisture content of not more than 12% for
joinery work and 20% for carpentry work.
Pressure treated surfaces to receive glue shall be
wire brushed or lightly sanded to remove dirt and
excess galts.
Actual dimensions of scantlings for both carpentry
and joinery shall not vary from the specified
dimensions and shall be uniform throughout.
131
Boards shall hold up to the specified thickness and

timber shall be as long as possible and practicable
in order to eliminate joints.
Joinery shall be accurately set out on board to full
size for the information and guidance of the
artisans before commencing the respective work,
with all joints, iron work and other works
connected therewith fully delineated. Such setting
out must be approved before joinery is
commenced.
Joinery shall be cut and framed together soon after
the commencement of the building or as is
practicable, but is not to be wedged up or glued
until the building is ready for fixing same.
Joinery shall be properly mortised, tenoned,
housed, shouldered, dovetailed, notched, wedged,
pinned, etc. as directed and all properly glued up
with approved resin type glue.
Joints in joinery shall be detailed, designed and
secured to resist or compensate for any stresses to
which they may be subjected. Nails shall be
punched.
Joints shall be made loose where shrinkage is liable to
occur, and glued where sealed joints are required.
Exposed surface of joinery work shall be wrought and
all arises "eased off" by planning and sand papering
to an approved finish.
132
xiv
Glazing
References
Reference is
standards.
made
to
the
relevant
Indian
Materials
Glass shall conform to I.S. cutting and edgework
on glass shall conform to I.S.
Glass shall be of such quality that surface
deterioration will not develop after glazing (if
under normal conditions of use).
Glass shall be free from flaws, bubbles, specks and
other imperfections.
Clear sheet glass for glazing shall be ordinary
transparent glass manufactured by the flat drawn
process.
Figured/frosted glass shall be clear cast glass
manufactured by the rolling process.
Figured/frosted glass shall be of the deep pattern
type to produce greater obscuration and diffusion.
Lead glass panels shall be panels of glass held
together with lead clamps.
Mirrors shall be 6 mm thick special selected (SSG)
silvered plate glass with polished edges.
Glass louvers shall be clear or frosted sheet glass
with ground edges.
133
Putty for glazing in metal frames shall be quick

hard-setting tropical putty specially manufactured
for use with metal windows.
Fixing And Cleaning
Rebates and grooves shall be clean, dry and
unobstructed and primed at the time of sealing
and glazing.
Edge clearance shall be equal all round each pane,
and no more than 2 mm play all around and
where puttied shall be clipped to metal frames.
External glazing shall be wind and watertight on
completion. Smears and excess compound and
sealant shall be removed.
Both faces shall be cleaned with approved cleaner
and the surface left free from scratches.
Fixing of mirrors to wall shall be with chromium
plated screws.
k)
Construction
Hardware
Specification
For
Rough
And
Finish

all labour, material, equipment, and performing the
operations necessary to complete the rough and finish,
Hardware work.
134

Cold Rolled Mild steel Bolt Hinges
Tower Bolts
Butt hinges
Tee and strap Hinges
Gate and shutter Hooks and Eyes
Door Handles
Sliding Door Bolts for use with
Pads locks
Parliament Hinges
Hasps and Staples
ii
I.S.
I.S.
I.S.
I.S.
I.S.
I.S.
1341
204
205
206
207
208
I.S.
I.S.
I.S.
281
362
363
Material :All material shall be new and delivered to the site in

unopened manufacturer's containers. All Hardware
shall be delivered complete with all component parts
including screws of proper size. They shall be sound,
strong and of the best quality. They shall be of brass
or oxidised brass of Aluminium.

Door Hinges 4" x 1" (100mm x 25mm)

Toilet Door Hinges 3" x 1" ( 75mm x 25mm)
Swinging Door Hinge
Skeleton Bolts sectional
Flush Bolts level type 6" x 1" (150mm x 25mm)
All drops 12" & 5/8" (300mm & 15mm)
Safety Hasps and Staples 6" x 1 1/2" (150mm x
38mm)
Finger plates 3" x 8"1/8" (75mm x 200mm x 3mm)
Coat Hook
Door stopper and holder
Toilet compartment Latch
135
Toilet Compartment latch for Administration

Buildings
Stair Nosing for Administration Building 2 & 1/2"
(65mm)
Door Pulls 10" x 1-1 1/2" x 1/8"
(250mmx38mmx3mm)
Rim Lock 4" (100mm)
Tumbler Holder
Locks and Handles
Barrel Bolts 9" x 1 1/2" (230mm x 38mm) with 1/2"
(12mm) sheet.
iii
Installation :All the fixtures shall be fixed to the joinery in a secure

and efficient manner or as specified by the
Manufacturer's directions and shall be installed
plumb, true and secured with the proper fastenings
so as to make all work, rigid and firm.
Any of the fixtures damaged during fixing shall be
removed and new ones fixed in their place and the
surface of joinery made good where affected, at the
Tenderers expenses.
All drops, safety hasps and staple locks and handles
and tubular latches shall be installed 36" (915mm)
from the floor.
Night latches shall be installed 48" (1200mm) from the
floor.
All locks and tubular latches shall be installed with
brass strike plates.
iv
Protection :Hardware that might be damaged by the construction

work shall be protected during the progress of the
work and uncovered at its completion.
136
Cleaning :Upon the completion of the construction, all

hardware shall be cleaned and polished and left in
perfect operating condition.
l)
Construction Specification For Plumbing

all labour, materials, equipment, and performing the
operations necessary to complete the plumbing work shown
on the approved drawings and specified herein.
i

Specification for white glazed
Earthenware Sanitary appliances
I.S.
Specification for Enamelled cast I.S.

iron Sanitary appliances.
772
Specification for flushing cisterns I.S.
774
Brackets and supports for lavatory

basins and sinks.
I.S.
775
Specification for metal gate, globe

and check valves
I.S.
778.
Specification for sand cast brass

screw down bib taps and stop taps
I.S.
781
Specification for caulking Lead
I.S.
782
771
137
ii
Specification for centrifugally cast

iron pressure pipes
I.S.
1536
Specification for vertically cast

iron pressure pipes
I.S.
1538
Specification for cast iron manhole

covers and frames
I.S.
1726
Work Included :The Tenderer shall furnish and install all the fixtures,
fittings, all piping, underground and above ground
complete with all valves, taps, fittings, insulation, and
all items including cutting all chases and restoring
them to their original condition.
iii
Materials :European type water closets Shall be new, unmarred,

white glazed, wash down type, of one piece
construction with integral flushing rim and water
inlet with integral "S" trap or "P" trap complete with
low level cistern
Indian type water closets shall be new, unmarred,
white glazed, wash down type with integral flushing
rim, and water inlet, 58 cm (23") long or as specified
in item confirming to I.S.771 type two complete with
"S" or "P"trap.
Wash basins shall be new, unmarred, white glazed,
flatback single tap 56cm. x 40cm. (22" x 16") or as
specified in item, complete with non-ferrous waste
chain, fittings and stopper, chrome plated "P" trap,
support brackets with studs, and nuts and backing
plate, confirming with I.S. 771.
138
Urinals shall be new, unmarred, white glazed, flat

back, one piece construction with an integral flushing
rim and water inlet, complete with fixing bolts and
backing plate, confirming with I.S 771.
European type water closet seats and lids shall be of
Bestolite
Sinks shall be new, enamelled, cast iron, two
compartment, one piece construction 106 cmx79 cm x
25 cm with centre over-flow with one waste outlet in
each compartment complete with waste plug, nonferrous waste chain, fittings and stopper, fixing
brackets with stud bolts, nuts, "S" trap and confirm to
I.S.772 except if specified otherwise.
Flushing water closets shall be (13.60 Lit) capacity
siphonic high level cistern, complete with concealed
type brackets
Faucet shall be 1/2" (12mm) chrome plated with
American standard tapered threads. For wash basins,
faucets shall be piller tap. For sinks, faucets shall be
combined mixing faucet with swivel nozzel similar to
shanks A-9287. For showers, faucets shall be
combined mixing faucet or as specified. For washing
troughs, faucets shall be similar to shanks D-5730
Galvanised pipe and fittings shall be new, free from
cracks, threaded with tapered threads and confirm to
I.S. 1239-1958. Pipe sizes from 12 mm through 40 mm
shall be medium class. Pipe sizes above 40 mm shall
be medium class.
Black iron pipe and fittings shall be new, free from
cracks, threaded with tapered threads and conform to
I.S 1239- 1958. Pipe sizes from 12 mm through 40 mm
shall be medium class. Pipe sizes above 40 mm shall
be medium class.
139
Cast iron pipe shall be new, free from cracks and

blow holes, with spigots and/or sockets suitable for
lead joints, without head, confirming to I.S. 1536 or
1537 class B.
Cast iron fittings shall be new, free from cracks and
blow holes, with spigots and/or sockets suitable for
lead joints, confirming to I.S. 1538 heavy type.
Gate valves shall be split taper wedge rising spindle
gunmetal, confirming to I.S. 778, except female ends
threaded to National Pipe Tapered threads.
Globe valves shall be renewable disk rising spindle,
all gunmetal, confirming to I.S. 778, except female
ends threaded to National pipe Tapered threads.
Stop taps shall confirm to I.S. 781 except female ends
shall have threads confirming to National pipe
Tapered Threads and shall be chrome plated.
Bib-taps except as hereinbefore specified, shall
confirm with I.S. 781, except threads shall confirm to
National Pipe Tapered Threads and shall have a G.I.
socket screwed on the male end.
Floor drains shall be cast iron with an integral "P"
trap. It shall have a separate grating which is
attachable with counter sunk screws.
Cowls for all events shall be cast iron and or PVC
with 12mm wide slots all around and a domes top.
The female end shall have National Pipe Tapered
Threads to receive a 75 mm pipe.
140
Water Coolers :- Shall be instantaneous pressure type

with a 14 G.P.H. nominal cooling capacity, with a
hooded angle stream jet, foot pedal operated. Toilet
paper holder at European type water closet shall be
white, shanks no. 7643
Soap Dishes in shower Rooms shall be shanks no.119
iv
Installation : Drainage Pipes :All lines shall be pitched at 3mm per 30 cm.
Hung lines shall be supported by at least 18 G x 11/2" galvanized iron strap hangers with two
straps per pipe length. Vertical line shall be
strongly secured to the structure.
Provide clean out at every change in direction of
waste lines. All clean outs under floors shall be
provided with flush to the floor plates of cast iron.
Outlet size for fixtures :
Outlet and vent lines shall be as follows :---------------------------------------------------------------------Fixtures
Drainage
Vent
---------------------------------------------------------------------Water closets
10 cm (4")
5 cm (2")
Urinals
5 cm (2")
4 cm (1-1/2")
Urinal Troughs
5 cm
4 cm
Sinks
5 cm
4 cm
Wash Basins
4 cm
4 cm
Drink fountains
4 cm
4 cm
----------------------------------------------------------------------
141
Joints :
Cast iron shall be caulked with Oakum and Soft
caulking lead.
Threaded joints reamed and with red lead on male
end only.
Vents
Vents shall be located and shall be increased to a
size to fit the cowl before going through the roof.
ON sloping roofs, vents shall be cut off 10 cm
above the high side of the roof at the vent, on Flat
roofs vents shall be cut off 30 cm above the roof.
v
Cleaning And Protection :All exposed metal surfaces shall be cleaned from dirt,
grease and other foreign material. Chrome plated
surface shall be polished upon completion of the
construction.
Fixtures shall be protected from damage during
construction and shall be cleaned in accordance with
manufacturer's instructions upon the completion of
construction.
At the completion of the construction, all surplus
material, cartoons, boxes and other debris, shall be
removed from the site.
vi
Tests :Waste pipes shall be tested by being water-filled to

the roof.
Water lines shall be tested by 100 pounds per square
inch (7.03 kg. per sq cm) pressure.
142
Air lines shall be tested by 200 pounds per sq. inch. (

14.06 kg. per sq. cm. ) pressure.
Steam line, before the insulation in installed, shall be
tested by 200 pounds per square inch (14.06 kg. per
square cm) pressure.
vii
Pipework - Pipes
Reference
General directions and descriptions of materials
and work which are included in this tender but
which also apply to the provision of pipework are
not necessarily repeated.
Pipelines below ground - inspections
The Tenderer shall give notice to the Owners
Representative for purpose of inspection
whenever sections of:
Excavations are completed
Concrete beds are laid
Pipework installations are completed and no
further work shall be executed until each stage
of the work has been inspected.
Asbestos cement pipes
Asbestos cement pipes shall comply with relevant
I.S. 'Asbestos cement pressure pipes'. Pipe joints
shall be made using one of the following types of
flexible coupling:
(i)
Rubber ring joint incorporating

asbestos cement sleeve
an
143
(ii)
Rubber ring joint incorporating a cast iron

or steel spacer and cast iron or steel
flanges.
Asbestos cement pipes shall be coated internally

and externally with bitumen in accordance with
relevant I.S.
Clay pipes
Vitrified clay pipes to be used for sewerage or
surface water shall be manufactured in accordance
with the requirements of relevant I.S. complete
with flexible spigot and socket connections.
Ductile iron pipes
Ductile iron pipes shall conform to relevant I.S.
joints shall be flexible spigot and socket
connections. Pipes shall be coated internally and
externally with a coal tar pitch or bitumen
material as specified in relevant I.S.
Steel pipes
Steel pipes shall comply with relevant I.S.
Diameters and thicknesses of pipe shall be
selected from those given unless otherwise
approved by the Owners Representative. Pipe
ends shall be prepared for butt welded, sleeve
welded, or slip-on coupling joints and in
accordance with I.S.
Internal protection shall be spun bitumen with
suitable primer, all to I.S.
144
External protection shall be fiber glass reinforced

bitumen sheathing for below ground installation
with suitable primer, all to I.S. For above ground
installation the pipe shall have one coat zinc
chromate primer and two coats of approved
bituminous aluminium paint.
Galvanized steel pipes
Distribution pipe work for potable water supply
shall generally be galvanized steel pipe
conforming to I.S. having plain ends suitable for
screwing to I.S. pipe threads.
Corrugated steel culverts
Corrugated steel culverts shall be Armco Type
E.100 bolted nestable culvert or approved
equivalent and shall consist of corrugated,
galvanized and bitumen coated steel sheets bolted
into rings to form a pipe of the required diameter.
The corrugations shall have a pitch of 100 mm and
a depth of 20 mm.
The steel used in the fabrication of the sheets shall
conform to the requirements, of I.S., condition
HR.
The sheets shall be hot-dip galvanized after
fabrication to ensure a coating weight of not less
than 755 g/m2. Where the zinc coating has been
damaged by field cutting or other means, the
damage shall be made good using an approved
zinc-rich paint.
145
Pre-cast concrete pipes

Pre-cast concrete pipes for foul and surface water
drains shall comply with I.S.
Pre-stressed concrete pipes for pressure pipelines
shall comply with I.S.
Unplasticized P.V.C. Pipe
Unplasticized P.V.C. (U.P.V.C.) pipes for cold
water
services
shall
comply
with
I.S.
'Unplasticized P.V.C. pipe for cold water services'.
Joints shall comply with I.S.
Unplasticized P.V.C. pipes for foul and surface
water drains shall comply with I.S.
Steel components and bolts
All steel components shall be hot dip galvanized
in accordance with I.S. 'Hot dip galvanized
coatings on iron and steel articles'.
Bolts, nuts and washers shall comply with the
following standards:
I.S. 'ISO metric black hexagon bolts, screws &
nuts'. I.S. 'Metal washers for general engineering
purposes'.
All bolts, nuts and washers are to be zinc coated in
accordance with I.S. 'Sherardized coatings on iron
and steel articles'.
All steel flanges shall comply with I.S..
146
Rubber rings and gaskets

Rubber rings and gaskets shall conform with I.S.
'Materials for elastomeric joint rings for pipe work
and pipelines'. Dimensions of gaskets shall
conform with I.S. 'Dimensions of gaskets for pipe
flanges to I.S.
Temporary storage
The Tenderer shall take into temporary protective
storage all pipes not required for immediate
installation in the Works, or for stringing out
along the pipeline.
Pipes in storage shall be laid on wedged timber
bearers so as to be at least 75 mm clear of the
ground; pipes other than thin shell pipes may be
stacked if suitable protective packing is placed
between the layers.
The period between taking delivery of a pipe and
the completion of its installation shall be kept to a
minimum. Any period during which the pipes are
laid out along the pipeline or placed alongside the
Works awaiting installation shall also be kept to a
minimum and if this period exceeds one month
pipes shall be raised at least 75 mm from the
ground on timber bearers.
147
Handling and installation generally

Throughout the construction of the pipeline
including the operations of off-loading on
delivery, handling, storing, and transporting pipes
and valves on or about the Site, the Tenderer shall
use such methods plant and equipment as will
prevent damage to the pipes and to any sheathing
lining or paintwork, and such methods shall
include the use in appropriate cases of pipehooks,
lifting beams, reinforced canvas slings, protective
padding, struts, cradles and pipe trailers.
No pipe shall be moved by rolling save over
suitable timber planking so arranged as not to
damage the pipe or its sheathing.
Setting Out
The Tenderer shall set out all drains and services
in accordance with the approved drawings and
shall set up and maintain temporary bench marks
and shall provide all necessary labour and
materials, instruments and boning rods and shall
erect and maintain all sight rails. Sight rails shall
be set up for all lines of drains, such that there will
always be at least three rails in position at one
time on each line of pipes, to any one gradient.
The drains shall be laid in straight lines and to
even gradients to the levels shown, with pipes and
specials of the kinds and diameters shown.
Level pegs shall be accurately boned in from the
sight rails and driven into the bottoms of the
trenches to the levels of the inverts of the lines of
pipes.
148
Excavation
The bottoms of all excavations shall be trimmed
and consolidated to the correct levels.
Unauthorized excavations below the required
level shall be filled with material of the same
composition as for pipe work beds. Where the
bottom is insufficiently firm, the Tenderer shall
excavate until, in the Owners Representative's
opinion, a firm bottom is obtained and the level
shall be made up with material of the same
composition as for pipe work beds. Particulars of
such additional work shall be agreed with the
Owners Representative before the work is
covered up.
The minimum trench width for all buried
pipelines shall be 600 mm or as described in the
following table:
Pipe dia
mm
200
225
250
300
400
450
500
550
600
650
750
900
1200
1250
1400
1600
Minimum Trench Width

mm
600
650
850
900
1000
1000
1100
1100
1200
1200
1300
1500
1800
1800
2000
2000
149
Laying Pipes
All pipes shall be inspected for defects prior to
laying. Any damaged pipes shall be rejected.
Pipes shall be carefully lowered into the trenches,
and all damaged pipes shall be rejected. Pipes
shall be laid truly straight on line and gradient
with sockets upstream.
The pipes shall be laid singly on the bed and the
level of each pipe shall be tested by a straight edge
laid in the invert of the pipe from the invert of the
pipe previously laid and on to the nearest level
peg. If the bottom of the trench or bed is too low,
it shall be made up with the appropriate bedding
material.
Care shall be taken to ensure that there is no
irregularity to the invert of the joints and the bore
of the pipe shall be cleared of any obstruction
before the next pipe is laid.
No pipes shall be laid on their collars or on bricks,
tiles or other temporary supports.
Where it is required to shorten any pipe, it shall be
cut off square and cleanly with approved
pipe-cutting equipment. Pipe runs shall be kept
free from mud, debris, superfluous cement or
other obstructions during laying and until the
completion of the Contract. In the event of any
pipe being fractured from any cause whatsoever,
after having been to all appearances properly laid,
the Tenderer in every instance will be held
responsible and any such defective pipes shall be
replaced to the satisfaction of the Owners
Representative.
150
Where possible pipes shall be laid with not less

than 1m cover. If the cover is less than lm or
under roads with less than 1.2m cover or where
ordered by the Owners Representative they shall
be haunched or surrounded with Grade 20
concrete, minimum thickness 150mm.
Jointing Of Pipes
Jointing of pipes shall be carried out strictly in
accordance with the manufacturer's instructions.
Welding Joints For Steel Pipes
Welding of joints in steel pipes shall be carried out
manually by the metal-arc process complying
generally with the requirements of BS 4515.
In all other respects the requirements for welding
set out in Class M shall apply.
Internal And External Protection
After completing a joint any protective paint or
bitumen lining shall be made good and any steel
joint which is not already coated shall be cleaned
and coated to the standard specified for the pipes.
The method proposed for making good of lining
at the joints shall be submitted for the Owners
Representative's prior approval.
Sleeves
All pipes, conduits, cables or the like passing
through walls or foundations shall be protected by
sleeves of U.P.V.C. pipe.
151
Backfilling
Where pipes are not surrounded by granular
bedding or concrete, the filling around and 300
mm above the pipe shall be of suitable material
free from stones which would be retained on 20
mm sieve.
Backfilling of trenches shall be done with suitable
material in layers not exceeding 150 mm. The
highest possible degree of compaction shall be
obtained with the provision that no mechanical
rammer will be used within one meter of the top
of any pipe.
Testing
The Tenderer shall give notice of testing to the
Owners Representative. All works shall be tested
as described and to the satisfaction of the Owners
Representative
before
backfilling
of
the
excavations is commenced.
The Tenderer shall locate and remedy all defects
before further pipe laying proceeds and shall
repeat the test until a satisfactory test is obtained.
Where a length of pipe under test terminates at a
manhole, the restriction on further pipe laying will
not apply.
The Tenderer shall provide and fix testing
branches and bends, as required and shall seal off
or remove them as directed by the Owners
Representative.
152
The Tenderer shall ensure that all sections of the

pipelines are completely clear of any obstructions,
debris and superfluous matter, before any tests are
applied to such sections and upon completion of
the Contract. Testing of pipelines shall comply
with the following as applicable.
i.
ii.
Foul gravity drains shall be filled with

water under a head of not less than 1,500
mm after the joints have been made and
before any backfilling is commenced. After
a reasonable period has elapsed, the water
level shall be made good by adding water,
as required. The water level shall then be
maintained for half-an-hour without
adding further water.
Pressure mains shall be subjected to
pressure and leakage tests which shall be
carried out on all pipelines at the direction
of the Owners Representative.
The
maximum section of pipeline under test
shall be 1,000 meters and joints shall be left
uncovered throughout the duration of the
hydrostatic test.
Pipelines shall be slowly filled with water
such that all air is expelled; after filling, the
pipeline should be left under operating
pressure for a period agreed by the
Owners
Representative,
such
that
conditions as stable as possible can be
achieved. Unless agreed in writing by the
Owners Representative, the test pressure
shall be 1.5 times the operating pressure at
the lowest point of the pipeline section
under test. This test pressure shall be
applied by means of a pump connected to
the pipe, in a manner satisfactory to the
Owners Representative, and shall be held
153
for a minimum of 30 minutes. If a drop in

pressure occurs, the quantity of water
required to re-establish the test pressure
should be carefully measured. This shall
not exceed 0.1 liters per millimeter of pipe
diameter per kilometer of pipeline per day
for each 30 m of pressure applied.
The Tenderer shall provide a duplicate
certificate test book for pipelines as follows:
Each test certificate shall be

consecutively numbered, the top
copy of which is retained by the
Tenderer. The book will remain the
property
of
the
Owners
Representative.
Each test certificate will indicate the
date of test, location of section under
test; pipe diameter; test pressure; test
duration; pressure drop (if any) and
any other pertinent remarks.
This procedure shall be carried out for each

test made whether the outcome of the test is
successful or not.
viii
Pipework - Fittings And Valves

Fittings Generally
Unless otherwise specified all bends, junctions and
reducers shall be of the same material and comply
with the same I.S. as for the main pipeline.
Butterfly Valves
Butterfly valves shall comply with I.S. 'Cast iron
and carbon steel butterfly valves' for general
purposes.
154
Sluice Valves
Sluice valves shall comply with I.S. 'Double
flanged cast iron wedge gate valves for
waterworks purposes'. Each valve shall be the
same nominal size as the pipe unless otherwise
specified, fitted with a spindle cap and arranged
for clockwise closure.
Check Valves
Check valves shall comply with I.S. 'Cast iron
check valves for general purposes'. For nominal
bore of 500 mm and above they shall be of the
tilting disc or double disc type with bolted split
casing.
Fire Hydrants
Hydrants shall comply with I.S. 'Underground fire
hydrants and surface box frames and covers'.
Air Valves
Each air valve shall be of the type and size
specified. It shall be suitable in all respects for the
operating conditions and in the case of a large
orifice air valve or air valves incorporating a large
orifice, it shall be designed to prevent valve
closure when discharging large quantities of air.
Each valve is to be complete with an isolating
valve to allow removal of the air valve under
operating conditions.
Protective Coatings
All valves shall be coated internally and externally
with bitumen solution to I.S.
155
Flanges And Gaskets

All flanges shall be to I.S. 'Flanges and bolting for
pipes, valves and fittings' unless otherwise
specified. Gaskets shall conform to I.S.
Slip On Type Couplings
Slip on type couplings, stepped couplings and
flange adapters shall be 'Viking Johnson' (V.J.) or
similar approved. They should be the proper
model for the pipe with which they are to be used
and be supplied with central register (standard
couplings only), galvanized bolts, and tapped
plugged holes (for application of internal
extensive coating).
In jointing plain ended pipes with couplings the
Tenderer shall take account of the manufacturer's
recommendations as to the methods and
equipment to be used in assembling the joint. In
particular the Tenderer shall render the end of
each pipe perfectly smooth so as to allow the joint
sleeve to slide freely and where necessary shall
re-coat the pipe ends with two coats of quick
drying bituminous solution.
If the internal diameter of the pipe is 500 mm or
more the coupling shall be sealed internally after
completion. A temporary flexible internal backing
strip coated with mould whiting shall be fitted
inside the pipe to seal the cavity between the pipe
ends and the joint sleeve and funnels shall be
screwed into the plug holes in the V.J. coupling.
Hot bitumen compound shall be poured in
through the lower plughole (the upper funnel
acting as an air vent) until the cavity is full. After
the bitumen has cooled the backing strip and
funnels shall be removed and the screw plugs
replaced.
156
Where the couplings are used for below ground

installation they shall be cased in bitumen using a
proper mould supplied by the coupling
manufacturer, into which hot bitumen compound
shall be poured as for the internal lining.
Installation Of Valves
Installation of valves shall include installation and
fixing of any operating gear and associated
fittings.
Before installing valves the Tenderer shall tighten
all loose nuts and bolts on the valves and
associated equipment and shall ensure that they
are watertight and in proper working order.
Flanged joints shall be made with steel bolts and
nuts which shall include two washers per bolt. All
nuts shall first be tightened by hand and nuts on
opposite sides of the joint circumference shall then
be alternately and progressively tightened with a
spanner so as to ensure even pressure all round
the joint.
After installation valves shall be cleaned inside
and out, any protective coating made good, and
shall be left in the closed position.
Ferrules
Ferrules for connecting service pipes to water
mains shall be of non-ferrous metal fitted by
clockwise screwing down. The nominal diameter
of a ferrule shall not exceed one quarter of the
nominal diameter of the main into which it is
inserted. The ferrule shall be screwed into the
main at an angle of 90 degrees to the vertical and
the outlet shall be directed along the main so that
the service pipe leads off with a right angle turn
away from the main.
157
Drilling And Tapping Mains

Tappings in pipes shall be made by first fitting a
purpose-made saddle on the main with wedges,
bolts and rubber washers or other equally effective
device. Using a sharp drill a hole shall then be
drilled slowly through the boss of the saddle piece
and through the barrel of the pipe and the hole
shall be tapped to give a continuous thread
through the saddle and the pipe.
ix
Pipework - Manholes And Pipework Ancillaries

Manholes
Manholes shall be precast concrete to I.S. or of
blockwork or brickwork construction. The design
shall generally comply with recommendations in
I.S.
Blockwork or brickwork walls shall be constructed
such that joints shall be well flushed up with
mortar leaving no internal voids, flush-pointed on
the inside of the manhole and weather-pointed on
the outside. Cement rendering of the inside
surface of the walls shall consist of two coats of
equal thickness, and the total thickness shall be 12
mm.
The surface to be rendered shall be
thoroughly cleaned and scored to form a key and
moistened with water twenty-four hours before
commencement of work. The surface of the first
coat shall be similarly roughened to form a key for
the second coat, which shall not be applied until
the first coat has thoroughly set. The second coat
shall be applied within three days of the first coat
and shall be floated to a smooth, even surface.
158
The base of the manhole shall be mass concrete

Grade 20 of minimum thickness 150 mm below
the pipes.
The channel may be formed using half-pipes or
constructed in concrete. It shall be a smooth
transition between the inlet and outlet pipes. Pipe
soffits shall be kept level when there is a change in
pipe diameter. Benching shall have a minimum
slope of 2 in 5 towards the channel and shall be
rendered to a smooth, hard finish. Particular care
shall be taken to provide a water-tight joint where
pipes enter and leave the manhole and a flexible
joint shall be made 500 mm from the manhole
wall. The centre lines of pipes shall intersect at the
centre of the manhole.
Step irons shall be securely grouted 150 mm into
the wall. After the grout has hardened each step
iron shall be struck a hard blow with a 2 kg
hammer and any rung which is broken shall be cut
out and replaced.
Manhole Covers, Surface Boxes And Gratings
Cast iron and cast steel manhole covers and
frames shall conform to I.S., surface boxes, valve
covers and the like shall comply with I.S..
Two sets of each type of key for locking covers
and gratings shall be provided and handed over to
the Owners Representative on Contract
completion.
Rodding Way Covers
The access to all rodding ways shall be covered by
a cast iron cover fixed to a frame with at least two
screws and sealed with a composition gasket.
159
Septic Tanks
Septic tanks shall be constructed in accordance
with I.S.
The septic tank effluent shall be piped to a soak
away the size of which shall be agreed with the
Owners Representative from approved seepage
trials to be completed by the Tenderer.
x
Copper Water Tubes And Fittings

Copper "domestic" water pipes shall conform with I.S.
solid drawn, supplied in straight lengths, suitable for
connection by means of compression fittings and
capillary fittings, which shall conform to I.S.
xi
U.P.V.C. Tubes And Fittings

U.P.V.C. waste and overflow pipes to cisterns and
geysers shall conform to I.S. all erected strictly in
accordance with the manufacturer's instructions,
using solvent welded joints.
m)
Construction Specification For Roads And Pavings

i
Reference
General directions and descriptions of materials and
work which are included in the tender but which also
apply to the provision of roads and pavings are not
necessarily repeated. Reference should, therefore, be
made to the Specification as a whole when dealing
with this part of the Works.
160
ii
Stripping
The areas shall be stripped of all top soil, which shall
be deposited evenly in the adjacent fields. All roots,
tree stumps, rocks and waste material shall be loaded
and carted to tip.
iii
Sub grade And Improved Subgrade

Unless otherwise specified or required by the
Owners Representative, materials forming the direct
support of the pavement shall comply with the
following requirements:
-
CBR (100% I.S. - 4 days soak) : minimum 5

Swell (100% I.S. - 4 days soak) : maximum 2%
Organic matter (% by weight) : maximum 3%
Where, in the opinion of the Owners Representative,

material unsuitable for the direct support of the
pavement occurs in cuttings, the Tenderer shall
excavate it to the depths and widths required and
replace it with selected fill material to form an
improved sub grade.
iv
Laying And Compacting Subgrade

The maximum compacted thickness which shall be
laid, processed and compacted at one time shall be
300 mm.
The layer shall be scarified, water shall be uniformly
mixed in or the material allowed to dry out to the
correct moisture content.
161
The upper 300 mm of the earthworks (that is to say

the sub grade) shall be compacted to a dry density of
at least 100% MDD (Standard Compaction) in cuttings
where there is no improved sub grade and
everywhere in fills and embankments.
In cuttings, where an improved sub grade is to be
placed, the upper 150 mm of the sub grade prior to
the placing of the improved sub grade layer(s), shall
be compacted to at least 100% MDD (Standard
Compaction) and the lower 150 mm shall be
compacted to at least 95% MDD (Standard
Compaction), unless otherwise specified.
All improved sub grade shall be compacted to a dry
density of at least 100% MDD (Standard Compaction)
for its full depth.
The moisture content shall be adjusted in order that
the above minimum compactions are obtained.
Unless otherwise accepted by the Owners
Representative, the moisture content at the time of
compaction shall not exceed 105% of the Optimum
Moisture Content (I.S.).
v
Forming Of Subgrade
During the above process, the final surface of each
sub grade layer shall be graded to level, parallel to the
cross fall and camber and profile shown upon the
approved drawings
162
The sub grade shall be cleaned of all foreign matter

and any potholes, loose material, ruts, corrugations,
depressions or other defects which have appeared in
the sub grade layer, due to improper drainage, traffic
or any other cause, shall be corrected. If required by
the Owners Representative, the Tenderer shall
scarify, grade and recompense the sub grade to line,
level and specification.
No work above the sub grade shall be executed until
the sub grade has been approved by the Owners
Representative.
Fill for sub grade or improved sub grade shall,
wherever suitable, be excavated material obtained
from drainage ditches and road cuttings.
vi
Drainage Of Works
All cuttings, embankments and borrow areas shall be
kept free of standing water and drained during the
whole of the construction.
Should water accumulate on any part of the
earthwork either during construction or after
construction until the end of the Maintenance period,
the Tenderer shall remove and replace any material
which, in the opinion of the Owners Representative,
has been adversely affected.
The Tenderer shall so order his construction
programs that the construction of culverts and drains
does not lag behind the earthworks. Well in advance
of commencing earth-moving operations over
swampy or waterlogged areas, the Tenderer shall cut
drains and ditches and carry out any other works as
necessary to assist in draining the ground.
163
All drains and ditches shall be maintained in proper

working order throughout the duration of Contract.
The Tenderer shall allow in his rates for draining the
earthworks satisfactorily at all stages during the
construction and arrange his methods and order of
working accordingly.
vii
Drainage Ditches
Drainage ditches, shall be shaped by excavating to the
lines, slopes and widths shown upon the approved
drawings and finished off so that the sub grade levels
and camber of super elevation of the sub grade, level
and cross fall of the shoulders and slope and invert
levels of the side ditches are required.
viii
Pavements Generally
The term "gravel" used throughout this tender shall
be deemed to include lateritic gravel, quartzitic
gravel, calcareous gravel, some forms of weathered
rock, soft stone, coral rag and conglomerate.
"Graded crushed stone" shall mean crushed stone,
with a smooth grading curve, which is within a
specified envelope.
A "gravel" base shall be made up of one of these
natural gravels, or of a combination of them, or of a
combination of gravel and sand, without the adding
of any stabilizing agent.
A "gravel wearing course" shall mean a top surfacing
course made from one, or from a combination of
materials and may be applied to some or all of a new
road formation where no pavement and final
bituminous surface is included.
164
A "crushed stone wearing course" shall mean a top

surfacing made from graded crushed stone and may
be applied to road base course where no final
bituminous surface is included.
A "surface dressing" shall mean a top surfacing of
bituminous binder and stone chipping applied to the
road base course.
ix
Material For Gravel Base And Wearing Courses

Unless otherwise required by the Owners
Representative, the Material shall comply with the
following requirements:
Gravel For
Base
Plasticity Index
Los Angeles Value Maximum
Aggregate Crushing Value
Maximum
CBR (95% MDD Heavy
Compaction 4 days soak)
Minimum
5-15
70
Wearing
Course
5-25
50
50
35
30
80
The grading curve of the material, after processing

and compaction shall be of a smooth curve within the
following envelope:
Sieve Size
Percentage by Weight Passing
(mm)
Base
Wearing Course
50
100
37.5
95-100
100
20
60-100
95-100
10
35-90
65-100
5
20-75
45-85
2
12-50
30-68
1
10-40
25-56
0.425
7-33
18-44
0.075
4-20
12-32
165
Material For Crushed Stone Wearing Course

The material shall consist of crushed stone, free from
clay, organic or other deleterious matter and have the
following properties:
(i)
Los Angeles Abrasion ValueAggregate Crushing Value
(ii)
Cleanliness and plasticity: The fines passing

0.425 mm shall be non plastic.
(iii)
Crushing, screening and mixing: Unless

otherwise
required
by
the
Owners
Representative, crushing shall be done in at
least two stages.
(iv)
Grading: The grading curve of the material,

after processing and compaction, shall be a
smooth curve within the following envelope:
Sieve Size
(mm)
37.5
20
10
5
2
1
0.425
0.075
Max. 40
Max. 30
Percentage by Weight
Passing
100
65-95
40-70
30-55
20-40
15-32
10-24
-
The screening and proportioning of materials, and

their subsequent mixing shall be carried out using
such methods and machines as may be approved by
the Owners Representative.
166
Where the graded crushed stone is deficient in fine

aggregate and, in the opinion of the Owners
Representative, the Tenderer has made every
reasonable effort to produce the required grading, the
Owners Representative will allow admixing of
approved non-plastic fine aggregate such as sand or
crusher-dust. No extra payment will be made for
providing and mixing of such fines.
Where the addition of fine aggregate is necessary, it
shall be thoroughly mixed in with the crushed stone.
The percentage of fine aggregate to be added to the
crushed stone will be agreed with the Owners
Representative and shall in any case not exceed 15 per
cent by weight of mixture.
xi
Order Of Work
Unless otherwise required by the Owners
Representative, the base or wearing courses shall be
laid starting as close as possible to the Materials Site
and working away from it so that the maximum
amount of compaction is given to the wearing course
by the Tenderer's vehicles, and the Tenderer shall
route his vehicles to give even wear and compaction
over the whole width of the wearing course.
xii
Laying And Compacting Base And Wearing Courses

The base or wearing course materials shall be
deposited and spread in a uniform layer across the
full width required so that the final compacted
thickness is nowhere less than required.
The compacted thickness of any layer laid, processed
and compacted at one time shall not exceed 200 mm
and where a greater compacted thickness is required,
the material shall be laid and processed in two or
more layers.
167
The materials shall be broken down so that the

maximum size of any particle is not greater than
specified. This may require a grid, cleat or sheepfoot
roller or a pulverize and the Tenderer shall allow for
such processing in his rates.
Any oversize material which cannot be broken down
to the required size shall be removed and disposed of
as required by the Owners Representative.
The layer shall then be scarified and water shall be
uniformly mixed in, as approved by the Owners
Representative. It shall be graded, compacted to a
dry density of at least 95% MDD (Heavy
Compaction), and graded to final level.
The moisture content shall be adjusted so that the
minimum compaction is obtained. Unless otherwise
approved by the Owners Representative, the
moisture content at the time of compaction shall be
between 80 and 105% of the Optimum Moisture
Content (Heavy Compaction).
xiii
Geometric Tolerances Of Pavement And Subgrade

The pavement layers and the sub grade shall be
constructed within the tolerances shown in the table
below.
Levels:
The levels of pavement layers and sub grade shall
be determined from the specified surface of the
wearing course, calculated from the carriageway
vertical profile and cross fall.
168
For checking compliance with the table,

measurements of surface level shall be taken at 20
m intervals along the centre-line and along a line
parallel to the centre-line but 500 mm from the
edge of the layer.
Pavement widths:
The half width shall be measured from the
centreline of the road to the edge of the layer.
The final average width of all kinds of wearing
courses, binder courses, bases and sub-bases
measured at six points taken at 20 m intervals
over a length of 100 m shall be at least equal to
the width specified or ordered.
Cross fall:
The cross fall of the pavement shall nowhere
vary by more than 1.0% from the specified
value.
Pavement Thicknesses:
In addition to the above tolerances, the
thickness of any pavement layer shall nowhere
be less than 90% of the specified thickness.
The final average thickness of all kinds of
wearing courses, binder courses, bases,
sub-bases and shoulders over a length of 100 m
shall be at least equal to the thickness specified
or ordered.
169
Layer
Subgrade
Base
Surface
Dressing
Shoulder
Gravel Wearing
Course
Crushed Stone
Wearing Course
xiv
Level
-40,+25
-30,+25
N.A.
+/-15
+/-25
+/-25
Variations Permitted (mm)

Irregularity
Half Width
Half
(under 3m
Maximum
straight
Width
Variation in
edge)
20 m
N.A.
N.A.
N.A.
+/-25
-50,+100
N.A.
N.A.
+/-25
30
+/-15
N.A.
N.A.
+/-25
-25,+50
50
+/-25
-25,+50
50
Surface Dressing
Primer:
The prime coat shall be a low viscosity medium
curing cut-back bitumen (MC-30 or similar
approved) sprayed uniformly over the road base
at a rate of between 0.5 L/m2 and 1.0 L/m2 as
approved by the Owners Representative.
Binder:
After a period of not less than 24 hours the primed
surface shall be sprayed uniformly with a medium
curing cut-back bitumen (MC-3000 or similar
approved) at a rate between 0.9 L/m2 and 1.5
L/m2 as approved by the Owners Representative.
170
Chippings:
Chippings shall be spread uniformly onto the
binder
and
rolled
with
an
approved
pneumatic-tyred or steel wheeled roller. The
chippings shall be single sized crushed stone as
cubical as possible and free from visible stone dust
and deleterious substances such as clay, salt, or
organic matter. The nominal size of chippings
shall be in the range 6 mm to 15 mm as approved
by the Owners Representative.
xv
Use Of Surfaces By Constructional Traffic

Constructional traffic used on pavements under
construction shall be suitable in relation to the courses
it traverses so that damage is not caused to the
sub-grade or the material constructed.
The wheels or tracks of plant moving over the various
pavement courses shall be kept free from deleterious
materials.
Bituminous base course material shall be kept clean
and uncontaminated for so long as it remains
uncovered by a wearing course or surface treatment.
The only traffic permitted access to base course
material shall be that engaged in laying and
compacting the wearing course or, where the base
course is to be blinded and/or surface dressed that
engaged on such surface treatment. Should the base
course become contaminated the Tenderer shall make
good by cleaning it to the satisfaction of the Owners
Representative and if this proves impracticable, by
removing the layer and replacing.
171
xvi
Concrete Roads
Concrete roads shall be laid on a sub-grade of
compacted fill as detailed in this tender document.
Levels of the finished layer shall permit the full
minimum thickness of concrete slab to be constructed
at all places.
The sub-grade shall be thoroughly wetted before
placement of the concrete.
Concrete road slabs shall be constructed using Grade
20 concrete having a minimum thickness of 200 mm.
Reinforcing layers are required at the top and bottom
of the road using 10 mm dia. mild steel reinforcing
bar at 200 mm centers both ways. These layers shall
be fixed and supported in place before the concrete is
poured and there should be a minimum concrete
cover over all steel of 50 mm.
All construction and expansion joints shall be as
indicated on the approved drawings with the
following maximum spacings, 60 meters (expansion
joints), and 20 meters (construction joints).
1.2
SCOPE OF WORK
The Tenderer is responsible for the entire scope of the cogeneration project
between the given terminal points. This document elaborates on the specific
requirements of this project and need not be considered comprehensive. All
plant & equipment, civil works and services required to commission the
cogeneration project are deemed in the scope of the Tenderer. All services, plant
& equipment will be as per relevant IS / ASME / IBR or other applicable
standards. Partial list of applicable standards are given in this document. In case
of conflict between given standards and alternate applicable standard, the more
stringent will prevail. In case of absence of detailed standard for particular
service / equipment, the Tenderer will follow good engineering practices as
approved by the Owner / Consultant.
172
The scope of work inter-alia will include :

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
Detailed engineering and design including submission of the same for all
civil, mechanical, electrical and I&C requirements of this cogeneration
project.
All required civil works for soil investigation, dismantling of any balance
RCC structures or columns , levelling, back filling, foundations, buildings,
chimney, cooling tower, internal roads, reservoir, drains, trenches,
sewerages, compound wall, rainwater harvesting and greenery
development, alongwith required site facilities including batching unit,
vehicles, excavators, dumpers, concrete pumps, vibrators and all tools &
equipments deemed necessary by the Owner / Consultant for appropriate
& timely execution
Steam generator & auxiliaries
Steam turbine generator & auxiliaries including air cooled condenser
Fuel & ash handling
Cooling tower & cooling water circulation
Electrical evacuation upto BSES substation in factory site, cogeneration
auxiliaries and power supply to sugar complex including sugar mill and
ethanol.
Water treatment plant & auxiliaries
Electrostatic precipitator
DCS
Fire fighting system
Overhead EOT for powerhouse and required monorails for all large
motors / fans / pumps / transformers.
All required cabling, piping and earthing within the terminal points
All required utilities to operate the cogeneration plant including DM
water, UPS power, DC power, compressed air, lighting, etc.
Required plant air conditioning and ventilation systems.
Obtaining all required statutory approvals for construction of
cogeneration plant including local body approval for construction of
cogeneration plant electrical inspectorate approval for power evacuation
scheme, IBR approvals, labours commissioner, excise, factory inspector as
applicable, electrical inspector for electrical works, required approvals for
synchronizing with grid, providing stability certificate as per local norms,
registration & payment of all taxes & duties for tenderers staff & labour,
as per all applicable laws, etc. Statutory fees, if any, will be paid by the
Owner and applications required, if any will be paid by the Owner.
173
1.3
TERMINAL POINTS
Utility
Raw water
Bio-gas
Export power
Effluent
Terminal Point
From delivery header of raw water pumps at
ground water reservoir to cogen plant and
further distribution, , thereof and from the
proposed borewells including the borewells
At one point at the boundary of cogen plant
Upto BSES substation for LILO arrangement in
sugar factory site
Neutralized effluent collected in the effluent pit
adjoining the DM plant and pumped upto the
intake well of the common ETP
Bagasse
Outside Biomass
At bottom RAV of ash silo at 3.5 m elevation

from FFL
At inlet of BC-1
At 0 m level in bagasse yard
Power supply to cogen

plant
All power supplies from generator or back

feeding, entirely in cogen package
Power supply to sugar

plant
At 2 Nos. 11KV Feeders identified in 11KV

Swichboard in Cogen Plant TG building
At 1 No. 415V, 1000A, TPN, MDO ACB
identified in Cogen Auxiliary LT Panel for
distillery load (Approx. 600KW)
Entirely in Tenderers scope within terminal
points
Ash
Power supply to ethanol

plant
Earthing
Power Distribution
including Panels, Cabling,
cable trays & Accessories
Lighting and Plant
Utility supplies

points
points
174
Utility
Steam supply
Condensate
Compressed air
Terminal Point
Upto and including MP & LP headers located
towards sugar side of the power house at 1.5 m
level from FFL with tappings and valves.
Required tapping on MP header for ethanol is
for 25 TPH and required tapping on LP header
for sugar is for 40 TPH
At outlet header of condensate transfer pumps
in evaporation and juice heater area of sugar
mill (35 m/hr, 40 m head)
points
Consumables including
At tanker transfer pump header of bulk acid &
acid, alkali, sulphur, lime,
alkali storage tank
etc.
As demarcated in the proposed master plan
Civil Works
given in Appendix IV
1.4
BUILDING DIMENSIONS
1
2
3
4
5
Boiler
Powerhouse
Cooling tower
DM plant
Switchyard
80 x 30
30 x 30
40 x 15
40 x 20
100 x 50
175
CHAPTER - 2
TECHNICAL SPECIFICATIONS FOR MECHANICAL &

ELECTRICAL EQUIPMENTS, INSTRUMENTATION &
CONTROL AND ERECTION & COMMISSIONING
2.1
STEAM GENERATOR & AUXILIARIES
2.1.1
The principal fuel will be bagasse or biomass. Biomass in general would include
sugarcane trash, rice husk and maize cobs.
2.1.2
Steam generator will be designed, manufactured and approved as per latest

amendment of Indian Boiler Regulation Act.
2.1.3
The steam generator will be complete including items as per the list given below:
Bagasse feeding system with bagasse silo
All pressure parts (drums, water walls, headers, etc.)
Refractory
Integral piping with insulation
Travelling grate system
Ash hoppers
ID, FD & SA fans with vibration isolators and VFD for ID, FD and SA
Ducting
Structural from RCC footings, ladders, platforms, supports and foundation
bolts, insert plates
j) All internal piping for steam, pegging steam, cooling water, feed water,
service & instrument air, economiser and air pre-heater, etc.
k) Instrumentation and control suitable for total operation through DCS
l) Dampers, soot blowers and associated controls / piping
m) De-aerator & DA storage tank
n) HP heater stations
o) PRDSH station
p) Grit separator chamber & cinder re-injection system before HRU to collect &
re-inject the cinder.
q) HRU including APH & economiser
r) Attemperator system comprising of direct spray type
s) LP and HP dosing system, SWAS analyzer
a)
b)
c)
d)
e)
f)
g)
h)
i)
176
t)
u)
v)
w)
x)
y)
ESP for 100 mg/Nm3

CBD with flash recovery & IBD with steel tanks
Steam, water & exhaust piping of HP heater
Valves and fittings
Vents up to safe elevation
External canopy for the boiler to cover bagasse feeding system, up to steam
drum operating floor.
z) Electrical and instrumentation control panels
aa) All other auxiliaries and steam generator components required for safe,
reliable and continuous year around steam generation.
bb) Pegging steam line from steam generator to de-aerator for start up.
2.1.4
Steam Generator Technical Parameters

1.
No. of water tube

generators (Nos.)
2.
Maximum Continuous Rating (kg/hr)
110,000
3.
Peak Generation
110% of M.C.R for half an

hour / shift
4.
Steam pressure at boiler MSSV
110 kg/ cm2
5.
Steam temp. at boiler MSSV
540oC
6.
Steam pressure at turbine inlet valve
105 kg/cm2
7.
Steam temp. at turbine inlet valve
535oC
8.
Feed water temperature to economiser
2200C
9.
De-aerator outlet temperature
110 0C to 130C
10.
Excess air
required
11.
Temperature of flue gas at the outlet 150C at MCR

of air pre-heater
of
type
steam One
Theoretical
air Not exceeding 35% at MCR
177
12.
Steam generator efficiency
13.
Fuel
Normal
14.
a)
70 % (minimum) on
bagasse having 50 %
moisture with GCV of
2270 Kcal / kg.
Bagasse & Cane trash.

Source of bagasse would be
from mill of 50 % to 52%
moisture or stored, with
moisture of 20 - 50 %. Cane
trash should not exceed 10%
of fuel fired on weight basis.
Off Season
Procured
biomass
Turn down ratio
1:4
bagasse
&
Note:

Steam generator to be designed for continuous operation through

the year with normal steam generation of 110,000 kg/hr
It is envisaged to supplement bagasse with sugarcane trash and
other biomass during season & off-season.
Steam generator to be top supported with minimum civil works.
Steam generator should be 100 % bagasse fired, travelling grate.
Boiler to be capable of 100% capacity with combination of bagasse
and biomass.
The heating surface of the steam generator shall be determined
with reference to Main Bank of the steam generator tubes, Front
wall, Side Walls, Rear wall and Roof tubes.
The Air pre-heater and economiser shall be designed so as to give
final flue gas temperature within 140C.
The final superheated steam temperature shall not exceed beyond
the design temperature.
The steam generator will be designed to keep the refractory works
to the barest minimum possible.
178
2.1.5
Steam Generator Drum

The steam generator shall be provided with one steam drum and the drum shall
be of fusion welded type. The drum shall be provided with Tori-spherical /
Semi-Ellipsoidal dished ends fitted with oblong man ways at either end. The
man way doors shall be hinged and arranged to open inwards. The drum shell,
dished ends and the man way doors shall conform to IBR. The steam drum shall
be liberally sized to assure low steam space loading, with adequate space to
accommodate the internals.
The steam drum shall be provided with internals of proven design, shall be
bolted type, and of size that will enable removal through the man ways. The
system of internals consisting of the primary and secondary separators shall
ensure steam of highest purity with dissolved silica carry over limited to a
maximum of 0.02 ppm. The steam drum of the Steam generator to be provided
with suitable internal fittings comprising of cyclones, primary and secondary
scrubbers to ensure steam of highest purity.
The necessary nozzle connections for the following, but not limited, steam
outlets, safety valves, feed water inlets, continuous blow down, level indicators,
remote level indicator at operating floor, chemical feeding, vents and drains,
sampling connections, down comers shall be provided on the drums as
applicable. All nozzle connections on the drums shall be of welded type and the
feed water inlet shall be provided with a suitably designed thermal sleeve.
The necessary drum suspension / support arrangements shall be provided.
All nozzle connections on the drums will be of welded type and FW inlet will be
provided with suitably designed thermal sleeve.
The steam drum of the steam generators to be provided with suitable internals to
promote circulation and to ensure high purity of steam. The final drum internals
shall be of stainless steel and bolted (dismantling) Construction to facilitate
cleaning of the internal surface of steam generator bank tubes and furnace tubes
etc.
The water distribution system in the steam drum will be through a distribution
header below low water level, to facilitate equal distribution through the drum.
The steam generator will be top supported.
179
2.1.6
Steam Generator Tubes

2.1.6.1 Furnace Water Wall Tubes
The Furnace envelope shall be constructed of fully water cooled
membrane / Fin welded walls and adequately supported. The design
shall be such as to prevent distortion of steel work due to thermal
expansion. The construction shall be fully gas pressure light, and the
furnace shall be strengthened by providing buck-stay and tie-bar system.
The furnace shall be adequately sized for burning bagasse and biomass.
Necessary provisions shall be made in the furnace for admitting the
required quantity of over fire air at various levels, considering the various
fuel mixes.
The furnace EPRS should be so selected to give acceptable furnace outlet
temperatures while firing bagasse or biomass or the combination of both
the fuels. The furnace design shall incorporate necessary manholes, peep
holes, openings for the fuel distributors, ignition / reflection arch and
refractory covering in the lower furnace area if required.
Adequate number of inlet and outlet headers, with the necessary stubs,
commensurate with the arrangement of the furnace shall be provided.
Each of the headers shall have at least two numbers of stubs for inspection
and cleaning. The down-comers, supply pipes and raisers sizing shall be
based on the circulation calculations.
The entire water wall will be of fin welded construction with minimum
refractory. The side wall tubes will be suitably bent for providing
required peak & access holes / doors. The front and rear wall tubes will
be stub welded to respective bottom headers and expanded into the drum.
The roof tubes will be staggered to allow the super-heater coils to pass
through. The fin welding to be carried out on appropriate jigs and
fixtures to minimise distortion and retain required uniformity of tube
array.
Note:
The water valve panel fin thickness and width shall be such that
the fin tip to base temperature differential does not exceed 70C.
180
2.1.6.2 Steam generator Bank Tubes

The boiler bank tubes will be of single pass design. The tubes will be bare
without any fins. The tubes will be provided in inline arrangement. The
tubes will be of HFS construction. Under all envisaged conditions, the
design to provide natural circulation
The tube spacing will enable easy removal of the tubes in case of any
failure.
There will be adequate approach space to the tubes of the bank for
maintenance. The flue gas velocity will be restricted to about 10 m /sec.
2.1.7
Steam Generator Headers

All headers in the steam generator shall have flat end covers, and a minimum of
one stub at each end for the purpose of cleaning and inspection.
No header shall be placed in the flue gas path.
The boiler headers will be located at front wall bottom, rear wall bottom, right
side wall bottom & top, left side wall bottom & top. The boiler headers shall be
manufactured from pipes. The headers shall be provided with drain & air vent
connections and hand-holes for inspection.
2.1.8
Bank Tubes
The bank design shall be of inline arrangement and the tube spacing shall enable
easy removal of the tubes in case of any failure. The bank tubes shall be
expanded into both the top and the bottom drums, and the tubes after expansion
shall be bell mouthed. There shall be adequate approach space to the tubes of the
bank maintenance. Baffles if required shall be of simple design with material
suitable for with standing the gas temperature.
181
Adequate number of soot blowers shall be provided to the cover the maximum
surface area of the bank. The total number of bank tubes shall be divided into
raisers and down comers, clearly identifying the number of down comers, their
locations and the type, heated or unheated. The flue gas velocity in the bank area
shall be restricted to a maximum of 10 meters/sec.
No butt joints shall be permitted in the bank tubes. The Steam generator bank
side walls shall be fin welded, or shall be of such construction totally eliminating
air ingress or gas leakage and with suitable openings for the man ways,
inspection peep-holes and soot blowers.
Steam generator headers to be constructed in accordance with the IBR
specifications. The headers shall be provided with end plates with extended
stubs. The extended stubs will be cut for inspection & cleaning and will be rewelded.
2.1.9
Super Heaters & Superheated Steam Header

The steam generator shall be provided with super heater of adequate heating
surface capable of superheating the steam generated by the steam generator to
the final steam temperature required at isolation valve of turbine and complete
with headers, its mountings and fittings including safety valves, motorised
isolation valves, NRV, start-up vent valves, flow nozzles, drain valves, air vent
valves and pressure and temperature gauges etc., as per I.B.R. Temp. at super
heater outlet will remain steady at design value from 60 to 100% MCR.
The tube elements of the secondary super heater shall be constructed from
Seamless alloy steel tubes as per IBR1 950 and its latest amendments.
The SH inlet header, shall be connected to the steam drum by means of suitable
number size of tubes which will be of carbon steel. The super heater manifold
shall be fabricated from solid drawn seamless alloy steel pipes.
The superheated steam manifold is to be equipped and complete with branches
for main steam take off, safety valve, air release valve, drains, temperature and
pressure gauges and other connection etc.
Additional thermo wells in the outlet manifold shall be provided to measure the
temperature of superheated steam.
182
The super heater design shall be such that the temperature of steam at super
heater outlet shall not exceed the design value in any case.
Design is a two stage super-heater with inter-stage attemperator.
(a)
Super-heater System
The super-heater (SH) system shall be of two (2) stage design with interstage de-superheating to achieve the rated steam temperature over 60 to
100% load range. The super-heater shall be of convection or a combination
of convection and radiation type arranged to give the minimum metal
temperature. The super-heater pressure drop, the inlet and outlet header
sizing, arrangement and sizing of their respective inlet and take off
connections shall be so as to give minimum unbalance and the tube
element material selection shall be based on the actual metal temperature
calculations.
The metal temperature calculations and the material diagram shall be
approved by the Owner / Consultant. The tube spacing of the superheater shall be designed to minimize bridging and tube erosion and shall
be suitable for proper on-line cleaning by means of soot blowers. Suitable
spacers shall be provided both along and transverse to the gas flow
directions.
The SH system shall be complete with required seamless pipe headers,
inter connecting piping, vents, drains, supports, tube spacers, valves,
fittings, etc. The super-heater header material selection shall be based on
the Average fluid temperature in the header plus 25C. The sealing at the
super-heater tube penetrations with the steam generator roof or the wall
shall be 100% leak tight and the arrangement shall be approved by the
Owner / Consultant. The unheated terminal portion of the super-heater
tubes shall be designed with adequate flexibility against thermal
expansion differentials. The outlet header shall be suitably supported and
anchored such that the piping forces and moments incident to the steam
piping will not cause excessive stresses in the element tubes.
183
(b)
Attemperator System
Inter-stage attemperator shall be located between the two super-heater
stages to control the final steam temperature at 540 +/- 5C between 60%
to 100% MCR load.
The attemperator system will be of spray type. The spray water will be
obtained from the boiler feed pump header.
The de-superheating system shall be complete with all required, control
valves, bypass regulating valves, piping and supports etc.
2.1.10 Furnace
Basically the steam generator shall be radiant furnace. Bi-drum natural
circulation, outdoor type with three stage super-heater. The steam generator
shall be designed with water cooled membrane in welded walls and the
refractory works shall be kept to the barest minimum possible.
Suitable furnaces to burn bagasse with up to 52% moisture and biomass with
preheated air shall be provided for the steam generator.
The furnace design will be with bagasse fed pneumatically, complete with
necessary Air piping, valves, fittings etc.
The steam generator shall be provided with Pneumatic Spreader for bagasse.
The firing floor will be of chequered plate of 8 mm thick min.
Ash hoppers are to be provided below each furnaces and the steam generator
height to be adjusted such that belt can be placed below ash hopper for quick
removal of ash. The furnace ash hopper cleaning doors shall be rack and pinion
type and the bottom most portion shall be at the elevation of + 2500 mm. or
more. By pass arrangement to be provided with ash discharge hopper.
The grate area loading will not exceed 2.2 million kcal/hr/sq.m.
Furnace to be of water-wall membrane type
184
The bagasse feeding doors for steam generator bagasse feeders at the bottom of
the bagasse carrier shall be of rack and pinion type to be operated by chain.
The manhole / inspection doors shall be in line with the bagasse feeding chute.
2.1.11 Fuel Firing System
The Steam generator is to be designed for firing 100% Bagasse, other biomass
through the bagasse feeding system.
2.1.11.1 Fuel Feeding System
The bagasse feeding system shall include a bagasse storage silo(s) with the
Bagasse storage capacity of 7 minutes of MCR requirements.
The excess bagasse in the slat conveyor shall be returned to the storage
yard through the return bagasse conveyor to be provided by the Tenderer.
The bagasse input to the steam generator shall be regulated by the feeding
system.
The bagasse feeding system in addition to the storage silo shall consist of
inlet chutes, feeders, feed chutes and the distributor. The bagasse silo
must have SS lining for smooth flow or should be of convergent type. The
screw feeders used for bagasse feeding should also be of SS.
The feeder shall be of proven design and shall be capable of handling
occasional lumps. Drum pin feeder will be preferred. If the feeder is used
for the regulation of fuel flow, variable speed drive shall be provided. The
inlet and the feed chutes shall be designed to prevent choking of bagasse
by providing necessary vibrators on the bagasse silos and necessary
poking facilities shall also be given. For sizing the feeding system the
density of bagasse shall be taken as 150 kg/m3 with moisture content of
52%.
The distributor or feeders could be mechanical or pneumatic and with AC
variable frequency drive. There shall be provision to vary the length and
the angle of throw. The parts facing the furnace radiation shall be of heat
resistant material.
185
The fuel feeders will be sized with one extra feeder to meet MCR fuel
needs, such that even with one feeder outage the MCR can be achieved.
2.1.11.2 Firing system / Travel Grate System
Front discharge twin travelling grate with individual hydraulic drives
complete with front plate, seals, grate casting, carrier bars, skid shoes, skid
rails, sprockets, shafts, bearings, forged chain links and structural framing
suitable for mounting on foundation.
The manufacturer should have a thorough understanding and experience
in manufacturing travelling grate system
The travelling grate system should be preferably shop tested in fully
assembled condition before dispatch
This system must maintain continuous tension in order to run smoothly
and avoid jamming of the grate and grate bars. The catenary grate should
be self tightening and should not require any expensive maintenance
labour or external mechanical tightening devices, counter balances, or
springs to maintain grate tension.
Travelling Grate System components specifications / requirements
Grates : High quality, heavy duty, heat resisting alloy CI or IS 3355 Gr.1
type C
Grate Air Seals : Under grate, front & rear air seals of Cast Iron and
Carbon Steel, self adjusting to maintain continuous close seating contact
with the Grates. Should be bolted type.
Forged Chain Links: To be fabricated from C45, Forged Steel with
hardened roller and pin assemblies designed for high heat duty and
tension loads.
Grate support: Through underlying grate bar should not damage even if
debris fall on the grates.
Graphite Bearings : Heavy duty graphite carbon bearings which do not
require any lubrication.
186
Hydraulic Drives: Low Horse Powered, self contained and mounted

directly to the stoker drive shaft at the stoker front. Should be capable of
regulating to control the grate output from 0 to 24 feet per hour and
transmit the speed to DCS. Should also have necessary oil cooling
arrangement. Alternatively, planetary gearbox with VFD is acceptable.
Stoker Front & Housing: The stoker should have a reinforced steel main
stoker front plate combined with dust tight front ash discharge extension
housing.
Pneumatic air swept distributors: Cast Iron Air Swept Fuel Distributor
assemblies mounted on the Stoker front Plate and designed to assure
uniform fuel distribution in the furnace. This should have a trajectory
plate.
Alternatively, 3-drum feeder type, which carries bagasse between two
sheets of secondary air for even distribution can also be considered. This
will prevent jamming of screw conveyors due to higher moisture by
eliminating the same.
Other requirements of the Travelling Grate System
The Grate Area loading shall not exceed 2.2 Million kcal /Hr/ Sq. Mtr
Cinder Re-firing System is to be included
Hot air duct connection shall be to the wind box of under grate.
Thermocouples to be provided in the under grate area to monitor the
grate temperature and connected to DCS
The total combustion air formed by the FD fan, heated in the air preheater to a temperature of about 2300C. The under grate air shall be
uniformly distributed under the grate. This distribution shall take into
account the non uniform fuel distribution that could occur during the
combination firing or during part loads.
187
The secondary air for distribution and for the over fire air (OFA) shall be
supplied by the secondary air fan, and the SA fan shall take suction from
the air outlet of the air-pre-heater. The secondary air handled by the SA
fan shall not be less than 25% of the total. The number of OFA levels shall
be decided based on the requirements for bagasse and biomass firing and
there shall be provisions to cut of the levels, if necessary. The OFA
pressure shall be selected to give a minimum penetration depth of two
third the furnace dimension along the OFA jet.
The travel grate structure and the travel grate are to be ensured not to sag
due to increased width or other factors more than the limit. Indication to
measure the chain sagging has to be provided.
Firing system consisting of:
Continuous bagasse feeding system:
a.
b.
c.
d.
Bagasse storage silo of 7 minutes storage capacity with support structure.

Bagasse extractors with Variable frequency drives
Screw feeders with constant speed electric drives
Air swept bagasse distributors with trajectory plate
2.1.12 Economiser
The flue gas velocity over the economiser tubes shall be limited to a maximum of
10 meters / sec. Suitable number of soot blowers shall be located in the
economiser for effective cleaning of the heat transfer areas. For the purpose of
maintenance and for accommodating the soot blowers the economiser may be
divided into suitable number of banks. Broadly the individual bank height could
be maintained at about 2000 mm with the inter bank gap at about 600 mm.
The economiser shall be complete with seamless inlet / outlet / intermediate
headers with drains and vents, coil supports, supporting structures for the
complete economiser, interconnecting piping for the inlet and the outlet, access
galleries and stairs, etc.
The economiser casing shall be of at least 6 mm thick, mild steel plate suitably
stiffened / reinforced.
188
The economiser gas path shall be of the pressure tight construction with the
proper design of the seals at the tube penetrations with the casing. The inlet and
the outlet headers are adequately supported and anchored to take care of the
loading from the connected piping.
The economiser tubes shall conform to SA 210 Gr.A1 cold drawn Seamless
(CDS). There shall be a minimum of two headers and the header material shall be
conforming to SA 106 Gr.B or BS 3602 Gr.360 HFS.
An economiser of suitable heating surface shall be provided for steam generator.
The economiser shall give rise in feed water temperature below saturation
temperature of steam at design value when supplied with water of 165C from
HP feed water heater or 115 C from de-aerator
The economiser shall be complete with tubes/economiser coils, supports, inlet
and outlet water temperature, casing and dusting, soot blowers, lagging, vents,
drains, safely valves, etc.
Velocity of the feed water in economiser tubes/coils shall be about 0.5 to 0.7
Meters/Second. The economiser shall be designed in accordance with the
requirements of I.B.R.
The economiser assembly shall be designed to suit the transient condition of
steam generators as prevalent in sugar plants. Load variations from 30 to 100%
will be accounted in its design.
To avoid erosion from incoming flue gas, the economiser will be provided
suitable cascade baffles or / and sacrificial empty coils or / and SS cladding on
first array of coils.
Cinder re-injection system prior to economiser to be provided. It will consist of a
grit collection hopper, with the collected grit being pneumatically re-injected into
the furnace.
189
2.1.13 Air Pre-heater

The Air Pre-heater (APH) shall be arranged as the last heat recovery section
downstream of the economiser. The APH & economiser will be on different axis.
The Air-heater shall be recuperative type with flue gas flowing inside the tubes
and the combustion air flowing over the tubes. The air-heater shall be arranged
with the tubes in the vertical direction. The inner diameter of the tubes shall be a
minimum of 50 mm. The tubes except those required for staying purposes, if any,
shall be welded into the tube sheets on both ends. APH tubes will be 13 g
thickness.
The air-heater arrangement shall provide for adequate access for replacing the
tubes- considering the high moisture in the flue gases, suitable precautions
should be taken to prevent the tube corrosion at the air inlet side of the airheater. If the air-heater is designed with more than a single pass on the air side
suitable guide vanes shall be incorporated in the connecting ducting to prevent
stratification. The cold end of the Air-pre-heater shall be designed to prevent
corrosion and the cold end material of the air-heater tubes shall be corten steel.
The last array or last block of APH tubes to be corten steel. At gas inlet side of
tube sleeve pipe or ferrules to be provided to avoid erosion.
Air pre-heater of suitable heating surface to heat the air by flue gases required for
combustion for steam generator. Air-heater should be complete in all respects
with ERW tubes, tube plates, supports, dampers, and ducting, etc.
Rotary airlock valves and side manual gates and the bottom of Rotary airlock
valves shall be provided.
The air pre-heater and the economiser shall be designed so as to give flue gas
temperature within 150C at the outlet of the air pre-heater. Suitable bypass
should be provided for APH for start-up purposes.
The cold end of the APH will be designed to prevent corrosion due to the
condensation of flue gas. The final array of tubes on the cold end i.e. entire low
temperature block will be of corten steel or anti-corrosive steel.
190
2.1.14 Electro Static Precipitator (ESP)

A suitable ESP so that the fly ash contents of flue gases leaving the chimney
confirm to the rules and regulations of the pollution act as applicable to the
factory and as outlet concentration below 100 mg/Nm3.
A certificate to this effect should be obtained from pollution control board under
whose jurisdiction this mills falls. It shall be the responsibility of the steam
generator manufacturer / Tenderer to provide all documents to pollution control
authority.
The ESP shall be installed on the suction side of the I.D. fan and shall to be
complete with rotary airlock valve with drive provided with local and remote
push button control, and a side manual gate. The minimum elevation of
discharge flange of the rotary airlock valve shall be at + 2500 mm.
Suitable platform, ladder, inspection and poking holes etc., shall be provided to
facilitate regular inspection and cleaning of the ESP.
Even with one field of ESP out of service the ESP must remain in operation.
Manufacturer / Tenderer to specify the emission level with only one field in
service at 100% boiler MCR with bagasse as fuel.
All electrical including MCC, rectifiers, panels, electrical & control cables,
earthing etc. in Tenderers scope. ESP control shall be from control room
The manufacturer is to design & supply suitable flue gas cleaning system to
ensure that the flue gases entering the chimney do not contain SPM in excess of
100 mg/Nm3.
2.1.15 Induced Draught Fan

There shall be two (2) ID Fans (2 x 60%), designed for a minimum capacity of
15% higher than the theoretical requirement at 1700 C
The I.D. fan shaft shall be both end supported, directly driven type, and
complete with drive equipment etc. Fan shaft design as per IS : 1570 - 1979.
191
The I.D. Fan maximum speed shall not be more than 750 rpm.
Renewable hard faced wear pads on blade shall be incorporated in the impeller.
The blade of the fan rotor should be fabricated out of minimum 5 mm thick mild
steel plate. ID fan blade will be of backward vane type. Variable inlet and outlet
control dampers to be provided. ID fan inlet damper for air control and outlet
damper for maintenance isolation.
The rotor of the I.D. fan shall be dynamically balanced and tested for its
parameters at their works and test certificate and inspection certificate to be
provided. The rotor shall be dynamically re-balanced at site if vibration levels
exceed limits.
Induced Draft Fan Drive
The I.D. fan shall be driven by an A.C. Motor drive with variable frequency
variable speed control system. (VFD)
The Drive unit shall be complete with control equipment, speed meter, voltage,
amp., frequency indicators, etc.
All electrical control accessories to be included.
2.1.16 Forced Draught Fan

There shall be two (2) FD fans, capable of handling min. 60% each of the total gas
flow. The Forced Draft fan shall be horizontal, radial and with backward curved
blades. The fan shall be supplied complete with motor, common base plate for
motor and fan, coupling, etc. The fan shaft shall be of simply supported design,
conforming to 35 C8 for IS- 1570-1979 material. Renewable hard faced wear pads
on blades shall be provided and the minimum thickness of the plates used in the
construction of the fan shall be 5 mm. The fan design temperature shall be 500C.
The forced draft fan is to be designed for minimum capacity of 15% higher than
the theoretical requirement at peak load capacity.
The F.D. fan shaft shall confirm to I.S.- 570, 1979.
192
The F.D. fan shaft shall be both end supported, directly driven type, and
complete with drive equipment etc.
The F.D. fan maximum speed shall not be more than 1500 rpm.
steel plate.
Variable inlet vane control dampers in the suction of the F.D. fan should be
provided. A thick welded mesh screen shall be provided before the damper to
avoid accidental entry of foreign material. The entry of FD fan will be on the Y
axis with suction from atmosphere.
The direction of rotation of the FD fans shall be same where more than one fan is
provided.
The rotor of the FD fans shall be dynamically balanced and tested for its
provided.
The rotor shall be dynamically re-balanced at site if the vibration levels, are
found unacceptable.
Forced Draft Fan Drive
The F.D. fan shall be driven by a variable speed electric drive.
A.C. motor drive - with variable frequency / variable speed control system.
(VFD)
The drive unit shall be complete with control equipment, Speedo-meter, voltage,
amp., frequency indicators, operator's control cubical local (lockable) and remote
(control room) etc.
The electric system to be complete with all electrical protections & control
devices.
Both the ID and FD fans should be interlock so that FD fan can be started only
when ID fan is running.
193
2.1.17 Performance requirements for Fans

Noise and vibration
All equipment and their accessories shall perform continuously with the levels of
noise and vibration as specified below:
a) All equipment shall provide acceptable and not excessive back ground
acoustical level. Measured noise level produced by any rotating equipment or
a group of equipment closely located shall not exceed 85 db (A) at a distance
of 3 m from it in any direction.
b) Vibration isolation of proven design shall be supplied by the Tenderer for
preventing transmission of vibration from the equipment to other
neighbouring equipment and structures for all fans.
2.1.18 Secondary / Primary / Cinder Recovery Fan
The Secondary Air or cinder re-injection fan & Primary Air Fan shall be two (1SA
+ 1 PA) in number shall be of constant speed, horizontal, radial, backward
curved or aerofoil bladed and electric motor (squirrel Cage TEFC) driven. The
fan flow control shall be with inlet guide vanes with manual control. The fan
shall be direct driven, with speed not exceeding 1440 RPM and shall be supplied
complete with motor, base plate for fan and motor, coupling, control driven etc.
The supply of SA air to the furnace should be through flexible SS tubes.
The SA / PA / CR fan is to be designed for a minimum discharge capacity of
15% higher than required at peak load capacity.
The SA / PA / CR fan shaft shall conform to C40.
The SA / PA / CR fan shaft shall be both end supported, directly driven type
and complete with drive equipment etc.
The SA / PA / CR fan maximum speed shall not be more than 1440 rpm.
steel plate.
194
Variable inlet vane control dampers in the sanction of the SA fan should be
provided. A thick welded mesh screen shall be provided before the damper to
avoid accidental entry of foreign material, in case of ambient air suction.
The direction of rotation of the SA / PA fan shall be same where more than one
fans are provided.
The rotor of the SA / PA fan shall be dynamically balanced and tested for its
provided.
The rotor shall be dynamically re-balanced at site if the vibration levels exceed
limits.
2.1.19 Blow Down Arrangements

Continuous blow down equipment as per I.B.R. /I.S.O. complete with all piping,
fabricated blow down tank, located at a suitable distance from the steam
generators (Approved by the Owner / Consultant). Tenderer in accordance with
IBR will provide one intermittent and one continuous blow down tank.
All blow down piping shall be as per I.B.R. and provided with supports and
slope etc., Adequate slope from the pressure parts outlet connections and
minimum nos. of bends shall be provided to ensure that the system remains free
from the blockages.
Flash steam to be recovered from blow down tank to de-aerator with required
piping, NRV, supports etc.
2.1.20 Soot Blowing Equipment

Steam operated and auto controlled soot blowing equipment with adequate
number of soot blowers for the steam generator at appropriate places to cover
bank of steam generator tubes and super-heater elements shall be provided.
Additional soot blower (s) shall also be provided for the economiser. In super
heater area, the soot blowers should cover 100% of the tube area.
195
All soot blowers will be motorised and logically controlled.

All steam piping for soot blowing to be provided
A suitable pressure reducing valve & system shall be provided for required
steam for soot blowers. The steam will have at least 500C superheat, as being
used for soot blowing.
The steam generator shall be provided with a complete system of soot blowers to
effectively dislodge deposits from the heat transfer areas. The soot blowers shall
be motor operated with steam, taken from the steam generator, as the cleaning
medium. The required pressure reducing station with pressure controller and
pneumatically operated control valve and downstream safety valve shall be
provided. The supply shall include all piping, fittings, valves, traps etc.
In the zones where the gas temperature exceeds 7000C only long retractable soot
blowers shall be given. For the blowers located in zones where the gas
temperature exceeds 4000C, the material shall be a minimum of stainless steel
type 304.
The entire soot blowing system will be auto controlled and operated with all
controls from its independent PLC or through the DCS.
2.1.21 De-aerator & De-aerated Water Storage Tank

Spray and Tray type de-aerator having auto control of temperature, flow and
level etc. mounted on de-aerated water storage tank of 45 m3 capacity and
suitable for maximum flow rate of 150 m3/hr shall be provided, to obtain a
temperature of feed water of minimum 1150C by using exhaust steam at 2
kg/cm2. All internals of de-aerator wetted part should be of stainless steel 316
materials. The design inlet water temperature to be 45C. Level & pressure
control valves to be provided, to sustain & maintain the design quality of DA
water.
The maximum dissolved oxygen in the de-aerator water shall not be more than
0.007 ppm. at 105C temperature.
196
The de-aerator storage tank shall be installed as per requirement of NPSH from
the feed water pump suction.
The water outlet (suction line of pumps) to be provided with all perforated pipe
inside the tank along its full length or with suitable vortex breakers.
The over flow from the de-aerator water storage tank shall be connected to feed
water storage tank through a suitable sealing arrangement.
The drain valves for feed and de-aerated water tank shall be at elevation of +
2000 mm from F F L and terminated at the common drain (factory drainage
system.)
A full range plate type level gauge glass is to be provided. The water level in the
de-aerator tank gauge glass should be visible to the steam generator control
room/ operator working platform.
The high and low water level indicator and alarms shall be provided. Auto
control is required from plant DCS.
Main FW control valve shall be pneumatically operated, by pass valve will be
motorised and pneumatic control valve for lower sizing (30%)
2.1.22 Boiler Feed Water Pumps

Electrical Driven Feed Water Pumps
Nos. of Pumps: 3 x60% with VFD
Each multistage electrical driven pumps set shall be suitable for pumping hot
water from de-aerator to steam generator. The BF water pump to be designed by
taking HP heater into consideration.
Auto circulation valve (with required arrangement) to be separately provided for
each pump. The ARC valve will be of Schrodehal make. On the suction side,
one operating and one isolation valve shall be provided.
The balancing chamber relief line shall be provided with the pressure gauges for
each pump and pipe line laid separately for each pump. Only, mechanical seals
to be provided.
197
Each pump should be provided with in-line strainer in the pumps suction line.
The pump and the drive (Electrical Motor) shall be placed on RCC foundation at
a foundation level of +500 mm.
The steam generator feed water pumps should be sized to include the flow need
of the steam generator, 3% blow down, 1% losses/unaccounted and 6 8%
margin for volume. Head to be sized as per Tenderers design with at least 5-10%
margin. Pumps to be sized for 110% MCR at design pressure level.
2.1.23 HP Feed Water Heaters
Tenderer to supply suitably designed (as per ASME / equivalent code) heat
exchanger to preheat the de-aerated water from 115C / 125C to 220C at MCR
conditions. Tenderer to provide steam at 25 & 8 kg/cm2, as per requirement to
the heat exchanger. Scope to include required control valves, I&C and piping as
required. All control valves to be motorised or pneumatically controlled. All
level controls to be through DCS. Vent line to be given to de-aerator.
Feed Water Heater Design Requirements
Type
Location
Shell & Tube Type with U tube

Between Boiler feed water pump and
economiser
Application
To heat feed water using low Pressure Steam
Code of Design &
A] TEMA, Class C
construction
B] IBR 1950 with all latest amendments
C] ASME SEC.VIII DIV I
D] HEI
Process data (for HP heaters 1 & 2)
Shell Side
Tube Side
Medium
Steam
Feed Water
Inlet Pressure,kg/cmg
25 & 8
110 135
Temperature Inlet /
As per design
165 & 220
Outlet, C
198
Steam quality
The steam for feed water heaters shall be supplied from turbine extractions
during normal operation
Additional requirements
a) Provision shall be kept for adding 10% heating surface on tube side.
b) Tenderer has to provide level switch to control the condensate level. Hence
suitable storage volume to be considered.
Material of Construction: Shell/Skirt

:
Tube Plate/Water Box Channel/Cover
Pipes
:
Fasteners
:
Tubes
:
SA 516 Gr 70
:
SA 266 Cl 2
SA 106 Gr.B
SA 193 B 7/ SA 194 2 H
SA 213 TP 304 (U Tubes)
2.1.24 Pressure Reducing cum De-superheating Station (PRDSH)

Tenderer to include pneumatically controlled pressure reducing & de-superheater of 50,000 kg/hr capacity, to reduce pressure from 110 kg/cm2 to 8 kg/cm2
& 8 kg/cm2 to 2.5 kg/cm2. The outlet temperatures required are 10C above
saturation temp. PRDSH to be capable of supply of 0 to 20000 kg/hr steam at 8
kg/cm and 0 to 30,000 kg/hr at 2.5 kg/cm. PRDSH to be placed on the roof of
the control room with minimum required tapping from the main HP steam line.
All bypass valves of the PRDSH will be manually operated.
2.1.25 Feed Water
Chemical Dosing System
Steam generator shall be provided with a tri- sodium phosphate based High
Pressure (HP) dosing system and a hydrazine and ammonia based Low Pressure
(LP) dosing system.
199
The HP dosing system shall add the chemical to the steam generator water to
take care of the ingress of the hardness salts and to increase the steam generator
water pH. The LP dosing is done to the feed water preferably at the outlet of the
de-aerator to scavenge the last traces of oxygen and to increase the feed water
pH.
Each dosing system shall include a stainless steel mixing tank with an electric
motor agitator. Each system shall have 2 x 100% capacity, motor driving positive
displacement type pumps, with wetted parts made of stainless steel, with facility
to vary the feed rate.
The HP and LP dosing systems shall be mounted on individual skids with their
respective tank, pumps along with all required piping, valves, fittings, supports
etc.
The complete piping for both the HP and LP dosing system from the skid to the
respective admission points to the steam generator water circuit shall be SS 304.
2.1.26 Instrumentation
2.1.26.1 General
The entire I&C package will be in Tenderers scope and will be interconnected to
the plant DCS.
Instrumentation shall be complete in every respect and liberal to the extent of
providing data on all operation variables sufficient for the safe efficient, easy
operation, start up and shut down of the plant.
The complete steam generator & auxiliaries packages will be normally operated
only through the DCS in the control room, except for manual drain valves.
Normal start-up operation should also be accomplished through the DCS.
Hence, start / stop of all drives, speed regulation where required, operation of
actuators / dampers / solenoid valves, operation of all motorised valves,
operation of sub-systems like soot blowers, SWAS, etc. should all be
interconnected through the DCS with appropriate & required I/Os.
200
All instruments and equipments shall be suitable for use in a hot, humid and
tropical industrial climate in which corrosive gases and / or chemicals may be
present. As a minimum, all instruments and enclosures in field shall be dust
proof, weather proof to NEMA 4 (IP:55) and secure against the ingress of flue,
dampness and vermin. All external surface shall be suitably treated to provide
anti-corrosion protection.
The instruments like control valves, thermo wells, orifice flanges, level
instruments etc. coming on pipes and vessels under IBR shall be certified by IBR.
Location of tap off connections shall be either from the side or from the top of the
steam generator equipment but not from the bottom. This requirement is
applicable to both pipes and vessels. The location of lower side connection shall
be high enough to prevent plugging due to dirt or other suspended solids. In
addition, the connections shall be short, vertical or horizontal and without any
pockets.
Materials of construction of instruments shall be consistent with temperature,
pressure, corrosion conditions and other steam generator requirements.
The design of control panel shall incorporate provision for expansion by
installing space capacity. Each panel shall be designed to accommodate 10%
minimum additional equipment including 10% spare cable/ tube entry points.
Instrument power circuits shall employ an isolation transformer and
individually protected from fault with the help of MCBs and fuses. Power
supply to the individual instrument shall be disconnect able with the help of
switch and protected with the help of fuse.
Ranges for instruments shall be selected, in general, such that in normal process
operation the indication on the indicator or chart is between 40% to 60% of span
for linear and 60% to 90% of span for square root.
The complete instrument system shall be designed for safe operation, by using
normally closed contacts which open on fault conditions.
201
Adequate alarms shall be provided to give audible and visual warning of

malfunction . The Tenderer shall also provide alarm contacts for the operation of
parallel alarms, common pre-alarm and shut down alarm by the Owner
wherever indicated.
All lamps shall be provided with lamp test facility.
Gauge glasses shall be provided for all level measurements requiring automatic
or manual control or monitoring. They shall have at least the same pressure and
temperature rating as that of equipments on which they are to be installed. They
shall have ball check auto shut off valves.
Isolation and bypass valves shall be installed with all control valves. Hand
wheels and air lock valves shall be considered for all control valves.
Control valve sizing formula shall, in general, be as per ISA-75, 07. Control
valves shall be sized for the available pressure drop at normal flow and shall
permit up to 110% of the maximum flow. The Tenderer shall submit the sizing
calculations for all control valves. DP shut off shall be 10% more than upstream
pressure for actuator sizing.
Orifice plate calculations shall in general, follow BS 1042. Orifice diameters shall
be selected so that d/D ratio is between 0.2 to 0.7 for gases and steam and up to
0.75 for liquids. Tenderer shall submit the sizing calculations for orifice plates.
Main steam generator stop valve & air vent valve will be motorized and shall be
designed in accordance with ASME code for valves (ASME B 16.34) and Indian
Boiler Regulations.
All transmitters shall be provided with output meter/output gauge at the
transmitters end. All transmitters will be smart type.
The Tenderer shall ensure that the packing of instruments and associated
equipment is adequate to prevent damage from such contingencies as rough
handling, weather, condensation, dew, vermin and vibrations.
All solenoid valves shall be universal type and continuous rated type.
202
Analysis for PH, Conductivity, Silica and Oxygen (SWAS) shall be complete with
sampling system and shall be supplied with complete calibration kit including
zero and span samples or buffer solution and special tools required for the
maintenance. SWAS analyser will conduct online monitoring of FW quality at
FW control station, drum water and superheated steam. The SWAS panels to be
located in the powerhouse building. The annunciations and results of the SWAS
to be communicated to DCS.
The steam generator shall be provided with a three Elements Automatic Feed
Regulator (thru. transmitter and controllers).
One pneumatic operating and one standby pneumatic / motorised control valve
(located such that its operator can see water level in steam generator gauge glass)
capable of passing the required amount of water, shall be provided. The steam
generator shall have two water level gauge glasses at one end of the top drum
independently connected. 30% manual bypass valve to be provided.
De-aerator Automatic Level and Pressure Controller
Remote Water Level Indicator (hydra-step type) for steam generator to indicate
the water level in the steam drum and visible at the operating floor.
Furnace draught control system will be provided to automatically control the ID
dampers to maintain design furnace pressure.
2.1.26.2 Instruments
The DCS shall be employed for the following and will be suitably interconnected
for:
a.
Closed loop controls of parameters for operation of boiler and turbine.
b. Open loop controls.
c.
Sequence and shut down logic of boiler.
d. Continuous monitoring of process parameters and drive running status.
e.
Mimic graphics
f.
Trends
g. Report generation
h. Alarm logging
i.
Event recording
203
Following closed loop controls shall be implemented in DCS:

i.
Three element control
ii.
Level control
iii.
Combustion control
iv.
Superheated steam temp. control
v.
Furnace draft control
De-aerator level and pressure control
vi.
vii.
Steam vent during start up
viii.
CBD/IBD level control
ix.
HP heater level control
Pressure reducing and de superheating temp. control
x.
Open loop control
Operation of Motorized control valves and dampers for
i.
Boiler feed water pump
ii.
Main steam stop valve and its by-pass valve
iii.
Air vent valve
ID, FD, SA fan inlet damper
iv.
v.
By-pass valves of PRDSH station
vi.
All valves of HP heater station
Start/stop critical drives
Monitoring of following process parameters of boiler :
Flow :
i.
ii.
iii.
iv.
Boiler outlet steam

Boiler feed water
Attemperator spray water
Combustion air
Pressure :
i.
Boiler outlet steam
ii.
Drum
iii.
De-aerator
204
Draft :
i.
ii.
iii.
iv.
v.
vi.
FD fan outlet
ID fan 1&2 inlet
SA fan 1&2 inlet
Furnace
Flue gas at boiler outlet
Economiser outlet
Temperature :
i.
Feed water at de-aerator inlet & outlet
Feed water at economiser inlet and outlet
ii.
iii.
Boiler outlet steam
iv.
Steam at de-super-heaters inlet and outlet
v.
Steam temp. of PRDS
vi.
Flue gas at boiler outlet
vii.
Flue gas at economiser outlet
viii.
Flue gas at air heater outlet
Flue gas at ID fan inlet
ix.
Current :
i.
ii.
iii.
iv.
v.
vi.
ESP
ID fan 1&2
FD fan 1&2
SA/PA fans
Boiler feed pump 1,2 &3
FW transfer pump
Positions :
Positions of all MOVs (FW control station, HP heater, de-aerator,
FW tank pumps, vents, MSSV, PRDSH, etc)
Level :
i.
ii.
iii.
iv.
v.
Drum
De-aerator
IBD
CBD
HP heater level
%O2 in flue gas
205
Speed :
i.
ii.
iii.
iv.
ID fans
FD fans
Rotary drum feeders
Bagasse screw feeder
Conductivity :
i. Feed water
v. Condensate water
vi. Blow down
vii. Drum steam
viii. Superheated steam
PH :
i.
ix.
x.
xi.
xii.
Feed water
Condensate water
Blow down
Drum steam
Superheated steam
Dissolved oxygen in boiler feed water

Silica for superheated steam, feed water & drum water
The I & C to provide for the following recording to occur in the plant DCS.
Parameters to be measured for recording in DCS :
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Steam Flow (also indicating & integrating)

Steam Pressure (also indicating)
O2 % (also indicating)
Steam temperature (also indicating)
Feed Water Temp. of Eco. inlet (also indicating)
Feed Water Temp. of Eco. inlet (also indicating)
Drum Water Level (also indicating)
Feed Water Flow (also indicating & Integrating)
Flue Gas Temp. at APH Outlet (also indicating)
Feed Water Pump Outlet Pressure (also indicating)
206
Alarms to be interconnected to plant DCS :

a.
b.
c.
d.
e.
f.
g.
h.
i.
Drum Water Level Very High & Very Low Alarm-Audio & Visual
Drum Water Level High Alarm - Audio & Visual
Drum Water Level Low Alarm - Audio & Visual
High Steam Temp. Alarm - Audio & Visual
Low Steam Temp. Alarm - Audio & Visual
ID, FD, SA Fans Trip Alarm - Audio & Visual
BFW Pump Trip Alarm - Audio & Visual
Bagasse Feeders Trip Alarm - Audio & Visual
Low De-aerated Storage Tank Level - Audio & Visual
Temp. Indicator (simultaneous indication of all the points) &

interconnected to plant DCS.
for Air
a) APH - Inlet
b) APH Outlet
c) + 2 Spare Point
Temp. Indicator (simultaneous indication of all the points) & for Flue
Gas interconnected to plant DCS.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
Furnace - Just above the grate

Furnace - Combustion zone
Furnace - Super-heater flue entry zone
Steam generator Outlet
APH Outlet
ESP Outlet
I.D. Fan Outlet
+ 3 Spare Point
Temp. Indicator (simultaneous indication of all the points) and for

Water interconnected to plant DCS
i.
ii.
iii.
iv.
v.
Steam generator feed water tank

De-aerated Steam generator feed water storage tank
Eco - inlet
Eco - outlet
+ 2 Spare point
207
Draft indicator (simultaneous indication of all the point) and for Draft
interconnected to plant DCS
i.
ii.
iii.
iv.
v.
vi.
vii.
Furnace
Steam generator Outlet
Eco Outlet
APH Outlet
ESP Outlet
ID Fan Outlet
+ 2 Spare points
AMP. (CURRENT) Indicator & Recorder interconnected to plant DCS

i.
ii.
iii.
iv.
v.
vi.
ESP
ID Fan Drives
FD Fan Drives
SA Fan Drives
BFW pump drives
FW transfer pump
AMP. (CURRENT) Indication

All other motors in Steam generator Station - individual indicator at
respective MCC
ON - OFF Indication of the Soot blowing operation showing individual
location of Soot blowing, interconnected to DCS, with logic control for
auto time based operations.
Bagasse Feeder Speed Control Units, interconnected to DCS.
ON/OFF - Push Button Units for all rotary Air Lock Valves
Any other required for the proper and efficient combustion control and
operation of the Steam generator.
208
Local Instruments
The steam generator shall complete with the minimum following local
instruments.
Steam Pressure indicator
One on each side Steam generator

drum.
Steam Pressure indicator
One on each side of Super Heater

and one at Steam generator Firing
Floor
One on each side of Super Heater
(with additional thermo-wells), and
one at Steam generator Firing Floor
One near the Flow Meter and one at
Steam generator Firing Floor
Steam Temp. indicator
Steam Flow indicator
Feed
water
indicator
temp.
Feed
Water
indicator
press
One each at Eco inlet and Outlet

One near Feed Water Control
system and One at FWP. Outlet
One each at Eco Inlet and Outlet
flow
One near Feed water control system

One at Feed Water Pump Delivery.
(common line).
One at Delivery. of each FW. Pump
Delivery.
One near the Flow control system
Feed
water
indicator
Flue Gas temp. indicator

at
Furnace - 3 places
a) Steam generator Outlet - Eco
Outlet
b) ESP Outlet
c) ID Fan outlet
Air Temp. indicator at
a) APH - Outlet
b) APH Outlet
209
Drum
Water
indicator
level
(level gauge) - 2 Nos. independently

connected to the Drum on each side
of the stream Drum.
One remote type at Firing Floor
Level.
Instrument to measure O2 in flue gas. (zirconium oxide or equivalent),

interconnected to DCS for the combustion control loop.
Necessary tapping arrangements with thermo wells to measure the
temperature of air, gas, steam and toppings to measure draft with
manometer shall be provided.
Steam generator to be provided with auto-combustion control, based on
O2% measurement by electrochemical or infra-red gas analysers and
linked to air supply drives to retain low excess air levels from 50 to 100 %
of MCR.
2.1.26.3 Other General Points
All required safety interlocks shall be incorporated in instrumentation system.
All control valves power cylinders for dampers shall have airlock facility.
The following drives shall have start / stop facility from the DCS. Illuminated
push buttons shall be used.
a.
FD Fans
b.
ID Fans
c.
SA Fans
d.
Bagasse Feeders
e.
BFW
f.
FW transfer pumps
g.
Hydraulic drive of grate
In addition to the instrumentation recommended, whatever additional
instrumentation is required to prove the performance of their equipment shall be
included.
210
a.
Material of Construction & General Instructions

Each steam generator shall be complete with necessary tubes, manifolds
integral pipe work, mountings and fittings with valves, gauges high and
low water alarm, drum level control with three element system.
Maintenance tools consisting of tube expanders, mandrills, ratchets, two
grease guns, a set of spanners, water gauge glass assembly with glasses,
and chemical injection valves etc.
The integral pipe work shall consisting of blow off bends, high and low
pressure drains, water gauge piping, water and steam connections to feed
water regulator, feed pipe work from feed control valve to economiser
inlet manifold, feed pipe work from economiser outlet manifold to the
steam generator steam pipe works, safety valves escape pipe works etc.
All the bends, elbows, ducts shall be suitably designed for to avoid the
draft losses.
The Air & Flue duct will be provided with Man Holes, Cleaning holes for
internal inspection, Cleaning & painting.
The entire ducting for Air as well as Flue shall be designed to achieve
minimum bends, minimum change of cross section. If change in cross
section is unavoidable, it must be very gradual. No dust accumulation
should occur where ash hoppers to be provided.
All ash hoppers including hopper below Dust collector, APH, Holders,
Drum, etc., shall be provided with steep angle (60 Deg.). All the ash
hoppers except for Furnace ash hoppers shall be provided with rotary air
lock valves. Ash hoppers having Rotary air lock valve shall have side
cleaning inspection Doors / Main holes etc.
Available galleries and ladders with gratings or open steel flooring for
affording access to the essential levels of the steam generator plant
complete with hand railing curb angles and supports shall be provided.
The marking in the pressure parts for measuring tramp expansion shall be
provided. All the details of tramp expansion details shall be provided.
211
All supporting steel work, hangers thrust brackets and castings for the
furnace would be provided for each steam generator.
All the necessary temporary lifting arrangements for drums, economiser
etc., shall be supplied. If any re- calibration required for the steam
generator instruments, the same shall be calibrated by the steam generator
Tenderer.
Tenderer will be responsible for obtaining all IBR certifications up to
provisional certificate for the steam generator and auxiliaries. Buyer will
pay the necessary statutory fees.
b.
Refractory
All refractory materials including standard and high grade refractory tiles
and bricks. Adequate quantity of high grade refractory cement, special
shaped refractory tiles, castables refractory bricks for furnace and high
temperature zones should be as per I.S:8. quality.
c.
Insulation
High grade insulation materials suitable for out door Steam generators
shall be supplied, ceramic blanket with mineral wool of multilayer with
aluminium cladding of 22 SWG, water proof lagging and protected from
rain water, wind and Dust etc. for the exposed portion of the steam and
mud drums, steam generator furnaces, integral pipe work from the feed
pumps to the steam generators, steam & exhaust piping, hot air & gas
dusting, condensates pipes, valves having high temperature fluids & hot
water / condensates feed water tank, de-aerated water tanks, and other
steam generator accessories to be provided.
Glass wool materials is used should confirm to I.S. 3690 - 1974 type 2
mineral wool shall confirm to I.S. 5696 - 1970. The thickness should be to
suit the diameter and temperature of pipes. The wire mesh should be of
galvanised wire and lugs/pins used should be galvanised.
212
The detailed tramp expansion of the steam generator pressure parts

corresponds to temperature from 30C to the maximum designs working
temperature shall be furnished. It has to be confirmed before safety valves
testing to the Owner.
d.
Staging, Galleries and Ladders

The complete steam generator & the auxiliaries structural steel supports
including the roof over the steam generator and side cladding from the
top to the drum operating floor, all foundation bolts, base plates & insert
plates for the structural shall be the responsibility of the Tenderer. The
entire civil works including preparation of finished floor, foundations and
all required structures, supports, ladders, etc. are in Tenderers scope.
The required structural columns, frame for the economiser, air pre-heater
ducting and piping equipment, stair cases to steam generator drum level,
soot blower locations, de-aerator & feed water tank, access openings shall
be provided with liberally sized stairs, handrails and walkways.
In addition, pipe supports, hangers, duct supports etc., shall be provided
for the complete systems covered in this specification.
The steam generator and its accessories will be provided with steel
supporting structure made from rolled steel sections, having adequate
strength for the loads imposed by the steam generator and associated
equipment. These will be including supporting columns, integral floor
structure, with gravity or open steel flooring stair cases / ladders, hand
railing, curb angles supports etc., for affording access to the essential
levels of the steam generator plant. All supporting steel work, hangers,
thrust brackets etc., shall be provided.
All gangways, passages, stair cases / ladders, working platforms and
railing shall be provided. A clear working platform of minimum 2000 mm
to be provided for the steam generator at all levels. All statutory
requirements regarding staging, platform/stair cases, safety devices etc.
should be observed.
213
An interconnecting platform from steam generator top working platform

to steam generator de-aerator water tank shall be provided. An approach
ladder from steam generator operating floor (+ 3500 EL or as confirmed
during detailing) to feed and de-aerator tank working platform shall be
provided. Interconnecting steel platform from boiler operating floor to
the control room operating floor in the power house to be provided with
handrails and steps.
The centre of the steam generator front steel supporting columns shall be
minimum 2500 mm away from the centre line of bagasse carrier.
The steam generator operating floor/working platform shall be minimum
10 meters wide from the steam generator front support columns in front of
the steam generators and the control room. An approach ladder shall be
provided from bagasse working platform to bagasse carrier working
platforms at both sides.
The steam generator control room shall be located to avoid obstruction
while furnace cleaning etc. The front wall of the control room shall be
minimum 10 meters away from the steam generator furnace doors.
Two staircases on either side of the steam drum to be provided with
suitable platform on the drum.
e.
Platforms and Walkways

Platforms, walkways, staircases and landings shall be provided for safe
operation and maintenance of the steam generator and auxiliary
equipment and in general conform to an acceptable and proven standard.
Arrangement of platforms, walkways and landings shall provide safe
access to all openings for inspection and cleaning purposes, permanent
and test measuring points, control devices, local instruments, vents and
drain valves, soot blowers, safety valves etc. Wherever possible platforms,
walkways and stair cases shall be supported from unheated structures of
steam generator or building and shall never be supported from pressure
parts or other moving parts of the steam generator or other plant.
Platforms & walkway panels and stair treads shall be made of structural
steel open bar gratings.
214
Minimum width of platforms and walkways shall be 1000 mm. Minimum

headroom above the top of platform or walkways should be 2200 mm.
Members supporting floor panel shall not deflect by more than 1/325 of
the span.
f.
Stairs and Ladders

All stairs shall have a minimum clear width of 750mm and the slope shall
not exceed 45 0C with the horizontal. Minimum width of tread of staircase
shall be 22 mm and the rise shall not exceed 200mm. Length of landing
should not be less than 900 mm or the clear width of stair, whichever is
greater. Maximum number of risers in a flight shall be restricted to 16.
Treads on open stairs should overlap not less than 15mm and shall have a
slip resistant nosing not less than 25mm wide. All roof tops will be
accessible by suitable staircase.
Fixed ladders shall be provided to platforms/roofs, which do not require
frequent access by the operating personnel. All roof tops will be accessible
by suitable staircase. Ladders should preferable of a sloping type with a
maximum inclination of 15 0C to the vertical. Clear width between strings
shall be 450 mm. Minimum thickness of strings shall be 10mm. Rungs
shall be MS rounds of 20mm diameter, spaced at 225 mm (min) and
275mm (max). Minimum clear space of 230mm shall be provided behind
each rung to allow foot room. Wherever the height of the stair exceeds 6.0
metres an intermediate platform shall be provided. Safety cages shall be
provided if the height of ladder exceeds 4.5 meters. The cages may start at
a high of 2.5 meters from the lower level. The diameter of the cage shall be
700mm (min) with 5 Nos. of 50 x 6 flats for vertical and 50 x 6 flat at a
spacing of 900mm (max) for rings.
g.
Grating For Platforms, Walkways And Stair Treads

Gratings shall be of structural steel with a minimum depth of 25mm and a
minimum width of 750mm and shall conform to BS;4952 Part I.
Minimum thickness of load bearing and spare bars shall be 3mm.
Thickness of other binding bars shall be minimum 6mm. Clear distance
between the load bearing bars shall not exceed 40 mm. for diamond
pattern and 30mm for rectangular pattern. The deflection of grating panel
shall not exceed span/200 or 10mm whichever is smaller.
215
h.
Handrails
Top rail, knee rail and vertical post shall be 32mm NB (medium) tube
conforming to IS:1239. The spacing of vertical post shall not exceed 2.5
meters. The height of handrail shall be 2.5 metre with rail at mid height.
At platform and landings toe guard of 100 x 5mm shall be provided.
i.
Joint Design
Generally all shop connections shall be welded and field connection
welded or bolted. All moment connections, if bolted shall be of High
strength friction grip bolts. Shear and other minor connections, if bolted
may be made with mild steel/high strength bearing bolts.
The sellers designs are acceptable for structures, platforms, galleries, etc.
provided this has to be approved by the Owners/Consultant.
j.
Checking of foundations
The Tenderer shall as a first field activity check the foundations for the
correctness of the same as per relevant drawings & and certify the same
for concreting and the same may be rechecked for its correctness after
concreting, such as levels, location of bolt holes, sleeves, pockets,
openings, fixture plates and other embedment in RCC works, etc. All the
structural fixtures required shall be supplied by the Tenderer.
k.
Steam generator Integral Piping

The steam generator integral piping consists of all the interconnecting
piping between the economiser inlet stop valve and the super-heater
outlet header. The number of size and the arrangement
of
these
integral piping shall be based on the permissible pressure drops in
these pipes and the distribution required in the respective headers of the
various sections of the steam generator. These piping shall be properly
supported and provided with the required tapping, stubs and thermo
wells for measurements.
216
l.
Sampling Facility
Sampling Facility with sample coolers as required shall be provided for
feed water, superheated steam, saturated steam and blow down water.
There shall be individual sample coolers for each of the above applications
with associated sampling lines, valves, cooling water lines etc. These shall
be provided complete with drain tray, drain piping up to nearby drain
trench.
m.
Ducting For Air and Flue Gas

Necessary Mild steel ducting of 5 mm thick. plate in case of air duct and 6
mm thick in case of flue gas duct with stiffeners shall be provided for
each steam generator comprising of cold air ductings extending between
the forced draft fan discharge and air inlet to air pre-heater, hot air
ducting from the air pre-heater outlet to the common duct and branches
there from to the furnace through the blowers. The flue ducting
connecting the steam generator with its accessories to the chimney. The
minimum design pressure for the ducts will be 200 mm WC.
Necessary regulating and isolating dampers at suitable points are to be
provided for the efficient operation and maintenance of the steam
generator. All the dampers shall have an effective area not less than that
specified for the ducts they control.
Suitable galleries and ladders with grating of open steel flooring for
affording access to the essential levels of the steam generator plant
complete with hand railing curb angles and supports shall be provided.
All supporting steel work hangers, thrust brackets and castings for the
furnace shall be provided for steam generator.
The air and flue gas ductings shall be straight, with necessary long radius
bends shall be provided. Sharp radius bends, diverging, converging in
ductings shall be avoided. All air and flue gas ductings shall be leak proof
to avoid pressure losses and atmospheric air entry etc.
The details of air and flue gas velocity, draft and temperature at various
points shall be provided.
217
All ducts shall be rectangular in cross section and will be of welded

construction, properly stiffened and reinforced. All the air ducts, shall be
fabricated from steel plates of minimum 5 mm thick, and all flue ducts
shall be of minimum 6 mm thick. The duct plate material shall conform
to IS 225/IS 2062 . The duct corners shall be stitch welded internally and
full welded on the outside.
The ducts, exceeding 600 mm width or depth, shall be suitably stiffened
and reinforced on the outside and designed to withstand the pressure
encountered, but however the minimum design pressure for the ducts
shall be 200 mm WC.
The internal struts wherever required for the ducts shall be of tubular
(ERW) construction. The ducting system shall be complete with all
required expansion joints, mating flanges, dampers, supports, access
doors, platforms insulations etc. The top of the ducts and /or the outer
cladding shall be cambered to facilitate drainage of water.
Ducts will be sized considering a maximum velocity of 14 m/ sec for hot
air and flue gases and 8 m/sec for cold air. The duct design consideration
shall include the operating internal pressure, medium temperature , dead
loads, ash loads, live loads, seismic loads, expansion joint reactions etc.
The ducting expansion joints are provided to take care of the duct
expansions and shall be of saw-tooth square corner type. The number of
expansion joints required shall depend on the ducting thermal movement
considerations. For the critical ducting sections, to be identified by the
Owner/ Consultant after the submission of the ducting layout drawing,
the Tenderer shall provide the calculations for the flexibility analysis and
the expansion bellows selection for approval.
Dampers, in the ducting system, shall be provided as called, for the
proper operation of the steam generator. All dampers shall be of the
louver or butterfly type with the necessary frames, shafts, blades,
bearings, linkages, seals, etc.
218
ID fan shall be located such a way to provide sufficient space to construct

ID fan shed to protect the drive motors, local panels etc., if any ID fan
drive motors shall be free from heat radiation from steam generator
chimney etc.
The steam generator will be top supported type or suspension type. The
steam generator shall be provided with a steel supporting structure from
rolled steel sections and designed with adequate strength for load
imposed by the steam generator. The steam generator shall be complete
with necessary tubes, manifolds, integral pipe works.
All ducting etc. must be located above 2500 mm level to clear off the man
and material movements.
All the steam gaskets as joints with a pressure of 7 kg/cm2 (g) and above,
shall be metallic grafted, high pressure steam gaskets suitable to twice the
working pressure and temperature. Spare gaskets for all joints in HP
steam line shall be supplied.
Adequate supports shall be provided for the roof tubes to avoid sagging
of tubes in the hot conditions due to the weight of the refractory materials
etc.
n.
Temporary Supports
The necessary temporary support of steam generator pressure parts such
as top (steam) drum, bottom (mud) drum, headers, steam generator tubes,
super-heater elements, economiser shall be supplied by steam generator
Tenderer only.
o.
Safety Valves
The safety valves shall be semi nozzle full lift, and open bonnet type and
the selection and sizing of the safety valves shall conform to the
provisions of the IBR. In IBR and addition to meeting these requirements,
the steam generator safety valves shall also meet the stipulations of ASME
with regard to the blow-down and over pressure requirements. The steam
generator safety valves and all other safety valves shall be with butt
welding end connection.
219
The valves shall be supplied with lifting level, test gag, cap and spring
cover and silencer for superheater safety valves and start-up vent.
The capacities of the safety valves provided downstream of pressure
reducing stations shall be the maximum flow permissible through the
control valves under 100% valve opening with the rated full upstream
pressure. S/V exhaust to be taken out from the roof of building with
silencer.
p.
Control Stations
All control stations shall be provided with a bypass with a motorised
regulating globe valve for DCS control and isolating valves on either side
of the control valve. The control valves shall be sized to have the
maximum flow at a maximum of 90% of the valve opening. The noise
levels at a distance of one meter from the control stations shall be less than
85 dB. All control stations shall be located in easily accessible areas with
adequate space around for maintenance.
Feed regulating station shall have two bypasses one with 100% MCR
capacity the another with 30% MCR capacity. The feed regulating valves
shall be capable of being operated in auto manual regimes from the
control room. It is preferred to have the operating valve as pneumatic,
standby as pneumatic and manual valve at 30% capacity.
q.
Cladding
Cladding for boiler roof will be meta-poly sheet.
220
2.2
STEAM TURBINE GENERATOR & AUXILIARIES
2.2.1
Scope of Work
The Tenderer will be responsible for providing an efficient, reliable and state of
art technology steam turbine, generator of triple extraction cum condensing type.
The Tenderers scope of work includes designing appropriate turbine / generator
sizing for maximizing power export from the cogeneration plant after meeting
the energy needs of the adjoining sugar mill. The detailed specifications given
below, attempt to define the Tenderers scope and specifications. However, the
onus of providing the appropriate steam turbine generator and auxiliaries rests
with the Tenderer.
The scope of work for the Steam Turbine, Generator & Auxiliaries covered under
the specification will include but not limited to the following.
a)
Supply
Engineering, Design, fabrication, manufacture, assembly, shop testing and
inspection at manufacturer's works.
Providing all labourers, materials and equipment for testing at shop as
required.
All spare parts required for the commissioning of the Steam Turbine,
Generator and auxiliary systems.
Recommended spare parts of the Steam Turbine Generator unit and
auxiliaries.
Special tools and tackles required for operation and maintenance,
inspection, and repair of the equipment / systems offered.
221
b)
Erection and Commissioning

Unloading, handling and storage at site, pre-fabrication/assembly if any,
erection, testing, commissioning, trial operation, final painting and
guarantee performance testing of one (1) No. Steam Turbine & Generator of
rating as specified in this tender document with all necessary accessories
and auxiliaries as well as associated electrical and instrumentation and
control equipment, as specified.
2.2.2
Scope of supply and services of basic equipment

Scope of supply and services for One number Turbo-generator with auxiliaries
are indicated below. Components and services not specifically mentioned here
but necessary to complete the stipulated work in all respects, regardless of any
omission in this specifications or drawings, is deemed to have been included in
this tender.
Scope of supply
a) Mechanical
One (1) No. Turbine and auxiliaries comprising of,
i. Triple extraction cum condensing, multistage, impulse & reaction
type or impulse type steam turbine, complete with casing, rotor,
blades, bearings and glands.
ii. Provisions for three extractions at 25, 8 and 2.5 kg/cm2. The 2.5
kg/cm2 extraction needs to be internally controlled. The 25 and 8
kg/cm2 bleeds will be externally controlled to maximise power
generation
iii. Heavy duty reduction gear box (double helical type) capable of
continuously transmitting the maximum power generated by the
turbine.
222
iv. High speed coupling between the turbine and the gear box, and
low speed coupling between the gear box and the alternator with
coupling guards.
v. Emergency trip cum stop valve with steam strainer throttle valve,
governing valves, etc.
vi. Microprocessor based Electro-Hydraulic or Electronic governing
system including speed changer, capable of operating in parallel
with the grid and also independently in case of islanding.
Woodward 505E digital governor with required actuator &
accessories. Governing console to be provided. Digital AVR of
approved make with auto power factor adjustment capability to
maximise power exports. One standby AVR of similar make also
required.
vii. Vibration monitoring system.
viii. Air cooled condensate system complete with required vacuum
breaker, rupture disc, tube bundles, fans with VFD, drains, vents,
structures, air ejectors, condensate collection tank, CEP, condensate
controlled station, etc.
ix. Interconnection between the turbine and the inlet of air cooled
condenser.
x. Gland sealing steam system consisting of gland steam condenser,
valves, steam jet ejectors etc. GSC to have CS tube sheet, SS /
admiralty brass tubes with shell, water box, foundation bolts, sole
plates, primer coating, 2 x 100% SJAE, water relief valve, stand
pipes, isolation and drain valves. All gland sealing steam to be
recovered & returned to hot well.
xi. Lube and control oil system common for turbine, gear box and
alternator.
xii. One oil reservoir complete with filters and oil vapour extractors.
223
xiii. Two 100% oil coolers with necessary three way switching valves.
Coolers to have tubes of SS / brass, removable tube bundle, CS
shell, water box & tube sheet, bolted end covers, sole plates,
coating, valves for change over & isolation, mating flanges.
xiv. Two 100% oil filters for the lube and control oil. Oil mist fan (1 no.)
xv. One main oil pump driven by the turbine shaft or A.C. motor , one
auxiliary oil pump driven by A.C. motor and one emergency oil
pump driven by D.C. motor. Jacking oil pump with AC motor.
xvi. One centrifugal type oil purifier.
xvii. Bolt heating equipment, shaft grounding device.
xviii. Automatic exhaust hood spray system.
xix. Overhead emergency oil tank (SS lining) of adequate capacity duly
interconnected to lube oil system, with SS piping.
xx. A.C. motor driven barring gear system with manual engagement
and automatic disengagement.
xxi. Main hydraulic stop & emergency valve suitable for manual
opening & emergency shut down, with internal strainer. Main
isolation valve, flow meters in throttle & extraction lines, temp. &
pressure transmitter, safety vales, QCNRV, control valve in
uncontrolled & controlled extraction.
xxii. 3 x 50% capacity motor driven vertical condensate extraction
pumps.
xxiii. Base frame for turbine, gear box, and alternator with necessary
foundation bolts or sole plates.
xxiv. Trip system for safe operation of turbine during abnormal steam,
vacuum or oil conditions.
224
xxv. Electric drive barring gear, to drive the turbine in-case of shutdown or start-up to prevent thermal distortion.
xxvi. Safety devices for speed, lube, displacement & steam parameters.
xxvii. Set of removable hot insulation
xxviii. Complete piping with valves, fittings & insulation as required
along with pipe supports associated with turbine, HP heater, lube,
drains & control oil system. Set of QCNRV (Quick close non return
valve), control valve, isolation valve and flow relief valves for the
three extractions. Set of diaphragm type regulating valve and
pressure transmitter for external control of bleed. Set of matching
flanges for all interconnections.
xxix. Adequate system of drainage from all steam spaces with in the
unit.
xxx. Flash tank for connecting all high pressure drains.
xxxi. Special lifting tackles and special tools required for the normal
maintenance work.
xxxii. Acoustic hood.
xxxiii. EOT crane of adequate capacity to lift the heaviest component
during maintenance, along with all electrical, rails, girders, etc
suitable for erection.
xxxiv. PRDSH for auxiliary steam needs from HP line and steam piping
thereon up to the auxiliaries.
225
b) Electrical
One (1) no. Three Phase Synchronous Generator
i. The complete excitation system consisting of the brush less
exciter with PMG and thyrister driven type AVR mounted on
the generator shaft and the excitation panel housing the
automatic voltage, VAR / power factor controller etc. Including
field breakers and field dischargers. In either case, voltage
regulation of + 1 % and adjustment of +10% to 12.5% is
needed. AVR to be digital type with auto and manual channel,
along with PF controller. One EOT crane of required capacity
along with electrical, rails, girders, etc ready for erection
(capable of meeting all erection loads). One additional standby
AVR to be added.
ii. Stator with output leads taken from sides, rotor suitable for
overhang, bearings, base frame, built-in RTDs.
iii. Local panel gauge to give all important inlet and outlet steam
parameters, major electrical parameters and oil / cooling water
temperatures.
iv. Auto & manual synchronizing system, with panel.
v. The closed air circuit water (CACW) cooling system for the
generator with ducting and coolers.
vi. Space heaters, CTs, PTs, LA and SP equipment.
vii. Generator protection panel.
viii. Metering and control panel.
ix. Neutral grounding resistor cubicle with connection from
neutral.
x. Lighting arrestor and surge protection.
xi. Relays as required and as described in the specification.
226
xii. Current and potential transformers for protection and metering

and voltage regulation.
xiii. Lightning arrestor for STG building up to earth mat.
xiv. Starter for EOP motor along with DCDB.
xv. Complete CO2 based fire-fighting system, if applicable.
xvi. Generator air coolers to be side / bottom mounted, tube sheets,
frame, water box, sole plate, anchor bolts, primer coating and
valves.
xvii. Special tools for the Generator and accessories and sling for
lifting.
xviii. All AC and DC motors required for the successful operation of
the plant. The motors shall be suitable for the equipment/area
specified and supplied as a complete unit with its driven
equipment. The terminal box of motor shall be complete with
cable gland and lugs.
xix. All pipe / equipment mounted local gauges as required.
xx. All pressure test points complete with root isolating valves
(bonnet less) and temperature test points complete with thermo
wells and screwed plugs and chain for performance
measurements.
xxi. Local gauge board at Turbine floor or in control room, complete
with gauges and accessories.
xxii. Local instrument panel or turbine control panel
xxiii. Safety devices and shut down systems.
xxiv. Complete I&C system to connect to DCS.
227
xxv. One set of special tools and tackles required for operation
maintenance, inspection and repair neatly packed in steel boxes
complete with instructions for the Turbine, Generator and all
other Equipment covered in this scope of work.
2.2.3
Correction Curves
The results of the performance test shall be corrected to the specific conditions by
correction factors, which shall be defined by means of correction curves. All
correction curves shall be submitted by the Tenderer.
A certified copy of the correction curves, giving the corrections to the steam
turbine generator unit performance for variations in the inlet steam conditions,
power factor, ambient conditions etc. as will be applicable to the plant shall be
submitted.
2.2.4
General Specifications
This specification is intended to cover the design, manufacture, delivery,
erection, testing and commissioning of one (1) Number turbo generator unit with
gear box, air cooled condenser and all other auxiliaries, with a nominal power
output of 20 MW (or best at given steam flow parameters) at the generator
terminals at the site conditions with 40C ambient and at 0.8 PF, 11 KV and 50
Hz. The unit will be operated in parallel with the local Electricity Board Grid
with the frequency variation of +/- 5% and voltage variation of +10% to 10%.
The steam turbine shall be a triple extraction cum condensing type with
extractions at 25, 8 and 2.5 kg/cm2
The supplies and services within the scope shall be rendered inclusive of all
appliances and interconnecting arrangements with other supplies, necessary for
installation of all accessories and for satisfactory maintenance and repair.
The scope of supply and services shall include all necessary work and supply of
equipment and material whether mentioned in these specifications or not, but
which are necessary for the satisfactory, reliable and safe operation and
maintenance and required for achieving guaranteed performance of the plant.
228
Any equipment, device or material even if not included in the original bid but
found necessary for the safe and satisfactory functioning of the unit under the
bid, shall be supplied, erected and commissioned by the Tenderer at no extra cost
to the Owner, as though, such equipment, material or work were originally
specified and formed part of the scope of work.
Scope of relays, metering & protection will necessarily meet BSEB standard
requirements.
2.2.5
Design Basis
The Turbo - Generator and the Auxiliary Equipment covered under this
specification shall be designed to achieve maximum power generation as per
normal steam flow rates from the double extraction cum condensing set.
Part of the generated power will be fed to the sugar complex plant and the rest
will be exported to the grid, after stepping up the voltage to EHV and
transporting the power through transmission lines to the nearby sub-station of
the BSEB. The extractions from the turbine provides the sources for the medium
and low pressure steam for the use in the sugar mill & power plant auxiliaries &
de-aerator.
The steam will be available at the turbine isolation valve at 105 + 2 kg/cm2 and
535 + 5C. All equipments shall be designed to operate continuously for 8000 hrs
per annum.
The turbo alternator shall be designed taking into consideration all possible
electrical parameters affecting the choice of the machine, assuring stable and
reliable operation in a rural network. The selection, if necessary, shall be based
on the complete study of the electrical system, including transient stability study,
short circuit study, load flow and reactive power short fall study etc. For this
tender the Tenderer shall offer his standard micro-processor based controls and
instrumentation system with panels etc, for the start up, shut down and
operation with all standard features.
229
2.2.6
Performance Parameters
2.2.6.1 Steam flow at the Turbine
normal : 100,000 kg/hr

Up to 110,000 kg/hr (max)
Min:15,000 kg/hr
2.2.6.2 Steam pressure at the

turbine stop valve
105 2 kg/cm2
2.2.6.3 Steam temperature at the

turbine stop valve.
5355 0C
2.2.6.4 Exhaust pressure with air cooled :

condenser
Performance guarantee
0.1 ata
2.2.6.5 Extraction steam requirements

Season
7,000 kg/hr
Off-season
5,300 kg/hr
Bleed at 8 kg/cm2
for HP heater no.1
and process
up to
35,000 kg/hr,
Normal 27500
kg/hr,
min: Nil
up to
20,000 kg/hr,
Normal 16000
kg/hr,
min: Nil
Controlled extraction
at 2.5 kg/cm2 for deaerator
and process
up to
45000kg/hr,
Normal 36000
kg/hr,
Min: 5000 kg/hr
up to
10,000kg/hr,
Normal 5600
kg/hr,
Min :Nil
Flow through
condenser
Min : cooling
steam Flow
As required to
generate, alternator
capacity
kg/cm2
Bleed at 25
for HP heater no.2
Normal :
as required to
generate 20 MW
230
Note :1) The steam flow figures given above are typical of the proposed
cogeneration plant and have included normal operation of
various power cycle components like de-aerator, auxiliary cooling
tower etc. Also, these values correspond to the normal crushing
rates of cane. It is hence, to be understood by the Tenderer that
the operating values of steam flow may differ from those given as
normal above but will generally be within the specified ranges.
However, in event of malfunctioning or outages of any of the
power cycle equipment or decrease in cane crushing rates, the
extraction and condensing steam flows will change. The Tenderer
should optimise the turbine design to maximise power generation
anticipating the possible fluctuations in extraction and
condensing steam flows. Tenderer to give power generation at
alternator terminals for all above conditions, with normal being
guarantees points.
Condensing pressure as achieved by Tenderers design, with
given cooling water temperature. For evaluation purpose, the
same to be 0.1 ata
Tenderer to submit power generation at normal flows during
season and off-season.
Turbine to be designed for continuous operation at 105 kg/cm2
and 5350C
2.2.6.6
The economical steam rate

required at percentage load
80 to 100
2.2.6.7
Nominal Generator Output
20 MW
2.2.6.8
Power factor (lagging)
0.8
2.2.6.9
Generation Voltage
11 KV
2.2.6.10 Ambient temperature for

Electrical equipment design
50 Deg. C
231
2.2.6.11 Parallel operation with grid
Required
Duty requirements
Continuous 8000 hrs per
The minimum continuous loads :

at which the TG is expected
to operate as percentage of
rated load
2.2.7
30% (However, STG to be

capable of running of
operating on only
auxiliary load of 1.5 MW
during any grid tripping
in off-season)
2.2.6.12 Atmospheric conditions
Dusty (as prevalent in the

existing sugar mill)
2.2.6.13 The maximum noise pressure

level at 3.0 m distance for
any equipment from the
equipment surface shall be
equal to or less than
85 db (A)
Utilities
2.2.7.1
Instrument Air
Pressure, kg/cm2 g
Temperature, Deg. C
2.2.7.2
4.5
40
32.0
2.0 (maximum)
Low pressure Auxiliary steam

Pressure
2.2.7.4
6.5
85
Cooling Water
Water temperature Dec. C
Water pressure, kg/cm2 g
2.2.7.3
5.5
45
kg/cm2g
2 2.5
Medium pressure steam

Pressure
kg/cm2g
232
2.2.7.5
A C Power
Voltage
Frequency
2.2.8
2.2.9
V
Hz
415 (Three Phase)

50
2.2.7.6
DC Power Voltage V
230
2.2.7.7
UPS Power:
230 V
Conditions of Service
a)
The steam turbine will be installed in a power house.
b)
The turbine control shall be located in the adjacent control room ,whereas
important indicating instruments shall be provided near the turbine in the
local gauge board & local panel in addition to the control room instruments.
Emergency stop arrangements shall be provided in the local panel.
Design and Engineering

The turbine shall be preferably single cylinder, single exhaust, double extraction,
condensing type. All castings and stator blade carries shall be horizontally split
and the design shall be such as to permit examination of the blading with-out
disturbing shaft alignment or causing damage to the blades.
The design of the casing and the supports shall be such as to permit free thermal
expansion in all directions. The Tenderer shall describe and illustrate by means
of diagrams the method used to support the casing and to accommodate the
expansion.
Solidly forged and machined rotor with integral disks is preferred. The rotor
after fully machined and bladed be given a over speed test. None of the critical
speeds of the rotor shall fall within the range of 20 % above and 20 % below the
normal running speed of the rotor. The turbo generator Tenderer, with the unit
responsibility, shall analyse the complete couple train for both lateral and torsion
vibrations, and ensure proper separation margins. The rotor shall be designed to
withstand the maximum shock loading that may occur during any power system
disturbance.
233
Such shock loading values shall be taken for the design of the gear box and the
generator rotor. The Tenderer shall clearly describe in his offer, the construction
of the rotor, the heat treatment proposed and the procedure for inspecting the
shaft to ensure soundness and homogeneity of the material. The material of
construction shall be consistent with proven practices and standards.
The blades shall be designed to withstand all vibrations, thermal shocks, and
other loading that may be experienced during service and system disturbances.
The blades shall be machined from forge bars or die forged and the materials
used shall be chromium steels consistent with proven experience and standards.
Any blade coating used to improve performance or resistance to erosion shall be
described.
The Tenderer shall clearly indicate the type of fastening of the blades on to the
wheels and also give the specific advantages of the particular fastening method.
The rotating blades are either shrouded or tied with lacing wires depending on
the stresses and the excitation frequencies, and the offer shall indicate the
arrangement. The details of the seal strips used to control the steam leakages
shall also be indicated.
The glands shall preferably of labyrinth type and sealed with steam. The
complete piping, valves, pressure gauges, regulators etc., required for the end
seals shall be provided by the Tenderer. A vacuum system if required by the
design shall be provided. All piping and components of shaft seal and vacuum
system, if provided, shall be sized for 300 percent of the calculated new clearance
leakages. Steam leaving the glands shall be condensed in seal steam condenser
and recovered in the hot well. It shall be possible to inspect and replace the end
seals without opening the casing and without damaging the thermal insulation.
The Turbine shall be provided with liberally rated hydrodynamic radial and
thrust bearings. The radial bearings shall be split for ease of assembly, and of the
sleeve of pad type, with steel shell backed, babbitted replaceable pads. These
bearings shall be equipped with anti-rotation pins and shall be positively secured
in the axial direction. The thrust bearings shall be of the steel backed babbitted
multiple segment designed type, designed for equal thrust capacity in both
directions.
A liberal flow of lube oil under pressure shall be supplied to all the bearings for
lubrication and cooling.
234
It is required that :
a) All integral piping for steam, water air, lube oil etc to be supplied in
pre-fabricated condition to the site to avoid delay in E&C.
b) Supply of cooling water to STG auxiliaries like SJAE, GSC, etc. to be
from CEP.
c) Condensate from cogeneration auxiliaries like SJAE, GSC, etc. to be
returned by Tenderer to the de-aerator.
2.2.9.1 Lubrication and control oil system
a) A pressure lubrication and control oil system shall be furnished for the
turbo generator unit to supply oil at the required pressure to the steam
turbine, gear box, generator and governing system. Oil in the reservoir
shall be maintained at appropriate temp when TG set is idle by
providing suitable electric heaters and temperature controls.
For the hottest ambient conditions to be encountered at the site oil
outlet temperature at any bearing shall neither exceed the maximum
permissible temperature for the bearing metal nor the maximum safe
operational temperature of the oil.
b) The oil system shall include the following:
i.
ii.
iii.
iv.
Main oil pump preferably driven by the turbine shaft /motor

driven.
A 100% capacity A.C. motor driven auxiliary oil pump arranged
to cut in automatically if the oil pressure falls to a preset value.
This pump shall also meet the requirements during the start up
and shutdown.
A D.C. motor driven emergency oil pump of sufficient capacity to
provide adequate lubrication in the event of a failure of the unit
A.C. motor driven pump. This pump also shall cut in
automatically at a pre set value of the oil Pressure.
Two 100% capacity (one working and one standby) water cooled
oil coolers.
235
v.
vi.
vii.
viii.
ix.
x.
Two 100 % duty oil filters arranged in such a way that it is

possible to clean one oil filter while the other is in continuous
flow transfer valves.
An accumulator to maintain sufficient oil pressure, during
transients conditions and while standby pump acceleration from
idling to full speed.
Oil storage and settling tank (can be part of main oil tank) with
adequate reservoir capacity, duplicate strainers, level indicators
with float switches and alarm contacts, vent and oil mist
eliminators.
Overhead oil tank for gravity flow to the system in case of
emergency.
Flow and temperature indication for oil from every bearing.
Centrifugal oil purifier.
Supply of the flushing oil and the first fill up of lube oil for turbine
and accessories shall be the responsibility of the Tenderer and
preferably from the Indian market.
c) Oil coolers
The oil coolers shall be water cooled with a duplicate arrangement and
changeover valves. The coolers shall be of shell and tube type with
removable tube bundle. The coolers shall be constructed in accordance
with TEMA class C. The provided surface area shall be adequate to
cool the oil with 32 Deg. C inlet cooling water temperature even with
20 % of the tubes plugged.
The sizing of the coolers shall consider a tube side (water side) fouling
factor of 0.0002. The water velocity shall be not less than 1.5 M/sec.
The material of the cooler will be ERW SS or admiralty brass and shall
conform to the requirements of ASME or API or HEI. The coolers shall
be amenable for easy inspection & maintenance and cleaning of one
cooler while the other one is in service shall be possible. The Tenderer
shall indicate any emergency cooling water requirements in his offer.
236
d) Filters
Full flow oil filters shall be used downstream of the coolers and shall
be piped in a parallel arrangement with a continuous flow transfer
valve. Filtration shall be 10 microns nominal. Filter cartridges shall
have a minimum collapsing differential pressure of 3.5 ata The
minimum design pressure for the filters shall be the maximum
discharge pressure of the oil pumps.
e) Oil reservoir
The interior of oil reservoirs shall be desalted and rust proofed with a
permanent coating. Reservoirs with top mounted equipment shall
have sufficient rigidity. All openings for piping shall be made dust and
water proof.
The oil reservoir shall be so located to permit draining of the contents
by gravity and shall be equipped with fine coarse mesh strainers.
f) All necessary piping, valves and fittings for the complete oil system
shall be provided by the Tenderer. The lube and control oil piping
from the outlet of the filters and up to the user point shall be of
stainless steel.
The piping from the reservoir to the filters and the return oil piping
shall be of carbon steel. The complete piping shall meet the
requirements of ASME / API. All piping from overhead tank will be
SS.
All governor oil piping to be of SS.
g) Oil purifier
A centrifugal type oil purifier shall be provided for the removal of
water, sediments and other oxidation products. The purifier shall be a
separate complete package. The capacity of the purifier shall be at least
one (1) percent of the rate of normal flow through the reservoir. Feed
to the purifier shall be from the drain end of the reservoir and it's
operation shall be independent of the oil systems.
237
h) Steam Turbine Governing System

The turbine governing system shall be electro-hydraulic designed for
high accuracy, speed and sensitivity of response. The electrical /
electronic and hydraulic component of the control system shall be
selected on the basis of reliability over a wide range of operating
conditions.
All components used shall be well proven to assure overall system
reliability and shall be designed for easy and quick replacement when
necessary. The governor shall ensure controlled acceleration of the
turbo generator and shall prevent over speed without tripping the
unit under any operating condition or in the event of maximum
rejection.
The governor (Woodward 505E) shall have linear droop characteristics
with a suitable range for stable operation and shall have provision for
adjusting the droop in fine steps.
The governing system shall have the following important functions:
Speed control
Over speed control
Load control
Extraction steam pressure control
2.2.9.2 External Forces and Moments
The Tenderer shall furnish the allowable forces and moments on the
turbine nozzles. The Tenderer shall furnish the stress analysis of the
piping to meet the same.
2.2.9.3 Thermal Insulation and Lagging :
The steam turbine and the other high temperature parts, including piping
supplied, shall be insulated with low conductivity insert material, where
required, reinforced by stainless steel wire net between applied layers.
238
The insulation shall be so arranged that it can be removed for access to the
flange bolting, control valves and other parts that require periodic
maintenance. MAT / blanket type removable insulation for the turbine is
required.
2.2.10 Performance Requirement
2.2.10.1 Controlled extractions
The bid document calls for three extractions at 25, 8 kg/cm2 and 2.5
kg/cm2. The low pressure extraction is to be internally controlled.
Tenderer to provide externally controlled system for the 25 and 8 kg/cm2
bleed. Tenderer will need to supply all control valves, as required after
the uncontrolled extraction. The system to be complete with the necessary
control valves, relief valves and non return valves included in the
Tenderer's scope.
2.2.10.2 Economic Load
The specific steam consumption shall be the lowest for operating loads
between 80 to 100%.
2.2.10.3 Over Loading
The Generator shall be suitable for an over load of 10% for 1 hour in every
12 hour and 50 % over load for 30 Seconds as per IEC.
2.2.10.4 No load and Minimum load operation
The turbine shall be capable of operating under no load condition during
loss of load for a maximum period of 15 minutes.
The minimum load at which the turbine is required to operate
continuously shall be 30% of the designed capacity.
239
2.2.10.5 Specific steam consumption

This guaranteed specific steam consumption / heat rate shall be for a load
range of 80 to 100 percent of rated capacity and the testing shall be as per
ASME PTC 6-S.
2.2.10.6 Governing Characteristics
When the machine is operating with rated steam conditions and at rated
speed, and the maximum load is thrown of, the operation of the electronic
speed governor shall prevent the speed rising to a value at which the over
speed trip is set to operate.
The speed governor droop i.e. permanent speed variation from no load to
rated output etc., shall be within the limits specified in IEC
Recommendations Publication 45
2.2.10.7 Parallel operation
The characteristics of the turbine shall be such that the turbine generator
set can be run in parallel with the State power grid and / or with a
machine to be added later on and possess no abnormal features either
individually or collectively.
2.2.10.8 Speed adjustment
The turbine speed at no load shall be adjustable between 5% below and
5% above rated speed. Means are to be provided whereby the speed of the
turbine at no load can be raised in a controlled manner for the purpose of
testing the over speed trip mechanism and provision made to ensure that
such means do not interfere with the action of the speed governor in
normal.
The device to raise speed at no load must incorporate limiting means to
Prevent it from reaching a dangerous speed.
During emergency condition, the turbine may be operated at speeds as
low as 98% of the rated speed.
240
2.2.10.9 Over speed trip

In addition to the speed governor, the turbine and generator shall be
protected against excessive over speed by a separately actuated over
speed device which operates the trip system.
In the event of sudden load rejection, should the speed governor fail to
meet the requirements the over speed trip shall operate to prevent any
damage.
The over speed trip setting shall be stated by the Tenderer in his offer and
in the operating instructions.
2.2.10.10 Trip system
The turbine shall be provided with a system for the complete and rapid
closure of steam valves effectively preventing all steam admission to the
turbine independently of the closure of the governing valves.
In order to avoid sudden re-admission of steam to the turbine the trip
system shall be fitted with interlocking devices so that trip resetting
cannot take place until steam admission can be achieved as per normal
operating procedure.
Essential trip circuits to be provided are:
a)
b)
c)
d)
Steam inlet pressure falling below / above pre-determined level.

Steam temperature falling below / above pre-determined level.
Condenser vacuum falling below / above pre-determined level.
Lubricating oil pressure falling below / above pre-determined level.
2.2.10.11 Maximum speed

An over speed test of the turbine rotor shall be carried out preferably at
the Tenderer's works. The over speed tests shall be at a speed exceeding
by 2% of the maximum calculated over speed that would occur if the
governor failed and if the maximum over speed was limited by the action
of the over speed trip device only. The duration of the over speed test
shall be less than 2 minutes. The over speed shall not be more than 20% of
the rated speed.
241
2.2.10.12 Vibration
Vibration measuring and monitoring systems shall be provided for the
bearings and the shaft.
This system shall include the generator bearings also. The maximum
allowable vibration under specified operating conditions shall be
indicated by the Tenderer.
Minimum two nos. vibration probes to be provided at each bearing of
turbine, generator and gearbox.
2.2.10.13 Critical speed
The critical speed for the combined turbine and generator shall be
sufficiently away from the rated speed to avoid any adverse effect of the
operation of the unit over the range of operating speeds.
2.2.10.14 Materials of construction
The selection of materials for parts of the machine shall be based on the
experience of the Tenderer and experimentally determined data and shall
conform that under conditions of stress temperature and time the
components will not fracture or deform to a greater extent than is
permissible. The materials selected shall be clearly indicated in the turbine
and auxiliary data sheets.
2.2.10.15 Variation of steam pressure and turbine
The turbine shall be capable of accepting variations from the rated
conditions within the limits specified by IEC Recommendation
Publication. 45.
242
2.2.11 Safety
a) All controls shall operate in a fail safe mode.
b) All coupling and gears shall be provided with adequate guards.
c) Piping shall be arranged in such a manner as to avoid tripping or overhead
problems.
d) Piping or tubing of insufficient mechanical strength which is standing or
hanging shall be protected from personnel traffic.
e) Surface temperature on any point shall not exceed 60 Deg.C.
f) Very high standard of safety shall be built into the set with high degree of
redundancy.
2.2.12 Condenser
a)
The condenser shall be of non-contact surface type condenser designed as

per the requirements of Heat Exchange Institute Standards for Steam
Surface Condensers.
The condenser shall sized to condense the maximum quantity of exhaust
steam (i.e. when there is no extraction to process and the only extractions
are for HP heater and deaerater) with the inlet cooling water temperature
at 32 Deg. C and outlet temperature of 40 deg. C. to generate power of
100% alternator rating. The temp. rise on CW side will be 8 0 C
The cooling water for the condenser will be supplied from the cooling
tower basin through cooling water pumps and the water will be treated.
The water velocity through the tubes shall not be less than One (1) meter
per second and the cleanliness factor on the tube side shall be 0.85.
The pressure drop on CW side not to exceed 6 mwc.
243
b)
The condenser design and supply shall be complete with the neck,
expansion joint, condensing chamber and tubes, tube sheets, epoxy coated
hot well, water boxes, air removal system and accessories, atmospheric
relief valve, bellows, surge & stand pipes, water expansion relief valves,
vent & drain valves, sacrificial anodes & baffles.
The condenser neck shall be suitably designed to reduce the inlet steam
velocity to ensure low pressure drop and to protect the tubes from
impingement of steam.
The condenser shall be adequately designed for the external pressure and
stiffeners and bracings wherever required shall be provided.
The tubes shall be provided with supports to eliminate any serious tube
vibration problems and sagging. The tubes shall be expanded into the
tube sheets at both the ends and flared at the cooling water inlet side.
The condenser neck shall be connected to the turbine exhaust hood with a
properly designed stainless steel expansion bellow, as applicable, which
allows free expansion of the condenser unit without exerting undue thrust
on the turbine exhaust hood and facilitate independent supporting of the
condenser on the foundations without resorting to springs.
The hot well at the condenser bottom shall have a minimum capacity of 2
minutes storage while handling maximum quantity of exhaust steam.
The hot well shall be provided with level gauges and connections for
condensate extraction and drain. A suitably designed level control system
shall be provided. No make up will be added in the condenser hot well.
Condensate of STG auxiliaries will be returned by Tenderer to the hot
well.
c)
The condenser shall be of divided water box design and the water boxes
shall provide easy accessibility to the tubes. It shall be possible to clean
one section of the tubes with the condenser load suitably reduced.
The circulating water inlet and outlet connections shall be of adequate size
to reduce the waterside pressure drop to the minimum.
244
The water boxes shall be coated with epoxy resin, internally to prevent
corrosion from the cooling water and shall be provided with sacrificial
anodes.
The condenser water boxes and the tubes shall be designed for a pressure
corresponding to the full shut-off head of the cooling water pumps which
will be about 4 ata.
d)
The condenser shall be provided with an atmospheric relief valve sized as

per the recommendations of HEI standards with water seal around the
valve disc to ensure proper sealing.
e)
The material selection for the various components of the condenser shall
be as per the Tenderer's standard and adequate to meet the duty
requirements. Condenser tubes to be of admiralty brass or SS 304 welded.
Tube sheet & shell to be of IS 2062.
The Tenderer's offer shall furnish the complete data on the condenser
including the material of construction for the various components. The
foundation bolts for the condenser shall be included in the scope of
supply.
f)
Condenser Air Removal Equipment

One steam operated hogging ejector (1 x 100%) of single stage shall be
furnished for the initial pulling of the vacuum in the system. The capacity
shall be so as to reach 60% vacuum in 20 minutes time.
Ejector shall be without any condenser, discharging to the atmosphere
through a suitably designed silencer (1 x 100%)
Two steam operated main ejector of two stage single element type with
inter and after condensers shall be provided.
Cooling medium in the inter and after condensers (2 x 100%) in the ejector
system shall be condensate from CEP discharge. Condensate after CEP
control station will be taken to deaerator. Condensate piping from hot
well to ejector & other auxiliaries in Tenderers scope. Condensate from
auxiliaries to be returned to hot well by Tenderer.
245
Both the ejector systems shall be complete with piping, valves, rupture
disk etc. Valves to include isolation for steam supply individual ejector
elements, expansion relief, vent & drain, etc.
The tenderer shall provide the complete details of the ejector systems with
material of construction and the steam consumption.
2.2.13 Condensate Extraction Pumps
Three numbers 50% capacity vertical condensate extraction pumps to pump the
condensate from the condenser hot well shall be provided.
Both the pumps shall be driven by electric motors and the flow shall be
controlled by discharge throttling and auto cut-in / cut-out of the pumps.
The pumps shall be of centrifugal, vertical, multistage type and shall be supplied
compete with all valves, inlet and discharge piping with manifolds.
The pump shall be designed to have a minimum discharge head considering
friction losses, deaerator head, pressure drop across deaerator nozzles and
control valves. However, the required head will be finalised during the technical
kick-off meeting with select Tenderer, based on design of boilers deaerator.
2.2.14 Barring Gear

The turbine, shall be provided with a barring gear of mechanical type driven by
an A.C. motor, to rotate the turbine and generator after shutdown to prevent
thermal distortion of the rotor.
The barring gear shall be capable of starting the rotor from rest and run it
continuously at low speeds.
The barring gear shall be interlocked with the lubrication system to prevent it's
operation without lubrication.
If provided, the system shall be capable of manual engagement and automatic
disengagement when the turbine speed goes above the normal barring gear
speed.
246
The system shall also have facility for manual turning in case of A.C. supply
failure. The turbine panel shall be provided with necessary push bottoms,
alarms and switches for the operation of the barring gear.
2.2.15 Base Frame

Suitable base frame or sole plates either common or individual shall be provided
for the turbine, generator and the gear box. Provisions shall be made to level
each piece of equipment separately and as a package.
2.2.16 Control System for Steam Turbine

In case of any failure of the DCS system, there should be a DCS bypass to start
the essential equipments of the STG & auxiliaries in manual mode. All
intelligent devices should be monitored and controlled through the DCS. All
intelligent devices should be realized in the DCS.
This specification outlines only the broad requirement of the controls for the
turbine. It is the responsibility of the turbine Tenderer to provide all the controls,
instrumentation and gauges required for the safe and efficient operation of the
turbine system.
The inputs and outputs are to be protected against polarity reversal. All inputs
to be potential free contacts. Outputs to be short circuit proof and provided with
fuses.
The basic requirements are as follows.
The complete steam turbine generator & auxiliaries package will be

normally operated only through the DCS in the control room. It is not
envisaged to have any operator or workman in the field. Normal start-up
operation should also be accomplished through the DCS. Hence, start /
stop of all drives, speed regulation where required, operation of actuators
/ dampers / solenoid valves, operation of all motorised valves, operation
of all sub-systems should be interconnected through the DCS with
appropriate & required I/Os.
247
The starting and stopping provision for steam turbine shall be provided at
the remote control panel in the control room.
All instruments and controls shall be supplied by the Tenderer and tested
along with the turbine / generator.
All sequential start-stop, shutdown / interlocking and other auxiliary

equipment shall be located within the remote control panel and shall be
through DCS.
The turbine shall be supplied with a self-checking solid state fully

automatic sequential start system designed to provide reliable
programmed starting, acceleration, synchronization and loading to
selected loads, operatable through the DCS.
The control system shall provide redundancy for key functions by use of
separate sensors, monitors, control valves, converters, etc.
The control system shall include all the standard control monitoring and
alarming.
Control panels shall be supplied fully wired and complete with all a
necessary special wiring for interconnection of panels.
Vibration detector/proximity meters/axial position detectors monitors

shall be provided for all bearings including the bearings of the turbine,
gearbox and the generator and for turbine axial displacement, shaft
vibrations at gearbox high & low speed shafts.
Annunciation scheme will be given as part of DCS.
Hard wired recorders shall be provided for critical service.
Control shall have suitable facilities for ON-line testing / trouble shooting
through provision of diagnostic lamps, bypass lamps / switches, test
switches, etc.
Remote on/off indication & control of all drives of lube oil system & CEP
should be available in control room.
248
The control panel must realize required annunciation & alarm windows.
2.2.16.1 Turbine Control System :

The turbine control system has to be capable to provide the following
inputs to the DCS system :
Centralized monitoring of turbine mechanical parameters (rotor axial
shift, relative expansion, relative shaft vibration, rotating frequency)
Control of control valves
Provides turbine protection against rotor rotating frequency rise above the
permissible limit.
2.2.16.2
Protection System :
Following protections are to be provided for turbine :
Over speed protection
Electronic (2/3 logic with 100% redundancy)
Low lubricating oil pressure
Increase of backpressure in condenser
Increase of condensate level in condenser
All other TG protections such as
High / low control oil pressure
High axial shift
High shaft vibration
Low steam temperature
Provision is made for the relay blocking the possibility to start-up
turbine during shaft turning device being in operation and automatic
start of start-up oil pump at turbine shutdown.
249
2.2.17 Local Panels
2.2.18
a)
Local panel shall be supplied for the Turbo Generator set with suitable full
size opening doors to provide access to all equipment.
b)
The local panel shall contain as minimum the following :

Steam inlet pressure and temperature
Steam extractions pressure & temperature
Steam turbine / generator speed indicator
Lube oil pressures at all headers
Steam turbine / generator stop push button
Run light
Control oil pressure
Emergency shutdown push bottom
Local horn for audible alarm and horn silence push button.
KW, pf, frequency
Pr. at CEP suction and discharge
Condensate pr. before & after SJAE, GSC, level control station etc
Controls & Turbine Control Panel

2.2.18.1 Controls
All control signals will be supplied to the DCS for safe, efficient, start up,
monitoring, control and shutdown operation of the steam Turbine.
The minimum supervisory instruments to measure the following shall be
provided, with provision of all signals to DCS : Speed, load, inlet &
extraction steam pressures & temperatures, turbine wheel case pr.,
emergency and control valve lift, control fluid pressure, journal bearing
metal temperature, thrust pad metal temperature, axial position of thrust
collar relative to its own housing, differential expansion between shaft
and casing at any critical point, axial expansion of casing from anchor
point, shaft eccentricity, bearing pedestal or shaft vibration, especially
with a view to ensuring safety during starting operations and under
transient conditions.
250
2.2.18.2 Control Panel

Control Panel shall house the following:
a. Electronic governor with keyed-in operating program for control of
speed, load, inlet & extraction pressures.
b. Relay based hard wired turbine safety interlocks and trip logic
c. Remote controls comprising of selector switches, ammeters, push
buttons & indicating lamps for ;
AOP motor
i.
ii.
EOP motor
iii.
Barring gear motor
d. Push buttons for turbine speed raise and lower
e. Turbine remote trip/reset push buttons.
f. Temperature scanner for Monitoring turbine and gearbox bearing
temperature
g. Alarm annunciator for Turbine fault monitoring.
The panel shall be complete with AC supply & DC supply on / off control
switches, indicating lamps and space heater.
2.2.19 Lube Oil System (with connectivity to DCS system)

a) Level gauge in main oil tank
b) Bearing temperature gauges for turbine + gear box and alternator
8 no. total
c) Bearing temperature RTD for turbine gear box + alternator
d) Alternator hot air and cold air temp gauge
e) Alternator hot air and cold air temp RTD
f) Alternator winding temp. 6 RTD
g) AOP & EOP discharge pressure gauge
h) Temperature gauge before filter
i) Temperature gauge after filter
j) Temperature element after filter
k) DPIS for lube oil filter
l) Pressure transmitter control oil
m) Pressure transmitter lube oil header pressure
n) Pressure switch for lube oil pressure
251
o) Lube oil pressure switch for auto start of auxiliary oil pump and
emergency oil pump
p) Pressure switch for barring gear interlock
2.2.20
Control Oil System (with connectivity to DCS system)

a)
b)
c)
d)
e)
f)
g)
h)
i)
PDIS across control oil filter

Pressure gauge after filter
Pressure gauge after oil pr. Regulator
Pressure gauge control oil pressure to ESV
Pressure switch control oil pressure to ESV
Pressure gauge control oil pressure to Trip device
Vibration probes for turbine & gear box bearing (8 points)
Axial movement sensor (1-point)
Pressure transmitter after CPC
2.2.21 Protection (with connectivity to DCS system)

Turbine Protection with interlocks, trip logic & annunciation
a)
b)
c)
d)
e)
f)
g)
h)
Over speed protection (high / very high)

Governor emergency trip
Axial shift protection, vibration high
Lube oil pr - low
Lube oil pressure too low
Manual trip
Remote trip
Bearing temperature hi (turbine front / rear, thrust, gear box
bearing, generator front journal)
i) Live steam temp low
j) Live steam temp hi
k) Live steam pressure low
l) Live steam pressure hi
m) Generator / Electrical Faults : Differential fault
n) Extraction pressures & temp. - high
o) Extraction pressures & temp.- too high
p) Control oil pr. low trip and alarm
q) Thrust wear high trip and alarm
r) Hot well level low, very low high, very high
252
2.2.22 Gear Box

The reduction Gear Box between the turbine and the generator, shall be of
proven design of double helical arrangement with proven performance on STG
of 18 MW and above.
It shall be capable of transmitting the maximum rating of the set and be able to
withstand 10% over speed over a period of minimum five minutes. The gear box
shall also be designed for the short circuit condition of the generator.
All bearings of the gear box shall be readily renewable and it shall be possible to
inspect the bearings and the gears readily without disturbing the shaft
alignment.
Non-Illuminated sight glasses shall be provided to inspect the lube oil drain from
each individual bearing. The gear box design shall be as per the requirements of
AGMA.
The flexible couplings between the turbine and the gear box and between the
gear box and the generator shall be of reputed make.
The power rating of the coupling shall be at least equal to the turbine rated
power times the service factor in accordance with AGMA 514. Easily removable
coupling guard shall be placed over each of the exposed coupling.
The service factor of gearbox to be 1.4
2.2.23 Specification for Generator

2.2.23.1 General
The equipment shall include one (1) No. Horizontal Shaft Three Phase
Alternating Current, synchronous generator of nominal capacity 22,500
KVA or higher as per Tenderers recommendation based on normal steam
flows, 11 KV, 50Hz at site condition of 50 Deg. C ambient, brushless
exciter, automatic voltage regulators.
253
Neutral grounding cubicle, lightning and surge protection panel, 11 KV

Switchgear, protection relay and metering panels, cooling water system,
instrumentation control and safety devices and other accessories, spares
and special tools that will be required for satisfactory erection and
efficient operation of the Station, including periodic maintenance.
The generator to be coupled to the turbine matched in respect of speed,
over speed, moment of inertia, overload capacities, coupling and other
relevant requirements.
The generator to be designed to be operated with the expected variations
in power generation. Tenderer to give loading vs. efficiency curve. Sizing
of the generator to be done keeping in view the maximum and minimum
power generated by the turbine as per specified steam conditions.
The generator shall be of closed circuit air cooled type housed in a IP54
(CACW) enclosure and driven by steam turbine through a speed reducer,
if necessary. The necessary coupling bolts shall also form part of the
supply.
The Nominal output of the unit shall be sufficient to deliver the maximum
output of the turbine obtainable under any conditions of operation at 0.8
pf., 11 KV, 50 Hz, at site conditions. Unit shall be capable of continuous
operation at 10% overload subject to permissible temperatures of the
windings.
The excitation system shall be suitable for maintaining the voltage for a
grid voltage variation of 10 % with a combined voltage and frequency
variation of 10 %, and shall have a control accuracy of 0.5 %.
Generation voltage of the unit shall be 11 KV, 3 Phase R,Y,B in anticlockwise rotation. The voltage within specified limits at generator
terminals shall be maintained.
The Generator is to be connected to 11 KV Switchgear including all
metering and protection.
The rating and specification of all the required accessories should be
suitable for 11 KV rated voltage.
254
Synchronous speed, short circuit ratio and the inertia constant shall be
specified by the Tenderer. The selection of the critical parameters of the
generator shall be to operate the machine parallel to the rural grid
The generators shall be suitable for operation in all respects and shall
deliver rated output over a range of voltage variation and operate
satisfactorily under system conditions stated earlier.
The generator shall remain stable on the sudden application of maximum
load or sudden loss of maximum load and during momentary short
circuits or sustained ground faults.
The generator shall be star connected and the main and neutral leads shall
be brought out of the stator frame for insertion of current transformer for
protection, metering and surge protection apparatus. The generator shall
be suitable for grounding through grounding resistor.
The Short Circuit Ratio (SCR) shall be optimized to ensure stable parallel
operation with a rural grid and to ensure minimum voltage changes
under fluctuating loads.
The selection of the SCR value, within IEC specifications, shall be fully
justified for the operation of the machine in a rural network and the
calculations shall be provided with the offer.
The generator shall be capable of withstanding without damage a stator
current of 150 % for a period of 30 seconds.
The generator shall be capable of withstanding without damage a three
phase, a line-to-line, a line- to-earth or two line-to-earth short circuit for a
period of three seconds, when operating at the rated speed and with an
excitation corresponding to a 5 % over voltage at no load.
The maximum line charging capacity at rated voltage that can be obtained
without negative excitation and with stable operation of the generator
may be indicated, which shall not be less than 43 % of rated KVA.
The rated direct axis transient reactance of generator should be
guaranteed without any tolerance and shall not exceed 30 %.
255
The moment of inertia of the generator shall be so selected that it meets

the requirement of over speed.
The machine shall be capable of operating continuously on an unbalanced
system such that, with none of the phase current exceeding the rated
current, the ratio of the negative sequence component of current (1/2) to
the rated current (I/N) does not exceed 0.1 and under fault conditions
shall be capable of operation with the product of (1/2 L/M) 2 and time (t)
in seconds not exceeding 20 or as per IEC.
In the design of generator, each part shall be so proportioned that the
maximum unit stresses therein resulting from any continuous operating
conditions specified shall not exceed one third of the yield point or one
fifth of the ultimate strength of the material whichever is less.
The design of the generator structure and housing in which resonance
might become objectionable shall be so proportioned as to avoid the
possibility of resonance with higher rated frequency or within the
frequency variation.
The synchronous generator shall be designed and constructed so as to
facilitate easy repair / replacement of generator stator bars and rotor
poles.
Suitable provision shall be made in the base frame of the Generator to
facilitate easy removal of the stator body by sliding on the bed plate.
The equipment offered shall be suitable for manual and auto control from
the machine control panels located near the machine
2.2.23.2 Over Speed
The generator shall be designed so as to be capable of running at over
speed of the turbine, and all parts of the generator and other equipment
shall fully and safely withstand stresses resulting from over speed
operation. The mechanical run test will done for 109% MCR turbine speed
for 15 minutes.
256
2.2.23.3 Insulation
a)
Detailed drawings shall be submitted during engineering showing

the arrangement of conductors and the thickness and nature of all
materials used both for insulation and mechanical protection in the
slots of the stator.
b)
Insulation of only 'F' class as specified in I.E.C., specification of the

latest issue shall be used for stator, rotor and exciter.
The quality of the insulation must be such that it is nonhygroscopic and no deterioration will take place when subjected to
the maximum, specified operating temperatures nor must it be
permanently injured when exposed as the machine is to operate in
a most tropical climate.
c)
The end turns and coil connections, shall have not less than full
insulation, equivalent to, and of the same construction as the coil
insulation in the stator slots.
The coil and end turns shall be impregnated with high grade
insulating varnish. Provision shall be made for tightly wedging the
coils in the lot with the wedges which shall not shrink or buckle.
Care shall be exercised that the blocking of air passages shall not
occur.
d)
2.2.23.4
The insulation and taping of the coils shall be such as to prevent

permanent injury from exposure to dampness to provide adequate
corona shielding, to withstand high temperatures without injury, to
prevent the entering of magnetic particles and to prevent formation
of zones.
Temperature Rise
a) Even through insulation of 'Class-F' must be used, when operating
continuously at the maximum continuous rating at its rated 0.80
PF at any working voltages and any frequency in the range
stipulated, the temperature rise shall not exceed the limits
specified for 'Class-B'.
257
The temperature of the bearing shall be measured by means of

mercury in steel dial thermometers in the bearings metal.
The thermometers shall have alarm contacts, apart from the dial
thermometers. The bearing metal temperatures shall be detected
by resistance type temperature scanner and realized at the DCS in
the control room.
b)
Measurement of temperature shall be made as specified in IEC. The

maximum temperature of ambient air shall be taken as 40 Deg. C
and the maximum cooling water inlet temperature as 35 Deg .C
and the guaranteed temperature rises in the windings for the rated
and 110 % loading shall be furnished.
These shall be within the Class 'B' insulation Temperature rise
limits.
c)
The machine shall further be capable of operating continuously at

full load at 0.80 power factor at 11 KV at frequency 5 % below
normal, satisfactorily and without undue heating.
d)
The machine shall be capable of generating more KW than the

rated KW during operation of the machine from 0.8 to 0.95 lagging
power factor but within the KVA rating of the machine.
2.2.23.5 Efficiency & Output Guarantees

a)
The guaranteed overall efficiency of the generator at rated terminal

voltage 0.80 PF lag and 75 Deg .C winding temperature, for the
percentage rated output of 100%, 80% and 60% shall be furnished
in the data sheet.
The efficiencies shall be determined by summation of losses
method as specified in the latest edition of IEC Publication No. 34.2
or IS4889 or equivalent standards. A tolerance will be permitted in
the determination of efficiencies as per IEC Code 34.2.
258
b)
The generator shall be guaranteed to be capable of giving its rated

output under the conditions described earlier without exceeding
the temperature rise as specified and without tolerance. The
equipment shall be rejected if the temperatures exceed the given
limits by 15 Deg. C.
c)
Guaranteed maximum temperature rise, for the stator and rotor

windings of the machine above the inlet temperature of the cooling
air, when operating under rated load conditions with all coolers in
service shall be as follows:
i. Stator winding by embedded temperature detectors : 86 Deg. C
ii. Rotor winding by resistance: 90 Deg. C
2.2.23.6 Cooling
a)
Each generator shall be provided with adequate cooling systems

based on air circulation principles complete with fans etc.,
depending on the capacity of the units.
The air passages in the stator, rotor fans, coolers, etc., shall be
designed to give a smooth and quick flow of air. The Tenderer
should explain in detail the cooling system he proposes for his
equipment so that it meets the requirements of the Owner as
stipulated earlier.
The Tenderer shall give a detailed description of the cooling system
taking note of the class of insulation and maximum permissible
temperature, size of the unit. Justification for the adequacy shall be
given in the description of the cooling system.
b)
Dial type thermometer or RTDs shall be provided in air coolers for

indication of inlet and outlet air temperatures and to provide
alarm in case of high temperature of inlet / outlet air. Thermostats
shall also be provided in the cold and hot air passages.
259
c)
The coolers shall be constructed out of seamless stainless steel tubes

or admiralty brass and shall be located clear of the stator at a lower
level. Any leakage from the cooler shall be drained safely and
properly and there shall not be any chance of the cooling water
finding it's way to the stator / rotor windings.
Suitable moisture detector device shall be used to detect and warn
accidental leakage of water into the cooling air stream.
The coolers shall be designed for the shutoff head of the cooling
water pumps which will be about 4 ata and tested for two times the
design pressure.
The cooler shall be sectionalised and designed to be suitable for
shutting off sections by section for cleaning.
The design shall be such that the generator can deliver its rated
output even with one section out of service.
2.2.23.7 Construction
a)
The generator shall be of synchronous type. The Tenderer has to

clearly specify the type of bearing arrangement provided, with
proper recommendations for its suitability.
b)
All parts of generator shall be designed and constructed to safely,

withstand maximum stresses during operation, over speed, short
circuit conditions, out of phase synchronizing. The pedestal of each
generator will be supported on the concrete foundation.
All necessary accessories like shims, dowel etc., shall be furnished
by the Tenderer. All sole plates shall be interchangeable and
suitably machined and prepared for use at site with minimum
amount of work.
c)
The Tenderer shall give full particulars of the extent to which the
generator will be assembled for purpose of shipment and the work
to be done at site.
260
2.2.23.8 Stator
The stator frame shall be a single piece to consist of a cylindrical
casing of welded plate construction, reinforced internally in the
radical and axial direction by stationary web plates making the
entire frame perfectly rigid. Light non magnetic alloy end shields
shall be made Up of segmental, annealed punching of high quality
silicon steel to give minimum electrical losses. The stator winding
shall be of the double layer lap type with Class 'F' insulations.
2.2.23.9 Rotor
a)
The generator rotor shall be forged from a single piece ingot of

special alloy steel carefully heat treated to obtain excellent
mechanical and magnetic properties, a comprehensive series of
ultrasonic examinations on the rotor body shall be done to ensure
that absolutely no inadmissible internal failures are present and
that the material meets the quantity standards.
b)
The design and construction of the rotor shall be in accordance

with the best modern practice and shall be fully described in the
offer. The factor of safely on yield point of material shall not be less
than 1.5.
c)
The insulation between turns of field winding shall consist of

special epoxy impregnated asbestos paper / equivalent.
d)
The rotor spider shall be of steel constructions. To facilitates

synchronization a shorted damper consisting of several round
copper bars in each pole head shall be provided.
e)
The field poles shall be provided with adequate damper windings

to ensure stability under fault conditions.
2.2.23.10 Earth Terminal

Two Nos. of Earth terminals shall be provided. The earth terminals shall
be designed to terminate Galvanised Iron conductors. The size shall be
as specified IEC 34-1.
261
2.2.23.11 Speed Regulation

The moment of inertia of the alternator together with that of the turbine
shall be sufficient to ensure stability and the speed regulation specified
in the section covering turbine for full load rejection. The fly wheel effect
shall be incorporated in the alternator and turbines as integral part and
not added in the shape of separate weights, rings or other means.
2.2.23.12 Shaft
a)
The generator shaft shall be made of best quality forged alloy steel,
properly treated. The shaft shall be of ample size to operate at all
speed, including maximum over speed without vibration or
distortion and shall be able to withstand short circuit and other
stress without damage. To prevent the flow of harmful shaft
currents damaging the bearings, suitable shaft earthing shall be
provided.
b)
A complete set of test reports covering metallurgical strength,

crystallographic and ultrasonic and baroscopic tests performed in
each shaft during various stages of its manufacturing shall be
furnished as also the complete specifications of the shaft material
forging and its design parameters such as stresses and critical
speed.
c)
The generator shaft shall be cylindrical for coupling to the turbine

/gear box shaft. The coupling shall be forged integral with the shaft
or be shrunk fit and the shaft coupling shall comply with the
requirements of IEC for shaft coupling. All coupling bolts, nut and
nut guards for coupling shall be furnished by the Tenderer.
2.2.23.13 Space Heaters

Suitably rated heaters shall be installed within the enclosure of the
generator. Location and the maximum temperature of the heaters shall
be such that no damage can be caused to any insulation. Heaters shall
be suitable for operation on a single phase 230 V AC supply. A suitable
double pole switch shall be mounted on or adjacent to the stator frame
for the manual switching of the heaters.
262
2.2.23.14 Excitation System

a)
A brush less exciter shall be used and it shall be mounted on the

out board end of the generator frame. A static voltage regulator
shall be included to control the voltage of the synchronous
generator by varying the current supplied to the field. Details of
the equipments shall be furnished along with the bid.
b)
A self excited static excitation system shall be provided. A high

speed, fully tropicalised, printed circuit, draw out type, automatic
digital/analog voltage regulator shall be provided. It should be
complete with necessary sensing PT's, cable entries, cast resin type
current transformer, adjusting rheostats, auto/manual and on/off
selector switches.
c)
Excitation Control System (AVR)
The excitation control system shall ensure the following operational

modes and parameters :
1.
Initial excitation
2.
Idle run of generator
3.
On-switch of generator to the power line by precise
synchronizing method.
4.
Operation in united (multiple STG or grid connected) and
independent power systems with loads from idle run up to
nominal.
5.
Steady regulation of excitation at sharp alternating loads up to
separate outbursts of load caused by simultaneous on-switch of
a synchronous motors with short-circuited rotor of total output
up to 35% of the turbo generator nominal output.
6.
Maintaining of voltage at turbo generator terminals in
accordance with the specified setting with accuracy of 1%
relative to the specified static characteristic. The value of
constant-error response of regulation shall vary from 0 to 10% in
the modes of reactive power generation and from 0 to 100% in
the modes of reactive power consumption.
Steady distribution of reactive power between generators
7.
united at the level of generator voltage.
8.
Change of automatic regulator setting at the rate of 0.5% within
the range for 80 to 110% of the generator voltage.
263
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Limitation of the rotor overload by time depending

characteristic in accordance with the generator data.
Limitation of the minimal current of excitation by a value
precluding the shift of generator into the mode of deep
consumption of reactive power at nominal active load.
Independence of voltage at generator terminals during variable
frequency within the range from 47 Hz to 52 Hz.
Forcing of excitation with ratio up to 2 vel. unit and duration up
to 50 S during faults in the power system, causing voltage
reduction at the generator bus bar relative to the specified
characteristic log of control system during forcing in no more
than 0.025 diameter-excitation of generator at nominal shut
down.
Field killing in emergency modes by breaking its excitation
circuit.
To ensure all specified parameters and modes during deviation
of feed voltage from nominal :
From 10% to 15% continuously
From 20% to 45% briefly up to 50s
Deviation of operative feeding from nominal from 10% to 15%
To sustain voltage rise up to 140% during 1 S.
To ensure the maintaining of operational mode during
disappearance of operative feeding.
The excitation control system shall comprise a stand-by
excitation regulator and provide the following protections:
Against internal short-circuits and short-circuits in the exciters
excitation circuit.
Against loss of excitation
Against rise of generator voltage
Against non-symmetrical short-circuits in circuits of rotating
core of exciter (inter phase short-circuit, break-down of diodes,
etc.)
The excitation control system shall provide for a unified signal 4
20 mA and pro-rata for the generator active power, to be
produced to the turbine governing system.
The excitation control system shall have signalling system of
principal modes: illumination type or Dry Control type..
264
d)
The system offered shall have the following facilities:

i.
Manual mode of operation.
ii.
Auto mode of operation.
iii.
Follow on mode for each operation to have bump less
Transfer
from each mode of operation.
Auto/ Manual changeover facility shall be provided. For Manual
mode Voltage lower/raise pistol grip type spring return type
switch shall be provided in the control panel. Following minimum
alarms shall be transmitted to the Unit control desk. The excitation
system shall have diode protection relays to detect failure of the
Rotating Diodes.
AVR Fault.
i.
ii.
AVR automatic changeover to manual.
iii.
Diode failure.
2.2.23.15 Accessory Equipment

a)
Terminal boxes shall be provided to enclose the leads and current

transformer. The terminal boxes shall be adequately designed to
accommodate termination of required busbars. The generator shall
be provided with stator temperature sensors installed in the stator
winding with leads, brought out to the terminal boxes.
Platinum RTDs shall be provided which shall be hooked up to the
temperature scanner in the control panel. Thermostats or RTDs for
bearing temperature, for anti-condensation heaters and for fire
detection shall also be provided. Necessary vibration transducer
shall be provided which shall be hooked up to the control room.
b)
Adequately rated neutral grounding resistor shall be supplied and

the resistor shall be of stainless steel edge wound type mounted in
shielded safe enclosure. A current transformer shall be provided for
ground fault current measurements for protection. The rating of
the resistor shall be furnished.
265
c)
Necessary surge capacitors and lighting arrestors shall be provided

for generator protection. The surge capacitors shall conform to the
latest IS:2834 and shall be rated 0.25 Micro Farad. The capacitors
shall be suitable for indoor mounting and shall be provided with
built in discharge resistor.
The lighting arrestors shall be heavy duty indoor station class
gapless metal oxide type suitable for repeated operation to limit
voltage surges on alternating current power circuits . The arrestors
shall conform to IEC 99-4. LA will be of 11kV grade.
2.2.23.16 Electrical Controls

Control and monitoring cubicles shall conform to international
standards. Protective relays, control switches indicators and monitoring
devices shall be mounted on the front. The relays, terminals, motor
starter and control circuit breakers shall be inside the panel. The
completed panel shall be factory inspected and tested and a standard
simulation test shall be performed on the system before shipment in the
presence of the Owners representative.
The electrical panels shall consists of:

Relay & Protection Panel.

Synchronization & metering panel (can be part of turbine
control panel)
Excitation Cubicle. (can be part of turbine control panel)
Auxiliary control panel for lube oil and other auxiliary system.
(redundant to DCS) (part of turbine oil system)
LA, SC and PT Panel / terminal box
NGR Panel.
266
2.2.23.17 Unit Control System

The unit control system shall basically have the following controls for
sequential operations for the start and stop of the unit with
Annunciation / Visual and Audible Alarm facilities.
The sequential start system shall have the following minimum functions,
which will be operated by the DCS system:
"Turbine-Generator power on" for start up after pre start

condition checks like main breaker open and MS stop valve
closed.
Control switches for auxiliaries etc. switched on remote control.
Master relay picks up.
Auxiliaries of the unit start.
MS stop valve starts opening and the unit starts rotating and
accelerates.
At slightly below no load speed, valve position is controlled to
accelerate the unit to synchronous speed at controlled speed.
At 95% speed, voltage regulator cut into service.
At synchronous speed, if phase sequences voltages and
frequencies match unit breaker closes and synchronises.
The unit should be ready for accepting the load.
Adequate monitoring facilities, checks and interlocks should be
provided in the sequential control, so that in the event of
incomplete operations, the unit shuts down giving requisite
annunciations.
2.2.23.18 Earthing
The Turbo-Generators shall be earthed through neutral grounding
resistors, lightning arrestors, surge capacitors, CTs and Voltage
Transformers for AVR etc.
267
2.2.23.19 Protective Devices

The Tenderer shall study the system conditions like voltage, frequency
variations, etc. level at the location of the proposed generating units and
offer suitable generating equipment with necessary accessories required
for satisfactory working of the generating units.
2.2.23.20 LA, SC and PT panel
a)
The Tenderers shall supply 1 no. terminal cubicle for housing surge
capacitor, potential transformers, current transformers, lightning
arresters, cable boxes, etc., The cubicle shall be complete with
necessary tapping for excitation system, etc,. The rating of the CTs
for AVR shall be decided by the Tenderer taking into account the
requirements of the AVR.
b)
The cubicles shall be sheet steel, suitably compartmentalised with

doors and shall be furnished complete with base mounting
arrangement, foundation bolts etc. The internal illumination or
cubicles shall be provided with guarded lamps with on/off switch.
Copper / Aluminium conductors shall be suitably insulated to
make them compatible with generator temperature rise and
insulation. The support insulators for the bus connection will be
provided as necessary, GL earth bus of adequate cross-section will
be provided in the cubicle.
LA 3 nos, 11kV grade, surge capacitors 11kv low resistance
grounded, PTs for protection, metering & AVR sensing 11kV,
ratio: 11kV 3/110kV 3, PT for generator protection
c)
2.2.23.21 Potential Transformers

The potential transformers will be single phase, epoxy cast, dry type
units. Potential transformer will be protected on primary and secondary
side by current limiting fuses. The PT shall confirm to IS: 3152. The
accuracy class for Metering will be 0.2 and protection 3P10.
268
2.2.23.22 Current Transformers

a)
The current transformer will be single phase, epoxy cast, dry type
unit confirming to IS:2705. The current transformer shall be
designed to withstand the thermal and magnetic stresses resulting
from the maximum short-circuit current. The accuracy class for
metering will be 0.2 and protection 5P20.
b)
The generator Tenderers shall supply suitable transformers for the

protection scheme and these shall be installed in the neutral
grounding and line terminal cubicles.
2.2.23.23 Tests
A)
The generator shall be completely assembled at works and type

tests as specified below shall be conducted on the assembled unit
and auxiliaries as per the latest edition of IS:4722. Detailed test
reports shall be furnished.
i) Type Tests
The following shall constitute the type tests.
a
b
c
d
e
f
g
h
i
j
k
l
Measurement of DC resistance of stator and rotor

windings.
Insulation resistance of stator winding (before and after
high voltage tests), rotor winding, bearings and embedded
temperature detectors.
Stator winding capacitance and tan delta measurement.
High voltage test of stator and rotor windings at industrial
frequency.
Phase sequence.
Determination of open-circuit characteristics.
Determination of short-circuit characteristics.
Over speed.
Pressure test on coolers.
Determination of efficiency by separation of losses method
Vibration.
Temperature-rise test of windings.
269
m
n
o
ii)
Instantaneous Three (3) phase short circuit test at rated

voltage and speed.
Voltage wave-form.
Determination of reactances and time constants.
Routine Tests.
The following shall constitute the routine tests.
a
b
c
d
e
f
g
h
i
j
k
l
Measurement of DC resistance of stator and rotor

windings.
Insulation resistance of stator winding (before and after
high voltage test), rotor winding bearings and embedded
temperature detectors.
High voltage test of stator and rotor windings at industrial
frequency.
Phase sequence.
Determination of open-circuit characteristics.
Determination of short-circuit characteristics.
Over speed.
Pressure test on coolers for close-circuit cooling.
Determination of efficiency by separation of losses
methods.
Vibration.
Impedance of the rotor winding.
Stator winding capacitance and tan delta measurement.
iii) TESTS ON EXCITERS AND REGULATING EQUIPMENT (FOR

ROTATING EXCITERS)
a
b
c
d
e
f
g
High voltage test

Temperature rise test
Measurement of resistance
Measurement of insulation resistance
Regulation test
Commutation test
Excitation response ratio.
270
iv) ROUTINE TESTS ON STATION EXCITATION EQUIPMENT

Additional Test:40% over voltage on open circuit excitation for five (5) minutes,
voltage recovery test after fault clearance over speed of 30% for
two (2) minutes
B)
Site test for each generator shall include the followings.

a Mechanical run and vibration measurement
b Measurement of stator and rotor winding insulation
resistance.
c High voltage dielectric test
d Measurement of shaft voltage (if applicable)
e Measurement of stator and rotor winding resistance
f Phase sequence test
g Load acceptance and rejection test at selected loads from no
load to full load.
h Overall response f machine and excitation system
i Adjustment of AVR
j Synchronising test
k Checking and commissioning of various other auxiliary
equipment
Test on the equipment like CTs, Pts, LAs, shall comply with routine
tests etc., as per relevant standards.
Test report or all the type tests on the generator, CTs, PTs, & LAs
carried out on similar equipment already supplied shall be
furnished for approval.
271
2.2.24 Specification for Neutral Grounding Equipment

2.2.24.1 Introduction
a) This specification cover the design, manufacture, testing, packing and
supply of neutral grounding resistors.
Rated voltage : 11kV/3 volts 10%, duty rating : 10 secs, grid type :
punched steel, to restrict fault current to 100 A for 30 secs.
b) Standards
The resistors covered by this specification shall conform to the
following and other relevant Indian Standards.
Wherever Indian Standards are not available, they shall conform to
relevant British or IEC Standards.
IS : 3043 Code practices for earthing.
BS : 162 Electric power switchgear and associated apparatus
(applicable to Class-B apparatus in BS 162)
Wherever the stipulation in this specification are in conflict with
any of the above standards, the
requirement under this
specification shall be binding.
2.2.24.2 General Specifications
Resistors
a)
Resistor element shall be made of unbreakable, corrosion proof,

joint less stainless steel grids. It shall be suitable for use in
monsoon tropical climate.
b)
Resistors shall be able to carry the rated current for the rated time
with temperature rise not exceeding 325Deg. C over the maximum
specified ambient temperature when the resistor is housed in a
covered space.
272
c)
Grids shall be mounted on steel rods insulated by special heat

resistant micanite paper tubes. Grid washers shall be of natural
mica. Porcelain insulators shall be used to used to insulate the
resistor element from body of the enclosure.
2.2.24.3 Enclosure (IP 42)

a)
The resistors shall be housed in a metal clad enclosure totally

enclosed type. It shall vermin proof, weatherproof and suitable for
outdoor installation.
b)
The enclosure shall have an arrangement for fixing it on concrete

foundations / floor and its thickness shall be not less than 3 mm.
c)
The terminals for neutral and earthing connection shall be housed

in a separate vermin proof, weather proof compartment.
d)
A canopy shall be provided on the top. It shall cover the terminal

compartment also. Hooks or handle shall be provided to lift the
canopy.
e)
It shall be possible to periodically clean the resistors after lifting the

top cover or canopy.
f)
It shall be possible to earth the cabinet or enclosure at two places

and for this suitable size of studs shall be provided on the sides, as
low as possible, to accommodate the GI strips size mentioned in
particular specification.
2.2.24.4 Terminals
a)
Porcelain insulated through terminals shall be provided for neutral

and earth connection and they shall be housed in a metal clad
panel. The terminals shall be suitable for terminating the XLPE
cables / bus duct.
b)
Suitable washers shall be provided between grid and terminals to

maintain good contact.
273
c)
The two ends of the resistor shall be brought out to weatherproof

bushing type terminals of adequate rating. Bolted type link shall be
provided for isolating the resistor.
d)
The connection between generator neutral and NGR shall be done

by means of single core XPLE armoured cable, having aluminium
conductor or bus duct.
e)
The connection between NGR and earth pit shall be done by means
of GI Earthing Strip.
2.2.24.5 Space Heater

Suitable space heater shall be provided inside the resistor cabinet to
prevent condensation of moisture. This shall be rated to operate from 240
V, 50 Hz supply. The terminals of the space heaters shall be brought out
in a separate terminal box.
The cable used for heater shall be aluminium conductor PVC insulated
armoured cable. The entire arrangement shall be complete double pole
switch, HRC fuse and thermostat.
2.2.24.6 Cooling
The NGR shall be natural air cooled and any type of forced cooling will
not be used. However, if required louvers can be provided in the
enclosure. But wherever the louvers are being offered it shall be
completely guarded on inside with a fine wire mesh (holes less than 0.5
mm) to make it vermin proof.
2.2.24.7 Nameplate Marking
The equipment shall have a nameplate located conspicuously giving
particulars, such as make, name the equipment, rating and other relevant
details.
274
2.2.24.8 Painting
After manufacture, all surfaces to be painted shall be thoroughly cleaned,
de-scaled, made free from rust and given a priming and final coat of the
paint.
2.2.24.9 Inspection & Test
Inspection shall be carried out by the Owner or Owners representative
and following tests shall be conducted.
a)
Measurement of resistance value at rooms temperature by Kelvin

Double Bridge.
b)
One minute power frequency high voltage withstand test shall be

as per applicable voltage.
2.2.24.10 Heat Run Test

The test shall be conducted by passing the rated current for rated time on
the complete assembly or by any method mutually agreed Upon.
2.2.25 Specification for Erection of Mechanical Equipment specific to STG

2.2.25.1 Checking of foundations
The Tenderer shall as a first field activity check the foundations for the
correctness of the same as per relevant drawings & and certify the same
for concreting and the same may be rechecked for its correctness after
concreting, such as levels, location of bolt holes, sleeves, pockets,
openings, fixture plates and other embedment in RCC works, etc.
2.2.25.2 Before starting erection job on turbine floor Tenderer shall ensure that
turbine area is sufficiently enclosed against ingress of dust and wastes,
and that all debris have been cleared off from the floor.
275
2.2.25.3 Where turbine holding down bolts carry washers and where these plate
washer rest on concrete surface such concrete surface shall be finished
and dressed true to get full surface contact between the concrete surface
and the plate washers as required.
2.2.25.4 Tenderer shall provide his tool stores for special tools and instruments at a
convenient location in the turbine hall.
2.2.25.5 Tenderer shall set up longitudinal and axial centrelines, and two or more
level bench marks accurately on turbine floor which shall be certified by
Owner / Consultant.
This certified turbine centre line and datum level shall be reference for
turbine and all auxiliary erection and alignment work.
2.2.25.6 Where required by manufacturers the concrete surfaces shall be chipped
and finally dressed up true to obtain the required contact between sole
plates and concrete surfaces. The fine dressing of the concrete shall be
with Prussian blue match checks.
2.2.25.7 Tenderer shall ensure that while lifting turbines/generator. piping and
other auxiliaries for transporting, slings shall be put over the points
indicated on the equipment.
Slings over casing shall have gunny bags or soft wood packing to avoid
the scratches and nicks on the equipment.
Slings / D-Shackles of proper sizes shall be used for all lifting and rigging
purposes. All care shall be taken to safeguard the equipment against any
damage.
2.2.25.8 Tenderer shall thoroughly clean all machine surfaces / slings,
surfaces/keys, brackets sole plates etc. and apply anti-scuffing paste or
other recommended equivalent before assembly of the said parts. The
components whose surfaces are coated with protective coating are to be
thoroughly cleaned.
276
2.2.25.9 The Tenderer shall carry out all necessary checks such as accuracy of
levels, centres lines, bolt positions, of installation of all equipment
covered in the scope of work.
2.2.25.10 Checking of Equipment after Grouting
After the grout is set and cured, the Tenderer shall check and verify the
alignment of equipments, alignment of shafts of rotating machinery, the
slopes of all bearing pedestals, centring of rotors with respect to their
seating bores, couplings etc. as applicable and the like items to ensure
that no displacement had taken place during grouting.
The values recorded prior to grouting shall be used during post grouting
check-Up and verifications. Such pre and post grout records of alignment
details shall be maintained by the Tenderer in a manner acceptable to the
Owner.
2.2.25.11 Shaft Alignment
All the shafts of rotating equipment shall be properly aligned to those of
the matching equipment to the required accuracy.
The equipment shall be free from excessive vibration so as to avoid overheating of bearing or other conditions which may tend to shorten the life
of the equipment.
All bearings shafts and other rotating parts shall be thoroughly cleaned
and suitably lubricated before starting.
2.2.25.12 The Tenderer shall maintain a record in the form acceptable to Owner /
Consultant of all the operations carried out on each weld and maintain a
record indicating the number of welds, the names of the welders who
welded the same.
All site joints shall be subject to acceptance of Owner / Consultant. Any
joints declared rejected shall have to be redone at the Tenderer's cost.
277
2.2.25.13 The Tenderer shall carry out the tightening of the bolts on the equipment
and piping covered under this specification by using either the calibrated
torque wrench method or the turn of nut method.
The methods used, the tools and the equipment deployed shall be subject
to the approval of Owner / Consultant. The bolting work shall be carried
out by competent technicians.
2.2.25.14 The Tenderer shall install all necessary platforms, stairways and ladders
required for the safe and convenient operation and maintenance of all the
equipments, valves etc. covered in this specification at no extra cost.
2.2.25.15 The Tenderer shall completely erect all the equipments for the complete E
& M portion including hangers and supports, valves & accessories in
accordance with the approved drawings.
This includes all necessary bolting, welding, testing and cleaning. Systems
shall be demonstrated in condition to operate continuously in a manner
acceptable to Owner / Consultant.
Welding shall be used throughout for joining pipes except where flanged
screwed or other type joints are lines & elevation as indicated in the
drawings.
2.2.25.16 While erecting the field run pipes the Tenderer shall check the
accessibility of valves, instrument tapping points and maintain minimum
head room requirements and other necessary clearances for adjoining
work areas.
2.2.25.17 The Tenderer shall be responsible for correct orientation of all valves so
that seats, stem and hand wheels will be in desired location.
2.2.25.18 All supports & hangers for the pipes have to be fabricated and provided
for approximately every three metre (3 meter.) of pipe.
However in any case sufficient numbers shall be provided so that the
deflection of pipe between hangers shall not exceed the limits indicated in
the drawings.
278
2.2.25.19 The Tenderer shall make all necessary arrangements including making of
temporary closures on piping / equipment for carrying out the
hydrostatic testing on all piping / equipment with motor operated pump.
2.2.25.20 All piping flanges are required to be blue matched using surface plate to
obtain at least 80% contact area before installation.
2.2.25.21 All welded joints of pipes shall be cleaned of welding slags, & burrs by
hand file wire brushes and flexible grinders wherever required and using
white cloth. No cotton waste shall be used while cleaning the equipment
/ piping.
2.2.25.22 The Tenderer shall dismantle the valves & actuator for overhauling,
servicing and lubricating wherever required as advised by Owner/
Consultant.
The Tenderer shall also lap or grind the valve seat for ensuring the
satisfactory performances of valves at no extra cost. All consumables such
as gaskets, gland packing which form the permanent part of equipment
shall be in the Tenderer's scope.
2.2.25.23 The hanger assemblies shall not be used for attachment of rigging to hoist
the pipes into position. Other means shall be used to securely hold the
pipe in position till pipe supports are completely assembled and attached
to the pipe & building structure.
2.2.25.24 All temporary rigging shall be removed in such a way that pipe supports
are not subjected to any sudden load. During hydro static testing of pipes,
all piping having variable spring type supports shall be secured in place
by temporary pinned or blocked solid during the test.
2.2.25.25 The Tenderer shall carry out the pre-commissioning activities such as
chemical cleaning of piping system, water flushing, flushing of oil
systems, flushing of control fluid system.
The scope of pre-commissioning activities covers installation of all
temporary piping, supports, valves, tanks, pumps & all other accessories
& services to complete the process.
279
2.2.25.26 The Tenderer shall carry out the edge preparation of weld joints at site in
accordance with the details acceptable to Owner/ Consultant.
Wherever possible machining or automatic flame cutting will be allowed
only wherever edges preparation otherwise is impractical. All slag /
burrs shall be removed from cuts and all the hand cuts shall be ground
smooth to the satisfaction of Owner / Consultant.
2.2.25.27 Tenderer shall carry out all the electrical pre commissioning tests on the
generator, excitation system, as stipulated by the relevant specification
and codes.
2.2.25.28 The Tenderer shall hand over all parts/materials remaining extra over the
normal requirement with proper identification tags, in a packed condition
to the Owner / Consultant.
2.2.25.29 The work to be carried out is of highly sophisticated nature requiring
quality precision workmanship, engineering and construction
management.
It should also ensure successful and timely commercial operation of
equipment in stalled. The Tenderer must have adequate quantity of
precision tools, construction aids in his possession. Tenderer must also
have adequate trained, qualified and experienced supervisory staff and
skilled personnel.
2.2.25.30 All temporary scaffolding shall be removed before the start of the
commissioning activities to prevent hazards.
280
2.3
EOT CRANE AND HOIST
2.3.1
Design and Construction

EOT will be to Class-MS (IS:3177, 1999 & IS: 807). Clause 8.0.0 of IS : 800 1962
Code of Practice for General construction in steel shall apply.
2.3.2
Minimum Thickness of Metal

For load carrying members, the component plates, bars, angles and other rolled
sections shall be minimum 8 mm thick. For tubes having both ends sealed, the
minimum thickness shall be 4.9 mm (6 SWG). For unsealed tubes, the minimum
thickness shall be 8 mm. The chequered plates for platforms shall be minimum 8
mm thick.
2.3.3
Connections
Unless otherwise specified, only welded joints shall be used
Transverse fillet welds on load carrying members shall be avoided.
Butt welds on structural members under tensile stress shall be checked by
Radiographic examination (100%)
Splices shall be designed to resist one and half times the forces and moments to
which it is subjected.
2.3.4
Deflections and Camber

The total maximum vertical deflections of the girders for the safe weight of
working load plus the weight of the crab in central, position (without taking into
consideration the impact factor) shall be considered
The girder shall be cambered by an amount equal to the maximum deflection
due to dead load plus one half the live load and trolley.
281
2.3.5
Bridge and Trolley Frames

Bridge and trolley frames shall be of fabricated structural steel sections.
Mounting shall be designed to facilitate easy removal of the wheels, bearings and
journals.
Buffers shall be provided on trolley and bridge frames to absorb shock of impact
without transferring to the frame.
2.3.6
Hooks
Hooks shall have swivels and safety latch. Locking pin shall be provided to
prevent swivelling of hook.
2.3.7
Hoist rope
The rope shall be of flexible steel with lubricated hemp (fibre) core construction.
Suitable attachment to the rope shall be provided for fastening to the drum.
Rope shall be sufficient length so that drum has two full turns when hook is at
the lowest position.
2.3.8
Drums
Rope and drums shall be grooved and welded steel conforming to IS 3177.
Drum shall have minimum one spare groove when this hook is at its highest
position.
2.3.9
Sheaves
Rope sheaves shall be of cast steel or fabricated steel with anti-friction bearings.
Sheaves shall be fully guarded to prevent rope coming off.
282
2.3.10 Gears
Gears shall be cut from solid cast of forged steel blanks or shall be of stress
relieved welded steel construction. Pinions shall be of forged carbon or heattreated alloy steel.
Split gears shall not be used. Gears and pinions shall be totally enclosed for all
motions and must be dust proof and prevent oil leakage. Gearboxes shall have
oil bath type for lubrication. Gearboxes shall have covers split horizontally for
inspection.
Necessary level gauge for indicating oil level, drain plugs, lifting lugs and guards
shall be provided.
2.3.11 Wheels and Rails

The track wheels of bridge and trolley shall be of forged steel and double flanged
with cylindrical straight tread and shall have hardness not less than 250 HB. The
wheel diameter and rail sizes shall be suitable for the wheel load and duty class.
2.3.12 Stoppers
Steel rail stops shall be provided at ends of rails for Bridge and trolley welded to
crane girders to prevent creeping of rails and running off of trolley. Stops shall
match wheel radius and buffers shall be provided as required.
2.3.13 Brakes
Brakes shall be provided on the high-speed side of gear reducer. It can also be
located on input shaft / extension of input shaft or gear reducer.
Coupling halves shall not be used as break drums.
The brakes shall be designed for 150% of rated torque.
283
2.3.14 Operating cabin

The operation cabin shall be enclosed type with ample space for mounting
control panel. The main control panels shall be mounted on the crane bridge.
The cabin shall be designed to give the operator clear view of the equipment
being lifted in the bay. The operators sea shall meet the above requirement and
shall be comfortable. The cabin shall be adequately illuminated and ventilated.
Necessary non-oscillating fan, audible alarm and plug points shall be provided.
2.3.15 Ladder and Platforms

Ladders shall be provided for access to the crane from the walkway along the
building columns and access to cabin from girder top.
Platform / walkways shall be provided for maintenance with 750 mm clear
insider width with 6 mm thickness non skid steel plate with toe guards of 75 mm
height above the floor level and of 6 mm thick.
2.3.16 Drive
Drive motor shall be of Crane duty. 15% margin on arriving at motor ratings
over and above the design requirement shall be considered.
2.3.17 Testing and inspection

The Owner shall conduct all tests required to ensure that the equipment
furnished shall conform to the requirements of the specification in compliance
with the requirements of the applicable codes.
The particulars of the proposed tests and the procedures for the test shall be
submitted to the Owner / Consultant for approval before conducting the tests.
All materials, castings and forging shall be of tested quality & certificates made
available. If mill certificates are not available, the Owner shall arrange for
physical & chemical testing at his own cost.
284
The crane shall be subjected to full load, overload tests and deflection test as per
IS : 3177.
The tests shall be conducted on the motors as per Indian standards IS : 325 and IS
: 4029 and routing test and type test certificates of the motors shall be submitted
to the Owner / Consultant for review.
All other electrical equipment and components thereof shall also be subject to
routine tests as per relevant Indian Standards.
Type test certificates shall be furnished wherever required by Owner
Butt welds on structural members in tension and seams of Welded Hoist Drum
shall be subjected to 100% radiography.
Non-destructive test (NDT) shall comply with relevant Indian Standards and is
the total responsibility of Owner for the quality of weld
Reports of all shop test shall be submitted prior to dispatch for review and
approval.
Test for flameproof electrical apparatus if applicable, as per relevant IS standards
shall be carried out and required approval / certificates shall be obtained from
the authority having jurisdiction. Test certificates for the same shall be
submitted.
2.3.18 SPECIFICATION CRANE ELECTRICALS
2.3.18.1 Motors
The crane motors shall be of TEFC type having class B stator insulation and class
F rotor insulation with temperature rise limited to class B operation. The
enclosure of the motors shall conform to IP 55 degree of protection for outdoor
service and IP 54 of indoor service.
The hoist, long travel and cross travel motors shall be motors shall be squirrel
cage type, designed for crane duty requirement of frequent starting, reversing
and plugging with motor pull-out torque of not less than 2.25 times of the rated
torque. These motors shall have class S4 duty class with a cyclic duration factor
of 40% (CDF)
285
Motors above 30 kW rating shall be provided with 240 V AC space heaters.

For motors below 30 kW the motor winding shall be suitable for continuous
heating from 240 V, 1 phase, 50 Hz supply
2.3.18.2 Main Safety Disconnect Switch

One (1) no. main disconnect switch shall be provided for each of the EOT cranes
and hoist for feeder power to the runway conductors. This switch shall be metal
clad, load-break type in IP 54 enclosure and complete with compression brass
glands and lugs to suit Owners power supply connection.
The switch shall be provided with visible ON-OFF inscriptions. Padlocking
arrangement for locking in IFF position shall be provided for this switch.
Further, the operating handle of the switch shall be mechanically interlocked
with the enclosure cover and cover shall not be possible to open unless the
switch is in OFF position.
PVC insulated and sheathed, round steel wire armoured and overall extruded
PVC sheathed power cables shall be provided by the Owner from the main
disconnect switch to the runway conductors.
2.3.18.3 Runway Conductors
The runway conductors shall be about four (4) in number for 415 V, 3 phase, 50
Hz supply and ground. These shall be of mild steel angle sections, liberally sized
for a current density of 0.42 A/mm2. Sufficient allowance (MIN 20%) for wear
and tear shall be provided over the calculated size.
The runway conductors shall be supported on brackets and insulators from the
crane girder with sufficient spacing in between the conductors. The collector
system shall have spring-loaded cast iron / high quality carbon metallic shoes to
maintain adequate contact pressure.
Two (2) nos. ON LED type indication lamps rated for 240 V supply and wired
through fuses shall be provided at each end of the bridge to indicate that the
runway conductors are in line..
286
2.3.18.4 Cross Conductors

The cross conductors on bridge shall be with PVC flexible trailing cables and
shall move on the separate roller / track arrangement which will move along
with the trolley.
2.3.18.5 Protection & Control Panel
a) Panel Power Distribution
Wiring shall be extended from the main collector shoes to a 3-pole, load-break,
safety disconnect switch located on the bridge within easy reach. This shall be
capable of cutting-off supply to all power driven and associated equipment of
the crane excepting the auxiliary loads such as fans, etc.
From the above safety disconnect switch, wiring shall be provided to a protective
panel containing the following as a minimum.
One (1) 3-pole incoming supply disconnect switch.
One (1) 3-pole, main magnetic contactor with HRC fuses back up. ON OFF
push buttons and RED-GREEN indication lamps. The duty of the main
contactor shall be AC3 or higher.
Suitably rated, 3-pole bus with a fault rating of 45 KA for one second. From this
panel, power wiring shall be taken to the individual panels of each motion. The
main protective panel and the individual motion panels may be clubbed together
to form a single panel unit with barriers in between for separation.
The outgoing motor feeders for each motion form the individual motion panels
shall consist of 3-pole switch fuse units, contactor and thermal overload relay
with single phasing preventions. The electro-mechanical brakes and electro
magnetic clutches shall also be wired through separate set of fuses and
contactors.
240 V, suitably rated thermostat controlled panel space heaters and fluorescent
lamp for internal illumination with ON-OFF switch shall be provided for each
panel.
Under voltage release shall be included. The crane shall hold its position when
the protection operates.
287
Contactor control gear or drum type controllers.

The control supply for the panels shall be tapped before the protective panel
incoming switch terminals and wired through DP switch and fuses and control
transformers. The control transformer shall be rated for 415 V / 110 V.
The main contactor shall be electrically interlocked so that it cannot close unless
all the motor overload relays are reset and all controllers are in OFF position.
The main contactor shall also be opened by means of emergency push buttons
and hoist limit switches.
All 230 V power requirements shall be arranged by 440 / 230 V lighting
transformer mounted on crane and shall be supplied by the Owner.
2.3.18.6 Emergency switch
Mushroom type emergency STOP push buttons to open the main contactor shall
be furnished one (1) at each end of the bridge platform, one (1) in the protective
panel and one (1) no. in the pendant push button station, the number of contacts
associated with this switch shall be 2NO+2NC.
2.3.18.7 Crane Controls
The long travel and main hoist speeds will be controlled by VVVF / VFD. The
auxiliary hoist and cross travel speed to be controlled by conventional inching
(resistor based) or VFD.
All controls shall be designed for fail-safe operation on loss of power. The
control circuits shall be designed for 230 V, 1 phase, 50 Hz supply complete.
2.3.18.8
Resistors
The resistors shall be housed in metal enclosures with provision for arresting
vibrations. The resistors shall be heavy duty; rust-proof type with stainless steel
grids and time shall be rated for 10 minutes duration. The maximum
temperature of the resistors at any time shall not exceed 250C. Sufficient space
shall be provided around the resistance to ensure adequate cooling airflow.
288
2.3.18.9
Limit Switches
Each hoist shall be provided with one (1) no. gravity operated hand reset type
limit switch for back-up protection against over-hoisting and one no. lever type
switch for LT & CT motions.
2.3.18.10 Illumination
Crane lighting, receptacle system and space heating systems shall be designed
for 240 V, 1 phase, 50 Hz supply. A separate panel with necessary dry type
control transformer having isolation facility and primary / secondary fuses shall
be provided for this purpose.
240 V, 5A, 3 pin industrial socket outlets one (1) no. on the protective panels, two
(2) nos. on the bridge along the walkway shall be provided.
All branch circuits for lighting and receptacles shall be individually protected by
switch fuse units.
Four (4) forty (40) watts fluorescent fixtures shall be used for lighting bridge
platform. 2 X 400 W, HPSV fixtures shall be provided below bridge for
illumination of working area. One (1) no. heavy-duty type industrial howler
shall be provided. The howler shall be operated from pendent push button
station.
One (1) no. portable 40 W hand lamps shall be furnished with adequate length of
flexible cable for inspection of crane components.
Crane overloading warning An audible alarm shall be given when the crane is
mechanically overloaded. This may be actuated by a mechanical strainmeasuring unit or by an electrical overload device.
Audible Alarm An audible alarm shall be provided, operated by self-resetting
push button to enable the operator to give warning at any time.
Operators Cab At the end of the bridge, an operators cab shall be provided
designed and located to give the operator a complete view of all operations of the
crane as practicable. The cab shall provided with 230 V socket outlets for the use
of portable electrical outlets.
289
2.3.18.11 Wiring
All wiring shall be done with 1100 V grade insulated wire, in conduits or 1100 V
Grade, PVC cable. All cabling shall run between each component and shall be
protected and supported to prevent mechanical damage due to vibration. The
minimum conductor size shall not be less than 2.5 sq mm copper.
All power, control and auxiliary circuit wiring shall be designed such as to
maximise shop wiring and minimise field wiring.
The cable size shall be selected taking into account the name plate rating of the
motor with de-aerating applied for ambient temperature, group factors, etc.
All lighting and control circuit wiring shall be routed through conduits. The
conduits shall be heavy gauge, rigid steel, GI conduits with threaded and
screwed, tight at all joints.
All wires and cables shall be connected to any terminal
2.3.18.12 Grounding
The cane rails, structures, motors frames, metal enclosures of all electrical
equipment conduits and tray system shall be effectively grounded in accordance
with IE Rules and Regulations. Two (2) common earth conductors shall be
provided along the bridge to which all earthling leads shall be connected. These
common earth conductors shall be connected to the ground conductor of the
runway conductors. Bonding of structures and cane rails shall be provided as
required to ensure electrical continuity.
The crane grounding system shall be connected to the station ground mat. For
this purpose, the Owner will terminate the crane system at two locations
agreeable to the Owner. The earth conductors shall be of GI Conductor,
shrouded type.
The grounding connection shall be suitable for accommodation of flexible
aluminium cables or GI flats as follows:
Motors above 30 kW up to 90 kW
Motors above 5 kW up to 30 kW
Motors up to 5 kW
35 X 6 mm GI flat
25 X 6 mm GI wire
8 SWG GI wire
290
2.3.18.13 Gantry Girder

Scope to include gantry girder and typical 90 lbs/yard rail. 25 mm diameter
anchor bolts to be used. Rail to be continuous over span. Maximum span to be 8
m.
Chain Pulley Block to be provided for Boiler Feed Pump, boiler fans, CW pumps,
CT fans, ESP transformers, air Compressor, etc. Wherever accessible, the EOT
crane in the powerhouse to be used for maintenance purposes.
General Information
Capacity
Span
Lifting height
Operation
:
:
:
:
Codes / standards
Minimum 10% higher than largest load

As required
As required
Indoor / outdoor use, as per
application
IS: 3938, Class II
2.3.19 System Description

The hoists used should be standard production hoists.
The hoists should be designed and calculated in accordance with the principles
of IS: 3938 Class II or according to accepted and equivalent standards.
The nominal carrying capacity of the hoists and of their attachment points to be
such that the heaviest objects to be lifted can be transported safely.
The hoists and crabs should be equipped with squirrel cage motors. Inching
control to be also provided on all electrically driven hoists and crabs. The crab
power supplies should be in the form of trailing cables with cable carriers
running in tubular track.
291
Electrical switchgear and control gear should be mounted directly on the hoists
in cabinets. The electrical hoists should be operated by pendant control units
fitted with push-buttons and should be fixed to the hoist in such a way that safe
operations guaranteed. Limit switches should be fitted to all lifting and travel
gear.
A key operated switch and an emergency off push buttons to be provided.
2.4
2.4.1
WATER TREATMENT PLANT

Primary Treatment of Raw Water
This package consists of the treatment plant consisting of alum, polyelectrolyte,
sodium hypo chlorite, and lime dosing systems, clarifloculator with bridge or
tube settler, flash mixer, raw water pumps, auxiliary equipments for clarifier /
tube settler, clarifier sludge pipes, related sludge discharge pumps, clarified
water pumps etc., sampling devices, plant instrumentation, metering /
measuring devices, pressure gauges, basket strainers, all piping etc., are to be
included in the scope of supply.
2.4.2
Secondary Treatment
Multi-grade filters / dual media filter
ACF
Strong acid cation unit
Degasser unit and auxiliaries
Anion unit
Mixed bed unit
Ultra filtration unit for silica removal, PLC operated. If required by the
design, Tenderer may provide additional tank and pump (1 W + 1
S/b) to transfer water to UF unit. Bypass to UF unit to be provided.
All associated instrumentation, piping, valves, fittings, controls, tanks,
reagents, resins, injectors, metering pumps, etc.
All inter connecting piping and fittings
Neutralising pit of suitable size to be provided and pumps to handle
the liquid should have SS 316 internals discharge pumps
292
For all regeneration system, two ejectors will be provided, one will be
stand by
All parameters measuring devices to be provided
Vortex type electronic water meter at the plant outlet in addition to
rotameter
Morpholine dosing system at the outlet of mixed bed for pH correction
Appropriate supporting structures / fixtures for supporting pipelines
tanks, etc.
All valves, piping, fittings, etc. within battery limits
Instrumentation & controls
MCC and all electricals including cabling, cable trays, supports,
earthing, starters, push buttons, etc. within battery limits
O & M manuals
2.4.3
Performance Guarantee
The Tenderer should guarantee that the net output and quality of treated water
from DM plant stream as given below :
Output of Pre-treatment plant stream : 40 m/hr
Output of DM plant stream
Net output of treated water
per regeneration
OBR
1000 m3
Flow rate
Maximum :
Minimum :
Normal
55 m3/hr
8 m3/hr
50 m3/hr
Quality of DM plant water

Specific electrical conductivity at
250C measured after degassing max.
us/cm : 0.2
Total iron
max.
ppm : nil
Total copper
max.
ppm : nil
293
Total silica (as SiO2)
max.
ppm : 0.02
pH at 25 Deg.C
: 8.5 - 9.2
Permanganate
2.4.4
max.
ppm : Nil
Total Hardness (as CaCO3)
ppm : Nil
Total CO2
ppm : Nil
Oil & Organic matter
max
ppm : Nil
Total dissolved solids
max
ppm : 0.1
Total suspended solids
max
ppm : Nil
Residual Phosphate
max
ppm :
Nil
Codes & Regulations

The water treatment plant shall comply with all applicable codes and
regulations. In addition, following standards shall be applicable:
Pressure
thickness)
Painting
vessels
Type of Flanges
Vessel sheet
Vessel dished ends
Rubber lining on vessels
DM plant guidelines
(for
ASME Section VIII DIV. I/IS 2825
Manufacturers
Standards
as
approved by karkhana / consultant
B Table
IS 2062
IS 2062
IS 4682 Part I
IS 13268:1992
:
:
:
:
:
294
2.4.5
Basis of Design
Pre-treatment
including dosing
MGF & ACF
DM Plant
Qty.
Source of water
plant
system,
Normal flow
No. of regeneration / day
Operation of the plant
Raw water inlet pressure
DM
water
discharge
pressure at Exit level
Raw water analysis
2.4.6
30 m3/hr or 600 m OBR
:
:
:
600 m3 OBR
1 no.
River water. In case of exigencies,
borewell water will be required to be
used for process and boiler. Hence
the water treatment plant should be
designed accordingly
DM plant 30 m3/hr
One (maximum of 4 hours)
Manual
2.5 kg/cm2g
1.5 kg/cm2g
:
:
:
:
:
:
As given in Appendix XVI. Tenderer

to design the water treatment plant
by considering 300% higher loading
than the given raw water analysis.
This is to accommodate usage of
borewell water during exigencies
Tenderer to also design the WTP for a
total silica load of 25 ppm
Technical specifications of Water Treatment Plant

The complete system shall preferably be skid mounted (on RCC foundation).
All ladders and platforms required for assessing equipment for operation or
O&M will be provided by Tenderer.
All equipments shall be designed for 1.5 times the maximum operating
pressure
All drain points shall be led to one point and to the neutralising pit
Resin traps shall be provided after every exchanger to remove fines, etc. of
the resin media caused by attrition and backwash.
Strainers of SS or PVC to be installed in the back wash outlet of exchangers.
295
Back wash flow should be measured by V notch provided by Tenderer.

All pressure gauges shall be provided with isolation valves
Polyelectrolyte dosing to be specified in the filtration system for removal of
colloids.
DM water pipe should be MSRL / SS 304
All degasser wetted components to be of SS / Polypropylene. Degasser
pump to have auto on-off based on degassed water level.
HDPE piping for acid / alkali measuring tank, MSRL / SS 304 for DM water
piping
All ion exchangers and acid & alkali storage tanks / measuring tanks /
dilution tanks shall be of MS rubber lined construction.
Piping and all flanges at battery limit shall be as per B Table
Material for pumps: feed water pumps CI, acid / alkali pumps PP, DM
water pumps SS 316
Online pH and conductivity meters with recorder with alarm for mixed BED
outlet and online pH measurement for SBA & MBU.
Flow meters of vortex type for DM water after mixed bed
Rotameters with bypass rotameter at inlet & outlet of DM plant.
Butterfly valves with EPDM seating are required. For smaller size, diaphragm
type valves with neoprene diaphragm can be used.
For corrosive
applications valves will be ebonite lined or with CF8M disc. PVC ball valves
are acceptable.
Electrical : local push button station shall be provided for pumps and fans
Painting : all exposed unmachined parts shall be painted with colour code as
per relevant IS specifications
Minimum resin life of five years or higher including attrition losses to be
specified, quality of resin, make, type, quantity for each stream to be specified
All pressure vessels thickness to be designed as per ASME Section VIII
All treated water tanks and piping to be MSRL
75% of free board (void space) in all vessels of DM plant exchangers and
100% for mixed bed exchangers for expansion
For internal parts of the bed, MOC of Polypropylene is required.
Instrument air, if required, will be provided by Owner at 4 kg/cm2g
For pipe sizing :
Pump suction
Pump discharge
Compressed air
:
:
:
0.7 m/sec.
1.5 m/sec.
20 m/sec.
296
Piping materials : For water, IS:1239 / IS:3589 ERW / EFW pipes will be used.
2.4.7
Minimum corrosion allowance of 1.6 mm to be provided.
Instrumentation List (With Connectivity To DCS)

Sr.
No.
1
2
3
4
5
6
10
11
Description
DP for basket strainers at raw water transfer pump
Level Indicator for clarified water storage tank
DP for basket strainers for clarified water transfer pumps
Level indicator for
a) Soft water storage tank
b) DM water storage tank
c) Service water storage tank
Low level alarms as above (4)
Vortex flow meters
a) softener outlet
b) MB outlet
c) RO outlet
Float type flow meter
a) inlet to MGF UFROMB line
b) Inlet to MGF softener line
Online pH meter
a) RO outlet 2 each
b) DM outlet 2 each
Conductivity meter
a) RO outlet 2 each
b) DM outlet 2 each
Level gauges
- Acid & Alkali Tanks & dosing tanks
Low level alarm
- clarified water storage tank
297
2.4.8
Material Of Fabrication Of Equipments And Piping Wherever Applicable

01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Clarifloculator
Inlet well
Alum Dosing Tank
NaOCl dosing tank
Polymer Dosing Tank
Lime Dosing Tank
Mixing channels
Clarifier
Clarified water storage tank
Multi grade filter
ACF
Acid Measuring Tank
Anti Scalant Tank
Fast Flush Tank
Backwash Tank
Degasser Tower
Degassed Water Tank
Degassed Blower
Degassed water pumps
MB Unit
ETP Pump
Acid and Caustic Lye Pumps
Neutralisation pit
Softener
Brine Dosing Tank
Sludge Sump
Sludge Pumps
DM water piping
Soft water piping
UFRO Unit
Rotating Bridge Type

RCC
HDPE / FRP / MSRL
HDPE / FRP / MSRL
HDPE / FRP / MSRL
HDPE / FRP / MSRL
RCC (Through flow pipe)
RCC
RCC
MSEP
MSEP
HDPE / MSRL
MS / MSRL
HDPE
HDPE
HDPE / FRP
MSRL
MSRL
SS 316 internals
SS 316
MSRL
SS 316
PP
RCC with acid proof tile lining
MSEP
RCC Bitumen
MSEP / Bitumen
RCC
SS 304
MSRL
MS
SS / PVC / MSRR
298
33
34
35
36
37
38
39
2.4.9
Effluent / Sludge Slurry

DM water tank
Soft water tank
Filtered water storage tank
All dosing pumps
Raw water pumps
Filtered water and clarified
water pumps
PVC
MSRL
MSEP
MSEP
SS 316 internals
CI
CI with SS 316 internals
Laboratory Equipments
Tenderer to include all lab items required to monitor all parameters specified in
the quality of DM water.
Sr.
No.
1.
Item with description and specifications

pH meter digital
Range 0 -14
Accuracy 0.01 pH
ORION/EUTECH make
Qty.
(Nos.)
2
2.
Conductivity / Salinity / TDS / Meter (Digital)

Range - 0-199, 990 in 4 ranges
Accuracy - 0.5 % FS
ORION / EUTECH make
3.
D.O. meter
Model - 850 (ORION)
Range - 0-20.0 mg/2
0-200 %
With salinity and barometric pressure compensation
with data logging
Modern water analyzer equipment to the following
broad specifications
(Spectrophotometer)
Wavelength 400 - 900 nm preprogrammed methods for
water analysis / waste water analysis. Capable of giving
results in direct concentration. RS 232 link interface for
down loading to printer or PC Data storage capacity.
4.
299
Program methods to analyze and test water for about 70

parameters including silica, chloride, phosphate, nitrate
hydrazine, iron etc. To operate on AC supply or battery
back up.
2.5
AIR COMPRESSOR & DRYER
2.5.1
System Requirements
The purpose of this system is for supply of compressed air for control drives,
control valves, pneumatic tools and miscellaneous control system and supply of
plant air to the power plant. Service air needs will also be provided by this
compressor and will be designed for minimum 40 m/hr. The system will
provide a reliable supply of air that is free of water, oil or solid contaminants.
The compressors are to be opposed, belt pulley driven, non-lubricating type
reciprocating air compressors complete with drive guards, AC electric motors,
LPBS, air receiver, intercooler, after cooler, moisture separators, air dryer,
moisture traps, all interconnecting pipe work & fittings, control panel, etc. The
heat exchangers shall be designed as per TEMA-C and coolers shall be mounted
horizontally. The air receiver shall be fabricated from SA 515 Gr. 70 or IS : 2002
material. The internal surface shall be galvanised.
Control air will be supplied to boiler and its auxiliaries, turbo generator and its
auxiliaries and common plant auxiliaries like water treatment plant, fuel
handling plant, ash, pump house etc. Compressed air will meet the requirements
as stated below :
Capacity
: 200 m3/hr or higher as per plant needs
Nos.:
: 2 nos. (1 operating & 1 standby)
Pressure at receiver outlet
: 7 kg/cm2 (g)
Dew point temperature at

atmospheric conditions
: (-) 400C
Particulate material size (max.) : 1 micron
300
Contaminants
: No corrosive, hazardous, toxic

Or flammable material
Oil Content
: 100% Oil Free
It is proposed to interconnect the service air system with the instrument air
system before the instrument air dryers. A non-return valve and a manual
isolating valve will be provided in this line so that instrument air cannot be
supplied to the service air system.
2.5.2
Operational Requirements
It is envisaged that the air compressor, air receiver and air dryer will operate in
series. However, the facility will be provided by suitable design / layout of the
station air pipe-work, to operate each item in a sectionalised manner.
It is proposed to have common compressed air system meeting both instrument
and service air requirement. With this approach compressed air after a common
air receiver, a part of air will be directed to an air- drying plant and balance will
serve the requirements of plant service air. The service air will be tapped off
from up-stream of the air-drying unit. Air from air-drying plant will be directed
to instrument air header, which will cater the requirements of instrument air for
plant operation.
2.5.3
Other Technical Requirements

Each air compressor will include the following accessories
a) Silencer and filter for air intake
b) Inter cooler for multi-stage compressor complete with trap station with
bypass arrangement.
c) After cooler complete with trap station with bypass arrangement
d) Air receiver of 1 m3 (water volume) or higher capacity to hold air and
minimize pressure fluctuations.
e) Instrumentation to monitor and control the whole compressed air system
including pressure gauge, pressure transmitter, temperature gauge and
temperature transmitter.
f) All pipes will be ERW heavy duty, C class.
g) Interconnecting valves, safety valves, NRVs and piping.
301
h) All valves for air will be ball valves with Teflon seating. All valves for water
to be ball valves designed for 5 kg/cm2(g) pressure.
i) Automatic moisture traps at both compressors and at receiver.
j) Water for cooling will be provided at 1.5 kg/cm2(g) to 2.5 kg/cm2(g)
k) Cooling water will be available at 320C
Air compressor package shall be skid mounted with inter and after cooler,
receiver, dryer, automatic control and monitoring system. The compressor
piping shall be galvanized. The heat exchangers shall be as per TEMA C
standards for heat exchanger, cooling water flow through tubes. Heat exchanger
tubes shall be of copper and carbon steel surfaces susceptible to corrosion shall
be hot dip galvanized. The shell material of moisture separator, after cooler shall
be of IS 2002 Gr. 2. The electric motor shall be as per IS 325 and compressor is
driven through flat belt-pulley. Electric motor shall be of IP 54 enclosure. All
interconnecting piping shall be galvanized.
2.5.4
Air Drying Plant

One no. heatless type air drying plant of 200 m3/hr capacity or as per compressor
capacity with 2 nos. drying towers with Activated Alumina as desiccant will be
installed at compressor outlet for producing moisture free air of instrument air
quality. Re-generation shall be done using purge air. The material of absorber
tower shall be of IS 2002 Gr. 2. The maximum air pressure drop shall be limited
to 0.3 kg/cm2. The air dryer plant outlet air pressure shall be 7.0 kg/cm2g and
the maximum air temperature shall be 400C. The mechanical design pressure of
air drying plant shall be 10.5 kg/cm2 (g)
2.5.5
Air Receivers
The receiver will be self-supporting cylindrical vessel. The receivers will be so
sized that in the event of a compressor failure, the receiver pressure will not fall
from the normal working pressure of 7 kg/cm2 (g) to 4 kg/cm2 (g) in less than 5
minutes time. The air receiver shall be designed as per IS 2825. Material of
construction shall be IS 2002 Gr. 2 and the design pressure shall be 10.5
kg/cm2(g). Minimum capacity of the receiver will be 1 m
302
2.6 FUEL & ASH HANDLING SYSTEM

2.6.1
Bagasse Handling System
1 No belt conveyor (BC-1) to feed the bagasse from Elevator to Slat Conveyor
(SC-2)
1 No slat conveyor (SC-2) to feed the bagasse to the boiler or to conveyor no

EX BC -3 from the bottom deck.
1 No belt conveyor (EX BC-3) to carry the excess bagasse to the belt conveyor
(EX BC-4)
1 No belt conveyor (EX BC-4) to carry the excess bagasse to the storage yard
Belt conveyor (UN BC-5) to feed the bagasse from the yard on to Belt
Conveyor BC-6. This conveyor (UN BC-5) shall be partially under ground so
that it should be possible to feed the bagasse to this conveyor by pay loaders
at the rate of 40 MT/Hr & partially inclined to receive the bagasse from two
nos. bale breakers. 1 No over band type magnetic separator suitable for 1200
mm width belt to be mounted on inclined portion of UC-BC5
1 No belt conveyor no BC-6 to feed bagasse to the top deck of slat conveyor
no SC-2.
2 numbers bale breakers of 20 TPH capacity along with 20 Mtr long feeding
belt conveyor of 800 mm width.
1 number de-trasher of 10 TPH capacity.
1 number wood chipper of 10 TPH capacity
Since the bagasse is sticky in nature, it is necessary that the scrappers

provided shall be of rotary brush type to ensure effective scrapping before the
run of the return belt.
The drive assembly shall include the gearbox, coupling, common base frame,
guards, electric motors, local push button stations etc.
303
The technical parameters of above conveyors are tabulated below:

Sr.
no
1
2
3
4
5
6
7
9
10
11
12
13
14
Description
Capacity TPH
Material
Bulk Density
Kg/M3
C/c Distance
Mtr
Lift Mtr.
Angle of
Inclination
No of feed
points
No of
discharge
points
Type of
conveyor
Conveyor
Width mm
Belt Weigher
Walkway
Hood Cover
Special
requirement
BC-1
SC-2
EX BC- EX BC-4
3
30
30
Bagasse
150
150
UN BC-5
BC-6
40
40
40
40
150
150
150
150
48
78
100
60
60
91
21
260
0
0
0
0
0
0
5
100
27
16.50
Through
out the
length of
underground
portion
1
Cleated
Belt
1200
Chain
Belt
Belt
Belt
Belt
1600
1200
1200
1200
1200
Required for conveyor no BC-1& BC-6

Both side walkways of 750 mm & 600 mm to be provided
Hinged type hood cover (100 % dust proof) to be provided for all
the conveyors
5 no rack
4 Nos. V
& pinion
ploughs
gates are
to be
to be
provided
provided
304
2.6.2
Ash Handling System:

Submerged belt type conveyor (SBC- 1) to collect & convey the ash from the
boiler bed & convey it to conveyor no ABC-3. This conveyor has to be
mounted in a MS trough; the belt should be submerged in water with a level
of minimum 250 mm.
Screw conveyor (ASC-1) to feed the ash from Economizer & Air pre heater on
to the cross belt conveyor (ABC-1)
Screw conveyor (ASC-2 ) to feed the ash from ESP Hoppers on to the cross
belt conveyor (ABC-2)
Cross belt conveyor (ABC-3) to convey ash from SBC-1, ABC-1 and ABC-2 to
ash silo.
Ash Silo of 50M3 capacity with the supporting structure and sector type
discharge gate of minimum 350 NB size
Ash Disposal : All the ash generated in boiler bed, economizer, air pre-heater
and ESP will be collected in a common ash silo through mechanical handling
system comprising of submerged ash, screw conveyor and cross belt conveyor as
shown in the layout.
Ash is then dumped in open space of through trucks / dumpers. This open
space should preferably be near to the cogen plant to minimize the
transportation cost.
305
The technical parameters of above conveyors are tabulated below.

Sr.
No
Description
Capacity
TPH
2
3
Material
C/C
distance, m
Lift, m
Angle of
Inclination
Type of
Conveyor
Width/
Diameter of
the
conveyor
One side
Walkways
4
5
6
7
2.6.4
Submerge
d Belt
conveyor
below Bed
Ash
Hopper
(SBC-1)
1.0 for
bagasse
Ash
Screw
Conveyor
below
ECO &
APH
Hopper
(ASC-1)
1.0 for
bagasse
Ash
18
10
2.1
160
0
0
0
0
Belt S H R
grade
1000 mm
Screw
Required
for partial
length
Screw
conveyor
below
ESP
Hopper
Belt
Conveyor
(ABC -1)
Belt
Conveyor
(ABC 2)
Belt
Conveyor
(ABC -3)
1.0 for
bagasse
Ash
3.0 for
bagasse
Ash
15
80
3.0
60
3.0
60
10
140
Screw
Belt
Belt
Belt
300 mm
300mm
500 mm
500 mm
650 mm
NA
NA
NA
NA
Required
for partial
length
(ASC-2 )
2.0 for
1.0 for
bagasse
bagasse
Ash
Ash
Bagasse / Biomass ash
13
15
Instrumentation & Controls

Safety switches for the system including zero speed, pull chord at a spacing
of 30 Meters. on both sides, belt sway switches at a spacing of 60 Meters,
emergency switches, as applicable.
Control System including control panel for the sequential operation with inter
phase facility to communication with the boiler control system.
Local instruments including switches, instrument cables, terminal boxes,
cable trays & accessories, as required to make the system complete.
306
2.6.5
General:

2.6.6
Interconnecting chutes, hoods over conveyors supporting structures,

maintenance Platforms ,approach ,etc as required
Any other item not specifically mentioned above but required for
satisfactory performance of the fuel and ash handling system
Consumable materials as required for erection & commissioning including
electrodes. First fill lubricants, flushing oil, etc.
Two coats of primer, one coat of finished paint & final painting at site.
Performance Test.
Detailed Technical Specifications

A)
Belt Conveyor
The length of the conveyors is indicated in the scope of work are drive
pulley centre to discharge pulley centre (c-c) distance & they are
approximate. The exact length and lift of the conveyor shall be determined
by the Tenderer based on the design parameters indicated and taking into
consideration the dimensions and arrangement of the equipment offered
by the Tenderer.
The carrying capacity indicated are the rates at which the equipment shall
be guaranteed to operate continuously. The angle of inclination of
conveyor belts shall not exceed 18 deg to the horizontal for standard belt.
For inclination up to 300cleated type belt shall be provided. The belt
conveyors and accessories shall be suitable for continuous operation
under severe duty working condition. Design &construction feature of the
belt conveyor shall be in accordance with IS: 11592.
The scope of supply shall include but not limited to the belting, idlers,
(carrying, return, impact, SACI & SCRI), pulleys including head, tail/ take
up, snub, bend., belt internal/ external cleaners, take up units, drive unit
complete with electric motors, reduction gear boxes, flexible coupling, for
both high speed and low speed sides, base frames, integral hold back
device, electric safety switches, auxiliaries like skirt board, deck plates,
dust seals, coupling guards, take up guards etc., structural item like
stringers, short supports, take up frames, conveyor gallery, walkway,
conveyor support columns and frames, hoods and all other accessories
that may be necessary to make each conveyor and the system complete.
307
The belt shall be of Nylon- Nylon type with suitable top and bottom
cover. The number of plies and weight of duck shall be suitably selected
with due regard to load/flexibility of troughing. Hot vulcanising shall be
considered for the joints.
The idlers shall be made of seamless /ERW steel tubes. The idler rollers
shall be fitted with deep groove ball bearings.
Troughed idlers shall be concentric and shall have 3 rolls, 20 deg.
Troughing angle. All bearings shall be designed for a minimum life of
40000 working hours. The return idlers shall be single roller flat type and
covered with rubber sleeve wherever required. Impact idlers shall be
provided at the loading each loading point. The roller assemblies shall be
designed to prevent dust accumulation.
The spacing for the troughing and return idler shall be as per IS
11592.Shorter spacing shall be considered for the bends and for reasons of
heavy loading. The impact idlers spacing shall not be more than 300 mm.
Self aligning carrier and return idlers shall not be more than 20 Meters
apart and more than 15 meters from each terminal.
The conveyor pulley shall be welded steel construction with closed ends.
The pulley diameter shall be designed for maximum belt life and confirm
to IS specification. The entire assembly of the pulleys shall be balanced
and grooved rubber lagging shall be provided for the drive pulleys.
The take-up shall be vertical gravity type for the inclined conveyors and
screw type for short conveyors up to 30 Mt. length. The unit shall be
complete with counter weights, take-up pulleys and structural frame to
make the installation complete.
Skirt board shall be provided at loading zones and in other places to
prevent spillage. The skirt plate thickness shall be minimum 6 mm and the
rubber strip thickness shall be minimum 10 mm. The deck plates shall be
2.0 mm for the entire length of the belting.
308
The belt conveyor shall be complete with coupling guards, discharge /

feed hoods, pulley guards drives supporting structure, maintenance
platforms and drive platform shall have adequate space on both sides to
attend to drive unit.
All conveyors shall have removable type hinged hoods with industrial
hinged & painting. The hood shall be fabricated from minimum 1.6 mm
thick M S sheets with suitable stiffeners & clamping arrangement.
B)
Chain & Slat Conveyor

The length of the conveyors is indicated in the drawing are from drive
sprocket centre to discharge sprocket centre ( c-c) distance & they are
approximate. The exact length and lift of the conveyor shall be determined
by the Tenderer based on the design parameters indicated and taking into
consideration the dimensions and arrangement of the equipment offered
by the Tenderer.
The carrying capacity indicated are the rates at which the equipment shall
be guaranteed to operate continuously. The angle of inclination shall not
exceed 45deg to the horizontal. The slat conveyor and accessories shall be
suitable for continuous operation under severe duty working condition.
Design &construction feature of the slat conveyor shall be in accordance
with relevant I S Standard.
The chain conveyor shall be of all steel construction suitable for outdoor
duty and for the specified conveying capacity. The linear speed of the
conveyor shall not be more than 25 M/ Min.
The scope of supply shall include but not limited to the chain, sprocket,
slat, take up units, drive unit complete with electric motors, reduction
gear boxes, flexible coupling, for both high speed and low speed sides,
base frames, integral hold back device, electric safety switches, auxiliaries
like deck plates, dust seals, coupling guards, take up guards etc.,
structural item like short supports, take up frames, conveyor gallery,
walkway, conveyor support columns and frames, hooks and all other
accessories that may be necessary to make each conveyor and the system
complete.
309
The chain shall be of forged steel with suitable attachment for mounting
the slats. The chain shall be supported on the suitable guides. The
minimum factor of safety for chain design should be 10.
The braking strength of chain shall be minimum 60,000 Kgs.
The slats should be made up of I S 2062 & the minimum thickness shall be
6 mm.
The sprocket shall be of cast steel with machine cut teeth & the diameter
shall be designed for maximum chain life and confirm to IS specification..
Suitable take up shall be provided. The arrangement drawing should be
furnished with the offer.
The slat conveyor shall be complete with coupling guards, discharge/
feed chutes, coupling guards, drives supporting structure, maintenance
platforms and drive platform & shall have adequate space on both sides to
attend to drive unit.
C)
Screw Conveyor
The screw conveyor assembly shall include the screw flight, pipe shaft,
trough, trough cover, end cover, bearings, hanger bearings , end shaft,
trough end seals, saddles, inlet & outlet spouts, drive unit complete with
electric motors, reduction gear box, couplings for both high speed sides,
weather hood for drive box, structural items like short supports, drive
platform, approach and all other accessories that may be necessary to
make the conveyor complete .
The screw flight shall be of 6mm thickness (minimum).
The trough & trough end cover thickness shall be minimum 6 mm &12
mm thickness respectively.
Provision for thermal expansion shall be provided if the outlet flange of
discharge point is directly connected to the screw conveyors. Necessary
expansion bellows are in the Tenderers scope.
Hard facing of the screw flight shall be out on the carrying side for 1 face
width (minimum)
310
Packed gland seal shall be provided at tail or drive shaft opening in the
trough ends to prevent material leakage.
Pitch of the screw shall be 0.8 to 1 D where D is the diameter of the
screw. However, to meet the required capacity, the pitch may be
maintained short, half or long.
D)
Submerged Belt Conveyor

The submerged belt conveyor assembly shall include belt, idlers, pulleys,
trough, pressure pulleys, return rollers, take-up arrangement, drive unit
complete with reduction gear box, belt internal & external scrapers etc. to
make the system complete in all respect.
Inter connecting chutes, supporting structure, safety / indicating
instruments, drive assembly, supports, maintenance platform, frames,
drive base, approach etc. as required by the conveyor.
Water piping, inlet & outlet drains up to the terminal points as required
by the system
Minimum of 200 mm water seal has to be maintained at the discharge
point of chutes in to the trough of the submerged belt conveyor.
The inside of trough shall be quoted with one coat of Tar paint and the
trough material shall be minimum 10 mm thick.
The belt speed shall be limited to 5 M/Min
E)
Chutes
All the conveyors shall be provided with discharge /receiving chutes for
the flow of material. The chutes shall be fabricated from minimum 6 mm
thick M S plates. Whenever required suitable liner plates shall be
provided to with stand the erosion due to falling material. The liner plates
shall be bolted to the main plate. Feed & discharge chutes shall be
provided from conveyor to conveyor.Sufficient number of pock holes &
access door shall be provided in long chutes.
311
F)
Supporting Structure
The complete supporting structure required for the Fuel and ash handling
system will form part of scope of supply. The complete structural work
above finished floor shall be of steel
G)
Fly Ash Silo

Silo shall be designed for storing the quantity of ash generated at various
points and the capacity shall be minimum 50 M3. The silo shall be of M S
construction and the conical portion of the silo shall be lined with
TISCRAL/ SISCRAL liner of 5 mm thick. Sufficient headroom & side
clearance shall be provided below the silos for bulk tankers/ trucks
movement.
H)
Discharge Gates/ Chutes

Manually operated discharge / diverter gates shall be provided whenever
required to facilitate flexibility of operation and maintenance of the
system. The gate shall be fabricated from minimum 10 mm thick M S
plates. The gate shall be provided with antifriction bearings with suitable
seal for free movement. The gate shall be of rack & pinion type.
All the conveyors shall be provided with discharge /receiving chutes for
the flow of material. The chutes shall be fabricated minimum 6 mm MS
plates. Whenever required suitable liner plates shall be provided to
withstand the erosion due to falling material.
I)
Discharge Hood & Chutes

All the conveyors shall be provided with discharge/receiving chutes for
the flow of material. Also the discharge chute shall be designed to cover
the belt scrappers at the bottom of the belt. The chutes shall be fabricated
from minimum of 6mm MS plates.
Wear & abrasion resistant (ultra high molecular weight polymer) liner
should be provided on material sliding surface. The liner shall be fixed to
MS plate by mechanical fasteners or welded washer system and discharge
chutes shall be provided from conveyor to conveyor.
312
Properly designed discharge for effective de-dusting and dust tight

flexible rubber access door (min 400sq.mm) shall be provided the height of
the discharge hood shall be 1500 mm from the belt top. Deflectors shall be
provided in discharge hoods wherever the belt conveyors are discharging
at 90 degrees.
The back end of discharge chute and return belt shall be properly sealed
by replaceable rubber strip to avoid dust nuisance.
Sufficient number of poke holes (min 100NB pipe) and access door
(min400sq.mm) to be provided in long chutes with access platform and
staircase.
J)
Junction towers
All junction towers shall have maintenance platforms, landings, hand rails
& toe plates. All floors & landings shall be provided with minimum 2500
mm clear head room.
2.6.7
Instrumentation
The material handing system (bagasse & ash) will be controlled by the DCS. The
interlocks will also be provided in the MCC. The ash handing system will have
all the primary sensors that are required for the sequential /safe operation of the
system offered.
2.6.8
Specific Requirements for the System Components

The reduction gear box used shall be of worm gear completely enclosed with
flash lubrication. The gear box shall be rated 24 hours continuous working with a
minimum service factor of 1.5 on the installed motor capacity.
The couplings provided shall be of flexible type and shall have a minimum
service factor of 2 on the installed motor capacity.
All bearings shall be preferably anti friction type and self aligning in nature The
bearings shall have effective and dust covered. The bearing shall be selected for a
minimum working life of 40000 hours Effective lubrication shall be provided for
all bearings and sliding surfaces .
313
All the structural steel used shall meet the requirements of IS: 2062 and the Steel
plates used shall not be less than 5mm thick.
A minimum walking /maintenance space of 750 mm on both sides shall be
provided for the entire length of the conveyors. The walkway shall be complete
with hand railing, approach ladders etc.
All the conveyors outside the building shall be covered by removable type hoods
.The hoods shall be fabricated from minimum 2 mm thick by MS sheets/ Metapoly sheets with suitable stiffeners and clamping arrangement.
All sprockets in the drive unit shall be of cast steel with machine cut teeth. The
shaft shall be of EN8.
2.7
2.7.1
COOLING TOWER & AUXILIARIES

Scope of supply and services of basic equipment
This section details out the scope of supply and services for package cooling
tower with auxiliaries as indicated
Scope of supply of cooling tower
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Three cells, cooling tower, 4800 m3/hr capacity with RCC basin and all
civil works (Capacity calculation to be furnished by Tenderer to include
all CW needs of the cogeneration plant with minimum 10% margin, with
out surface condenser temperature pick-up of 8C)
Recovery stack
All supporting structures
Entire fills and support
Drift eliminators
Ladders for easy accessibility to fan deck
Fans, gearbox, motor, vibration and oil level limiters / indicators /
alarms and control
All associated instrumentation
Required partitions, supports, etc.
NaOCl dosing system
Following digital / analog signals to be given.
314
A.
Level indication and alarm for low level : for water in the
cooling tower basin. Vibration alarm for the fan assembly.
B.
Temperature of CW inlet at CT entry and CW outlet at

terminal points with annunciation for high / low level
C.
Low oil level indicator switch with transmitter to be

provided for each Fan Gear Box
The Tenderer further guarantees the following:

The total pumping head required (including static height and losses in
pipes and distribution system) with respect to normal water level in the
basin at Tenderers terminal point shall not exceed 25 MWC at design
flow.
The hot water returning from the auxiliaries is cooled in the cooling tower,
designed for a cooling range of 8 Deg. C and an approach of 5 Deg. C
while operating under the atmospheric wet bulb temperature of about 28
Deg. C.
The structure shall be designed for wind and other loads as per IS:875 and
earthquake resistance as per IS:1893. The cooling tower shall be carefully
sited such that there is no re-entrainment of the vapours into the auxiliary
cooling tower.
2.7.2
Features of Construction
The induced draft counter flow cooling tower shall be complete with tower,
basin foundation and mechanical equipment as described below, the tower shall
be of double inlet flow type of construction. The tower shall be of induced draft
type with the fans located on top of the tower. The Tenderer will supply asbestos
free cooling tower.
a. Casing
Casing of field erected towers shall be of RCC. External casing as well as
partition walls in between cells shall be provided with air tight access
doors.
315
b. Inlet Louvers (as applicable)

The water loss in the louver openings shall be prevented with proper
slope, width, spacing and tightness of louvers, RCC Louvers must be
properly designed to give uniform distribution of air with minimum
pressure drop and must be able to withstand corrosive atmosphere.
Slip fit type louvers may be provided for access to interior of tower, as per
design.
c. Fill and Fill Supports
Modular film fill made of extruded PVC supported on RCC beams. They
shall be adequately supported to prevent sagging and damaging. The
tower shall be levelled so that water will be uniformly distributed over the
film fill and does not cause channelling.
d. Supporting Structure
RCC supporting structure shall be designed to withstand the wind or
earthquake loads, dead load such as weight of the tower and circulating
water and line load and live load.
e. Drift Eliminators
The drift eliminators shall be designed to keep the drift loss to a maximum
of 0.1% of the circulation rate. The air pressure drop across the eliminators
shall be kept to a minimum by providing a proper number of air flow
direction change across the eliminators, the water collected in the
eliminators shall be returned to the tower basin and shall not mix with the
discharge air stream, eliminators shall be multi-pass. Herring bone type or
angular honey comb arrangement or cellular type.
Asbestos materials are not to be used and only PVC or HDG materials are
to be used.
316
f. Water Distribution System

The hot water shall be distributed to the fill through distribution basins
through, distribution nozzles. Hot water shall be distributed to the basin
by steel pipes. The water shall be equally distributed among the working
cells by having control valves in the supply pipes. These shall also serve as
isolating valves for the cells. The control valves shall be easily accessible
for any maintenance work.
g. Recovery Stack
Recovery stack shall be of proper shape to improve the fan performance.
The height of the stack shall be sufficient to recover the velocity and
discharge the humid air at a sufficiently high level to minimise recirculation. The minimum clearance between the stack and fan blades
shall be maintained along the entire periphery of the stack to prevent the
rubbing of fan blades while rotating.
The height of the RCC stack shall be sufficient to recover the velocity and
discharge the humid air at a sufficiently high level to minimise recirculation. The minimum, clearance between the stack and fan blades
shall be maintained along the entire periphery of the stack to prevent the
rubbing of fan blades while rotating.
h. Fan Deck
The fan deck should be sturdy in construction to transmit the live loads to
the frame, to support a stack and act as an access plat form for the
mechanical equipment and distribution system.
i. Internal Walkways
Walkways with platform and toe bolts and suitable handrails shall be
provided inside the towers. The drift eliminators shall be easily accessible
from these walkways.
317
j. Hardware
The hardware used shall be a combination of hot dip galvanised steel,
naval brass, phosphor bronze, silicon bronze and stainless steel, Generally
all hardware material above fan deck level shall be hot dip galvanised
steel and below fan deck shall be of phosphor bronze. All bolts nuts and
washers and rails shall be SS 304 and nails shall be screw shank type. All
hardware items to be SS 304.
2.7.3
Mechanical Equipment
a. Fans
Fans shall be of open type, multi blade construction with the blades of
aerofoil section. Fan blade shall be of cast or moulded construction. These
shall be of easily removable and adjustable pitch type. Blade shanks and
hubs shall be suitably insulated to prevent electrolytic corrosion.
b. Fan Drives
Fan drives shall be as follows :
Reduction Gear Drive The gears shall be of spiral bevel, helical or

worm type. The gear reduction may be of single stage or
multistage. All gear drives shall be of enclosed type and shall
operate in oil bath. Remote oil level indicators, fill and drain lines
of SS:304 shall be provided. The service factor of the gear drive
shall be minimum 2 for bevel and helical gears.
For worm gear drive the service factor shall be 1.5 for more than 22
KW continuous duty and 1.2 for less than 22 KW continuous duty.
Low oil level indicator switch to be provided for gear boxes. All oil
piping to be in SS.
The drive shafts shall have flexible coupling at both driving and
non driving ends. This shall be of hollow hot dip galvanised carbon
steel. The flexible, tyre coupling shall be used. Drive shafts shall be
dynamically balanced.
318
c. Prime Mover
The fan driver shall be an AC electric motor of squirrel cage induction
type confirming to attached specifications and Data Sheet.
2.7.4
Accessories
The following accessories shall be provided :
a. Staircase
A RCC staircase shall be provided on one side of cooling tower for access
to the fan deck.
b. Distribution Basin Cover
The hot water distribution basin, shall be provided with a suitable cover
to avoid direct sun rays falling on the distribution through or basin, to
minimise algae growth and to prevent choking of distribution nozzles
from external falling objects.
c. Hand Rail
Double hand rail of hot dip galvanised steel pipe, (32 mm nominal dia)
shall be provided on all open sides of the fan deck and distribution basin
cover.
d. Locally Mounted Instruments
The following instruments shall be supplied by Tenderer :
Float switches and transmitter to indicate high/low levels in the basin

Tenderer shall loan all necessary instruments required for testing the
cooling tower.
Low level oil indicator and annunciation in plant DCS (signal cabling
will be done by others)
e. Vibration limit switch to stop the fan on excessive vibrations and

annunciation in plant DCS
319
2.7.5
RCC Basin
Concrete cooling tower basin with a common outlet channel shall be constructed.
The structure shall designed as per IS:3370. Cooling tower basin shall be
provided with partition for isolation purposes basin shall be water tight without
the use of any fillers, paints or sealing compounds.
The blowdown system should be constructed in the RCC basin with all the
necessary isolation compartments, isolation valves/control valves, as per the
standard practices and good engineering practice for each cell to enable
controlling the blowdown cycle of CT basin water. Drain pipes should have
valves and lead to the common drain.
2.7.6
Materials of Construction
All materials of construction shall be of tested quality. These shall be free from
defects, imperfections, of latest manufacture and shall be of certified quality for
physical and chemical properties. Materials shall be of IS, ASTM, BS or any
equivalent standard.
2.7.7
Tests and Inspection

a. Performance Test
Field erected units after complete erection and commissioning shall be
field tested for performance. The test shall be conducted a time when the
atmosphere conditions correspond to as soon as possible the design
conditions. The test shall be conducted in accordance with the standard
procedure for acceptance test of Cooling Tower Institute USA.
The performance of the cooling tower shall be guaranteed over the
following ranges:
a) Cooling water flow 90% to 110% of design flow
b) Cooling range 80% to 120% of design range
c) Wet bulb temp (+) 1.70C to (-) 3.90C of design inlet wet bulb
temperature.
320
Tests shall be conducted at the works on the fans, gear reducers drives
etc., for satisfactory performance. Tests certificates for these shall
submitted for Owners approval.
Tenderer shall include in his bid for the supply and maintenance of all
instruments for the duration of tests period.
For the measurement of flow, during testing of cooling towers, Tenderer
shall supply pitot tubes (calibrated) for each of the risers for each tower.
Dry bulb and wet bulb temperature shall be measured by three identical
mechanically aspirated psychrometers or Vick type located at three
equidistant stations near each tower. The above thermometer shall be with
graduations not exceeding 0.10C
All water temperature shall be measured with mercury in glass
thermometers with 0.10C graduations
The wind velocity shall be measured by means of anemometer
An approved independent or National Laboratory shall calibrate all the
instruments used
b. Visual Inspection
After completion of work, equipment shall be offered for visual inspection
by Owner and/or his representatives. Any work or component not in
accordance with the specification and approved drawings shall be redone
or replaced to the specification of the inspector. Stage inspection if
specified shall be offered to improve the quality of the final product.
c. Painting & Protections
All parts which are subjected to wetting and drying alternatively shall be
painted with three water proof coats as detailed below :
First coating Bronze 75% coal tar 25%
Second coating Bronze 50% coal tar 50%
Third coating Bronze 25% coal tar 75%
321
All exposed steel and cast iron surface shall be given one coat of red oxide
anti corrosive primer and 2 coats of enamel paint of approved colour.
2.8
FIRE FIGHTING SYSTEM
2.8.1
System Requirement
The fire protection system is required to ensure protection of the facility in order
to combat an outbreak of fire, so as to reduce damage and consequential losses.
The fire protection system includes fire detection, containment and suppression
systems. The proposed fire protection system will be designed to provide
adequate safety measures in the areas susceptible to fire in the power plant in
compliance with the recommendations of the Tariff Advisory Committee (TAC)
for insurance companies of India, so as to enable the Owner to obtain the
available rebate on the insurance premium.
The entire fire fighting system will have a centralised panel housing the required
electrical, mimic of the system and will be hard wired to the centralised DCS to
show the mimic and provide alarms.
The indicative area wise requirement of fire detection and protection system will
be as given below:
SR.
AREA
NO.
1.
Transformers above
5 MVA rating in
Transformer Yard
2.
STG
Lube
Oil
Storage Tanks and
Purifiers
3.
Cable
Vault
in
Electrical / Control
Building
4.
Control Room
TYPE OF DETECTION
TYPE OF
PROTECTION
Quartzoid Bulb Detectors
Automatic High
Velocity
Water
Spray System
Quartzoid Bulb Detectors
Automatic High
Velocity
Water
Spray System
Ionisation
type
smoke Portable
Fire
detector
extinguisher
Addressable smoke detector Portable
Fire
of Ionisation & Photoelectric extinguisher
type
322
5.
6.
7.
8.
9.
Switchgear Room, Addressable smoke detector Portable

Fire
MCC Rooms in of Ionisation & Photoelectric extinguisher
Control/Electrical
type
Building
Battery Room
Portable
Fire
extinguisher
Electrical Rooms in
Portable
Fire
various
Plant
extinguisher
Buildings
Generator
Automatic
CO2
fire
fighting
system,
as
applicable
Conveyors
Smoke detectors will be Pressurised water
installed at all junction sprinkler system.
towers, at all locations of fuel
transfer and at every 30 m of
conveyor
length
with
interconnectivity to a water
sprinkler system
Apart from the above station building, transformer yard, boiler area, pumps,
compressor and fuel handling plant will be protected with hydrant system.
2.8.2
Indicative Bill Of Material

The power plant falls under ordinary hazard category.
Power house building, control room, switch gear room in control and other
electrical building, battery room, pumps and other area will be provided with
only portable fire extinguishers.
Water for fire fighting purposes will taken from the raw water reservoir and
stored in a fire water reservoir in the cogen premises.
323
2.8.3
Technical Requirements
Fire Water Pumps
All the fire pumps will be horizontal split case centrifugal type and jockey pump
end suction type. Suitable priming arrangement will be provided in case pump
is under suction lift condition of operation. All the pumps will be direct-coupled
type. The pumps will have the following features:
a.
b.
c.
d.
e.
f.
g.
2.8.4
The pumps will be designed for continuous operation at their best

efficiency points, which will be same as/close to the specified duty
points.
Pumps will have continuously rising head characteristic from the
operating point towards shut off without any zone of instability and
power capacity characteristic will be preferably non-overloading type.
The operating range of the pump will be between 40% of rated flow &
150% of rated flow.
The pumps head capacity curves will have a steady rise from 150% to
zero flow.
The jockey pump and the motor driven fire-water pumps will operate
satisfactorily and continuously at run out capacity conditions.
The maximum speed for all the main fire pumps will be 1500 rpm.
The motor will be of continuous rating type and maximum continuous
rating (at 500C ambient) will be at least 15% above the maximum load
demand of the driven equipment, under the entire operating range.
One of the main fire hydrant pumps shall be diesel engine driven.
Hydrant System
Pressurized fire hydrant system will consist of a pipe network and hydrants
positioned around the station in sufficient numbers and so located that all
buildings and risks are readily protected. Necessary number of loops will be
formed around various risks.
The loops will be interconnected for better reliability of the system. To isolate a
portion of the ring main because of damage/repair, suitable nos. of valves will
be provided.
324
The hydrant network will be sized and analysed to ensure that about 3.5 Kg/cm2
pressure is available at the hydraulically remotest point in the system with the
hydrant pump discharging at rated head and capacity. The velocity in the
hydrant main will not exceed 2 m/sec.
Hose pipes of suitable lengths along with standard accessories like branch pipes,
nozzles, spanners, etc. will be provided. These will be kept in a central hose
house for the outdoor hydrants. Each internal hydrant valve will be provided
with individual hose box having glass front containing hose pipes, hose reel,
branch pipes and nozzles etc.
Minimum running pressure will be 3.5 Kg/Cm2 at the base of each hydrant.
The general design of hydrant valve will conform to IS: 5290.
2.8.5
Portable Fire Extinguishers

Following types of portable fire extinguishers will be provided for the entire
power plant area at strategic locations.
a)
b)
c)
d)
2.8.6
2 kg capacity dry chemical powder fire extinguisher.

5 kg capacity dry chemical powder fire extinguisher.
2 kg capacity CO2 type fire extinguisher.
5 kg capacity CO2 type fire extinguisher.
Piping System And Valves

Both Hydrant and spray system piping will be run underground and through
Hume pipe at road crossings. Piping will be of mild Steel pipes(galvanized or
un-galvanized) of Medium grade confirming to IS: 1239/ 3589 or equivalent
acceptable international standard and coating and wrapping as per IS:10221.
Provisions will be made for extension of hydrant and spray system piping for
future extension of the project.
Piping for compressed air, breaching connections, drains, down stream of deluge
valves will be of heavy grade galvanized type.
All firewater piping will be capable of being drained completely and provided
with drain cocks / valves at low levels.
325
2.8.7
Layout Considerations
The fire water pumps, jockey pumps, diesel engine drives, etc. will be located in
the water pump house adjacent to the raw water cum fire water tank. The
firewater tank will be of concrete construction. Indicative plant layout is
provided in Appendix IV.
2.9 PIPING AND FITTINGS

2.9.1
Piping
All cogeneration plant piping will be as per applicable IBR / ASME standards.
All piping will be aesthetically and neatly laid on pipe racks with approved
colour coding. The cogeneration plant piping will inter-alia include raw water
intake from the plant water reservoir, water treatment plant to boiler &
auxiliaries, cooling water circulation, auxiliary cooling water circulation, plant
service water, plant potable water, plant sanitation, compressed air ring, drain
piping, treated effluent piping, steam piping from boiler to turbine, steam piping
from HP line via PRDSH stations to LP & MP headers, HP / MP / LP steam
piping to all cogeneration auxiliaries, steam piping upto LP & MP headers.
Appendices IV, XII, VII, VIII and V provides the plant layout, typical pipe
material specifications, CW system, plant water system and plant steam system.
HP piping to be sized for highest safety valve pressure at 110% MCR with
maximum pressure drop of 5 kg/cm for the entire piping. The pipeline will be
duly approved by IBR by the Tenderer on the buyers behalf. Standard fittings
like expansion loops, stream traps, supports etc. are to be provided. The line
should insulated to suit weather conditions and preferably of ceramic blanket
with mineral wool and aluminium cladding (22 g), to achieve skin temperature
of not higher than 65C. Stress analysis for the HP piping to be submitted by the
Tenderer along with IBR approved steam pipe drawing.
326
Piping design will be as per ASME B 31.1. All piping required for effectively
connecting the steam generator with the steam, feed water, and other systems
shall be provided. The piping provided shall be complete in all respects
including valves, fittings, supports etc. as required. Necessary supporting
materials, towers and trestles to support and anchor the pipelines at regular
intervals shall be supplied. Suitable expansion loops and hangers shall be
provided wherever necessary.
The correct locations of hangers and supports, with as applicable spring stiffness,
shall be considered for the flexibility analysis.
Suitable expansion loops restraints and anchors shall be provided so as to ensure
compliance with the applicable codes and to limit the stress and reactions to
within the allowable values.
i) The flow velocities in pipes shall be limited to the following values:
Super-heated Steam..
Saturated Steam..
Cooling water..
30-60m/sec depending on pipe size

20 to 35 m/sec
Up to 3 m/sec
ii) Drains at all low points and vents at all high point shall be provided.
iii) All local instruments shall be located on pipelines so as to render them
observable from the nearest available platform.
iv) Oil drains shall be sized to run no more than half full when flowing at
a velocity of 0.3 m / sec, and shall be arranged to ensure good
drainage.
All high pressure drain or vent valves or other valves to be provided with one
control & one isolating valve set, to prevent any passing of the operating valve.
All pipe to pipe joints shall be by butt welding only and no couplings shall be
used.
All flanges, when provided #300 class and above shall be weld neck type.
327
Pipe fittings like elbows, equal tees and reducers shall be as given below:
a)
For pipe size 50 NB and above shall be butt welded type.
b)
For 40 NB and below shall be socket welded type.
Branch connections:
a)
Socket welding half coupling, as per B16.11, for size NB 40 and below.
b)
Welded branch connections with proper reinforcements for sizes above
NB 40.
All pressure tapping for pressure applications above 40 kg/sq. cm. shall be of
size NB 20 with two root valves. For pressures 40 kg/cm2 and less the size shall
be NB 15 with one root valve.
All thermo-well boss shall be one(1) inch NPT.
The design of the piping system shall be based on the ANSI B37.1 code. In
addition the statutory requirements Flexibility analysis shall be made for all
piping systems with operating temperatures above 100C. The correct locations
of hangers and supports, with as applicable spring stiffness, shall be considered
for the flexibility analysis. suitable expansion, loops, restraints and anchors shall
be provided so as to ensure compliance with the applicable codes and to limit the
stress and reactions to within the allowable values.
Drains at all low points and vents at all high points shall be provided.
All local instruments shall be located on pipelines so as to render them
observable from the nearest available platform.
2.9.2
Piping Synopsis for WTP

1.
2.
3.
Service water for miscellaneous

requirement about 5 m3/hr from
service water pumps and to
potable water with pumps
DM water to feed water tank for
make up (DM storage tank pumps)
Neutralised
effluent
from
neutralization pit / pump
All
distribution
cogeneration plant
within
All
distribution
within
cogeneration plant
Up to ETP with PVC pipe of
appropriate size
328
4.
5.
2.9.3
Clarifier sludge from sludge pit Up to sludge drying beds in

pumps
ETP
WTP Integral piping
Includes piping from raw
water
reservoir
to
pretreatment plant From clarified
water tank to DM plant and
softening plant.
From DM
plant to DM storage tank
Piping Synopsis of Steam generator

Complete soot blower piping from the tap off on the primary superheater header
up to the individual soot blowers including all the pressure reducing station,
valves and fittings.
Feed water delivery piping from steam generator feed pumps up to the
economiser inlet header to the steam generating unit, via the HP feed water
heater.
Feed water line from feed water transfer pump outlet to the de-aerator.
Piping for high pressure and low pressure chemical dosing systems.
Required steam condensate and MP steam piping for HP heaters.
All the drain points provided for various equipment shall be suitably piped and
brought up to plant drain. The piping shall be provided with necessary fittings
like trap, valves, etc.
The complete blow down piping up to the drain trench including all valves
fittings etc.
The blow down lines from each blow down valves of the steam generator shall
be drawn individually up to the blow down tank.
Cooling water piping wherever necessary.
329
The steam generator integral piping consists of all the interconnecting piping
between the economiser inlet stop valve and the super-heater outlet header. The
number of size and the arrangement of these integral piping shall be
based on the permissible pressure drops in these pipes and the distribution
required in the respective headers of the various sections of the steam generator.
These piping shall be properly supported and provided with the required
tapping, stubs and thermo wells for measurements.
Test (sample) valves shall be provided to collect water/steam samples with
necessary cooling arrangements in steam drum, mud drum, superheated steam
header etc.
Two control valves (pneumatic and motorised) of cast steel/alloy steel (located
such its operator can see water level in gauge glass) capable of passing the
required amount of water shall be provided.
The steam generator shall have two water gauge glass units (suitable for
visibility and reliability) at the top drum independently connect on each side
with isolating valves such that when one is to be attended, the other one will be
in line. One remote water level indicator at the operating floor to be provided.
2.9.4
Piping synopsis for turbine

All piping required for effectively connecting the turbine with the subsystem
shall be provided. Condensate from condenser will be returned to deaerator.
The piping will be supplied in pre-fabricated condition.
The piping provided shall be complete in all respects including valves, fittings,
supports, etc. as required.
2.9.5
Piping synopsis for Compressed Air, Effluent

All compressed air piping for service and instrument needs from compressed air
receiver within the power plant will need to be carried out. All compressed air
piping will be above ground and required drains and filters will be provided.
All liquid effluent from all drains, blow down, neutralisation pit, ash system, etc.
will be led through below ground drains or CI / RCC pipes though the power
plant ETP. Treated effluent will be discharged from the power plant ETP to the
boundary of the power plant.
330
2.9.6
Hangers and supports

The Tenderer shall design, fabricate and furnish erection drawings for all
hangers, anchors, guides, clamps, stops and supports, auxiliary structures, etc.
required for the proper installation and support of the piping.
It is desirable that supports should as far as practicable, be arranged adjacent to
the pipe joint.
Constant load hangers/ spring hangers shall be provided wherever necessary
for critical piping systems such as main steam piping and steam generator feed
delivery piping. The variation between hot and cold loads, if variable spring
hangers are used, shall not exceed 25% of the rated load.
Lugs and additional structural members should be suitably welded to the pipes
wherever necessary for hangers and restraints.
2.9.7
Valves
All HP valves to be 1500 Class (or as per IBR) and glandless
All valves shall be suitable for the service conditions i.e., flow, temperature
and pressure under which they are required to operate and those performing
similar duties shall be interchangeable with one another unless otherwise
approved and of a higher rating than design pressure.
Globe valves shall have preferable curved or spherical seating and the discs
shall be free to revolve on the spindle.
All non-return valves shall have an arrow cast or embossed on the side of the
valve body to indicate the direction of the flow. For severe service conditions
cushioned check valves are preferred to obviate valve clatter. In the case of
swing - check valves the body seat shall be inclined at such an angle to the
vertical as will facilitate closing and prevent clatter.
331
The internal diameter of all valve ends to be connected to pipes shall be the
same as the internal diameter of the pipe to which they are joined so as to
minimise use of reducers/ expanders.
Where applicable valves shall be of the outside screw and yoke type.
Main steam stop valve shall be fitted with indicators so that percentage of valve
opening can be readily determined locally.
All the important valves shall be fitted with indicators so that percentage of
valve opening can be readily determined locally and in the control room
Steam valves shall not be fitted in an inverted position. Eye bolts shall be
provided wherever necessary to facilitate handling heavy valve or part of
valves.
Special attention shall be given to operating mechanism for large size valves
with a view to obtaining quick and easy operation and to ensure that minimum
of maintenance is required . For valves of size 2150 mm and above and the
rating above 600 Psig, bevel spur gearing shall be provided to facilitate manual
operation.
All sampling and root valves furnished shall be of integral body bonnet type.
2.9.8
Pipe routing
a. HP pipe from boiler to turbine will be routed with required loops and bends
to meet the allowable forces & movements. The Tenderer will submit the
stress analysis. The piping will be routed in the boiler area taking support of
the boiler columns and through the pipe rack between boiler and turbine
area. This pipe rack could be below the connecting platform between the
powerhouse and boiler operating floor. In the powerhouse area, the PRDSH
stations will be located on top of the control room slab and HP pipe will then
enter the powerhouse taking support of powerhouse columns and take entry
to the turbine as per the STG design. The MP & LP extractions will be
connected to respective headers placed at 0m level. Balance piping will
include: process return condensate and other miscellaneous piping.
332
b. Cooling water piping will be routed in trenches below ground. Trenches will
be provided at inspection doors and piping will be provided with suitable
pipe wrap to avoid earth attack.
c. Water piping from raw water reservoir to water treatment plant and onwards
to all usage points will be laid on pipe racks.
d. Compressed air piping from receiver to usage points will be on pipe racks
and along boiler and powerhouse columns.
e. Boiler feed water piping from powerhouse BFW bay will rise along the
powerhouse building and later will be supported by the HP steam pipe rack.
f. Fire fighting piping will be located in trenches as per TAC recommendations.
g. The integrated piping layout including locations of all pipe trenches and pipe
racks will be provided by the Tenderer during engineering for approval of
Owner / Consultant. The pipe racks will be essentially located for aesthetic
appropriateness and ease of man / material / vehicle movement. Minimum
height of the pipe rack will be 5 m. All the pipe racks will be designed for
existing pipe loads with 25% additional load bearing capacity. Typical design
of the pipe rack on STADPRO or equivalent software will be submitted by the
Tenderer to the Owner / Consultant during engineering.
2.10
PAINTING
All metal scrubber shall be chemically cleaned, degreased and pickled in acid to
produce a smooth surface, free of scale, grease and rusts.
After cleaning, phosphating and passivation treatment, the surface shall be given
two(2) coats of zinc rich epoxy primer and backing in the oven.
Sufficient quality of touch up paint shall be furnished for application at site.
All parts which are subjected to wetting and drying alternatively shall be painted
with three water proof coats as detailed below :
a) First coating Bronze 75% coal tar 25%
b) Second coating Bronze 50% coal tar 50%
c) Third coating Bronze 25% coal tar 75%
333
All exposed steel and cast iron surface shall be given one coat of red oxide anti
corrosive primer and 2 coats of enamel paint of approved colour.
i)
All metal surface shall be thoroughly cleaned and degreased to remove

mill scale, rust, grease and dirt. Fabricated structure shall be pickled and
then rinsed to remove any trace pf acid.
The under surface shall be prepared by applying a coat of phosphate paint
and a coat or yellow zinc chromate primer. The under surface shall be
made free from all imperfections before undertaking finishing coat.
ii)
After preparation of the under surface, the relay and control panel/desk
shall be spray painted with two coats of final paint.
Colour shade of final paint shall be Smoke Grey and shall be duly
approved by the Owner before final painting is done. The finished
panel/desks shall be tried in stoving oven in dust free atmosphere.
iii)
Panel finish shall be free from imperfections like holes, orange peels, run
off paint etc. The Tenderer shall furnish painting procedure details along
with the bids.
All unpainted steel parts shall be cadmium plated or suitable treated to
prevent rust corrosion. If these parts are moving element then these shall
be greased.
Motor external parts shall be finished and painted to produce a neat and
durable surface which would prevent rusting and corrosion. The
equipment shall be thoroughly degreased, all rust, sharp edges and scale
remove and treated with one coat of primer and finished with two coats of
grey enamel paint.
The motor fan shall also be painted to withstand corrosion.
Appendix XIV provides the typical painting summary for exposed steel
334
2.11
ELECTRICAL EVACUATION SYSTEM

2.11.1 Broad Scope of supply
a. Outdoor Switchyard :
- 11 KV, (UE) 3Cx300 sq.mm, XLPE insulated, aluminum conductor
armored cables for Supply to 11KV outdoor kiosk
- Indoor type Heat Shrinkable cable end termination kit for 11 KV,
(UE) 3Cx300sq.mm, XLPE insulated, aluminum conductor armored
cables
- 11KV Outdoor Kiosk with VCB
- Outdoor type Generator transformer 11 KV/132KV, 20/25MVA,
50 Hz transformer with all accessories including OLTC, RTCC,
AVR etc.
- 145KV, 3 pole SF6 Circuit Breakers
- 132 KV, isolators with earth switch and without earth switch
horizontal operated with operating rod.
- 132 KV, current transformers outdoor duty suitable to mount on
the structure for metering and protection
- Potential transformers outdoor type suitable to mount on the
structure for 132 KV
- Bus bar arrangement with structures, insulators, Al. tubes etc.
- Complete steel structure with galvanized coating for mounting
current transformers, PT, breakers, lightening arrestors, HT yard
compound, etc.
- 132 KV Insulators, LAs with necessary hardware.
- Earthing and Lightning protection system including earth mat in
switchyard.
- Illumination system for switchyard.
- Safety equipments in switchyard.
b. Co- generation auxiliary systems :
- Auxiliary transformers 11KV/433V, 2000 KVA 2 Nos.
- Bus bar trunking from Aux. Transformers to Cogen Aux.
Panel.
- L.T. Panel for cogeneration plant auxiliaries having Incomer EDO
ACBs and outgoing ACB / FSU for cogen plant auxiliary
systems
- APFC Panels with Capacitors.
335
MCC for Cooling Tower and Water Pumps

L.T. Power, control cables and cable accessories up to incomer of
system panels
L.T. Power and Control Cables up to motors for Cooling
Tower and Pump MCC Loads
Earthing system for Cogen Plant Eqpts..
Illumination system for cogeneration plant including Lighting DB,
panels, cables etc complete.
c. Panels :
- 132 KV switchyard metering, relay and protection panel including
Islanding and line protection relays.
- Transformers control and relay panel.
- Battery and Battery charger system with DCDB.
- ACDB with MCB incomer outgoings
d.
-
Import and Export metering :

Energy Import and Export meter 4 quadrant type for check
meter having approved specifications of BSEB
Associated cabling system.
2.11.2 Scope of work in services

a. Design and engineering :
-
Preparation of design calculations, detail drawings for switchyard

and allied work.
Preparation of cable layouts, Earthing Layouts and Lighting
Layout drawings
Preparation of cable schedule, interconnection schedule and detail
BOQ.
Preparation of foundation drawings and structural designs for
switchyard equipments.
Preparation of inspection plan and schedule.
Preparation of schedule for site testing and commissioning.
Preparation of relay co ordination schedule and synchronizing
with generator protection relays including islanding scheme.
336
b. Erection and Commissioning :

-
Inspection of civil work in foundations, trenches and allied jobs.

Unloading, unpacking, shifting to locations, positioning, aligning
and fixing of equipments.
Pre-commissioning checks.
Commissioning , testing and trials
Completion of documentation and records.
c. Statutory approvals :
-
Obtaining approvals on drawing and designs from BSEB, local

Electrical Inspector and Chief Electrical Inspector authorities.
Liaison with BSEB authorities for testing, tie up and commissioning
of switchyard equipments.
Arranging inspections and approvals for commissioning of total
cogeneration plant electrical from Local and Chief Electrical
Inspector PWD
Liaison with TQ & A as well as O & M division of BSEB
authorities for obtaining approvals on drawings, arranging
inspections for metering CTs, PTs and other equipments,
interlocks etc.
d. Inspections
-
Making the arrangements for periodical and final inspection of all

major equipments in the system at manufacturers works
2.11.3 Data Required Along with Bid
All data sheets included in the tender should be duly completed and
submitted along with bid.
Single line drawing of the proposed electrical system to be submitted
along with the bid.
Plan and elevation of 132 KV HT switchyard to be submitted along
with the bid.
List of manufacturers of the major equipments like transformers,
circuit breakers, meters, relays, panels, etc. to be submitted along with
the bid.
337
The letter from transformer manufacturer confirming the

transformer losses quoted by Tenderer.
List of all shop and site inspection tests.
The No Load and Full Load losses and regulations at 25%, 50%,
75% and 100% load and 0.8 and Unity P.F. on Generator and
Aux. transformers.
2.11.4 Bill of Materials

Sr. No.
1.
a.
b.
c.
d.
e.
2.
a.
b.
c.
Particulars
Indoor type, 11 KV, 40KA for 1 sec.
switchboard in Cogen Plant comprising
of Vacuum Circuit Breakers (VCB), having
suitable CTs, PTs, metering and protective
relays etc for following application,
1 No. Incomer VCB to receive power from
20 MW, 11KV Generator with metering and
protection
2 Nos. Outgoing VCBs to cater Sugar Plant
Load with metering and protection
1 No. Outgoing VCB for export power
with metering and protection
2 Nos. Outgoing VCB to cater for cogen
plant aux. power with metering and
protection
1 No. Outgoing VCB with metering and
protection as spare
H.T. Outdoor Switchyard equipments
Outdoor type Generator transformer of
11/132KV,20/25MVA,50Hz,ONAN/ONAF
transformer with all accessories OLTC, RTCC
and AVR Panel (including oil filtration at
site)
Outdoor type 11 kV,,2000A,40KA for 1 sec.
VCB Kiosk with CTs, Relay, Load Manager
etc complete
145kV, 40KA for 3sec.,1250A, 3 Phase SF6
Circuit Breaker with standard accessories
Quantity
No.
No.
1
2
1
Nos
No
Nos
2
1
No
No.
No.
No.
338
Sr. No.
d.
e.
f.
g.
h.
j.
k.
l.
m.
n.
Particulars
145kV, 40KA for 3sec.,1250Amp. Double
Break, Center Rotating Isolator with earthing
switch having motorized operation with
insulators base channel, aux. contacts etc.
145kV, 40KA for 3sec.,1250Amp. Double
Break, Center Rotating Isolator without
earthing switch having motorized operation
with insulators base channel, aux. contacts
etc.
132kV , 40KA current transformers, 5 core
out door duty 150/1A suitable to mount on
the structure for metering and protection
132KV potential transformers outdoor type 3
core, 132KV/V3 / 110V/V3 suitable to
mount on the structure
132kV,40KA current transformers, out door
duty 150/1A suitable to mount on the
structure for check metering & tariff meter
132KV potential transformers outdoor type,
132KV/V3/110V/V3 suitable to mount on
the structure for check metering and tariff
meter
Station class, Gapless type MO outdoor
pedestal mounted Lightning Arrester with
surge counter suitable for nominal system
voltage of 132 KV, effectively earthed
system having rated voltage of 120 KV
and discharge current of 10 KA
145kV,40KA string insulators and
suspension type insulators with required
hardware suitable to mount on the structure
for ACSR conductor
Galvanized steel structure complete with
hardware for mounting current
transformers, PT, breakers, Lightning
Arrestors, insulators, gantries and columns.
etc.
Switchyard chain link fencing and gates
Quantity
1
No.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Sets
Lot
Lot
339
Sr. No.
o.
p.
q.
r.
Particulars
Junction box for CTs, PTs secondary side
connections
Bay Junction box for CTs, PTs secondary
side connections
Rigid Aluminum tubular bus bars and
ACSR ZEBRA conductor for line tapings
supported on post /string insulators for
interconnection between equipments with
hardware etc complete
Power Transformer protection Panel
fabricated from 3 mm thick CRCA sheet
steel duly painted / powder coated having
all the control and protection equipments
including but not limited to the following,
a. Metering section with Voltmeter,
Ammeter with selector switches, Frequency
meter, Load Manager (Multi Function
Meter) with KW, KWH, KVA, KVAR,
P.F.,KVAH parameters with
communication facility through RS 485 port
and MODBUS protocol.
b. Transformer Protective relays including
Inst. Over Current and Earth Fault relay,
IDMT Over Current and Earth Fault relay,
Transformer Differential protection relay
including ICT if needed, Transformer
Restricted Earth Fault Relay, Under Voltage
and Over Voltage relay, Annunciation,
High speed Trip relay, Stand by Earth
Fault Relay in Neutral circuit, etc.
c. Line Protection and Islanding relays
including Frequency relay, Rate of change
in frequency (DF/DT) relay, Vector Surge
Relay, Annunciation, High speed Trip relay
etc. complete
d. Control wiring complete for metering,
protection section with control fuse
fittings, terminals etc.
Quantity
10
Nos.
1
No.
Lot
340
Sr. No.
s.
t.
u.
v.
3.
a.
b.
Particulars
Indoor metering panel with check metering
(export and import metering Electronic 4
quadrant type)
SMF Lead Acid Battery, Float and Float
cum Boost Battery Charger 40A and DCDB
with 110VD.C.,150AH rating with
stationary, tubular Battery set, stand,
charger and standard accessories including
18 way 16 A, DCDB.
Fire fighting equipment
Fabricated stand with 4 Nos. Sand bucket
of 13 Lit, Capacity filled with sand, cover
etc complete
CO2 fire extinguishers 22.5 kg capacity
trolley mounted type
Erection / commissioning of all the electrical
equipments as per specifications given
and good engineering practices
Equipments in Cogen plant auxiliary
Two winding step down Transformer for
cogen auxiliary load outdoor application
with rating of 2000KVA,11KV/433V,ONAN,
Connection Dyn11, with OCTC with +5% to 10% in steps of 2.5% taps, having all
standard accessories including but not
limited to Buccholz Relay, WTI, OTI,MOG,
Neutral CTs for Inst. Earth Fault and REF
relay. Transformer to be supplied duly
routine and heat run tested
415V,3200A, TPN, aluminium Bus bar
trunking between 2000 KVA Transformers
and L.T. Panel for cogen plant aux.
supply with enclosure fabricated from 2
mm thick CRCA sheet with canopy for
outdoor portion, duly painted /powder
coated. The trunking shall have bends, flex.
copper connections at transformer end, zinc
passivated hardware etc. complete
Quantity
1
Set
Set
set
Nos.
Lot
Nos.
set
341
Sr. No.
c.
Particulars
(Approx. Length of 15M each.)
415 Volts, Cogen Plant Auxiliary Panel
fabricated from 2 mm thick CRCA sheet
steel and painted/ powder coated as per
shade 632 of IS 5, with following major
components,
a. 2 Nos. Air Circuit Breakers 3200 Amps, 4
pole, EDO with shunt trip & earth fault
release for incomer cubicles for 2000 KVA
transformers 1 No. Air Circuit Breaker 3200
Amps, 4 pole, EDO with shunt trip & earth
fault release as Bus Coupler & and 630
Amps, 4 pole, EDO with S/C, O/C shunt
trip & earth fault release for incomer cubicle
for 250KVA DG
b. 5 Nos. Outgoing feeders with TP, MDO
Air Circuit Breakers 2000 Amps, 4 Nos.
with 1000A TP,MDO ACB with shunt trip
release, 2 Nos. Outgoing feeders with TPN,
FSU 400 Amps, 2 Nos. TPN FSU 250A , 9
Nos. Outgoing feeders with TPN, FSU 125
Amps
c. Bus bar sections with epoxy insulator
supports and Al. bus bar sections suitable for
433V, TPN, 3200 A, 50KA for 1 sec. rating
d. C.T.s for metering, protection having
suitable accuracy class
e. Metering section with Voltmeter, ammeter
with selector switches, multifunction meters
(Load Managers)
f. Protective relays with 3 Phase IDMT over
current, Earth fault relay complete
g. Control wiring complete for metering,
protection section with control fuse fittings,
terminals etc
Quantity
1
set
342
Sr. No.
d.
e.
Particulars
415 Volts, MCC s for Boiler, Turbine,
Cooling Tower , Water Pumps , Fuel & Ash
handling and all cogen auxiliaries fabricated
from 2 mm thick CRCA sheet steel and
painted/ powder coated as per shade 632 of
IS 5
a. 1 Nos. Air Circuit Breakers of required
capacity, TPN, MDO with shunt trip & earth
fault release for incomer and
b. Outgoing feeders with TP, MDO Air
Circuit Breakers of required capacity,
Outgoing feeders with TPN, FSU of
required capacity with starters as specified.
c. Bus bar sections with epoxy insulator
supports and Al. bus bar sections suitable for
433V, TPN, 1000 A, 50KA for 1 sec. rating
d. C.T.s for metering, protection having
suitable accuracy class
e. Metering section with Voltmeter, ammeter
with selector switches, multifunction meters
(Load Managers) for incomer and
Ammeter with Selector Switch for
outgoing feeders.
f. Control wiring complete for metering,
protection section with control fuse fittings,
terminals etc
g. Local Control Station Al. die cast with
ON, OFF Push Buttons and suppressed
scale Ammeter of suitable range for the
motors
Self Standing Self Supporting VFD Panels
with SFU, 6 Pulse Conv / Inv system,
including required components for
maintaining harmonic distortion within
limits as per IEC
Quantity
1
set
Set
343
Sr. No.
f.
5.
a.
b.
c.
i
ii
iii
iv
v
vi
vii
viii
ix
d.
i
ii
iii
iv
Particulars
APFC panel with 400KVAR (8 x 50KVAR)
APP type L.T. capacitors operated through
digital APFC relay, individual FSU,
capacitor duty contactor, PBs and
indicating lamps aux. contactor, selector
switches etc complete
Cables and accessories
Cross linked Polyethylene (XLPE)
insulated, PVC sheathed,11 KV (UE), 3C x
300 sq. mm. Power cable having Aluminum
conductor for connection between 11 KV
switchboard and transformers
Heat shrinkable indoor cable termination
kits for 11 KV, 3C x 300 Sq. mm XLPE (UE),
Aluminum Cable
1.1KV Grade, XLPE insulated, Aluminium
conductor, armoured, Power Cables for
inter phasing of all panels in the system,
switchyard equipments, lighting etc.
4C x 6 sq. mm
4C x 16 sq. mm
3.5C x 35 sq. mm
3C x 50 sq. mm
3.5C x 50 sq. mm
3C x 120 sq. mm
3C x 185 sq. mm
3.5C x 185 sq. mm
3.5C x 300 sq. mm
1.1KV Grade, XLPE /PVC insulated, Copper
conductor, armoured, Control Cables for
interfacing of panels in the system,
switchyard equipments and Lighting
3C x 1.5 Sq. mm
4C x 1.5 Sq. mm
7C x 1.5 Sq. mm
12C x 1.5 Sq. mm
Quantity
2
Sets
3300
Meter.
30
Set
1700
1400
350
800
250
450
1400
300
1400
M
M
M
M
M
M
M
M
M
350
900
900
750
M
M
M
M
344
Sr. No.
v
vi
vii
Particulars
3C x 2.5 Sq. mm
4C x 2.5 Sq. mm
7C x 2.5 Sq. mm
e.
Termination of all sizes of cables with

single compression brass cable gland
crimping type copper / Aluminum lugs
ferrules consumables etc complete, as
required
f.
GI, Ladder type prefabricated cable trays

and accessories of suitable sizes for
supporting the cables in tier formation to
be laid in built up cable trenches with
required MS angle supports having
following sizes
600 mm. Width
450 mm. Width
300 mm. Width
150 mm. Width
i
ii
iii
iv
6.
a.
b.
c.
d.
e.
f.
g.
Earthing System
Earthing arrangements for Entire cogen
plant as per IS 3043, IS 2309 and IEEE 80,
including earthing pit having 150 mm dia.
CI pipe electrode funnel, CI chamber cover
charcoal etc.
75 x 10 GI flat for switchyard earth mat
and risers and main earthing grid
50 x 6 Cu flat for 20/25MVA power
transformer and other transformer neutral
earthing
50 x 6 GI Flat for earthing of various
switchyard equipments
25 x 3 GI flat for lightning protection and
lightning down comers
8 SWG GI wire
12 SWG GI wire
Quantity
4600
M
600
M
450
M
Lot
750
200
150
150
Meters.
Meters.
Meters.
Meters.
75
Nos.
2500
Meters.
125
Meters.
600
Meters.
250
Meters.
400
400
Meters.
Meters.
345
Sr. No.
h.
i.
7.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Particulars
Lighting Ariel terminals with globe and
spikes
Test Link Boxes for lightning down comers
Illumination system
Main Lighting Panel with 125A MCCB
Incomer and 8 Nos. 32 A 4P ELMCB
outgoing feeders.
Sub lighting DBs with 32 A 4P, ELMCB
incomer and 18 Nos. 10A, SP outgoing
MCBs
Lighting poles welded construction 9m
long with cross arm and hardware for
mounting 150W HPSV street light fixture
Lighting fixture 150W, HPSV Pot Optic
Light fixture with lamp, control gear box
etc complete
Industrial High Bay Lighting fixture 250W,
MH Lamps
Industrial well Glass integral Lighting
fixture suitable for 125W,HPMV Lamps
Industrial Fl. Lighting fixture 2 x 40W,
Lamps
Control Panel for outdoor lighting with
32A,4P, ELMCB, Contactor 24 hr. timer
and 6 Nos. 16A outgoing SP MCB with
wiring etc complete
Concealed Point wiring with PVC copper
wiring of 1.0 sq. mm. and sub mains of
2.5 sq. mm. for office areas including
molded switchboards and accessories
(Average length from switch to fixture 10
meters)
High mast lighting fixture with 30 m high
tower including cradle, motor operated
mechanism, 8 nos. 400 W metal halide
lamps
Quantity
10
Nos.
10
Nos.
No.
10
Nos.
50
Nos.
50
Nos.
50
Nos.
150
Nos.
100
Nos.
Nos.
150
Nos.
Nos.
346
Sr. No.
8.
Particulars
Design, Detail Engineering and drawing
preparation for the complete package
9.
Miscellaneous items as per statutory

requirements including but not limited to
the following,
a. Rubber mat of 12 mm thick with suitable
length to be provided in front of all
Panels, 11 KV switchboards, 415 V ACB
Panels etc.
b. Shock Treatment Charts in Marathi ,
Hindi and English in Glass frame.
c. Sand Buckets 4 Nos. mounted on
fabricated stand in switchyard.
d. First Aid Box with necessary medicines,
ointments etc.
e. Rubber Hand Gloves suitable for 36KV
system voltage, for operation of Isolator
in switchyard.
10.
Quantity
1
lot
100
Meters.
Nos.
sets
sets
sets
Liaison with BSEB and Electrical

Inspector for drawing approval and
Inspections including grid synchronizing
etc complete
The quantities indicated above are as estimated and for bidding purposes.
Tenderer will also provide unit rates for all above equipments for any variations in
actual as build quantities
2.11.5 Technical Specifications :
a)
132KV Switchyard equipments :

The power evacuation arrangements from the cogeneration
project is proposed to be done at 132KV Sub Station which is
proposed within sugar mills campus at a distance of 500 meters
from TG set building.
347
The key single line diagram of electrical installation is enclosed

with this document which shall be referred for the ratings of
equipments.
b)
132 KV Isolators :
c)
The isolators shall be outdoor, manually operated,

horizontal, double break, center rotating type and suitable
for mounting on structural members.
The isolator operating mechanism shall be twist and turn
type.
The isolators shall be designed with suitable short circuit
current rating of 40KA for 3 sec. The design shall permit
breaking the charging current of 132KV transmission line.
The isolators shall be suitable for operated on no load
condition. The mechanical and electrical interlocking
arrangements shall be made with circuit breaker to prevent
the operation of Isolator on load condition.
The ratings shall be as given in data sheets and key SLD.
Creep age distance for insulators in Isolator shall be . 31
mm./ KV
Lightning Arresters :

Lightning arresters are proposed to be installed in switchyard at

the locations given on Single Line diagram as per the ratings
given.
The lightning arresters shall be single phase, station type
gapless
construction, outdoor type.
Suitable mounting structure shall be provided for lighting
arresters.
KA rating 10 KA,
Creep age distance for insulators in Isolator shall be . 31
mm./ KV
348
d)
Current Transformers :

e)
Potential Transformer :

f)
The potential transformer shall be of electromagnetic type to

suit the functional requirement.
The ratio and burdens shall be as given in data sheets and SLD.
The PT shall be single phase, outdoor type oil immersed design.
Bus bar system :

g)
132KV Current Transformers shall be provided as per the

ratings and locations given in data sheets and key SLD.
The Current transformers shall be single phase, outdoor type,
oil immersed dead/ live tank design.
The current Transformers shall have the core arrangements as
given in data sheets.
The bus bar system comprising of insulator supports and bus

bar sections. It is proposed to use
tubular Aluminum
conductor and post insulators for connection between
equipments.
For interfacing all the equipments with strain insulators with
ACSR ZEBRA conductor shall to be used. Suitable type and
number of connectors are to be provided in both the cases.
The bus bar size shall be suitable to carry the normal and short
circuit currents as specified.
Clamps made from aluminum alloy shall be used for end
terminations.
Supporting Structures :

The supporting structures shall be provided for insulators, CTs,

PTs, Isolators, LAs etc.
The structures shall be of bolted type construction and
fabricated from GI material.
The structures also include towers and beam structures required
for 132KV incoming lines.
349

The structure designs shall be made considering the minimum

ground clearance of 4.6 M required as per IE rules.
The structure designs shall be suitable for the wind pressure of
150 Kg / mm2,
Wind Velocity of 50M/sec. and site
temperature of 50C.
The design calculations for structures shall be submitted for
approval.
2.11.6 Generator Transformer :

This transformer is generator transformer proposed for power export to
132KV grid. However, the transformer shall necessarily be suitable for bidirectional operation. The OLTC design in transformer shall be
modified to this requirement. Sugar Complex and Cogen Plant
auxiliary power in the tune of 10MVA will be made available by BSEB
grid through this transformer.
The transformer shall have following specifications,
a. Construction :
Transformer tank shall be of welded sheet steel construction

and provided with gaskets steel cover plates. Base shall be
suitably reinforced to prevent any distortion during lifting. Base
channels shall be provided with skids and pulling eyes to
facilitate handling.
All covers and seals shall be oil and air tight and shall not be
affected by mineral oil or synthetic oil action. Detachable
radiators equipped with air vent drain plug and lifting lugs
shall be provided with cut off valves to permit removal of any
radiator unit without emptying the tank. Radiators shall be
securely braced to prevent undue vibration.
All fasteners and bolts etc. shall be galvanized or zinc
passivated. All surfaces to be painted shall be thoroughly
cleaned, descaled, made free from rust and given a priming coat
of rust resisting paint followed by two finishing coats of
approved shade. Paint shall be suitable to withstand specified
atmospheric conditions.
350
b. Terminals and marshalling box :

Windings shall be brought out and terminated on terminal
bushings and cable box.
- Cable end box shall be supplied with cable lugs & glands. The
lugs shall be non-soldering, long barrel, crimping type
- Terminal chamber for cable box shall have gasketed cover plate
bolted to it.
- Marshaling box shall be weatherproof, waterproof with IP 55
enclosure. All protective devices and neutral CTS shall be wired
by means of PVC insulated armored cables up to the marshaling
box. Terminals shall be bolted type only. Removable gland plate
with compression type glands of non-magnetic material shall be
provided.
c. Cooling :
The cooling of the transformer shall be ONAN / ONAF. The
operation of forced air circulation fans shall be controlled
automatically by temperature in oil tank.
d. Oil :
The Transformer shall be supplied with first filling of oil.
Additional 10% quantity of oil shall be supplied in sealed drums.
The cost of the additional oil shall be included in tender.
e.
Accessories :
Following minimum accessories shall be necessarily included in
the scope of supply in addition to the accessories required as
per CBIP guidelines.

Oil conservator complete with oil filling plug & cap. Oil drain
valve & magnetic oil level gauge .
Silica Gel Breather It shall be mounted such that the silica gel
shall be visible from the ground level and the breather is
removable from the ground.
Shut off valve between conservator & main tank.
351

Explosion relief vent mounted on the tank with double

diaphragm & equalizer pipe. The explosion vent shall be
rotatable in all directions.
Air release plugs.
150 mm dia. magnetic oil gauge with low level alarm and trip
contact.
150 mm dia. oil temperature indicator with maximum reading
pointer and a set of contacts for alarm and trip.
150 mm dia. winding temperature indicator with
maximum reading pointer and set of contacts for
alarm & trip.
Thermometer pocket with mercury in glass
thermometer (0-120 C)
Bottom drain valve- with pipe nipple. It shall be
possible to drain off 90% of the oil within 10 minutes.
Sampling valves with plug.
Filter valves with threaded adapter top & bottom.
Inspection cover on top plate.
Two grounding (Earthing) Pads placed on opposite sides with
tapped holes, M-12 Bolts and spring washers.
Jacking pads, hauling lifting lugs.
Bidirectional Flanged Wheels.
Rating plate. terminal marking plates & name plates.
Double Float type Buccholz Relay with Alarm and Trip
contacts.
Cable disconnection chamber for LV side.
Neutral CT on HV side for Restricted Earth Fault and
Stand by Earth Fault.
Forced air Circulation Fans with required control gear and
support structures.
g. Core and winding :

-
Transformer shall be double wound, core type with cold rolled

grain oriented lamination perfectly insulated and clamped to
minimize vibrations and noise.
Care shall be taken to insulate core fastening bolts to reduce
losses and avoid hot spot. All parts of the magnetic circuit shall
be bonded to earth.
352
Windings shall be of copper and shall be designed to withstand

the specified thermal and dynamic short circuit stresses.
h. Tapping :
-
On Load Tap Changing arrangement shall be provided on High

Voltage side of the transformer.
The OLTC mechanism shall be provided with Oil surge relay,
Automatic Voltage Relay and RTCC panel.
Under conditions of external short circuit, the tap changing
equipment must be capable of carrying the same current as the
winding.
i. Inspection and testing :

-
Owners representative shall be given free access in the works

from time to time for stage inspection & progress reporting.
Tests shall be carried out at manufacturers works at his
expenses in presence of the Onwers representative. All routine
tests as specified in IS 2026 shall be conducted.
Heat run test and type tests as per IS 2026 shall be
conducted on the transformer at manufacturers works.
Impulse Test shall be carried out on all three phases of H.V.
winding of the transformer.
j. Packing and transport :

-
The main tank shall be oil filled during transportation. All

accessories shall be packed separately during transportation.
Care shall be taken to pack the radiators such that radiator fins
are not damaged during transportation. Packing dimension
shall be furnished much in advance of transportation.
All accessories shall be wrapped with polythene sheets before
packing.
All valve flanges including those for the radiators shall be
closed by blank flanges.
353
2.11.7
Earthing :
Earthing arrangement in 132KV switchyard shall be strictly as per the
statutory regulations. The earthing shall include,
-
Provision of earth electrodes for LAs, switchyard equipments, body

earthing, T.G. set Alternator , D.G. set Alternator Neutral and
Body earthing, Transformer neutral earthing, earthing of
structures, earthing of Boiler ESP transformers earthing to
motors in Cooling tower and Pump motors etc.
Provision of earth mat as per IEEE 80.
Provision of lightning conductor over 132KV switchyard.
Provision of earthing grid conductor as per fault level considered.
Lightning protection of Cogen Plant buildings including
Earthing Electrodes for Lightening, Down comers, Test Link
boxes etc.
The measurement of soil resistivity shall be done by Tenderer

after award of the assignment. For design purpose, the soil
resistivity value of 100 meter shall presently be considered.
The earthing in switchyard shall have following specifications,

The entire earthing installation shall confirm to IS 3043

Earthing electrode shall be CI Pipe type.
The earthing electrode shall be 150 mm diameter 3M long C.I.
pipe buried under ground up to the level of 2.5 mtrs.
Earthing terminal shall be complete with watering pipe, funnel
screen & earthing bus bars.
Earthing pipe buried under ground shall be surrounded by 300 mm
thick homogeneous layer of charcoal and salt..
Earthing chambers shall be provided with CI covers of size 450mm
x 450 mm or with circular cover having 600 mm dia.
All the material required for the earthing system shall be supplied
and installed by the Tenderer. The main grid conductor shall be hot
dip G.I. strips of 75 mm x 10 mm size.
All the material required for making earthing stations/ pit like
plate, charcoal, salt etc. shall be supplied by the Tenderer.
The entire earthing installation shall be done in accordance with IS
specifications and standard engineering practices.
354

The entire earthing system shall fully comply with Indian

electricity act and rules, The Tenderer shall carryout any changes
desired by the electrical inspector & state electricity board
authorities in order to make the installation conforming to I.E. rules
at no extra cost.
The main earth grid shall be laid at a depth of 600 mm below
Ground level. In case of built in trenches, earth strip shall be laid
along the trench and shall be firmly cleated to the wall or cable
supports. It shall be protected against mechanical damage. Joints
and tapping in the main earth grid shall be made in such a way that
reliable and good electrical connections are permanently ensured.
All joints below grade level shall be welded and suitably protected
by giving two coats of bitumen and covering with tar tape.
When the earthing strips are joined together minimum overlap of
100 mm shall be provided. To have better joint, the overlapped
portion shall be properly welded and covered with tar tape
Conduits in which cables have been installed shall be earthed
bonded and earthed. Cable amour shall be earthed at both ends by
providing GI/ copper clamp and PVC wire of suitable size near
each cable gland.
The electrodes shall be tested for earth resistance by means of
standard earth tester.
A disconnecting facility shall be provided for individual earth pit to
check earth resistance.
Earthing system includes provision of earthing to switchyard
equipments, structures, panels etc. with suitable earthing
conductor.
All paint, scale and enamel shall be removed before earthing
connection are made.
Anchor bolts or fixing bolts shall not be used for earthing
connections.
Entire earthing system and lighting protection system shall be
tested for continuity by earth testing equipment after completion of
the installation.
Earth resistance value shall be checked and verified. If it is high
then corrective measures such as addition of earth pit shall be taken
to obtain desired value.
The record of earth resistance and test results shall be maintained
for future reference.
355
2.11.8 132KV Control and Relay Panel :

Scope of Work
The scope of design, manufacture, testing and supply of equipment
covered under this specification shall include but not necessarily be
limited to the following:
a. Design, engineering and fabrication of panels / desks as per the
specifications.
b. Supply and mounting of all the equipment and auxiliary
equipment like auxiliary relays, test switches, test blocks, plugs,
timers, indicating instruments, etc., necessary for satisfactory
functioning of the control and protection of the turbine generator
systems.
c. The protection system shall be provided with additional auxiliary
contacts for the purpose of Data Acquisition system.
d. All internal wiring between all equipment up to the terminal blocks
and the inter panel wiring.
e. Preparation and furnishing of all date /drawings/ documents as
per the tender requirement and specifications.
f. Testing at works of the panels and the mounted equipment.
Design Requirements
a. Constructional Features
-
The control panels shall be 'Simplex' type for the relay and
metering panel.
Panels shall be sheet steel enclosed dust and vermin proof floor
mounting, free standing, formed on a framework of standard
sections.
The enclosure shall be of cold rolled sheet of 2mm thick. Panel
supporting structure shall be so designed to form a rigid
structure.
All doors and openings shall be provided with neoprene
gaskets.
356
The panels / desks shall be suitable to be installed on a base

frame supplied in one-piece along with foundation bolts. These
base channels shall be despatched 3 months in advance to the
despatch of panels so that they can be buried and grouted in the
concrete floor. Amply dimensioned oblong holes shall be
provided at the bottom of all the panels for their installation on
base frame in addition the panels shall have an additional base
channel at the bottom with smooth surface.
A suitable removable un drilled gland plate shall be provided
for cable entry from bottom. Suitable double compression type
cable glands for control cables of sizes, quantity and material
shall be included in the scope of supply.
b. Mounting
-
All instrument and control gears and relays shall be mounted

on the front. All equipment shall be flush or semi-flush type.
Checking and removal of components shall be possible without
disturbing the adjacent equipment. It shall be possible to set all
the measuring relays 'insitu'.
All mounted equipment inside the panels /desks shall have
"identification tags of self sticking Engraved tapes, in addition
identification numbers shall be pained on panel wall to give
permanent identification mark. The mounting of terminal
blocks and any other auxiliary equipment such as transducers,
interposing CTs etc, shall be done in such a way so as to be
readily accessible but without impeding the access to internal
wiring and components.
The centre line of switches, push buttons and indicating lamps
shall be not less than 750 mm from the bottom of the panel. The
centre line of relays, meters, and recorders shall not be less than
450 mm from bottom of the panel. All switches, push buttons,
indicating lamps, relays, etc., shall be neatly arranged in a
matching manner.
The control panels/desks shall be matched with other
panels/desks in dimension, colour and mimic.
357
c. Wiring
-
All wiring shall be done with PVC insulated, 650 V grade,

single-core multi strands (minimum 3 strands) annealed copper
conductors suitable for temperature and humidity specified.
The cross sectional of the wires for voltage, current and control
circuits shall be 2.5 Sq.mm. and that for the alarm circuits shall
be 1.5 Sq.mm., the wires shall be vermin proof and shall be laid
in plastic gutters.
Each wire shall be identified at both ends with wire numbers by
means of PVC ferrules. Colour coding for the wires shall be as
per IS:375.
The terminal boards shall be set at 45 Deg. to the side panels for
easy access. Minimum 20 % spare terminals shall be provided
on the panels.
The bolted type terminals shall be suitable to receive crimped
wires to give positive connection. All terminals shall be
properly shrouded against accidental contact.
Sufficient terminals shall be provided so that not more than
two wires are connected to each terminal. The terminal blocks
shall be 600 V grads 10 amps rated, one piece moulded
complete with insulated barriers, stud type terminals, washers,
nuts and lock nuts and identification strips. Clip on terminals
shall not be used in this panel.
Terminal blocks for the CT and PT secondary leads shall be
provided with test links and isolation facilities. Also CT
secondary leads shall be provided with short circuiting and
earthing links.
d. Painting
-
All metal surface shall be thoroughly cleaned and degreased to

remove mill scale, rust, grease and dirt. Fabricated structure
shall be pickled and then rinsed to remove any trace of acid.
The surface shall be prepared by applying a coat of phosphate
paint and a coat or yellow zinc chromate primer. The under
surface shall be made free from all imperfections before
undertaking finishing coat.
358
After preparation of the under surface, the relay and control

panel/desk shall be spray painted with two coats of final paint.
Colour shade of final paint shall be Opulence Green and shall
be duly approved by the Owner before final painting is done.
The finished panel/desks shall be tried in stove oven in dust
free atmosphere.
Panel finish shall be free from imperfections like holes, orange
peels, run off paint etc. The Tenderer shall furnish painting
procedure details along with the bids.
All unpainted steel parts shall be cadmium plated or suitable
treated to prevent rust corrosion. If these parts are moving
element then these shall be greased.
e. Panel illumination
-
Compact Fluorescent Lamps working on 240 V AC, operated by

door switches shall be provided for internal panel illumination.
A 240 V, 1-Phase, 5Amp, 3 Pin Socket shall be provided in the
panel corridor or interior of each cubicle with on-off switch for
connection of hand lamps. This socket shall be metal clad type
with a spring loaded flap.
f. Earthing
-
A continuous 25mm x 3mm copper (tinned) shall be provided

running along the full lengths of the panels.
Suitable arrangement shall be provided at the two ends for
connection to the plant earthing system.
Each panel and the equipment mounted on each panel shall be
securely connected to the earth bus.
For this purpose, the earth wire shall be looped from
equipment to equipment and both ends of the earth wire shall
be connected to the earth bus.
g. Space Heaters
-
Panel space heaters shall operate off 240 V AC and shall be

supplied complete with on-off switch, fuse and thermostat.
359
A common thermostat shall be provided for the entire panel.

The thermostat shall maintain the internal temperature above
the ambient temperature to prevent moisture condensation.
h. Mimic
-
Mimic diagram shall be provided on panels. Mimic diagram

shall be screwed on to the panels / desks and shall be made of
anodised aluminium or plastic of approved fast colour. The
mimic shall be 10 mm wide for horizontal run and 5 mm wide
for vertical run.
Semaphore indicators used for isolator positions, they shall be
so mounted in the mimic that isolator (or breaker) closed
position shall complete the continuity of the mimic. The mimic
diagram shall incorporate red and green lamps for isolator
position indication and controlling switches with indicating
lamps for breakers.
The lamps will remain steady where the hand operated
semaphore position correspond with the breaker position. The
lamps shall flicker with a time delayed alarm if the semaphore
position does not correspond with the breaker position.
2.11.9 Equipment Specifications

a. Instruments
-
All instruments shall be switchboard type, back connected,

flush mounted, dust tight and tropical zed. They shall be of
square pattern and comply with IS:1248 and shall be of accuracy
class 1.0. They shall have 90 Deg. scale range.
Zero adjustment for pointers shall be accessible from the front
of the instruments. All auxiliary equipment such as shunts,
transducers, interposing C.T./V.T. etc. that are required shall be
included in the scope of supply.
All instruments shall be subjected to an applied potential test of
2.0 KV for one minute. Whenever specified, digital meters shall
be proved to indicate frequency and power factor parameters.
360
Frequency Meters
The Frequency Meters shall be long range, calibrated for 45-5055c/s. These shall be digital type and shall operate off 110 V
AC.
b. Indicating Lamps
-
These shall be multiple LED type of low power consumption,

lamps shall be supplied complete.
Lamps shall be provided with screwed translucent covers to
diffuse light. The lamp covers shall preferably be unbreakable,
moulded, heat resistant material and shall be provided with
chromium plated bezels.
c. Control Switches
All control switches shall be rotary, back connect type having cam
operation contact mechanism. Phosphor bronze contacts shall be
used on switches. The handle of control switches used for circuit
breaker operation shall turn clockwise for closing and anti-clockwise for tripping and shall be spring return to natural from
close/trip with lost motion device.
Each switch shall be provided with external red and green
indicating lamps. Ammeter selector switches shall be with make
before break feature and shall have 3 - position, suitable to read
phase voltages.
d. MCB for Control circuits
All control circuits shall be provided with suitably rated MCBs.
These shall generally be mounted on the top half of the panels. All
MCBs shall be provided with suitable identification labels.
e. Annunciation
-
Facia type static annunciations shall be provided on the control

panels/desks wherever called in the equipment list.
361
There shall be one translucent window for each alarm for point
with engraved inscription. Number of windows shall be as per
the equipment list.
Unless stated otherwise, the annunciations shall be suitable for
operation with normally open fault contact which closes on a
fault.
One common audible alarm, one common acknowledge push
button, reset one push button and one 'all lamp test' push
button shall be provided common to all annunciations.
On occurrence of a fault(s) one of the following alarm sequences
shall be followed.
D. C. supply failure indication shall be provided separately with
DC under voltage relays. On failure of DC supply to the panel, a
lamp and a horn operated off AC shall operate. There shall be
provision for cancelling AC horn. The DC bell and AC horn
shall have distinctly separate tones.
Standard Alarm Sequences

1. Flashing Alarm with manual reset

Alarm Indicating Visual Module Audible Condition

Contact Lamps Alarm
Normal Off
Alert Abnormal Flashing On
Accept Abnormal Steady-on Off
Return to Normal Steady-on Off
normal reset Normal Off
2. First out sequence with flashing alarm & manual reset

Alarm Indicating Visual Module Audible

Condition Contact Lamps Alarm
Normal Off
Alert
First out Abnormal Flashing On
Subsequent Abnormal Steady-on Off
Accept Abnormal All steady-on On
New Alarm Abnormal Flashing On
362

Subsequent Abnormal Steady-on On

Accept Abnormal All Steady-on Off
Return to Normal All Steady-on Off
Normal
Reset Normal Off
3. Relays
All relays shall be switchboard pattern, back connected draw
out type suitable for flush mounting and fitted with dust
tight covers. The relays confirm to IS:3231 or BS:3950 and
BS142. The relays shall be of Microprocessor based and
communication type with RS 485 port.
A set of test block and test lead for necessary secondary
injection tests shall be included. All relays in draw out cases
shall have suitable spring loaded contacts for inserting test
block.
Relays shall be provided with hand/auto reset type contacts
and flag indicators. The flag indication shall be suitable for
external hand resetting and mechanically interlocked to
prevent falling when relays is subjected to vibration. The
rating of the auxiliary contacts shall not be less than 5 amp at
240 V AC and 1.5 amp for 110 V DC..
All the circuit breakers controls shall be supplied with trip
circuit supervision relays.
4. Name and Identity Plates
-
All instruments, relays and other electrical devices

mounted on the control panel shall be provided with
plates bearing the manufacturers name, serial number
and the electrical rating data.
Plastic plate at least 10 mm wide bearing suitable
identification marks shall be fixed in the interior of the
switchboard, at the test blocks, at the fuse blocks and the
cable terminals.
363
Similar plates shall be fixed to the exterior of the

switchboard in appropriate places to indicate the
functions of control switches, push buttons, lamp and
other equipments not incorporated in the mimic
diagram.
Brass or plastic plates bearing respective circuit
designation of 50 mm width etched in 40 mm high letters
shall be mounted on the front side and back side of each
panels shall be supplied and fixed in a such way that
these can be removed and refitted when desired.
Instrument Tagging
Each equipment shall have a rust proof metal tag
permanently attached to it with the tag number.
5. Auxiliary PT & CTs

Necessary auxiliary potential transformers for open delta
potential polarisation and auxiliary current transformers,
wherever required, shall be included in supply.
Auxiliary CTs required for summation of two or more
feeders and auxiliary PTs required for galvanic isolation of
different synchronising inputs shall be included.
The instrument transformers shall have the following
accuracy class
Potential Transformer
Measurement
Protection
0.2
3P
Current Transformer
Measurement
Protection
Differential
0.2
5P20
PS
364
F. Load Managers
Load managers shall be provided to indicate all
operating electrical parameters in single unit. These Load
Managers shall have a communication port with Modbus
/ Universal protocol for communication with PLC/
SCADA system. Necessary hardware and protocol shall
be included in the cost of this panel.
f.
Inspection and Tests

Following tests shall be carried out on the control panel desks in
the presence of Owner or his authorised representative :
- Checking of correctness of wiring of circuits and continuity.
- Electrical control, interlock and sequential operation test.
- High voltage test 2000 volts to earth for one minute.
- Insulation resistance of the complete wiring with all equipment
mounted on the panels/desks.
- Routine tests according to the standards followed by the
manufacturer on the instruments, relays and other devices.
- D.C. tests.
Certified copies of all routine test certificates shall be submitted to
the purchase before despatch for review by the Owner.
2.11.10 11KV Switchboard and L. T. Panels :

a.
General technical specifications :

-
The panel shall be self supporting, free standing, floor mounted,

modular type
with construction having degree of protection
of IP 54 as per IS 2147.
11KV Switchboard shall be fabricated from 2.5mm thick CRCA
sheet steel. L.T. panels shall be fabricated from 14 SWG CRCA
sheet steel for frame & load bearing surfaces. Partitions may be
fabricated from 16 SWG CRCA if no components are mounted on
them.
365
The panel shall be painted with 2 coats of primer after pre

treatment and 2 coats of Polyurethane / epoxy paint with shade
631 of IS 5. Alternately epoxy powder coating shall be done in place
of paint.
Stiffeners shall be provided at corners & between modules to make
panel rugged. The stiffeners will necessarily be required for relay
compartments or doors where heavy components are mounted.
The open able covers shall be provided with lift off type hinges,
quarter turn door locks and flexible copper wire for earth
connection.
The panel shall be dust and vermin proof. Synthetic or neoprene
gaskets shall be provided at all openings
The panel shall be of dead front construction suitable for front
operated and back maintained functioning.
Panel shall be provided with fl. lamp of 20 w capacity operated by
door operated limit switch. Panel shall also have space heaters and
thermostat arrangement.
Panel shall be provided with 3 pin switch socket combined unit of 5
Amp capacity.
Lifting hooks shall be provided at the top of the panel.
The hardware components used in the panel shall be hot dipped
galvanized.
The control components shall be fixed on mounting plate by
drilling & tapping.
Aluminum anodized legend plates shall be provided for all the
components. For components mounted on front fascia, legend plate
from inside shall also be provided.
Pretreatment by 7 tank process shall be done before painting /
powder coating the panel.
Panel shall be have provision of drawing pocket.
The panel shall be designed to ensure maximum safety during
operation inspection, connection of cables and maintenance. Inside
panel, checking and removal of components shall be possible
without disturbing other units.
Cable entries will be from bottom. The opening of cable entry shall
be covered by 3 mm thick gland plates.
The panel shall be provided with all necessary components /
devices and instruments as per the enclosed schematic diagram and
functional requirements.
366
The components such as protective relays, auxiliary relays, push

buttons, switches, instruments shall be flush mounted on the front
side of a panel.
The control wiring shall be done with PVC insulated flexible
copper wire. For CT secondary circuits 2.5 sq.mm. wire shall be
used. For control wiring 1.5 sq.mm.
wire shall be used.
Earthing bus bar of suitable cross section shall be provided
throughout the length of panel.
The panel shall be fully wired All the terminals shall be brought
out for cable connections. 10 % spare terminals shall be provided
on each terminal block. Separate terminal block shall be provided
for different voltages. All wire shall have P.V.C. ferrules as per
wiring diagram.
Proper shrouding to incoming and outgoing terminals shall be
provided to ensure safety during operation, inspection and
maintenance.
Indicating lamps shall be with multiple LEDs & shall be suitable for
the voltage specified .
All the components in the panel shall be properly labeled. The
labels shall be made of non rusting metal or engraved PVC material
properly fixed by screws.
The panel layout shall be made in such a way that it will always
facilitate easy removal and reconnection of control cables without
disturbing other wiring.
Centre lines of control switches, push buttons and indicating lamps
shall be matched so as to give neat appearance. Similarly top lines
of indicating instruments and relays shall also be matched.
The panel shall be provided with electrolytic grade aluminum bus
bar of suitable cross section so as to maintain max current density
of 0.75 AMP/ Sq. mm. Bus bar sizing calculations shall be
submitted along with drawings for approval.
Bus bars shall be provided with color coded heat shrinkable
sleeves. The bus bar joints in 11KV switchboard shall be
provided with shrouds.
Bus bars shall be supported by high quality epoxy insulators
provided at specified distances so as to withstand to the given short
circuit withstand current.
367
The bus bar chambers shall be provided with suitable ventilation

arrangements so as to limit the maximum temperature of
85C while carrying rated current.
Proper clearance of minimum 25mm shall be maintained between
phase bus bars and between bus bars for L.T. panels. For 11KV
switchboard
minimum
clearance
of
125mm shall
be
maintained..
The panel shall be inspected at manufactures works before dispatch
to site.
All routine tests shall be carried out on the panel in presence of
Owner or his representative. These tests shall include following,
a. Verification of components ratings and operation.
b. High voltage measurement test.
c. Insulation Resistance measurement.
d. Control testing.
Approval on following drawings shall be obtained before
manufacturing the panels
a. General arrangement drawing.
b. Wiring Diagram.
c. Detail bill of material.
d. Type test certificate
2.11.11 Battery, Battery Charger cum DCDB :

Battery, Battery Charger cum D.C.D.B. shall have following specifications,
a. Construction :
The specifications for construction of Battery Charger cum DCDB
panel shall be same as that of LT panel given in earlier section of this
document.
b. Component Specifications :
(i) Batteries : Batteries are the main component in this panel. The
batteries shall be Sealed Maintenance Free (SMF) type. Batteries
shall be free from orientation constraints, eco friendly, and ready to
use.
368
The same shall be long service life and shall have low self
discharge. The battery used in this panel shall have excellent charge
retention capability. SMF battery used shall have high rate of
discharge and is expected to have highest functional reliability.
In addition to the above requirements, batteries shall have
following specifications
a.
b.
c.
d.
e.
Type:- Lead Acid Stationery sealed type, storage

battery set.
Rating 110V D.C., 150 AH at 8 Hr rate of discharge.
Standard: IS 1651 1979, Performance as per JIS C 8702
Container : Plastic Resin , ABS or PP
Terminal posts : Designed to accommodate external
bolted connections suitably.
(ii) Battery Charger : The battery charger unit shall have following
specifications,
- Charger shall be of Constant Potential type with current
limiting facility.
- Charger shall have provision to change the charging voltage on
the front panel. Normal charging voltage shall not exceed 2.25
volts per cell.
- MCB of suitable rating shall be provided as incomer to charger.
The rating shall be suitable for battery short circuit current.
- D.C. output voltage during float charging shall be stabilized
within 1% of the set value of D.C. bus voltage for variation in
parameters as follows,
Input A. C. voltage : 10%
Input Frequency : 5%
D.C. Load variation 0 to 100%
- The ripple contents shall be within 3% of the nominal D.C. rated
voltage.
- Load Limiting feature of charger shall be designed for short
time overload to take care of intermittent loads coming on D.C.
bus.
- All PCBs shall be of plug in type, If more than one PCBs are to
be provided in panel then the same shall be interlocked to
prevent insertion in wrong slot.
369
Normal operating condition shall be indicated by LED mounted

on PCB.
The boost charging voltage shall be adjustable between 70% to
100% of max. value of 2.45 volts per cell. Boost charge current
shall have provision for adjustment between 30% to 100% of its
maximum value.
Battery charger panel shall be provided with one potential free
contact for collective trouble in battery charger system. This
contact shall be wired up to terminal block for interfacing with
Master Control Panel.
Following minimum protections shall be provided in charger,
Charger shall go in current limiting mode if battery current or
charger current exceed the set value.
Charger shall trip in case input voltage decreases beyond set
value.
Charger shall trip in case of D.C. voltage is increased.
D.C. current is increased beyond set value.
Following indications, metering and protections shall be
provided on battery charger unit,
A.C. input supply ON,
D.C. supply ON,
Charger ON,
Battery on LOAD,
Battery under voltage and over voltage,
Battery Charger Failure,
Input A.C. supply Voltmeter with selector switch,
Input A.C. Ammeter with selector switch,
Output D.C. supply Voltmeter with selector switch,
Output D.C. Ammeter with selector switch,
Under voltage Relay to isolate battery from load when voltage
drops less than 80 % of set value.
Fault annunciation such as control card failure, thyristor failure,
fuse failure etc.
Charging voltage and current adjustment potentials.
370
c. Panel Wiring :
All the components discussed in earlier section of this document shall
be supplied completely wired and in ready to interface condition at the
terminal strip. The wiring inside panel shall be carried out with 1.1 KV
grade P.V.C. insulated stranded copper conductor wires. Minimum
conductor size for wiring shall be 1.5 sq. mm. For control wiring. For
D.C. circuits 4 sq. mm. Wires shall be used. Wire terminations are to
be made with crimping type tinned copper lugs which firmly grip the
conductor and insulation. Each wire shall be terminated with separate
lug. Engraved P.V.C. ferrules shall be provided for each wire
corresponding to the approved wiring diagram. The ferrules shall be
firm and shall not come out on disconnection of wire from the
connector. Clip on type connectors shall be used for all terminal blocks
with suitable barriers end clips, terminal studs and hardware. All
terminals shall have identification marks/ nos. Not more than two
wires shall be terminated on any terminal. The rating of terminal block
shall be suitable for current rating with minimum size of 6 sq. mm.
Separate terminal blocks shall be provided for different voltage levels.
2.11.12 Bus bar trunking :
-
The bus trunking shall be suitable for 3 phase 4 wire, 433 V 50 Hz, 0.8
power factor and rating as given in SLD.
The bus trunking shall be connected between LT side of transformers
to the L.T. Panel and between L.T. Panels as per SLD.
The bus bars shall be EC 91 E grade Aluminum as per relevant
standards.
The earth bus bar of GI Strip 75 X 10 mm shall run through out the
length of the bus trunking.
All the above bus bar shall be mounted on epoxy type insulators at
equal intervals
The bus trunking shall be fabricated from 2mm thick CRCA sheet steel
with angle supports where necessary.
The sheet structure shall be carried out by 7 tank process and stove
enameled type with grey color shall be applied
Set of flexible copper joints shall be provided at transformer end.
For the outdoor portion of the bus trunking canopy over and above the
bus trunking shall be provided.
The necessary supports also be supplied along with bus bar trunking.
371
2.11.13 H.T., L.T. Power and control Cables :

a. H.T. cables are to be considered from 11KV Switchboard in TG hall
to 132KV switchyard and for transformer
b. The cables shall be provided as per the details given in data sheets.
c. The cables shall be considered for all the equipments given in battery
limit of this contract and specifically mentioned for other items in this
document.
d. The H.T. cables shall be with XLPE insulation and suitable for the
functional requirements. All other cables shall be 1.1KV grade PVC/
XLPE insulated.
e. The cable sizing calculations shall be submitted by Tenderer as per
the fault level of system. The cable sizing shall be done with 40KA
fault current for the duration of 0.5 sec.
f. The necessary derating factors as recommended by manufacturers
shall be considered while deciding the cable size. These shall be mainly
comprising of,
Derating for temperature
Derating for depth of laying,
Grouping factor,
g.
The instructions given for erection of the cables shall be followed as
per manufacturers recommendations.
2.11.14
Illumination System :
The illumination system shall consist of Lighting panels, lighting
fixtures, cables, junction boxes etc complete
a. The illumination system shall be provided as per the recommended
lux levels and good engineering practices followed in industry today.
Following lighting sources are considered,
TG Hall Industrial type High Bay MH lamp for normal lighting
Industrial type High Bay HPMV lamp for Emergency
Lighting (About 25% of total lighting)
Control Room - Mirror Optic Fl. Lamps
Outdoor Lighting in switchyard HPMV and MH Flood light fittings
Boiler and Other outdoor plant areas Well glass fixtures with
HPMV lamps.
372
b. Following lux levels are recommended,

Control room - 300 Lux
TG Hall - 200 Lux.
Switchyard - 100 Lux.
c. The illumination system shall be comprising of following main
equipments,
Main Lighting Panel
Lighting MCB DB.
Lighting Fixtures with junction box.
Cabling / point wiring
2.11.15 Auto controller and islanding scheme :
Islanding scheme : Tenderer to supply a suitable islanding scheme to trip
the circuit breaker connecting the plant with the grid in event of high grid
disturbances. The same will be with voltage and frequency relays,
VECTOR SURGE RELAY reverse power relay with timer and lock out.
Suitable annunciation scheme to be included.
2.11.16 L.T. Capacitors
a. Construction Features :
-
The Capacitor bank shall be complete with the required capacitors

along with the supporting post insulators, steel rack assembly,
copper bus bars, copper connecting strips, foundation channels,
HRC fuses, fuse clips, etc. The cable entry shall be at the end of the
cable box.
The Capacitor bank shall comprise suitable number of single phase
units in series parallel combination. However, the number of
parallel units in each of the series racks shall be such that failure of
one unit shall not create an over voltage on the units in parallel
with it, which would result in the failure of the parallel units.
The assembly of the banks in cubical shall be such that enclosure
provided sufficient ventilation for each unit. Necessary louvers
shall be provided.
373
b.
The voltage rating shall be selected to form an economical and

compact design. The selection of voltage rating shall take into
account the increase of voltage at the capacitor terminals above the
actual system voltage due to the presence of series reactors, if any.
The permissible over voltage will be based on this increased
voltage rating.
Each capacitor unit/bank shall be fitted with directly connected
continuously rated, low loss discharge device to discharge the
capacitors to reduce the voltage to 50 volts within one minute.
The discharge resistors shall be insulated to avoid terminal faults.
For the sheet, steel and support structural members cleaning,
degreasing, phosphating followed by two coats of Zinc Chromate
primer and two coats of finish paint shall be done.
The Capacitor units of bank shall be connected to each other by
continuous running earth bus.
Individual capacitor unit :
The ratings of Capacitors shall be as indicated in Data sheet A.

A stainless steel or anodized name plate shall be provided on
each capacitor unit.
Bushings shall be of glass or porcelain and shall be joined to the
case by solder / welding or other method which ensures an
adequate and permanent seal.
Each unit shall satisfactorily operated at 135% of rated KVAR
including factors of over voltage, harmonic currents and
manufacturing tolerance. The units shall be capable of continuously
withstanding satisfactorily and any over voltage up to a maximum
of 10% above the rated voltage, excluding transients.
c. Unit Protection
-
Each Capacitor unit shall be individually protected by HRC fuses

so that a faulty capacitor unit shall be disconnected by the fuse
without causing the bank to be disconnected. The fuse clearing
time shall coordinate with the pressure built up within the unit to
avoid explosion.
Mounting of the individual fuse shall be external to the capacitor
case.
374
d.
Test and Test Reports

-
All routine test shall be conducted in accordance with the latest

edition of IS:2934.
Type test certificates for similar capacitor units shall be furnished.
One capacitor unit shall be type tested for thermal stability test.
The tested unit shall not form a part of supply to us.
2.11.17 VFD Units

a. Construction Features
VFDs are envisaged for fuel feeders, boiler ID & FD fans, boiler feed
pumps and main cooling water circulation pumps.
The Panels shall be dust , vermin corrosion proof construction sheet
steel clad, totally enclosed compartmentalized cubicle design with
front and rarer access. All the Panels shall be single busbar
arrangement type with bottom cable entries.
The VFD unit shall be suitable for the following operating system.
Rated Voltage
Rated Frequency
Fault Level
Enclosure
415 V + & - 10 % , 3 Ph, 4 Wire.

:
50 Hz + & - 5 % DC
50 KA for 1 Sec for AC

:
IP 42
Individual feeder modules organized in metallic segregated

compartment. Vertical busbar serving to feeder modules in the vertical
Panel or running through insulated cables. Cable Termination
compartment , suitable for terminating the cables specified in the
drawings Perforated sheet steel / insulating material enclosed
horizontal auxiliary bus way for control, interlock, indication and
metering wiring running horizontally.
375
The front of the boards shall comprise of individually enclosed Drives,

Starters, ACBs, MCCBs, and Switch disconnectors
All auxiliary devices .for control, indication , measurement and
protection such as control and selector switches, indicating lamps
ammeters, voltmeters, energy meters, and protective relays shall be
mounted on the front side of the respective compartment only.
The design shall be such that unless required from maintenance/
inspection purpose all power on / off on start / stop and relay reset
operations shall be performed without opening the panel board.
b. Busbars :The Cross section of the busbars shall be uniform throughout . The
main busbar shall be sized for minimum 120 % of the full load current
of the respective secondary of transformer. In any case , the current
density shall be not more than 0.8 A/Sq.mm.for continuous operation
or suitable for 50KA rating for one (1) second, whichever higher, for
other busbars.
Marshaling Compartments .
A common Marshalling Compartments / cabinets, as an extension, for
the switchboards shall be provided, for connection of multicore cables
from DCS racks. Marshalling compartments of adequate size shall be
provided, 1 No. in each switchboard ( Common for all VFD feeder in a
particular switchboard ) to house the interposing relays, multiplying
relays . The terminal blocks shall be mounted in such way that FIELD
terminal blocks/ termination and DCS terminal blocks / termination
are accommodated on either side (Front and rear). However, submarshalling compartment may be considered and the interconnection
between the sub-marshalling compartment and the main marshalling
compartment through inter panel wiring shall be arranged by the
Tenderer. All inter panel wiring between the individual modules, submarshalling compartment and the main marshalling compartment
shall be with shielded cables through metallic troughs with cover.
376
Marshalling cabinets shall house terminal blocks and transducers for

connection to VFD compartments/ DCS racks, as shown in the
drawings. However, local push button stations and other field
instrument cables shall be directly connected to the respective motor
feeder compartments. All analog cabling / wiring shall be of shielded
type. Control supply shall be with 230 V AC.
The terminal block arrangement shall be arranged as below :
All Digital Inputs (DIs) from different feeders to be terminated at a

separate array of terminal blocks.
All Digital Outputs (DOS) from different feeders to be terminate at

a separate array of terminal blocks.
All analog inputs (AIs) From different feeders to be terminated at a

separate array of terminal blocks.
All analog Outputs (AOS) from different feeders to be terminated

at a separate array of terminal blocks.
All terminal blocks shall be identified with the respective feeder

names. The coloring of terminal blocks for the DIs, Dos, AIs, & AOs
shall be unique for easy identification.
The Communication port of all the Tri Vector Meters / KWH meters in
the VFD Panel Board shall be connected in series through screened
twisted pair cable of 0.5. Sq.mm. and a single point connectivity shall be
provided in the marshalling compartment for hooking up these signals to
the plant DCS . However, there shall be an independent terminal block
individually for all the Tri-Vector Meter/ KWH Meter.
.
The continuous current rating VFD shall be at least 110 % of respective
connected motor FLC.
The Output Choke shall be provided for the drives , which is provided
with cable length beyond stipulated / recommended length by the VFD
manufacturer.
377
Each Out going feeder from VFD drive/ module shall be feeding to only
one motor.
Ammeter with selector switch and three (3) Nos. of CTs of Class 1
accuracy with selector switch shall be provided for all VFD
The requirement of auxiliary contactor shall be provided to meet the
control Philosophy as furnished.
Each VFD shall be provided with suitable rating of semi-conductor fuses.
Space heater supply for the motors more than 30 KW shall be extended
from the respective VFD, When VFD is in OFF condition.
All the control circuits shall be provided with MCB control for isolation
purpose.
Thermistor relay shall be provided in the circuit wherever applicable.
2.11.18 Cables :
Following 11KV (UE), 3Cx 300 sq. mm. XLPE insulated, Al. conductor
Cables, are envisaged for this project.
Cable from
11KV Switchboard
11KV Outdoor Kiosk
in 132KV Switchyard
11KV Switchboard
11KV Switchboard
Cable to
11KV Outdoor Kiosk in
132KV Switchyard
Approx. Length
meters.
5 Runs
550mtr.
Generator Transformer
5 Runs x 20mtr.
Cogen Aux. Transformer
1Run x 75mtr
2000KVA, T1
Cogen Aux. Transformer
1Run x 75mtr
2000KVA, T2
378
Cable trays :
Pre fabricated G.I. cable trays shall be considered by the Tenderer.
For size up to and including 150mm. the cable trays shall be
perforated. The trays including and above
300mm size shall be
ladder type. The fabrication of cable trays shall be done with 2mm
thick sheet. Cable trays shall be hot dip galvanized having minimum
galvanizing of 110gm/sq. m uniform.
The quantities are estimated quantity Tenderer to estimate based on scope
and plant layout. Unit rates shall be given for any addition or deletion
of quantities.
2.11.19 Steel supports :
Apart from the switchyard structures which are separately
considered MS steel material shall be used for following,
Below Panels on cable trench.
Supporting cable trays at every 1.5M in built up cable
trenches. The insert plates in cable trenches will be provided
by other agency.
The required quantity of 5 MT is to be considered for this purpose.
2.11.20 132 KV Metering and Relay Panels :
a. Metering :
Following meters shall be provided in metering panel for monitoring,
indicating and integrating power export to BSEB and Aux. for Plant
:
- Ammeters
- Voltmeter 0 150 KV
- Frequency meter
- Semaphore
- Indication lamps
- Selector switches for Voltmeter and Ammeter
- Load Manager to read & store various electrical parameters of
power export
379
b. Relays
Microprocessor based numeric relays are to be used.
- Diff. protection relay for MAIN Trafo.
- Restricted Earth Fault Relay (64)
- Instantaneous over current relay (50)
- Non directional earth fault relay(51 N)
- Directional Over current fault relay (67)
- Buccholz trip
- Oil temp. trip
- OLTC oil surge trip
- Master trip unit
- Trip circuit supervision relay
- Stand by E/F relay
- IDMT O/C and E/F relay for Main and Dist. Trafo.
- Instantaneous O/C relay
- df /dT relay and vector surge relay
- Annunciation
2.11.21 Earthing system :
-
Earth mat as per IEEE 80 and IS 3043 requirements.

Earthing Electrodes CI pipe type
GI Earthing strip as per IS 3043.
Earthing grid GI 75 x 10 mm
Lightning conductor 8 SWG GI
Earthing risers and pads - as required.
2.11.22 Details of Trivector meters in metering Panel

a.
b.
c.
d.
e.
f.
g.
Application
- Measurement of Electrical parameters
Installation
- Indoor
Rated Voltage - 110V, 50 Hz.
Rated Current - 1 Amp
Accuracy Class - 0.2
Ref. Amb. Temp - 50C.
Make
- BSEB Approved
380
2.11.23 Bus bar Trunking Following are the requirements of bus bar trunking sets,
From 2000 KVA transformer to L.T. Panel (Cogen Auxiliaries)
Rating 3200Amps Approx. Length 15 meter. 2 sets
Sr. No.
1
1.1
1.2
1.3
1.4
Particulars
General
Location Indoor/Outdoor
Reference Ambient
Temperature
Climatic Conditions
Power System
A) Voltage, Phase, Wire,
Frequency
B) Short Circuit Level
1.5
C) Neutral Earthing
Type Of Bus Duct
2
2.1
Bus Bars
Material
2.2
Rated Voltage And Continuous

Current
Short Time Current & Duration
2.3
2.4
2.5
2.6
2.7
Dynamic Current Rating

Air Clearance
A) Phase To Phase
B) Phase To Earth
Insulator Creepage Distance
Temp. Rise Over Specified
Ambient Temp. When Carrying
Continuous Current at 50 Hz
Specific Data
Outdoor / Indoor
50 C
Tropical, hot humid &
dusty
415V, 3PH, 4W, 50HZ
50KA SYM for 1 sec
for 3200 Amps ratings
Solidly earthed
Non segregated phase
rectangular
Alumi. on Alumin
alloy (ECE 91 E grade)
433V, as specified
50KA SYM for 1 sec
for 3200 Amps ratings
100KApeak for 3200A
25 mm
25 mm
40 mm
35 C
381
Sr. No.
2.8
2.9
3
3.1
3.2
Particulars
Withstand voltage
a) 1 min, power frequency
b) Impulse 1.2/50 micro sec.
wave
Size of Bus Bars
Enclosure
Degree of Protection Provided
Color
Interior
Exterior
Special Paint
3.3
Material And Thickness
3.4
3.5
3.6
Length of Bus Duct

No. of L Bend
No. of CU flexible joints
4
5
6
7
8
9
10
Bus duct support

Wall frame assembly
Material and size of earth bus
Portable hot air blowing
equipment
Space heaters
Phase transposition assembly
Applicable Standard
11
Configuration
Specific Data
3 KV for 1 min.
-As required.
IP:55 for outdoor /
IP52 for indoor
portion
manuf. STD.
Light gray (631 OF
IS:5)
Epoxy finish & Zn
chromate primer
CRCA sheet steel 2.0
mm thickness
As given above
As required
1 set per transformer
as per rating
MS Channels / angles
Required
Al. 50 x 10 MM FLAT
Not required
Not required
To be considered
IS:8084 and IS:5082
Inter linked
Note : Short circuit calculations and temp. rise calculations for bus
bar trunking shall be approved before manufacturing the
trunking.
382
2.11.24 L.T. Panels :

Following are the technical particulars of L.T. Panel
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
Switchgear Cubicle & Bus bars

Type of switchgear
Metal Clad, Indoor, Draw out
type
Rated Voltage and Frequency
433V, 3Ph., 50 Hz.
Max. System Voltage Class
457V, Indoor switchgear
P.F. withstand Capacity for 2.5 KV
1min.
Short
Circuit
Withstand 50 KA for 1 sec.
Capacity at rated voltage
Design Amb. Temp.
50C
Cont. Current Rating of Bus 3200 Amp for main bus bar in
bar
Cogen Aux. Panel and
with
maximum current density of
0.75A / sq. mm.
Max. Temp. at cont. Operating 85C
Current
Applicable Standard
As per relevant IS
Switchgear Construction
2.3
2.4
Material of construction
Thickness of Sheet steel
Panel, Frame, Gland Plate,
Doors, Removable
covers,
Partitions
Degree of protection
Color of Finish shade
2.5
Bus bar Material
2.6
2.7
Earthing Bus bar Material

Minimum Clearance in Air
2.8
Cable Entry
CRCA sheet steel

14 SWG
16 SWG
IP 54 as per IS 2147
Light Gray Semi glossy finish as
per Shade 631 of IS 5 for Exterior
and Brilliant White finish for
interior
Electrolytic Aluminum with Heat
Shrinkable Sleeves
Aluminum Flat 50 x 6 mm
25 mm between phases
20 mm between phase and earth
Bottom
383
3.0
3.1
Incoming Breaker Details

Type
3.2
3.3
Rated Current at amb. Temp.

Accessories with ACB
3.4
3.5
Rated Breaking Capacity

Type of operating mechanism
3.6
3.7
4.0
4.1
4.2
4.3
Min. No. of auxiliary contacts

Auxiliary Control Voltage
Current Transformers
Type
Winding Material
Accuracy Class
4.5
5.0
5.1
Applicable Standard
Wiring Details
Material for wiring
5.2
5.3
Voltage Grade
Wiring size ( Minimum.)
6.0
Outgoing Feeder details
Electrical Draw Out type Air

Circuit Breaker
As per SLD
P based S/C, O/C and E/F
release, U / V, shunt trip and
Aux. Contact Block
60KA for 1 sec.
Motor Operated spring assisted
latch mechanism
4NO + 4 NC.
440V, A.C. for U / V coil
Cast Resin bar primary
Copper
Class 1 for metering
Class 5P10 for protection
IS 2705
PVC insulated stranded Copper
wire.
650 V
a) For power circuits as per
current Rating 2.5 sq.
b) For CT secondary circuits 2.5 sq.
c) For other circuits 1.5 sq. mm.
As per SLD with SFU and
ACB
384
2.11.25 L. T. Capacitors
Designation
Quantity and Output In Kvar
Rated Voltage
Ref. Standard
Upper Limit of Temperature
Category as per IS:2834
Location of Capacitors
Connection and Switching
Device
Size And Material Of Earth Bus
Air Clearance for Live Parts
Phase-Phase
Phase-Earth
Type of Dielectric Material
2.12
:
:
:
:
:
Shunt capacitors
50 KVAR each bank
440 V, 3 PH, 50 HZ
IS 2834,IS 13925
85 C
: Indoor
: Connected in LTPCC
through FSU & Contactors
: 50 x 6 MM GI
:
: 25 mm
: 20 mm
: APP
CABLING
2.12.1
General Construction
The cables shall be brand new and in good condition. These shall be
suitable for laying in laying in trays, trenches, ducts, conduits and
underground buried installation with uncontrolled backfill and possibility
of flooding by water.
The Tenderer shall also include in his scope cable tray/packs, double
compression cable termination kits, cable lugs, armour clamps, cable
glands, identification tags, insulating tapes and compounds, sleeves,
supporting structure, bolts, nuts, washers and all other installation
materials. The Tenderer shall provide the details and necessary drawings
of cable trenches with sectional views.
Extra PVC/ Rubber and caps for each XLPE Cable size shall be supplied.
The terminating and straight thro' joint kits for the cables shall be suitable
for the type of cables offered and for storage without deterioration up to
50 deg C ambient temperature.
385
a)
PVC Cables
All the power cables shall be of aluminium and all the control
cables shall be of copper.
All power / control cables for use on medium voltage systems shall
be heavy duty type, 1100 V grade with aluminium / copper
conductor, PVC insulated, inner sheathed, armoured and overall
PVC sheathed. with FRLS PVC insulation .
The construction of the conductors shall be 'stranded'. Conductors
of nominal area less than 25 Sq. mm shall be circular only.
Conductors of nominal area 25 Sq. mm and above may be circular
or shaped.
The core insulation shall be with PVC compound applied over the
conductor by extrusion and shall conforms to the requirements or
Type 'A' compound of IS : 5831. Control cables having 6 core and
above shall be identified with prominent and indelible Arabic
numerals on the outer surface with a spacing of maximum 500 mm
between two consecutive numbers.
The inner sheath shall be applied over the laid- UP cores by
extrusion and shall be of PVC conforming to the requirements of
Type STI PVC compound of IS : 3831. The extruded inner sheath
shall be of uniform thickness of size not less than 0.5 mm up to 16
Sq. mm 0.8 mm from 25 Sq. mm up to 120 Sq. mm and 1.0 mm
above 120 Sq. mm conductor size.
For multi-core cables, the armouring shall be by single round
galvanized steel wires where the calculated diameter below
armouring does not exceed 13 mm an galvanized steel strips where
this dimension is greater than 13 mm.
The outer sheath for the cables shall be extrusion FRLS (Fire
Retardant Low Smoke) PVC compound
386
b)
XLPE Cables
Power cables for 11 KV system shall be with Aluminium
Conductor, XPLE insulated, screened, sheathed, armoured and
overall FRLS PVC sheathed.
The construction of the conductors shall be stranded and
compacted circular for all cables.
The cables shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with nonmetallic extruded semi-conducting shielding.
The core insulation shall be with cross-linked polyethylene unfilled
insulating compound.
It shall be free from void and shall withstand all mechanical and
thermal stresses under steady state and transient operating
conditions.
The insulation shielding consist of non-metallic extruded semiconducting compound in combination with a non-magnetic
metallic screening of copper.
The insulation screen shall be strippable without application of
heat. The copper screen shall be capable of carrying the single line
to ground fault current for a duration of one (1) second.
The screen XPLE insulation and insulation screen shall all be
extruded in one operation by "Triple Extrusion" process to ensure
perfect bonding between the layers.
The core identification shall be coloured strips
numerals.
or by printed
387
The inner sheath shall be applied over the laid Up cores by

extrusion and shall conform to the requirements of Type ST 2
compound of IS : 5831. The extruded inner sheath shall be of
uniform thickness of size not less than 0.7 mm for all sizes of
cables.
For multi core cables, the armouring shall be by galvanized steel
strips armouring for single core cables shall be with hard-down
aluminium round wire of 2.5 mm diameter.
The outer sheath for the cables shall be extrusion FRLS (Fire
Retardant Low Smoke) PVC compound
c)
Cable Accessories
The termination and straight through joint kits for use on high
voltage systems shall be suitable for the type of cables offered as
per this specification. The termination and joints shall be supplied
in kit form.
The kit shall include all insulating and sealing materials apart from
conductor fitting and
consumable items.
An installation
instruction shall also be included in each kit.
i) Termination Kits
The terminating kits shall be suitable for termination of the
cable to an indoor switch gear or to a weather proof cable box
of a outdoor mounted transformer / motor. the terminating kits
shall preferably be one of the following types or equivalent :

Heat-shrinkable sleeve type of M/s. Raychem.

'TAPEX' of M-SEAL make using non-linear resistance
material for stress grading.
'PUSH-ON' type of CCI make using factory moulded
silicone rubber insulators.
Cold shrinkable type 3 M Birla
For outdoor terminations, whether shields / sealing ends and

any other accessories required shall also form part of the kit.
388
ii) Jointing Kits

The straight thro' jointing kits shall be suitable for underground
buried installation with uncontrolled backfill and possibility of
flooding by water. The jointing kits shall be one of the following
types :
'TAPEX' of M-SEAL make.
'TROPOLINK' type of CCI make.
Heat shrinkable sleeve type of M/s Raychem.
Cold shrinkable type 3 m Birla
2.12.2 Inspection & Testing
The cables shall be tested and examine at the manufacturer's works. All
the materials employed in the manufacture of the cable shall be subjected,
both before and after manufacturer of the cable, to examination, testing
and approval by Owner / Consultant.
Manufacturer shall furnish all necessary information concerning the
supply to Owners inspectors.
The inspector shall have free access to the manufacturer's works for the
purpose of inspecting the process of manufacture in all its stages and he
will have the power to reject any wire or other material which appears to
him to be of unsuitable description or of unsatisfactory quality.
a)
CABLES
i) After completion of manufacture of cables and prior to
despatch, cables shall be subjected to type, routine, acceptance
and special tests as detailed below.
Consultant / Owner reserves the right to witness all tests with
sufficient advance notice from Tenderer. The test reports for all
cables shall be got approved from the Engineer before despatch
of the cables.
389
ii) All routine tests, acceptances tests, type tests as well shall be
carried out on PVC cables as listed in IS : 1554, Part-1.
iii) The inner and outer sheath of XLPE cables shall be subjected to
all the tests applicable for FRLS PVC cables.
The test requirements for insulation and sheath of PVC cables.
The test requirements for insulation and sheath of PVC cables
shall be as per latest revision of IS : 5831.
The following tests shall be carried out on XLPE cables as per IS
: 7098 Part-II.
iv) Type Tests
The following shall constitute type tests :

Tensile test
Wrapping test
Conductor resistance test
Test for armour wires
Test for thickness of insulation and sheath
Physical tests for insulation
Physical tests for PVC sheath,
Fire resistance
Cold-impact
Bleeding and blooming
Particle discharge test
Bending test
Heating cycle test
High voltage tests
v) Acceptance Tests :

Tensile test (for aluminium)

Wrapping test (for aluminium)
Test for thickness of insulation and sheath
Partial discharge test
High voltage test
390
vi) Routine Tests :

b)

Partial discharge test
High voltage test
Cable Accessories
Type tests shall have to be carried out to prove the genera qualities
and design of a given type of termination / jointing system. The
type test shall be conforming to the latest IEC 502-2, 466
specifications. The type test certificates shall be submitted along
with the offer.
2.12.3
Packing and Marking

Cable shall be despatched in wooden drum of suitable barrel diameter,
securely battened, with the take-off end fully protected against mechanical
damage. The wood used for construction of the drum shall be properly
seasoned, sound and free from defects. Wood preservatives shall be
applied to the entire drum.
On the flange of the drum necessary information such as manufacturer's
name, type size voltage grade of cable, length of cable in meters, drum
No. cable code, ISI Certification mark, gross weight etc. shall be printed.
An arrow shall be printed on the drum with suitable instruction to show
the direction of rotation of the drum.
2.12.4 Information Required

Catalogue and brochure giving technical and physical details of the cable
like current rating, de-rating factors, etc.
'Type Test' certificates.
Shelf life of cable accessories for the ambient temperature specified.
391
2.12.5 Other Cables:

a) Signal Cable:
Signal cable shall be tinned copper conductor, PVC insulated twisted,
each pair shielded over all shielding inner sheath armoured PVC
jacketed. Shielding shall be Aluminium Mylar with 25% overlap & 100%
coverage with minimum shield thickness of 0.06 mm. Drain wire shall be
provided for individual pair and overall shield, which shall be of 18
AWG, 7 stranded tinned copper conductor. Cable shall be PVC insulated
and primary insulation shall be 90C PVC. The insulation grade shall be
600 V as minimum. The cable shall confirm to the relevant I.S. standards.
b) Control Cable:
Control cable shall be stranded conductors of electrolytic grade copper.
PVC insulated twisted, intermediate sheath extruded-overall armoured.
Cable shall be PVC insulated and primary insulation shall be 90C PVC.
The insulation grade shall be 600/1100 V as minimum. The cable shall
confirm to the relevant I.S. standards.
c) Compensating Cable:
Compensating cable shall be P/K type. PVC insulated twisted, each pair
shielded over all shielding. Inner sheath armoured-PVC jacketed as per
ANSI 96.1. Shielding shall be Aluminium Mylar with 25% overlap &
100% coverage with minimum shield thickness of 0.006mm. Drain wire
shall be provided for individual pair and overall shield, which shall be of
18 AWG, 7 stranded tinned copper conductor. Cable shall be PVC
insulated and primary insulation shall be 90C PVC. The insulation grade
shall be 600/1100V as minimum. The cable shall confirm to the relevant
I.S. standards.
d) Cable Gland:
Cable gland shall be nickel plated brass and shall be double compression
type weatherproof.
Structural carbon steel rolled / channel / ISMC100 / ISA 50x50x6 / ISA
40x40x5 / IS 2062 Gr-A/0
392
e) Control Panel Wiring

Wiring Material
Wiring sizes
Wire colour
: Insulated
tinned
copper
stranded
conductor. In case any wiring is done on
door mounted items it shall be with
multi-strand wires with adequate loop
length
: Control, signal, etc. - 1.0 mm2
Power
- 1.5 mm2 (min)
: Colour code shall be
230 V AC
: L = Brown
230 V AC
: N = Blue
Earth=green/yellow
24 V DC (power)
: +ve = Red
24 V DC (power)
: - = White
4-20 mA
: 4-20 mA Black (+)
White (-)
Digital inputs / outputs: Grey
f) Cable Dressing:

Wiring carrying different voltages shall be grouped separately

Wiring shall be arranged to ensure free access to all devices for
maintenance services
No wiring shall be routed across face or rear of any device, which
will restrict opening of covers or obstruct access to leads, terminals,
etc.
Tapping or splicing between terminal points is not permissible.
Groups of wires shall be bunched with cable straps at suitable
distances.
Common connections should be limited only to 2 wires per
terminal.
Ducting : suitably grouped wires shall be placed in PVC wiring
trays with covers.
Terminal lugs : crimpable, insulated sleeve, ring / pin / U type as
per Tenderer standard for internal terminations.
393
Identification : Wire number of each termination shall be by means

of sleeve ferrules. Cross ferruling shall not be used. Instrument tag
number and terminal number shall be used on terminal end.
Power supply individual 2 pole MCBs shall be used for each power
consuming device mounted in the panel & in field. The main
switch shall be non-fuse type breaker.
g) Terminals:

Terminal size shall be 1 size higher than wire size subjected to a

minimum of 2.5 mm2. Terminals shall be segregated accordingly to
voltage levels. 25% capacity shall be provided in the terminal
blocks wherever supplied.
Care shall be taken to separate signal and power supply cables
providing separate ducts, terminal strips / blocks, etc.
Generally no more than two wires shall be terminated on one side
of a single terminal. Additional terminals shall be provided for
looping if necessary. The use of shorting links for looping shall be
avoided.
Terminal housing shall be sized with due consideration to
accessibility and maintenance.
50 mm minimum space shall be provided between terminal strips
and sides of the box parallel to the strip for up to 50 terminals and
an additional 25 mm for each additional 25 terminals.
100 mm minimum space to be provided between two terminal
strips for up to 50 terminals and an additional 35 mm for each 25
additional terminals.
75 mm minimum space shall be provided between terminal strip
and top or bottom of the box for up to 50 terminals and an
additional 25 mm for each additional 25 terminals.
The bottom of any terminal strips shall not be lower than 300 mm
from the gland plate unit in any cabinet.
All terminal strips shall be mounted on suitable anodised metallic
or plastic stand off.
Removable cover plate shall be provided for all terminals other
than low voltage instrument signals.
Identification: Wire number of each termination / wire shall be by
means of number and letter ferrules. Direct ferruling of black
letters on white sleeves is required.
394
2.12.6 Cable Termination & Testing

All PVC cables shall be terminated at the equipments/ panel by

means of single compression type glands and tinned copper lugs.
Power cables shall be identified with red, yellow and blue PVC
tapes. Where copper to aluminium connections are made necessary
bimetallic washers. shall be used.
In case of control cables, all cores shall be identified at both ends by
their terminal numbers by means of grooved PVC ferrules. Wire
numbers shall be as per inter-connection diagrams to be furnished
by Tenderer.
Tenderer shall drill holes for fixing glands wherever necessary at
no extra cost.
The cable shall be taken through adequate size gland inside the
panel or any other electrical equipment. The individual cores shall
then be dressed and taken along the cable ways
Cable leads shall be terminated at the equipment terminals by
means of crimped type solder less connectors. Crimping shall be
done by hydraulic crimping tool and conducting jelly shall be
applied on the conductor. Insulation of the leads should be
removed immediately before the crimping
After completion of the termination the waste material such as PVC
insulation removed from cables, cable pieces & armour strips etc.
Shall be immediately removed from the work place and shall be to
appropriate place allotted for this purpose.
Before energising the cables following tasks shall be carried out
checking of identification Nos.
Measurement of resistance.
Insulation resistance.
Pressure Testing in case of 11KV XLPE cable.
Proper records shall be maintained for future reference.
395
2.12.7 H.T., L.T. Power and control Cables

a.
b.
c.
2.12.8
11KV (UE) cables shall be with XLPE insulation Aluminium

conductor armoured cables. All other cables shall be 1.1KV grade
PVC / XLPE insulated armoured cables. All power cables up to 4
sq. mm. will be with stranded copper conductors. The cables
above 6 sq. mm. will be with Aluminium conductors
The cable sizing shall be confirmed by Tenderer as per the fault
level of system.
The necessary de-rating factors as recommended by manufacturers
shall be considered while deciding the cable size. These shall be
mainly comprising of,
De-rating for temperature,
De-rating for depth of laying,
Grouping factor,
Voltage drop as follows,
(i) Steady state voltage drop shall be limited to
3% and
(ii) voltage drop during starting of motors shall be
limited to 10%
Metering:
Following meters shall be provided in metering panel for monitoring,
indicating and integrating power export to BSEB and Aux. for Plant:

Ammeters
Voltmeter 0 200 KV
Frequency meter
Semaphore
Indication lamps
Selector switches for Voltmeter and Ammeter
Load Manager to read & store various electrical parameters
of power export
396
2.13
DCS BASED INSTRUMENTATION & CONTROL

This section gives the general philosophy of the Instrumentation and Control
System proposed for the proposed cogeneration power plant.
The cogeneration power plant will be complete with the basic instrumentation
and control system, necessary for its safe and efficient operation.
Comprehensive instrumentation and control equipment will be provided for
each major areas i.e Boiler, Turbo-generator, Electrical system and Balance of
Plant.
The control system shall be based on the State-Of-The-Art Distributed Control
System (DCS) technology, with Data Acquisition and control of the key
operational parameters.
The Centralized control / monitoring shall be from a Remote Central Control
Room, where the DCS and its sub systems including the operator console, shall
be located. The same will be located at turbine operating floor level. In addition
to the same, a centralised monitoring terminal is required in the administrative
block. This terminal is required for viewing the critical operation of the cogen
plant alongwith sugar & ethanol plant. Control cabling from cogen DCS to
administrative building in Tenderers scope
The key instrumentation and control system shall be as follows:
2.13.1 Boiler and its auxiliaries
The control of the boiler like operation / start up / shut down / trip, shall
be realized directly from the DCS. All the signals required for controlling
the boiler operation shall be processed by the DCS and necessary
actuating signals for the various final control elements shall be driven
from the DCS. The major control of the boiler includes the following, as a
minimum:
i.
Drum level (3 element) control
ii. Combustion control
iii. De-aerator level control
iv. De-aerator pressure control
397
v.
vi.
vii.
viii.
Furnace draft pressure control

Superheated Steam Temperature Control (2 element)
Blow down tank level control
Soot blower control
Signals from the following shall be taken to the DCS for monitoring /
interlocking purpose.
i.
ii.
iii.
iv.
v.
Electro static precipitator

Boiler feed pumps and transfer pumps
De-aerator
Chemical dosing
Boiler safety and protection interlocks
2.13.2 Turbine & auxiliaries

The following controls of each of the turbine shall be performed by the
DCS, as a minimum:
i.
ii.
iii.
iv.
v.
vi.
Lube oil
Control oil
Gland sealing steam
Turbine protection and safety interlocks
Turbine start up / stopping sequence
Generator cooling system
The following functions of the turbine shall be realized by dedicated

independent micro processor based systems and shall be interfaced with
the DCS through serial communication for monitoring / interlocking
purpose :
i. Turbine vibration monitoring
ii. Turbine governing
The information of the following shall be monitored by the DCS for Data
logging / Interlocking purpose :
i. Power generation details
ii. AOP / EOP / MOP / CEP status
iii. Temperature of windings / Bearings of various pumps, generator
etc.
398
The following details on the electrical signals shall be processed /

monitored by the DCS for interlock / data acquisition purpose :
i. Safety relay status
ii. Breaker status
iii. Generated voltage, current, kilowatt, KVAR, power factor,
frequency
iv. Lin voltage, current, kilowatt, KVAR, power factor, frequency
v. Synchronization
The instrument air compressor shall be controlled by their individual
dedicated PLC system. This system shall be interfaced with the DCS
through serial communication for monitoring and data acquisition
purpose.
Various electrical inputs from the transducers and the digital signals from
MCC panels shall be processed in the DCS system for achieving the
necessary interlocks / controls.
The water treatment system monitoring shall be by DCS, data acquisition
will be by serial communication mode.
The PRDS functions, fuel and ash handling system, shall be directly
processed by the DCS.
The design of the total control system will be such that the following sub
system functions will be handled by the respective equipment:
i. Data acquisition, display and logging sub system for monitoring,
display, logging and printing of process parameters like flow,
temperature, pressure, level, power, current, voltage, analytical and
status will be performed by the operator station.
ii. Start / Stop Sequence & Interlock sub systems consisting of the
safety interlocks, Sequence of starting and stopping of the power
plant and alarm generation will be achieved through the DCS.
399
iii. Closed loop control sub system consisting of the continuous

monitoring of the operational parameters like Level, Pressure, Flow
etc. and controlling of the same using the PID functions will be
achieved by DCS system.
iv. Engineer / Operator Interface sub system consisting of setting /
changing the operational parameters based on the experience of the
operator and as a reaction to emergency situations will be achieved
by the computers used as the operator station.
v. Communication sub system for interconnecting all the above
systems.
vi. Data highway and network for connecting the control and data
acquisition sub systems, operator interface sub systems to a
duplexed data highway such that there will be information
exchange among each one of them.
vii. Auxiliary units such as system cabinets, printer consoles,
marshaling cabinets and power supply distribution cabinets.
The Distributed Control System is proposed for control and
instrumentation system, keeping in view the safety, reliability and
availability for comprehensive presentation of plant operation status,
trends and essential operator interaction facility.
The DCS based plant control will have the following inherent advantages:
i. Integration of information from different individual controls
provides centralized data on plant operation.
ii. Increased reliability due to the use of Large Scale Integrated (LSI)
components.
iii. Increased flexibility for modification at any stage due to software
configuration capability.
iv. Modular design concept provides easy expandability for future in
hardware and software.
v. Higher maintainability due to improved self-diagnostic and display
features.
400
The major design aspects of the system will be as follows:

i.
Control will be of the type which normally relieves the operator of

continual regulating duties and will be backed up by interlocks and
safety systems that will take pre-planned action in cases where
unsafe trends and / or conditions develop faster than the
operators ability to respond.
ii.
Continuous self checking features shall be incorporated in system

design with automatic transfer to healthy / redundant circuits to
enhance the reliability of the complete system.
iii.
All the closed loop analog signals shall be processed by the DCS.
iv.
Redundancy will be provided in the Central Processing unit, power

supply (both at the CPU & I/O), I/O modules and communication
modules (both between the controller and the operator station and
between the I/O modules and the controller).
v.
Redundancy will also be provided for the communication cables.
vi.
Power supply used for interrogation with field devices shall also be
redundant.
vii. The DCS shall be provided with processor, power supply,

communication and I/O redundancy for critical I/Os.
viii. The Input / Output modules will be provided with noise filter and
galvanic / upto isolation from external control source.
ix.
The Input / Outputs modules will also be provided with protection

against reversal of polarity of supply voltage
x.
The inputs modules shall be suitable for processing the field

signals. The outputs will be short circuit proof and protected by
fuses.
xi.
The memory will be non volatile or battery backed up as required.
401
xii. The DCS programming language shall be based on logic statements

/ ladder logic.
xiii. On line replacement of modules shall be possible without affecting
the process.
xiv. Auto boot up facility for the DCS shall be within 2 minutes.
xv. Display response time shall be less than 2 sec.
xvi. Data communication net work response time shall be less than 100
m Sec.
xvii. Closed loop control task execution (control response time) shall be
done within 250 m Sec.
xviii. Sequence control / Interlocks scan time should be within 100 m sec.
xix. Display update time shall be less than 1 sec.
xx. The system shall be designed so that the failure of any monitoring
device or control components or spurious intermediate grounding
in the signal path shall not open the signal loop nor cause the loss
or malfunction of signal to other devices using the same signal.
xxi. All equipment / systems located in the field shall be suitable for
continuous operation without loss of function, departure from the
specific function or damage at the ambient temperature and
humidity conditions.
xxii. The control system software shall have all the essential capabilities
to perform advanced control algorithms as a minimum. It shall be
user friendly, easily programmable and have excellent data
acquisition, graphic display and logging capabilities.
402
The field instruments that are primarily responsible for measuring the
process parameters will be having the following major design features:
i.
All the field instruments / equipment that are used shall be of the
same make for ensuring the smooth and optimal maintenance
including efficient spare parts management.
ii.
All field instruments used for sensing transmission and measuring

shall be of electronic smart type with signal transmission in current
mode of 4-20 mA.
iii.
All control valves and control damper drives will be of pneumatic

type because of their fast response and ease of maintenance.
iv.
Appropriate de-rating of electronic components and parts.
v.
All the panels outside the DCS shall have communication facility
through RS 485 interface.
vi.
Important plant parameters, that are required to assess the plant

efficiency, must be serially communicated to the operator station
for the purpose of display / logging.
vii. All solid state systems / equipment shall be able to withstand the
electrical noise and surge as encountered in actual service
conditions and inherent in a power plant and shall meet the
specification requirements of surge protection.
viii. All solid state electronic system / equipment furnished shall meet
the requirements of Burn-in and Elevated temperature test.
ix.
All the instrumentation cables shall be flame retardant low smoke

type.
x.
The instrumentation cables and wires shall function without

breakdown for surges experienced in the control system. Voltage
class and insulation level shall be compatible with the signals they
convey.
403
The turbine shall be provided with an electro-hydraulic governing system.

The system shall be designed such that the governing of the turbine shall
be automatic and provides for safe operation.
All the conventional recording and annunciation methods will be
dispensed with and instead it will be taken care by the DCS operator
station with the SCADA software.
Apart from the above integrated control system, local gauges will be
provided near the equipment / pipelines at essential parts of the plant for
the purpose of operator guidance.
2.13.3 Scope Of Supply
a. Design, system & software engineering, manufacture, supply of
hardware & licensed software, testing, inspection, Factory Acceptance
Test (FAT) packing, forwarding, transportation, Site Acceptance Test
(SAT), erection & commissioning, post commissioning assistance till
plant stabilisation.
b. The integration of all the inputs / signals for continuous monitoring,
operation, data logging, data analysis, alarms, safety interlocks,
annunciations etc. will be achieved through the DCS.
c. The DCS will include the DCS control station, related licensed software
& hardware, instrument & control cabling from the marshalling
cabinet receiving signals from junction boxes of all cogeneration
equipment, all MCCs and software links with Turbo-visory panel,
Woodward Governor and turbine temperature scanner.
d. The
scope
includes
training,
documentation,
establishing
communication between operating station and DCS and any other
item, which is necessary for smooth operation of the system.
e. Tenderer to carry out engineering of system hardware and software to
meet functional requirement outlined elsewhere. However, the system
shall be freely expandable to reasonably high level, by adding
hardware and related software without in any way, compromising the
system capability with respect to system communication and memory
to handle additional software.
404
f. The entire cogeneration plant will be smoothly started, normally

operated, provided with necessary interlocks & emergency trips,
monitored, controlled and smooth shut down from the DCS. The DCS
to have required software or compatibility to internet.
2.13.4 General Specifications For DCS

Distributed Control system shall be provided for the safe and efficient
monitoring & operation of Co-generation plant (i.e. Boiler, Turbine,
Generator and its auxiliaries, Balance of plant, electrical breakers etc) in all
regimes of operation.
The system shall be microprocessor based having functional distribution
and data base distribution sub-system wise.
Signals from thermocouples & RTDs will be converted to mA signal by
converter cards in Tenderers marshalling cabinet.
The marshalling cabinet to have MTL 3013 or equivalent P&F isolation
amplifiers for signals received from proximity switches.
a)
Digital Inputs
Digital inputs shall be potential free. The inputs to the DCS shall be
contact closures, closed during process normal conditions. Contact
interrogation voltage shall be 24 V DC.
Loop current
: to be informed by Tenderer
Galvanic / optical isolation
: required for input channels
Max. number of inputs per card : 32 nos.
405
b)
Dynamic colour graphic displays

All the process parameters, variables shall be displayed
dynamically on graphic displays. Process data shall be visible on
this screen with its equipments. Equipments shall be displayed in
standard ISA symbols.
Normal operation & control of the process shall be possible using
numerical keypads and functional keys on the console by
monitoring the same on the screens.
The OS should perform all the normal plant operation, control &
monitoring functions. It should be possible to select displays either
through keyboard or mouse. Display should be updated at least
once in one second.
Hyperlinks (Navigation buttons) shall be configured for navigating
from one page to the other for a particular service.
c)
Alarm:
Alarms shall be software configurable and shall be divided under
following two categories
Process alarms : First out
Process alarms : Normal
Hardware & diagnostic alarms with error codes and description
Alarms shall be displayed on the console screen at the time of its
occurrence. The same shall appear in the first out sequence.
Alarms shall occur on the screen with its tag / description /
process data.
Critical alarms should have time stamping in milliseconds. The
same shall be also printed on the printer. Tenderer shall add alarm
text. ISA sequence shall be followed for alarms.
406
d)
Push Buttons and Selector Switches :

Shall be software configurable on the screen which includes
following
Momentary NO & NC push buttons
Latched push buttons
Two or three way position selector switches
e)
Bar Graphs:
Bar graphs shall show the dynamic value of process parameters,
which will correspond to numeric value in Engineering. Unit. This
shall also be displayed in percentage value, engineering units. Bar
graph for PID controller includes process variable, set point, remote
SP, manipulated variable (MV) in different colours. Status of loop
i.e. auto / manual / cascade shall be displayed alphabetically and
with colour change.
f)
Controller faceplate / Switch face plate:

Controller faceplate shall include numeric Engineering. Unit
display and Bar graph for process variable, set point &
manipulated value. Auto / manual / cascade operation shall be
possible. Set point change & manual operation shall be possible
from this faceplate. Manual to auto changeover & vice versa shall
be bump less. Changeover from local set point also shall be bump
less. PV / SP tracking in PID controller shall be possible.
Switch face plate shall include ON / OFF switches including start /
stop PBs. Operation of start / stop push buttons / selector switches
shall be possible from this faceplate. Feedback of start / stop
operation shall also be displayed on this faceplate.
g)
Tuning Display:
This display shall be useful for tuning of PID controller. This shall
include controller faceplate. P, I, D values shall be accessible from
this screen and can be changed only by engineer with password
facility. Trending display to be configured for tuning controllers.
407
h)
Totalliser:
Totalliser shall display the numeric totalised values of flow
parameters. Reset facility for totalliser shall be available from same
display screen with password or engineer login. It should be
possible to change the totalliser constant from the faceplate. (These
features shall have password lock facility)
All DOs shall be converted to plug in relays. Relay contacts shall
be wired up to the terminals (1 fused terminal per output).
24 V power supply to digital input interrogation and analog
transmitter power shall be provided. All phase supplies shall be of
SMPS type of Phoenix / Mean well.
The system shall be able to operate satisfactorily up to 50 Deg.
and 10% to 90% non-condensing humidity.
Modular system shall be adopted to facilitate easy system
expansion. The type of modules shall be kept minimum possible in
order to have inter-changeability and low inventory.
On-line replacement of any module shall be possible in such way
that removal and addition of module shall be possible without
switching off the power supply. Furthermore, there should not be
any interruption of the system while replacing a faulty module
wherever redundant modules are provided.
The system design shall ensure that no single failure in system
results in any loss in system operation.
The system shall provide safe operation under all plant
disturbances.
Galvanic / Optical isolation shall be provided for all field signals.
Isolation shall also be provided between operator / engineering
station and controller subsystem.
408
The system software shall be governed by the operation system

running in a real time mode and shall be to meet all functional
requirements specified elsewhere as a minimum.
i)
Software
The configuration software for the DCS shall be in the functional
flow diagram or ladder. Programs shall be protected from
accidental changes by use of password. Development mode of
MMI software to be provided for graphics modification.
MMI Software to be loaded on a PC, i.e. operating station. There
will be common PC operating cum engineering station.
Engineering changes shall be password protected. Tenderer to
provide configuration details of PC.
Both run time and development software for intelligent devices like
governor to be included.
Necessary tags to permit future
developments to be included in H.M.I.
Only permanent license software to be provided
There must be total integration of all intelligent devices including
AVR, governor LGPG relays and the DCS system.
Tenderer to note that all testing / checking / configuration of DCS
will be carried out from a PC. The alarm registration time
stamping shall be done at CPU level, Tenderer to inform the
resolution time.
The system shall be capable of adapting to program changes
without affecting the hardware and plant operation. It shall be
possible to make logic changes and MMI changes on line without
affecting control operation.
For the programming / configuration of DCS, the operating station
itself shall be used. Necessary hardware & software to carry out
configuration, testing, debugging, editing of both DCS & MMI
Software shall be supplied and loaded in the OS.
409
Self-diagnostics should be in the form of error codes to indicate the

type of error encountered by processor and other hardware. The
various error messages with text shall be displayed on the
operating station. The diagnostic features shall be programmed
such that the error messages will appear on the operating station
along with the text and can be acknowledged and cleared,
whatever additional programming needs to be done for this shall
be in Tenderers scope.
The system shall have self-surveillance, monitoring and diagnostic
facility so that failure / malfunction can be diagnosed
automatically to the level of individual channels of module level.
The system shall be internally protected against system errors and
hardware damage resulting from Electrical transients on power
wiring Electrical transients on signal wiring and connecting and
disconnecting devices or removing and inserting PCBs in the
system.
The system shall be capable of accepting various signal inputs for
its direct use while preventing noise errors due to electromagnetic
interface or radio frequency.
j)
CPU
The CPU shall be redundant and shall be provided with sufficient
memory for the initial configuration plus 30% additional memory
for future expansion. DCS should have adequate memory with
EEPROM back-up and real time clock feature.
CPU shall retain its memory in the event of a power failure, with
provision of battery back up, EEPROM and RAM
The DCS should be capable of freely mixing analog & sequence
logic, executing user defined functions not included in standard
functional blocks, storing control configuration in on-board nonvolatile memory and providing an alarm indication for back-up
battery low voltage, on-line tuning of PID control loops and other
parameters. System shall be provided with protection against
overload current and line voltage spikes.
410
Scan rate for the close loop/open loop on full load shall be 250msec
(max)
The CPU shall be capable of executing the following control
functions as a minimum
Filtering
Linearization including sq. root extraction for flow signal
Alarms, limits, checking switches
Integrating & totalisation
Ratio / bias
Mid value selection
Transmitter failure detection
Function curve systems
PID loops, PID action and values shall be settable from OS
Auto manual bump less transfer
Output reversal block.
Range suppression for analog inputs
Set point ramp up / down function
Manipulated variable ramp up / down function
AND / OR / NOT and other logic gates / Time delays /
Counters / Latches
Diagnostics
Feed forward control
Mathematical functions
Alarm / acknowledge / reset function
Auto / manual stations
Manual loader
Drum level pressure compensation
Bump-less switch over should take place from single
element mode to three element mode and vice versa.
An alarm output shall be generated to announce the failure
of any critical component such as DCS, power supply, I/O
module, communications, etc. on the operating terminal.
k)
The capacity of the DCS system should be such that even after
considering the space for future expansion, the loading should be
lesser than 70% to permit required response time during peak
loading. Free memory to be minimum 30%
411
2.13.5 Other specifications for Distributed Control System (DCS):

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Processor redundancy
Communication redundancy between
processor & HMI
Power supply redundancy
I/O redundancy
Time for backup processor to take over
Required
Required
Required
At card level
Less than one scan
cycle
Memory utilisation of its capacity
60% max.
Online configuration
Required
Galvanic isolation for power supply
Required
Optic isolation for Input / Output signals Required
No. of points per analogue input module
12
No. of points per analogue output module 12
No. of inputs per digital input module
32
No. of outputs per digital output module
32
Installed spare I/Os
25%
Spare module space in racks
25%
Spare capacity for system memory & user 30% minimum
memory
Future expansion capability
25%
All spare points in I/O modules wire up Required
to the marshalling cabinet
Commissioning spares and consumables
Required
2.13.6 Spare
Installed spare of 25% shall be provided for each type of the modules.
The controller and data acquisition racks shall have 25% usable spare
space for installing additional I/O modules in future. In addition internal
wiring for the same shall be completed up to I/O Terminal.
412
2.13.7 Other details

Location: Central control room (CCR)

Monitoring of process parameters, equipments running status,

motorised valves open / close positions
Open loop controls viz. opening and closing of dampers,
control valves, motorized valves, speed setting of variable
speed drives in manual mode
Closed loop controls i.e. automatic controls viz. drum level
control, furnace control etc.
Alarms: Process alarms viz. level high, pressure low etc. and
overload / trip alarms of drives
Operation: Start / stop drives, opening and closing of
motorised valves. The operation from CCR shall be with safety
interlocks, which shall be executed in respective panels or DCS
from where the operation is carried.
2.13.8 Miscellaneous Items

Some special precautions to be taken by panel manufacturer during panel
manufacture are as follows:
Terminal lugs shall be crimpable, insulated sleeve type for
terminating external wires in the panel.
Sockets for powering external instruments shall be supplied /
mounted by Tenderer
Shrouding shall be provided for all terminals other than low
voltage level instrument wiring
MCBs / Switches to have service and switch nos. punched on tags,
duly installed on MCBs.
Instrument wires (for termination at site, if any) shall be terminated
on plastic strip for easy identification at site.
10% spare contactors and 25% spare terminals shall be given on
each terminal strip
Terminals and wires for power incoming and distribution will be
suitably sized.
Mounting arrangement to be provided for Back of panel
instruments
Door limit switch should be covered.
Some field instruments shall be powered from control panel.
413
2.13.9 DCS shall have following features:

Alpha numeric and bar graph display of process parameter values

Running status indication of drives on graphics
Safety interlocks
Close loop controls
Open loop controls
Controller facia with indication of PV, SP, MV, A/M status, P, I, D
values
Setting of SP, manual loading, tuning of P, I, D constants
Trend
Alarm logging
Shift reports
2.13.10 Controller And Data Acquisition Sub-System

Controller and data acquisition subsystem is the main field interface
subsystem and is capable of performing control and data acquisition
functions either as one integrated subsystem or separate subsystem for
each of these functions.
2.13.11 Controller sub-system
The control function of the system shall be executed by microprocessor
based Controllers consisting of power supply modules, communication
modules and I/O modules and a set of algorithms which are easily fields
configurable using user friendly software.
The hardware capability of the controller shall primarily be exploited for
regulatory control functions only. However, the sequencing and
interlocking capability shall also be used.
Controllers shall be able to scan close loop in less than 200 milliseconds
Controllers shall be capable of accepting process signals from various
field junction boxes, generator / turbine control panels and MCCs
without any additional conditioning equipment.
414
The controller shall be capable of processing linear and non-linear analog

inputs, providing square root extraction for flow signals, linearization and
compensation for thermocouple. The controllers shall be able to generate
4-20 mA DC current signals for analog outputs and potential free contacts
for the discrete outputs as minimum.
Loop integrity shall be maintained in controller sub-system architecture
by providing one to one controller backup. In case failure is detected in
the active controller all the loops of the failed controller shall have
automatic control transfer switching, which shall transfer the entire
configuration and data base of failed controller to the back up controller.
Design must ensure that data integrity is maintained during switch over
and no portion of data to be transferred is corrupted before and during
switch over to the backup controller . The indication of the failed
controller shall be displayed at local as well as on the central level.
Loop integrity shall be applicable to power supply modules and any other
device associated with the controller subsystem.
The controllers shall be able to operate in either manual, auto and cascade
mode. In cascade loops, the primary controller shall be able to track the
steeping of the secondary controller is not operating in cascade mode. All
controllers shall have facility for slow and fast ramping of steeping and
output.
The controllers shall be provided with redundant power supply.
2.13.12 Data acquisition system.
Data acquisition system shall interface and multiplex analog and discrete
inputs from open loops. The inputs shall include 4-20mA DC
thermocouple, resistance temperature detector and discrete contacts.
The system shall be capable of processing linear and non-linear analog
inputs linearization of RTD inputs, square root extraction for flow inputs.
415
a)
Analog input
Modules shall accept 420 milliamps signal from the 2 wire field
transmitters
Max. number of inputs per card : 8 / or 16 nos.
24 V DC power required for 2 wire transmitter powering shall be
supplied from a separate redundant power pack, which will be in
Tenderer scope.
b)
Digital Output module

The output from DCS module shall be 24 V DC, which shall be
supplied from the module itself. All the outputs going to MCC /
solenoid valves (about 40 nos.) / lamps or any other panel shall be
though interposing relays.
Type of Digital O/P
Interposing relays
: 24 V DC Potential output
: Relay Board with Phoenix,
miniature relays, coil voltage 24
V DC, with LED for ON / OFF
indication on relay board, contact
rating 5 Amps, 230 C AC
Output status indication
: Required
Galvanic / optical isolation : Required
for O/P channels
Surge withstand capability
: IEC 255-4
On DCS failure or card failure outputs should drop to ZERO State
Max. no. of outputs per card
32 Nos.
DCS Tenderer will require to provide power supply for the
solenoid coils of boiler & turbine installation. About 40 solenoid
coils each having 12 VA hold will need to be supplied.
The scan time for critical loops will be less than 50 m sec and for
analog the cycle time will be less than 200 m sec.
416
Data acquisition system shall be provided with redundant power

supply.
Each I/O shall be isolated from the external control circuit.
Each I/O shall be protected from short circuit and reverse polarity
of power voltage.
Logic controller sub-system
The control functions required to implement the logic scheme shall
be executed by microprocessor based logic control system, which
consisting of power supply module, CPU module, memory
module, communication interface module and I/O modules.
Memory shall be non-volatile. However in case volatile memory is
provided, battery backup shall be provided with a minimum of 3
months lifetime to keep program storage intact. A battery drain
indication shall be provided at least one week before the battery
gets drained.
Redundancy shall be provided in such a way that in case of failure
of the main processor, the standby shall take over automatically.
The changeover shall be bump-less and the system shall be fail
proof. The indication of the failed device shall be displayed at
operator station
Each processor and each I/O rack shall have a separate
independent power supply. Failure of one power supply shall not
affect the system operation
Each I/O shall be galvanically isolated from external control circuit.
The minimum isolation level between I/O and logic circuit shall be
1000 volts DC
Each I/O shall be protected against the reversal of polarity of the
power voltage to I/O module.
Each I/O module shall have a LED per channel to indicate the
status of each I/O
417
Input / Output modules shall be mounted by the DCS Tenderer on

suitable mounting rack in the panel. Replacement of I/O modules
shall be possible without disconnecting field wires. It shall be
possible to accommodate any type of I/O module in any sequence.
All I/O modules shall have indicated LED on field side of I/O.
Blank covers shall be provided for the spare I/O module slots on
the I/O rack. All DCS hardware should be suitable for ambient
temperature 60 C and humidity 85%
Each input shall be provided with filters to filter out any noise in
the input line and contact bouncing noise.
All inputs shall be provided with only dry contacts. All the inputs
shall preferably be double ended i.e. two wires per input and not
with common return for all inputs.
The interrogation voltage to the input contacts shall be powered
form separate power supply.
The output from the system shall be potential free dry contacts
Each output shall be short circuit proof and protected by fuse.
Visual indication of fuse blown must be provided for each module.
2.13.13 Controller and data acquisition system loading
The system loading for controllers and data acquisition system shall not
exceed 60% or maximum 70% after considering the provided and required
future space. The loading as indicated is the worst case of high system
activity referred to the use of memory.
2.13.14 Communication System
The communication system shall be digital communication bus that
provides a high speed data transfer rapidly and reliably between the
operator station, process I/O devices and other devices connected to it.
418
Communication system shall be dual redundant, consisting of two

separate communication buses and two separate communication system
interfaces for each device.
The overall system performance shall not be degraded whether
Communication system is 10% loaded or 100% loaded. Communication
speed on the communication bus shall be sufficient to update the operator
station data base one in every second.
In case of main bus failure or any communication device failure, the
Transfer to the back-up device or bus shall be automatic without
interrupting the system operation and without any operators
intervention. Information about the failed device/bus shall be displayed
on the operator station.
It shall be possible to switch over the communication form main bus to the
redundant bus manually without disturbing the system operation. It shall
also be possible to connect or disconnect a device from the system without
disturbing the operation.
Web Enabling Software to view or transmit data through internet to be
provided.
2.13.15 Operator / Engineering Interface Sub-System
a)
The operator interface sub-system shall provide the centralized

information to the plant operator / Engineer in the following
details.
Indication of all analog and digital process variables of
i.
control loops, open loops and all loop related parameters.
ii.
iii.
iv.
v.
vi.
vii.
Manipulation of control loops including changing set point,

mode, output, configuration, turning and computational
constants.
Graphic displays and status indication.
Alarm displays and annunciation.
Compilation of graphic displays.
Self-diagnostic messages.
Required interlocking schemes
419
b)
The Engineering interface sub-system shall be used for configuring,

tuning and maintenance of the system. It shall be possible to
perform the following system configuration functions.
Data base configuration including overview, group, loop,

multi-loop and Multi-variable control configuration.
Configuration or re-configuration of alarms settings, their
values, addition or deletion of any control block or
component in loop
Tuning of control loops like changing P.I.D., dead time
values, etc.
Compilation of graphic displays.
Compilation of logs/report/historical trend points.
To call detailed self-diagnostic displays for maintenance aid.
c)
The operator /engineering interface sub system shall consist of two

operator stations, in which any one of the stations shall be used as a
engineering station
d)
Each operator station shall consist of TFT monitor and keyboard,

each driven by independent electronics.
e)
The operator stations shall be housed in the consoles.
f)
Each Station shall be of industrial type and size shall be 19.
g)
LCD data, display update rate shall be less than one second.
h)
All the operator station shall be interchangeable. However under

normal operating Condition, each operator station shall be assigned
a specific area. The system shall have global database available at
each operator station. Further any change made in the database of
one operator station shall automatically update the database of
other operator station.
i)
One logging printer and one alarm & event printer shall be
provided. Alternatively, each engineering / operator station will
be provided with one printer for sequentially logging data and
alarm & events.
420
j)
Keyboard
Keyboard shall be self explanatory, easy to operate and shall meet
all the functions to configure, operate and maintain the system. A
conversational user friendly software shall be used for operation
configuration and maintenance of system.
Keyboard shall preferably be touch sensitive QWERTY membrane
type. Each keyboard entry shall be registered with an audio beep.
k)
Process displays
(i)
Overview display
Each display shall incorporate a minimum of 120 analog or
discrete inputs which can be monitored simultaneously on
the LCD screen i.e. page. Each page shall be organized into a
suitable number of groups. Each group shall further
incorporate suitable number of inputs i.e. tags. Suitable
identifications and description shall be shown for each
group on the overview display to relate it to a loop display.
All analog points in the overview shall be represented as
variable lengths indicating deviation above or below the
normal operating value or set point. .
Alarms shall be displayed in change of colour against each
variable.
An input in alarm condition shall be identified by flashing
Control loops operating in manual mode shall be indicated
(ii)
Group display
Group display shall be limited to the group of inputs as
displayed in the overview display. Each group shall
preferable include eight number of inputs.
421
Each input in the group shall be identified by the tag

number, unit of measurement and process description which
shall be displayed on the LCD screen.
Display, as a minimum, shall show following degree of
details:

Process variable in analog form shall show as a

percentage of the transmitter span on a linear scale
bar graph of 0-100% engineering units and in digital
form as alphanumeric display in engineering units.
Set point value in analog form as a percentage of the
transmitter span on linear scale bar graph of 0-100%
engineering units and in digital form alphanumeric
display in engineering units.
Output value in analog form as a percentage of the
transmitter span on linear scale bar graph of 0-100%
and digital form as percentage.
Controller modes i.e. auto, manual & cascade.
Process alarm on process variable, deviation or
velocity
Control valve failure position.
The contact input/ output shall be represented by
simulated
graphic
lamps
and
configurable
alphanumeric status description.
It shall be possible to control the process from group view.

Following control actions shall be possible.

Increase/decrease of set point value either slow or

fast.
Change of controller mode i.e Auto / manual transfer
Changing output to the final control element
For digital points start/stop or open/close command.
422
(iii)
Loop Display
Loop display shall provide a separate detailed display for
each of the process inputs. The graphic representation of
analog and digital points shall similar to group display.
However in addition following information shall also be
presented in alphanumeric form as a minimum.

Controller tuning constants.

Process variable zero and span values.
Alarm set point on various parameters.
Limits on set point, output, velocity etc.
Controller action (direct/ reverse).
Failure position of final control element.
Engineering units.
It shall be possible to change the following through the

keyboard of operator.
Changing tuning constants (restricted by password)
Changing scale, zero and span (restricted by
password).
Changing limits on set point, output, velocity etc.
Changing configuration of any loop (restricted by
password)
Changing alarm set points.
Changing control mode.
Changing output to the final control element.
To issue start/ stop or open/ close command for
digital points.
Loop display shall also contain a trend displaying process
variable, set point and output with sample interval time of
maximum 1 second and full scale time base of minimum 60
seconds for tuning the process control loops.
423
(iv)
Graphic display
It shall be possible to display dynamic graphic of different
sections of the plant on the engineering station.
Graphic display shall be interactive type through which it
shall be possible to control the process. It shall be possible to
send motor start/ stop and shut down valve open/ close.
It shall be possible to view the process variable and alarm
points and view and change steeping value, manipulated
variable, controller mode etc from the graphic display.
The system shall have the capability of having and
developing graphic symbol library as per ISA-5.1 and 5.3.
Various colours used in the generation of graphics like
colour of process lines, utility lines etc. The same shall be
finalized during detailed engineering.
It shall be possible to go from any graphic page to related
graphic pages or any group view or alarm summary.
(v)
Trend display
The system shall be capable of displaying the real time and
historical trends for the parameters or variables like
measured variable, set point, output, calculated variable etc.
The system shall also have a multi-trend capability in such a
way that it shall be able to display set point, measured
variable and output on the same display.
It shall be possible to display by scrolling or expanding the
time base for all the time base for all the trends.
424
Historical data shall be stored on the non-volatile memory

device like hard disc in such a way that such historical data
can be utilized for archival storage and subsequent recall.
Maximum possible period of storage shall be indicated by
the Tenderer.
Historical data trends shall be displayed for a minimum up
to 25 hours for a data-sampling rate of 1 minute.
2.13.16 Alarm monitoring and display
a)
Alarm management
It shall be possible to display process as well as system alarms on
the operator station for operators attention and action.
Alarm messages shall be displayed by flashing the page and group
number of the input under alarm irrespective of type of display.
All alarms shall be displayed as and when they occur or generated
with change in the colour of display in the following sequence,
activating an audio signal.
The system shall not put off the audio alarm and visual flashing
even after the condition returns to normal unless the operator
acknowledges it.
b)
Alarm summary display

It shall be possible to display summary of all alarms in the
sequence of their occurrence and shall disappear from display only
when they are acknowledged and cleared. The alarm display shall
list the following for each alarm as a minimum.
The date and time of occurrence.
Tag number identification.
Point description.
Serial number of alarm in the sequence of its occurrence.
The system shall be able to display an alarm summary
425
c)
Alarm history
The history of alarm conditions shall be maintained in the database
for alarm history display and printed on shift wise basis. The alarm
display and print out shall list the following for each alarm as
minimum.

d)
The data and time of occurrence.

Tag number identification.
Point description.
Time of acknowledgement.
Time of return to normal.
The system shall be able to display and print out the alarm
history of min of 300 alarms.
System alarm
Any abnormal condition in sub-system or any other functional
device shall be displayed as system alarm messages on the operator
station irrespective of the display selected.
e)
Configuration display
Configuration display shall provide a separate detailed display for
each loop indicating the configuration of that loop. When control
requires more than one loop, all interrelated loops shall also be
displayed. The following information is required in configuration
display.

Loop configuration giving designation of each block.

Control block interconnection.
Value of each block parameter time P.I.D, ratio, bias. deadtime etc.
426
2.13.17 Logging function

All parameters required for logging shall be stored in memory in
accordance with data base update rate. However it shall be possible to
perform basic arithmetic calculations such as averaging, summing,
efficiency calculations etc prior to logging.
In general log format shall be user definable. However the same shall be
given at the time of detailed engineering.
2.13.18 Self diagnostics
The self diagnostic message for a sub system failure shall appear on the
operator station irrespective of display selected.
The system shall have an extensive set of self-diagnostic routines which
shall locate and identify the system failure at least up to module level
including redundant components.
At local level, failure of a module in a sub system shall be identified by an
individual display.
Failure of a subsystem shall be annunciated with the change in colour.
One display page shall be available for each subsystem on the
communication subsystem.
Data storage, archival and retrieval.
Historical data shall be stored on a non-volatile memory device like hard
disc which can be subsequently recalled by operator on any screen.
It shall be possible to store and retrieve this data on removable mass
storage media like compact disc.
427
2.13.19 Measurement
The following parameters, in minimum, will be measured, monitored,
logged, integrated, displayed and collated in the DCS.

Power (kWh, kVA, kVARH and other available parameters) from

generator metering, export metering, power to sugar complex,
feeder wise for cogeneration PCC, DG set, etc.
Steam generated, steam to turbine, bleed steam flow, controlled
extraction steam flow, MP & LP steam exported to sugar factory.
Water (flow and total) for raw water, DM water, softened water, CT
make-up, etc.
Calibrated feeder movement for bagasse
All other measurements required for the control loops.
2.13.20 Instruments
Details of field instruments have been provided in the specifications of
respective equipments. The same is also summarised below:
a)
All instruments and equipments shall be suitable for use in a hot,

humid and tropical industrial climate in which corrosive gases and
/ or chemicals may be present. As a minimum, all instruments and
enclosures in field shall be dust proof, weather proof to NEMA 4
(IP:55) and secure against the ingress of flue, dampness and
vermin. All external surface shall be suitably treated to provide
anti-corrosion protection.
b)
The instruments like control valves, thermo wells, orifice flanges,

level instruments etc. coming on pipes and vessels under IBR shall
be certified by IBR.
428
c)
Location of tap off connections shall be either from the side or from
the top of the steam generator equipment but not from the bottom.
This requirement is applicable to both pipes and vessels. The
location of lower side connection shall be high enough to prevent
plugging due to dirt or other suspended solids. In addition, the
connections shall be short, vertical or horizontal and without any
pockets.
d)
Materials of construction of instruments shall be consistent with

temperature, pressure, corrosion conditions and other steam
generator requirements.
e)
The design of control panels, if applicable, shall incorporate

provision for expansion by installing spare capacity. Each panel
shall be designed to accommodate 10% minimum additional
equipment including 10% spare cable/ tube entry points. However
centralised monitoring and control through DCS is preferred.
f)
Instrument power circuits shall employ an isolation transformer

and individually protected from fault with the help of MCBs and
fuses. Power supply to the individual instrument shall be
disconnect able with the help of switch and protected with the help
of fuse.
g)
Ranges for instruments shall be selected, in general, such that in

normal process operation the indication on the indicator or chart is
between 40% to 60% of span for linear and 60% to 90% of span for
square root.
h)
The complete instrument system shall be designed for safe

operation, by using normally closed contacts which open on fault
conditions.
i)
Adequate alarms shall be provided to give audible and visual

warning of malfunction . The Tenderer shall also provide alarm
contacts for the operation of parallel alarms, common pre-alarm
and shut down alarm by the Owner wherever indicated.
All lamps shall be provided with lamp test facility.
429
j)
Gauge glasses shall be provided for all level measurements

requiring automatic or manual control or monitoring. They shall
have at least the same pressure and temperature rating as that of
equipments on which they are to be installed. They shall have ball
check auto shut off valves.
k)
Isolation and bypass valves shall be installed with all control

valves. Hand wheels and air lock valves shall be considered for all
control valves.
l)
Control valve sizing formula shall, in general, be as per ISA-75, 07.

Control valves shall be sized for the available pressure drop at
normal flow and shall permit up to 110% of the maximum flow.
The Tenderer shall submit the sizing calculations for all control
valves. DP shut off shall be 10% more than upstream pressure for
actuator sizing.
m)
Orifice plate calculations shall in general, follow BS 1042. Orifice

diameters shall be selected so that d/D ratio is between 0.2 to 0.7
for gases and steam and up to 0.75 for liquids. Tenderer shall
submit the sizing calculations for orifice plates.
n)
Main steam generator stop valve & air vent valve will be motorized
and shall be designed in accordance with ASME code for valves
(ASME B 16.34) and Indian Boiler Regulations.
o)
All transmitters shall be provided with output meter/output gauge

at the transmitters end. All transmitters will be smart type.
p)
The Tenderer shall ensure that the packing of instruments and

associated equipment is adequate to prevent damage from such
contingencies as rough handling, weather, condensation, dew,
vermin and vibrations.
q)
All solenoid valves shall be universal type and continuous rated

type.
430
Analysis for PH, Conductivity, Silica and Oxygen (SWAS) shall be

complete with sampling system and shall be supplied with
complete calibration kit including zero and span samples or buffer
solution and special tools required for the maintenance. SWAS
analyser will conduct online monitoring of FW quality at FW
control station, drum water and superheated steam.
The SWAS panels will be located in the powerhouse. The
annunciations and results of the SWAS to be communicated to
DCS.
r)
Tenderer will adhere to the approved makes for all instruments as

provided in this document. Tenderer will provide data sheets for
all gauges, transmitters, thermo-wells, flow meters, energy meters,
electrical meters, orifice, vortex meters, rota meters, impulse
piping, etc. for approval of Owner / Consultant during engineering
2.13.21 Basic Controls Design

Generator, gearbox, turbine bearing temperature monitoring shall be
through the temperature scanner.
Critical AI/AO/DI/DO signals will be redundant while non-critical &
DAS points will be non-redundant. All controllers for critical controls will
be redundant. The field inputs for critical inputs will be1/2 logics. 25% of
the I/Os to be considered as critical.
Sequence of event recorder will be provided
Required Annunciation windows shall be included
25% spare I/Os to be considered.
TG governing will be by Woodward 505E. However the critical
parameters will be monitored by providing serial Modus Interface
All I/Os will be potential free
431
2.13.22 Estimated Bill Of Material

Sr.
No
I
Description
DCS System
As per I/O count to be derived by Tenderer and approved
by Consultant / Owner
II
2 Sets of redundant servers, three 19 colour monitors, and
2 colour Graphic printer.
III Interconnecting cables between System Cabinets
Marshalling cabinets Relay Cabinets
IV Power Cable for system cabinets
V. Erection Hardware
1.
Erection Material
2.
Cable Gland Wiring and cabling accessories
VII. Software
Runtime + Development
Run time software
Project application engineering
Documentation
Supervision
of
installation
&
commissioning
VIII. Field calibration instrument
Function: Smart transmitter calibration and hart
communication
Accessories: (a) case & manuals
(b) battery pack with AA batteries
(c) lead set
IX. Software link RS485, mod bus protocol for temperature
scanner, TSI monitor, temperature scanner, Woodward
governor, etc. (all placed within a radius of 15m)
432
2.13.23 I/O counts

The I/O Counts to be derived by the Tenderer based on the approved P &
IDs. An indicative list of I/Os is provided below:
I/O summary for steam generator & auxiliaries
DI (potential free)
DO (potential free)
Analog outputs (4-20mA)
Analog inputs
Analog inputs (thermocouple, mV)
: 450
: 300
: 60
: 175
: 30
I/O summary for turbine & auxiliaries:

Digital inputs
Digital outputs
Analog inputs (4-20mA)
Thermocouple
RTD inputs
Analog output
: 400
: 200
: 75
: 25
: 15
: 15
I/O summary for ESP:

Digital inputs
Digital outputs
Analog inputs
Analog outputs
: 150
: 40
: 20
:4
I/O Summary for balance of plant:

Digital inputs
Digital outputs
Analog inputs (4-20mA)
Analog inputs (RTD)
Analog outputs (4-20mA)
Analog inputs (thermocouple)
: 200
: 75
: 75
: 50
: 15
: 25
433
List of minimum controls loop to be considered for Boiler

Drum level control loop

Steam temperature control
Combustion control
Furnace draft control
Soot blower control
De-aerator level control
De-aerator pressure control
PRDS steam pressure & water flow control MP
PRDS steam pressure & water flow control LP
CBD level control
SWAS signal monitoring and annunciation pH, conductivity
The following interlock schemes for steam generator & auxiliaries will be
operated through DCS and will have status indication on DCS:

Boiler feed pump 1

Boiler feed pump 2
Boiler feed pump 3
ID fans
FD fans
SA / PA fans
Boiler interlocks
Pocket feeder # 1
Pocket feeder # 2
Pocket feeder # 3
Pocket feeder # 4
Pocket feeder # 5
Pocket feeder # 6
Pocket feeder # 7
Pocket feeder # 8
Screw feeder # 1
Screw feeder # 2
Screw feeder # 3
Screw feeder # 4
HP dosing pump # 1
HP dosing pump # 2
LP dosing stirrer
434
LP dosing pump # 1
HP dosing pump # 2
HP dosing stirrer
Main steam stop valve
Main steam bypass stop valve
Air vent valve

Steam turbine generator & auxiliaries

Lube oil system

Turbine Protection
Generator Protection
HT Panel Protection
Turbine Run-up system
Bleed & Extraction system
CEP control station level monitoring
Temperature Scanner
Generator Cooling System
Turbo Supervisory signals monitoring
Minimum close loop controls of steam turbine generator achieved through

DCS:

Turbine gland steam pressure control

Auxiliary steam pressure control
Spray water pressure control
Auxiliary steam temperature control
Uncontrolled extraction temperature control
CEP operation based on hot well level

Transformer start, trip, current, voltage

Micro-tapper panel feedback, fault
Hopper heater feedback, trip
Insulator feedback, trip
RAV feedback, trip
Hopper level high, temperature high, inlet temperature high
All safety interlocks
ESP
435
DM water, Water treatment plant

MCW / ACW pumps ON / OFF

MCW pumps speed vs. pressure control
MCW / ACW pressure with high / low
MCW / ACW temperature with high / low
Air compressors ON / OFF
Compressed air pressure
DM tank, FW tank level high, low, low-low
SWAS panel indications and alarms
Storage tank level
Conductivity and pH meters
DI / DO of all motors
Electrical

Switchyard Control and DAS

HT relays controls
LT relays controls
Synchroniser, Relays & breaker status
UPS status signals
DC power status signals
TVM meter and other energy meters - generation & export
KW / amps / on-off status of all continuously operating
motors
Operation of OLTC
Switchyard SCADA
Balance of Plant Area

Ladder logic of fuel & ash handling system

Status of fire fighting system
Status & pressure of forced air ventilation system
Monitoring of control room temperature
All required mimics of the power plant
436
2.14
UNINTERRUPTED POWER SUPPLY (UPS)

2.14.1 Scope Of Work
General Information
Rated voltage
Rated frequency
Rated power
Configuration
Codes / Standards
:
:
:
:
:
230 VAC
50 Hz
30 kVA
Parallel redundant
IS
2.14.2 Specifications of UPS

2.14.2.1 Requirement
The Tenderer shall supply 30 kVA or 25% higher than peak
requirement, parallel redundant Un - interrupted Power Supply
(UPS) in the scope. UPS with AC distribution board and accessories
shall meet AC requirements of instruments, instrument panel,
governor, relay, metering cum synchronizing panels and other
Owners loads.
2.14.2.2 Standards
The equipment covered by this specification shall be in line with
the requirements of the following IS, unless otherwise specified.
IS 1248
IS 3136
IS 3700
IS 3895
IS 4540
IS 5001
IS 5060
Direct acting electrical indicating instruments

Polycrystalline semiconductor rectifier equipment
Essential ratings and characteristics of semi conductor
devices.
Mono-crystalline semiconductor rectifier cells and
stacks
Mono-crystalline semiconductor rectifier assemblies
Guide for preparation of drawings of semiconductor
devices
Code of practice for use of semiconductor junction
devices
437
2.14.3 System Operation

The uninterrupted power supply system shall be complete with chargers,
inverters, static switches, bypass transformer with Automatic voltage
regulator and manual bypass switch. Normally the system will supply the
load in UPS mode. In case of any trouble with one of the Inverter Sections,
the load shall be catered by the redundant system if both the inverters fail,
loads shall be transferred to the bypass transformer without any
interruption.
A manual by pass switch (make before break) shall be provided to isolate
the inverters and static switches for maintenance.
When it becomes necessary to boost charge the battery (i.e. when the
battery has discharged during mains failure), the charger shall be set to
the boost mode manually. The rectifier section shall now cater for boost
charging the battery and at the same time supplying the inverter. After
completion of boost charging, the charger shall be reset to float mode
manually.
It shall be possible to run the system at rated load for half an hour and at
about 75% load continuously without any damage in case of failure of
cooling fans.
2.14.4 Design
The charger shall have necessary features to prevent damage to the
battery. The output voltage (110 V AC, single phase and 230V AC single
phase) shall be stabilised to within +/- 5% variation, for mains input (415
V AC, three phase) variation of +/- 20% in voltage and +/- 5% in
frequency. The source fault level at the point of supply shall be 50 MVA.
Charger shall have adjustable current limiting feature controlling the
output current and the battery current in float and boost mode. Charger
output to the battery shall be passed through a smoothing circuit so that
the ripple content is limited to a value safe for the battery.
438
The charger shall be designed to boost charge the completely discharged,

batteries in 10 hours. The changeover between boost charge mode and
float charge mode shall be affected manually. Necessary alarms to indicate
battery discharged and DC over voltage conditions shall be provided.
Selector switch shall be provided for selecting the float charge or boost
charge mode.
The inverter unit shall be designed to operate from the charger output
continuously without use of battery smoothing effect. With the battery
connected to the UPS system, a filter shall be provided at the input of
inverter unit to reduce-the AC feed back from the inverter to the battery to
a maximum of 2%. Efficiency of the Inverter shall not be less than 80% at
rated load and pf. The output waveform distortion shall not be greater
than 3%.
The inverters shall be suitable for synchronising with the mains having
frequency variation of +/- 3%. The inverters shall be de-linked when the
variation exceeds this and shall run on its own oscillator maintaining its
output frequency to +/- 1 % of 50 Hz.
Current limit protection shall be provided which will protect the inverter
against overloads and short circuits at the output. The current limit shall
be adjustable. Once the overload is removed, the inverter shall
automatically resume normal operation.
UPS shall be designed to withstand 125% overload for 15 minutes and
150% overload for 10 seconds.
The inverter output shall have spike / surge suppression filters to protect
the loads
By-pass transformer shall be natural air-cooled type suitable for indoor
location. Links shall be provided on 415 V windings to give offload
tapings of +/- 2.5% & +/- 5% of normal voltage.
439
A manual Bypass switch, make before break type, shall be provided to

take the system out for maintenance without interrupting power to the
load. The switch shall be mounted in the inverter section. The enclosure to
be of IP 3X or better.
The Tenderer shall ensure that neutral of the all transformers are solidly
connected to earth to ensure that the potential between earth and neutral
is zero at all conditions
2.14.5 Cabinets
The UPS shall be housed in a 2 mm thick sheet steel Cabinet with
separated panels for housing the charger, inverter and Bypass
transformer. The panels shall be freestanding, front aligned, dust and
Vermin proof with suitable ventilation Louvers and cooling fan. Hinged
doors shall be provided at the front and back, as required, with dust tight
gaskets. Inter panel sheet steel barriers shall be used.
The enclosure degree of protection shall be minimum IP 21. The cable
entry shall be from the bottom. A removable bottom gland plate shall be
provided fitted with double compression type cable glands for external
cable connections. Elmex type clamp terminals shall be provided for wires
up to 16 sq. mm. and terminals for, large size shall be bolted type
complete with cable lugs.
All switches shall be rotary type mounted on the front of the door. Fuses
shall be HRC link type. Busbars shall be colour coded and live parts shall
be properly shrouded to ensure complete safety to operating /
maintenance personnel. All instruments shall be switchboard type, back
connected, 96 mm square. Scale shall have red mark indicating maximum
rating.
An earth bus, suitably sized, shall be provided at the bottom of the panels
with provision for earth connection at both ends to existing main earth
grid. All non-current carrying metallic parts shall be earthed.
440
Anti condensation heaters, thermostatically controlled shall be provided

in each vertical panel complete with switch fuse unit/MCB.
Each panel shall be provided with one 5A receptacle and switch and panel
lighting.
Distribution board at the outlet of UPS system shall be provided with
adequately sized incomer FSU (single phase) and outgoing FSU feeders as
below, for continuous use.

Incomer 250 Amps

Outgoing 32 Amps
Outgoing 16 Amps
1 No.
3 Nos.
6 Nos.
2.14.6 Battery
Set of indoor sealed maintenance-free battery of capacity to meet the UPS
back -up requirement for half-an-hour with all necessary accessories and
devices as required for satisfactory functioning of the system shall be
included in scope.
By pass Supply Voltage Stabilizer
By pass supply shall be taken through servo stabilizer.
Voltage stabilizer output regulation shall be + / - 1 % for 0-100% load
variation and full range of input supply variation over the entire power
factor range.
2.14.7 Static Switches
Static switches shall be solid state with performance characteristics
matching with the Inverters. Controls permitting manually actuated
transfers to either source shall be provided. Actuating device of such
controls shall be so located or guarded to prevent accidental operation. On
the front of panel an indication shall be provided for each static switch to
show its position.
441
2.14.8 Metering, Indications and Alarms

The following metering and indications shall be provided on each panel :
a)
Charger Panel
b)
Incomer AC supply voltage with selector switch

Incomer AC line current with selector switch
Output voltage charger
Output current charger
Battery charging/discharging current
Indicating lamps for A. C .input supply 'ON, output supply
'ON.
Indicating lamps for battery on float / Boost.
Inverter Panel

D.C. Input current

Bypass transformer secondary voltage
UPS output voltage with selector switch
UPS output current with selector switch
Frequency meter
Power factor meter
Indicating lamp for Battery output 'ON'.
Bypass supply 'ON'
Load on Bypass
Mains synchronized.
2.14.9 Audio Visual Alarm

Audio Visual Alarm shall be provided for the following complete with
ACCEPT, RESET and TEST facilities
a)
Charger Panel

Mains Under Voltage, single phasing, in case of three

phase input.
Charger / Diode Failure
Cooling fan tripped (Common for all fans)
442

b)
Low battery voltage

DC over-voltage
Battery earth fault
Inverter Panel

DC input failure
Inverter -1 output failure
Inverter -II output failure
Load-on by pass
SCR fuse failure
UPS output under voltage
Potential free 'NO' contacts for annunciation for all the above (rated for 2
A, 230 V DC) mentioned alarms shall be provided, wired up to terminal
strip and to be grouped separately for charger and inverter unit.
2.14.10 Inspection and Testing:The following tests shall be carried out on the system to ensure its
successful operation as per the specification.
The system shall run under rated load at rated power factor for a
minimum continuous period of 10 hours. Output voltage, current,
frequency and critical temperatures shall be recorded. Test shall also be
done with the fans off and the system loaded as described in this
specification.
Output voltage and frequency regulations on various load combinations
from 0-10 % load.
Over load withstand test as per this specification shall be carried out
immediately after continuous operation on rated full load and maximum
operating temperature (hot condition)
443
Waveform analysis with Oscilloscope under the following conditions shall

be done.
2.15
Full load conditions
Simulation of input AC-power failure to the rectifier.
Simulation of battery charger failure and battery failure.
Simulation of failure of inverters (causing the full load to be

transferred to the By Pass supply)
Manual return of full load at rated power factor from Bypass

supply to the inverter.
Short circuit the output bus to record the current limiting effect of
the inverter.
Reverse input polarity test.
Test on all controls and Alarms for correct setting and operation.
Test and calibrate the instruments.
ERECTION & COMMISSIONING

2.15.1 General Specifications
Tenderers scope for erection and commissioning services includes:
a. Receive / Handling
b. Stock
c. Security
d. Issue
e. Installation
f. Erection
g. Commissioning
h. Supply of commissioning spares
i. Handing over
444
j. Drawings & Manuals and

k. Training to Owners project and O & M teams
Unloading, handling and storage at site, pre-fabrication/assembly if any,
civil works, erection, testing, commissioning, trial operation, final painting
and guarantee performance testing.
Providing warehousing, testing facilities, obtaining approvals from
statutory authorities and providing required documentation, data etc. All
Equipment and instruments required for erection, start-up, initial filling,
commissioning and performance guarantee tests.
The Tenderer shall deploy erection Tenderers who have carried out
similar or larger jobs and will present their credentials for approval of
Owner / Consultant.
The Tenderer shall be required to erect all mechanical & electrical
equipment, Steel work, chutes, hoppers, instruments and controls cables
and conduits. etc complete in all respect.
The Tenderer shall provide all skilled, semi skilled and unskilled workers,
Supervisory staffs, tools and tackles, erection materials hosting testing of
equipment and other related services required to complete the erection
and commissioning all equipment with auxiliaries.
The work shall include the following.
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Receipt of material at site

Providing storage and safe custody of the equipment.
Checking of the foundations.
Alignment , levelling and grouting .
Current / drilling / welding as required on the existing structure /
buildings.
Complete assembly and erection materials .
Minor rectification work wherever required.
Final painting .
Initial lubrication and greasing.
Trial run and commissioning.
445
2.15.2 Specification for Erection of Mechanical Equipment

a)
Checking of foundations
The Tenderer shall as a first field activity, check the foundations for
the correctness of the same as per relevant drawings & and certify
the same for concreting and the same may be rechecked for its
correctness after concreting, such as levels, location of bolt holes,
sleeves, pockets, openings, fixture plates and other embedment in
RCC works, etc. All the structural fixtures required shall be
supplied by the Tenderer.
Where required by manufacturers the concrete surfaces shall be
chipped and finally dressed up true to obtain the required contact
between sole plates and concrete surfaces. The fine dressing of the
concrete shall be with Prussian blue match checks.
Tenderer shall ensure that while lifting turbines/generator, piping
and other auxiliaries for transporting, slings shall be put over the
points indicated on the equipment.
Slings over casing shall have gunny bags or soft wood packing to
avoid the scratches and nicks on the equipment.
Slings / D-Shackles of proper sizes shall be used for all lifting and
rigging purposes. All care shall be taken to safeguard the
equipment against any damage.
Tenderer shall thoroughly clean all machine surfaces / slings,
surfaces/keys, brackets sole plates etc. and apply anti-scuffing
paste or other recommended equivalent before assembly of the said
parts. The components whose surfaces are coated with protective
coating are to be thoroughly cleaned.
The Tenderer shall carry out all necessary checks such as accuracy
of levels, centres lines, bolt positions, of installation of all
equipment covered in the scope of work.
446
b)
Checking of Equipment after Grouting

After the grout is set and cured, the Tenderer shall check and verify
the alignment of equipments, alignment of shafts of rotating
machinery, the slopes of all bearing pedestals, centring of rotors
with respect to their seating bores, couplings etc. as applicable and
the like items to ensure that no displacement had taken place
during grouting.
The values recorded prior to grouting shall be used during post
grouting check-Up and verifications. Such pre and post grout
records of alignment details shall be maintained by the Tenderer in
a manner acceptable to the Owner.
c)
Shaft Alignment
All the shafts of rotating equipment shall be properly aligned to
those of the matching equipment to the required accuracy.
The equipment shall be free from excessive vibration so as to avoid
over-heating of bearing or other conditions which may tend to
shorten the life of the equipment.
All bearings shafts and other rotating parts shall be thoroughly
cleaned and suitably lubricated before starting.
The Tenderer shall maintain a record in the form acceptable to
Owner / Consultant of all the operations carried out on each
weld and maintain a record indicating the number of welds, the
names of the welders who welded the same.
All site joints shall be subject to acceptance of Owner / Consultant.
Any joints declared rejected shall have to be redone at the
Tenderer's cost.
The Tenderer shall carry out the tightening of the bolts on the
equipment and piping covered under this specification by using
either the calibrated torque wrench method or the turn of nut
method.
447
The methods used, the tools and the equipment deployed shall be
subject to the approval of Owner / Consultant. The bolting work
shall be carried out by competent technicians.
The Tenderer shall install all necessary platforms, stairways and
ladders required for the safe and convenient operation and
maintenance of all the equipments, valves etc. covered in this
specification at no extra cost.
The Tenderer shall completely erect all the equipments for the
complete E & M portion including hangers and supports, valves &
accessories in accordance with the approved drawings.
This includes all necessary bolting, welding, testing and cleaning.
Systems shall be demonstrated
in condition to operate
continuously in a manner acceptable to Owner / Consultant.
Welding shall be used throughout for joining pipes except where
flanged screwed or other type joints are lines & elevation as
indicated in the drawings.
While erecting the field run pipes the Tenderer shall check the
accessibility of valves, instrument tapping points and maintain
minimum head room requirements and other necessary clearances
for adjoining work areas.
The Tenderer shall be responsible for correct orientation of all
valves so that seats, stem and hand wheels will be in desired
location.
All supports & hangers for the pipes have to be fabricated and
provided for approximately every three metre (3 Mtr.) of pipe.
However in any case sufficient numbers shall be provided so that
the deflection of pipe between hangers shall not exceed the limits
indicated in the drawings.
448
The Tenderer shall make all necessary arrangements including

making of temporary closures on piping / equipment for carrying
out the hydrostatic testing on all piping / equipment with motor
operated pump.
All piping flanges are required to be blue matched using surface
plate to obtain at least 80% contact area before installation.
All welded joints of pipes shall be cleaned of welding slags, &
burrs by hand file wire brushes and flexible grinders wherever
required and using white cloth. No cotton waste shall be used
while cleaning the equipment / piping
All welding procedures adopted for performing welding work
shall be qualified in accordance with the requirements of Section
IX of ASME & IBR.
These welding procedures shall clearly state the type of material,
thickness, the joint details, the repeat temperature maintained, the
post-weld heat treatment given, the welding current and voltage
used during qualification of welding procedures.
For all high pressure piping welding, the latest applicable
requirements of the Indian Boiler Regulations must be complied
with.
All records of the welding procedures, the welders qualifications,
tests and welders performance details for the work performed
under these specifications shall be maintained by the Tenderer
and be made available to the Owner on request.
449
Wherever applicable, the Tenderer will submit :

All non-destructive examination procedures, stress relief and

/repair procedure actually used during fabrication.
Welder and welding procedure qualification certificates.
Welder identification list, listing welder's and welding

operator's qualification procedure and welding identification
symbols.
Material mill test reports on components as specified by the

specification.
The inspection plan with verification, inspection plan check

points, verification sketches, if used, and method used to verify
that the inspection and testing points, in the inspection plan
were performed satisfactorily.
Sketches and drawings used for indicating the method of trace

ability of the radiographs to the location on the equipment.
Non-destructive examination result report.
Stress relief time temperature charts.
The Tenderer shall dismantle the valves & actuator for overhauling,
servicing and lubricating wherever required as advised by
Owner/ Consultant.
The Tenderer shall also lap or grind the valve seat for ensuring the
satisfactory performances of
valves at no extra cost. All
consumables such as gaskets, gland packing which form the
permanent part of equipment shall be in the Tenderer's scope.
450
The hanger assemblies shall not be used for attachment of rigging

to hoist the pipes into position. Other means shall be used to
securely hold the pipe in position till pipe supports are completely
assembled and attached to the pipe & building structure.
All temporary rigging shall be removed in such a way that pipe
supports are not subjected to any sudden load. During hydro static
testing of pipes, all piping having variable spring type supports
shall be secured in place by temporary pinned or blocked solid
during the test.
The Tenderer shall carry out the pre-commissioning activities such
as chemical cleaning of piping system, water flushing, flushing of
oil systems, flushing of control fluid system.
The scope of pre-commissioning activities covers installation of all
temporary piping, supports, valves, tanks, pumps & all other
accessories & services to complete the process.
The Tenderer shall carry out the edge preparation of weld joints at
site in accordance with the
details acceptable to Owner/
Consultant.
Wherever possible machining or automatic flame cutting will be
allowed only wherever edges preparation otherwise is impractical.
All slag / burrs shall be removed from cuts and all the hand cuts
shall be ground smooth to the satisfaction of Owner / Consultant.
Tenderer shall carry out all the electrical pre commissioning tests
on the generator, excitation system, as stipulated by the relevant
specification and codes.
The Tenderer shall hand over all parts/materials remaining extra
over the normal requirement with proper identification tags, in a
packed condition to the Owner / Consultant.
The work to be carried out is of highly sophisticated nature
requiring quality precision workmanship, engineering and
construction management.
451
It should also ensure successful and timely commercial operation of

equipment in stalled. The Tenderer must have adequate quantity
of precision tools, construction aids in his possession. Tenderer
must also have adequate trained, qualified and experienced
supervisory staff and skilled personnel.
All temporary scaffolding shall be removed before the start of the
commissioning activities to prevent hazards.
2.15.3 Specification for Erection of Electrical Equipments

a)
Scope
The specification covers the installation, testing and commissioning
of all electrical equipments and accessories required for the power
plant for efficient and trouble free operation.
b)
Standards
The electrical installation work covered by this specification shall
unless otherwise stated comply with the requirements of the latest
edition of relevant Indian Standard, statutory regulations and
codes of practices.

Indian Electricity Rules.

Tariff advisory committee.
IS-10118 : Code of practice for selection, installation & maintenance
of switchgear and control gear
IS-6600 : Guide for loading of oil immersed transformers
IS-3043 : Code for practice for earthing
IS-2309 : Code of practice for protection of building and allied
structures against lightning
IS-2274 : Code of practice for electrical wiring installation
IS-6665 : Code of practice for industrial lighting
452
c)
General Requirements
The installation shall be carried out by an electrical Tenderer
holding a valid license as required by the State Government. The
Tenderer shall provide particulars of the license held by him or his
sub-Tenderer to the Owner.
The installation shall require approval of the Chief Electrical
Inspector to the Government of Bihar and the Tenderer shall
prepare all necessary drawings / documents in obtaining the
approval.
He shall also fully assist the Owner in obtaining approval from any
other statutory authorities for the successful commissioning of the
power plant and the Substation.
Any modification in the equipment or installation that may be
demanded by the inspector shall be carried out at no additional
cost to the Owner.
In accordance with the specific installation instructions or as
directed by the Owner, the Tenderer shall unload, erect, assemble,
install, wire, test and commission all electrical equipments
included in this tender. Equipments shall be installed in a neat
workmen like manner with highest regard for safety.
Erection materials, tools, testing instruments or any other
machinery of any nature shall not be supplied by the Owner.
The Tenderer shall arrange for the same in a timely manner and he
shall not be allowed to claim for any delay or extra cost of any
nature.
Consumable materials of any nature required for the job shall also
have to be arranged by the Tenderer.
453
Clearing the site after completion of erection as well as regular

clearance of unwanted materials from site, returning all packing
material and excess material shall also be covered under the scope
of work.
All equipments and instruments of indoor and outdoor, shall be
inscribed with number, nomenclature, danger boards and other
instructions.
The Tenderer shall touch up the surface for all equipments, which
are scratched and / or damaged during transportation and
erection. The paint used shall match exactly the surface being
touched up.
The Tenderer shall employ skilled and semiskilled labourers for
erection, installation & testing as required.
All electricians, cable jointers, wiremen, welder and others
employed shall be suitably qualified possessing certificates /
licenses recognised by the competent authorities.
The Tenderer shall also furnish a list of Engineers /Supervisors
and staff employed by him for erection and installation jobs, giving
in brief, qualification and experience of such staff and indicating
whether they hold such competency certificates / licenses to
supervise the electrical installation jobs as required under Indian
Electricity Rules & State electrical inspectorate Rules.
The Tenderer shall set up his own workshop and other facilities at
site to undertake fabrication jobs, pipe bending, threading etc.
The Tenderer shall be responsible for recording of all readings and
observations during erection, testing and commissioning, in
registers or on prescribed performs.
All such test data and records shall be duly signed by the
Tenderer's Engineer / Owners representative and shall be
submitted to Owner in triplicate.
454
The Tenderer shall carry out all tests at site for outdoor and indoor
Electrical equipment and commission the installation in the
presence of Owners representative . The Tenderer shall be
responsible for final adjustment of relays, instruments, meters
breakers etc . and also for submission of relay settings and
calculations.
All support insulators, Circuits breakers,
Isolators, Power
Transformers, Instrument Transformers, etc. shall be properly
handled and erected as per the relevant codes of practice and
manufactures drawings and instruction manuals.
For power transformers, drying out oil filling as required, after
checking and testing the dielectric strength shall be carried out by
the Tenderer. If required oil filtration shall be carried out and the
Tenderer shall arrange for the necessary equipment.
Handling equipment, sling ropes etc. should be tested before
erection and periodically for strength.
Necessary Junction boxes for CTs and PT's shall be supplied and
installed.
d)
Switchgear, Control & Relay Panel

Switchgear, control and relay panel, etc. shall be installed in
accordance with the latest edition of IS-1011B and manufacturer's
instructions.
The panels shall be installed on finished surfaces. The correct level
shall be ascertained before final grouting.
The Tenderer shall take utmost care in handling delicate
equipments and mechanism like instruments, relays. Dragging
shall be avoided as for as possible. Proper pipes shall be provided
underneath when dragging for short distance.
Wherever the instruments and relays are supplied separately, they
shall be mounted only after the associated control panels have
been erected and aligned.
455
Any damage to relays and instruments shall be immediately

reported to the Owner. Tenderer shall also make all necessary
adjustments as specified by the manufacturer for proper
functioning of the equipment.
Tenderer shall also carry out the following :
e)
Cleaning of internal parts like chambers, insulators etc. by

vacuum cleaners.
Prepare base for mounting the equipment including
levelling.
Drying of equipment in case of low insulation resistance.
Illumination system :
Outdoor type street light fittings shall be mounted on GI pipe
bracket with clamps welded to fabricated tubular pole.
Power supply to street light fitting is to be provided by looping the
PVC cables coming from Lighting Panel up to junction box. From
junction box flexible copper cables shall be provided to fitting.
All hardware items such as nuts, bolts, washers, anchor fasteners
used for mounting lighting fixtures shall be zinc passivated
The lamps / tubes shall be handled carefully and shall be fitted just
before commissioning of illumination system.
For installation and termination of PVC cables the details
specifications are given elsewhere in this document with shall be
followed.
Before energizing the installation, insulations resistance test shall
be carried out.
Illumination level shall be measured with lug meter in indoor and
outdoor areas.
All the test results shall be handed over to client.
456
f)
Panels :
All the switchgears shall be checked for dimensions as per
manufacturers drawings. The locations of switchgears shall be
checked as per the layout drawing. The base plates, channels to be
embedded in the trenches well in advance of the actual erection of
panel. Clearances required as per drawings shall be checked by the
Tenderer.
The switchgear shall be handled with care under guidance of a
competent supervisor. Base channels shall be grouted, on levelled
cement concrete. All foundations grouted bolts shall be cured for a
minimum period of 48 hours.
All the panel shall be assembled, aligned and levelled as per the
instructions of the manufacturers given in respective drawings. It
should be checked that panel to panel coupling bolts and bus bar
links fit properly without any strain on any part. It should also be
checked that lowering, lifting, racking in and out of breakers and
all motions are free from any obstructions. The fixing bolts shall be
grouted only after satisfying all the requirements. The hardware
used for this purpose shall be zinc passivated.
After completion of the panel erection, all the cubicles, switches,
starters, CTS, bus bar chambers should be cleaned and checked for
tightness. All wiring connections shall also be checked for their
correctness as per drawings. Metering and protective CT as per the
polarities and phase sequence.
All starters, switches, contactor contacts should be cleaned with
C.T.C.
At Hinges of panel, doors should be lightly lubricated to give free
and noiseless movement.
All the control wiring, bus bars, other live parts of switchgear and
incoming and outgoing cables should be meggered with 1000 V
megger for L.T. panels.5KV megger shall be used for 11KV Breaker
Panel.
457
The panels must be completely sealed to prevent entry of any dust,

vermin & rodents.
The gland plate shall be drilled for the no. of cables as per cable
schedule, extra holes shall also be drilled and sealed with rubber
grommets for any additional cables. Gas cutting shall be never be
done.
The panels must be cleaned with a vacuum cleaner. All loose
material lying in the panel shall be removed.
Before commissioning any switch gear panel, the following points
must be checked and ensured for safe energisation of the board.
(i) The erection of panel to be commissioned is complete in all
respects including all mountings and earthing.
(ii) That all the openings in floor inside and outside the panel
have been sealed off.
(iii) That all the metering instruments have been checked and
calibrated.
(iv) That all control fuses are of proper rating and showing
continuity
(v) That all the indicating lamps are healthy and in position.
(vi) That the H.V. Test of breakers bus bars and outgoing and
incoming cables has been conducted and is satisfactory.
(vii) That IR value has been recorded for bus bars. Circuit breaker,
incoming and outgoing cables.
(viii) That all the surroundings and panels have been cleaned and
temporary earth leads have been removed.
(ix) That mechanical and electrical interlocks are OK.
(x) Each panel before erection shall be checked for all above and
shown to Owner at site. Joint inspection report shall be made.
(xi) The record of tests carried out/changes made in wiring and
locations of panels shall be made for future references.
(xii) The specifications given in this section are also applicable to
all panels in general. The guidelines provided in this section
need to be followed in addition to the specific instructions
provided by individual panel manufacturer.
458
g)
Cables:
All the cables required for the work will be supplied by Tenderer.
This shall include taking the delivery at site, shifting to locations,
cut to lengths, laying, dressing, testing and commissioning with
termination arrangements.
The cables shall be laid in trenches, trays or conduits Cable routing
given on the drawings shall be checked in the field to avoid
interference with structures, piping ducting and minor adjustments
shall be made to suit the field conditions.
All cables shall be carefully measured and then only cut to the
required length leaving sufficient length for final connections to the
equipment on site.
The Tenderer shall confirm the exact requirement of cable for
particular feeder by measuring at site along the actually finalized
route. He shall prepare cut length schedule of cables before taking
up cable laying.
Cables shall be laid in complete uncut length from one equipment
to other.
Cables shall be neatly arranged in the trenches/trays in such a
manner, that crisscrossing is avoided and final take off to the
motor/switch gear facilitated. Arrangement of cables within the
trench/ tray shall be the responsibility of the Tenderer.
All cables shall be identified close to their termination point by
cable numbers as per schedule. Cable numbers will be punched on
aluminium strips (2 mm thick) securely fastened to the cable and
wrapped around it.
Temporary ends of cables shall be protected against dust and
moisture to prevent damage to the insulation. While laying the
cable, ends of cables shall be taped with PVC tape
459
Cables shall be handled carefully during installation to prevent

mechanical injury to the cables. Ends of cables leaving trenches
shall be coiled and provided with protective cover until the final
termination to the equipment is completed.
Where cables rise from trenches to motor, control station, lighting
panels etc. They shall be taken in GI pipes for mechanical
protection up to a minimum of 1000 mm above ground level. The
diameter of the GI pipe shall be at least 3 times the diameter of the
cable. The upper end of pipe shall be sealed to prevent ingress of
water.
Cable ends shall be carefully pulled through conduits to prevent
damage to the cable.
Wherever cables are taken in conduits, the Tenderer shall ensure
that the area of conduit filled in by cables shall be as under :1 Cable in pipe
: 53 %
2 Cable in Pipe
: 50 %
3 Cables in pipe
: 43 %
More than three cables
: 40 %
If more cables are passing, additional conduit shall be laid after the
cables are installed and all testing is complete, conduit ends above
grade shall be plugged with suitable weather proof plastic
compound.
Where cables pass through foundation wall or other underground
structures the necessary ducts or openings will be provided in
advance for the same. However, should it become necessary to cut
holes in existing foundations, structures, the electrical Tenderer
shall identify the same and obtain an approval before cutting the
same.
Cables installed above ground level shall be run in trays, exposed
on walls ceilings / structures and shall be run parallel to or at right
angles to beams walls or columns. The cables shall be so routed that
they will not be subjected to heat.
460
Individual cables or small groups which run along structures will

be clamped by means of 16 SWG GI saddles on 25 x 6 mm saddle
bars at a spacing of 300 mm. The cost of such saddles shall be
included in the cost of installation of cable.
Cables shall be supported so as to prevent sagging. G.I. clamps
required as per the diameter and number of cables shall be on
cables at every 300 mm.
Cable carrier system i.e. cable trays / supports and supporting steel
shall be painted black before laying of cables.
h)
Cable Termination & Testing :

All XLPE / PVC cables shall be terminated at the equipments/
panel by means of single compression type glands and tinned
copper lugs.
Power cables shall be identified with red, yellow and blue PVC
tapes. Where copper to aluminium connections are made necessary
bimetallic washers. shall be used.
In case of control cables, all cores shall be identified at both ends by
their terminal numbers by means of grooved PVC ferrules. Wire
numbers shall be as per inter-connection diagrams to be furnished
to the Tenderer.
Tenderer shall drill holes for fixing glands wherever necessary at
no extra cost.
The cable shall be taken through adequate size gland inside the
panel or any other electrical equipment. The individual cores shall
then be dressed and taken along the cable ways .
Cable leads shall be terminated at the equipment terminals
means of crimped type solder less connectors. Crimping shall
done by hydraulic crimping tool and conducting jelly shall
applied on the conductor. Insulation of the leads should
removed immediately before the crimping
by
be
be
be
461
After completion of the termination the waste material such as PVC

insulation removed from cables, cable pieces & armour strips etc.
Shall be immediately removed from the work place and shall be to
appropriate place allotted for this purpose.
Before energizing the cables following tasks shall be carried out - checking of identification Nos.
- Measurement of resistance.
- Insulation resistance.
- Pressure Testing in case of 33KV and 11KV XLPE cable.
Proper records shall be maintained for future reference.
i)
Cable trays & supporting system :Cable trays of sizes as per drawing shall run in concrete trenches or
overhead supported from columns, slabs etc.
Cables shall be clamped in both horizontal and vertical runs by
suitable clamps.
Cable trays and supporting system shall be adequately provided to
provide mechanical support during operating as well as short
circuit conditions.
The cable trays and supports shall be applied with two coats of red
oxide primer and two coats of epoxy paint.
Cable trays shall be fabricated from MS angles and strips as per
sizes given in respective drawing.
462
j)
Transformer :
The transformers shall be installed as per following specifications.
Through external examination shall be made for any damage

during transport particularly to radiators, explosion vents &
for oil leakages.
Transformer shall be lifted by crane of adequate capacity or
by applying jacks at jacking pads provided on tank. The
transformer shall be placed on its foundation & locked by
means of wedges or angles driven in foundation.
Breather shall be mounted on extension pipe fitted to
conservator. It shall be ensured that breathing hole of the
seal is not blocked by foreign material. Colour of silica gel
shall be blue when filled.
Earthing to transformer neutral and body shall be completed
before energizing.
The insulation resistance between windings and between
winding to earth shall be checked by 1000v megger / 5000V
megger in case of EHV winding while testing no external
lines shall be connected in circuit. Before testing all bushings
in cable box and busbar chamber shall be thoroughly
cleaned.
Tap changing mechanism shall be checked for its proper
functioning & locking arrangements.
Check shall be made on proper line connection of cable and
alignment of busbars.
General checks on installation such as oil level in
conservator, oil leakages, earthing, cable connections,
possibility of movement during operation shall be made
before energizing the transformer. On energizing the
transformer shall be checked for unable noise & vibrations.
After 4 to 6 hours of energization on no load the transformer
shall be loaded gradually. The currents & voltages at steps of
loading shall be recorded for future reference.
463
CHAPTER - 3
SPECIFICATIONS FOR CIVIL & STRUCTURAL

CONSTRUCTIONS
3.1
MAJOR CIVIL WORKS

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.
q.
r.
Site clearance by removing and disposing any impediment for

commencing construction
Contour survey, soil testing, tests for ascertaining the soil bearing
capacity, water tables at site, wind direction etc.
Back filling and levelling, if required
Compound wall, chain link/barbed wire fencing, gates, entrance arches
etc., for sugar plant, housing, and plant and non-plant buildings etc.
Foundations for cooling systems for all plants
Foundations for bagasse, fuel and ash handling equipments
Workers rest rooms, panel rooms, workers rest room, first aid facility,
fire fighting facilities including sheds for fire tenders, foundations for
fire fighting equipments, pipe lines for fire fighting/fire hydrants etc.
and other auxillary buildings
Non plant buildings such as administrative offices, canteen, laboratories,
toilet blocks.
Foundations for large tanks, pumps, fuel conveyors, pipe racks,
electrical equipment, pipe / cable racks, water treatment equipment
Panel rooms, sheds for equipments, sheds for D.G. sets
All internal roads to be of RCC and RCC approach roads to be provided
for all building / structures including green areas, road side drains,
culverts, pipelines and other provisions for street lighting, yard lighting,
area lighting etc. within battery limits, as shown in plant layout.
Drainage channels, storm water drains
Underground cable & bus ducts, tunnel for fuel handling, trench for CW
piping, etc.
Covered bagasse storage
Earthing pits and earthing mats
Required plumbing and sanitary fittings & equipments.
Rain water harvesting, compound wall, sewage treatment plant and
green belt
Pile foundation to be provided, if required, based on soil investigation
464
s.
3.2
All building and civil work commencement certificates, building

completion certificates, stability certificates, any other certificates as per
statutory requirements of the Bihar and the Central Government, NOC
of the BPCB, NOC of Airport Authority etc., all necessary permissions
from the statutory authorities.
DESIGN DATA:
The following basic design criteria are used in the designs of various structures.
Soil bearing capacity (to be verified
by Tenderer, prior to civil design)
Min grade of concrete for RCC works
Grade of reinforcement steel
Type of Cement
All structural steel members
Seismic zone of factory area
Wind velocity & direction
3.3
: 20 ton/m at 2 m from NGL

: M20
: IS : 1786
: 43 grade Portland cement
: As per IS 800
: As per IS 1893-2002
: Velocity : As per IS : 875
South-West (May- Sep),
North East (Oct Apr)
SYSTEM DESCRIPTION AND SPECIFICATIONS

3.3.1
Site Grading and Levelling

The site clearance and grading work has been considered only of the area
for the plant. The grading work will be done by cutting-filling balance
method and no earth will be transported from outside. All excavation and
back filling shall be in Tenderers scope. The contour survey and all
necessary surveys of the cogen area shall be carried out by the EPC
Tenderer.
465
3.3.2
Plant Internal Roads And Culverts

Internal roads within the plant boundary and roads for access to
equipment and buildings will have to be provided. Layout of the roads
will be based on Plot Plan. Adequate turning space for vehicles will have
to be provided and bend radii will be set according to maximum vehicle
speed of 20km/hour. Roads will be as short and straight as possible. All
internal roads shall be well designed RCC roads. All roads shall be
designed as per IEC 58. Wherever drains or other underground facilities
cross the roads, concrete pipe culverts class NP2 or NP 3 as required or
RCC box culverts shall be provided. Roads shall be provided with kerb
stones and the same shall be painted as per specification.
All plant roads will be constructed so as to permit transportation of all
heavy equipment. Internal roads will be minimum 6.0m wide.
3.3.3
Soil Investigation
Soil investigation will be done by EPC Tenderer for the determination of
safe bearing capacities for the design of foundations for various structural
elements. Earth resistivity will be determined.
3.4
DESIGN CRITERIA
The design criteria for various structures and structural elements will be as
follows:
3.4.1 Steel Framed Structures
The design of steel framed structures will be done by linear elastic method
as per the provision of IS: 800.
3.4.2 Reinforced Concrete Framed Structures
All reinforced concrete structures will be moment resisting frames along
both longitudinal & transverse directions. The suspended slab will be
considered as continuous over secondary beam and will not form part of
the framing system. However it will be considered to be transferring the
shear to the framing system. RCC structures/members will be designed as
per IS:-456 using limit state method.
466
3.5
FOUNDATIONS
3.5.1
Introduction
All main plant structures i.e. all plant and non-plant buildings for the
cogeneration project will be supported on RCC foundation- isolated,
combined or raft. Machine foundations for Compressors, BFP and misc.
pumps and equipment foundations will be supported on RCC
foundations - Isolated or Block foundations. Pile foundations will be
provided, if required, by the soil investigation report
3.5.2
Design
The foundations will be designed for the most critical combination of
forces and moments, resulting from all the possible combinations of the
various loading from the structural system. The effect of water table will
be considered and the foundation will be checked for overturning for
minimum and maximum vertical loads. There should be no uplift under
any portion of the foundation for any loading condition. The foundation
sections will be sized and reinforced adequately for bending moments and
shear stresses. A levelling course of plain cement concrete will be
provided before casting the foundation.
3.6
MACHINE FOUNDATIONS
3.6.1
Introduction
This section outlines the design philosophy & construction aspect for
foundations for large equipment as follows:
a)
b)
c)
d)
e)
f)
Steam Turbine Generator foundation

Powerhouse foundation
Steam Generator & Auxiliaries foundation
Electrical equipment, DG set, compressor foundations
All bagasse handling foundations
All Miscellaneous machine foundations
467
3.6.2
General
A necessary requirement for all rotating machinery is that it should be
properly supported. Thus the foundation becomes an important element
of machine installation. It has to resist both static and dynamic forces
exerted by the machine and transmit these to the ground. In doing so, it is
responsible for smooth running of the machine by ensuring that
amplitudes are limited to values that are permissible for the machine and
for local environment, including structures and people. The foundation
must have sufficient structural strength to withstand all applicable forces
and most severe combination of individual load cases that result in the
maximum foundation loading for any conceivable set of normal or
abnormal circumstances. Spring supported foundation shall be provided
for low frequency machines, wherever the same are required from
technical consideration.
3.6.3
Design Parameters
The data required for the analysis and design of machine foundations may
be listed as under:
a)
Loading diagram showing static and dynamic loads on the
foundations, points of application of loads, area over which these loads
will be distributed etc.
b) Operating speed of the machine.
c) Capacity or rated output of machine.
d) Critical speeds of the machine.
e) Geometric limitation.
f) Opening limitations, depressions, projections etc.
g) Details including sizes and locations of anchor bolts, pipe sleeves,
inserts, embedded parts etc.
h) Layout and distribution of pipe lines, ducts etc. and their supporting
details.
i) Temperatures in various areas during operation.
j) Mass moment of inertia.
k) Allowable amplitudes at the machine bearing points, etc.
l) Tolerance in bearing and clearances of various components.
468
3.6.4
Loads
The loads to be considered for analysis and design are:
a. Static loads of the stationary components of the entire assembly along
with the static weight of rotating parts.
b. Dynamic loads from start-up torque.
c. Loads on foundation resulting from admissible forces and moments
of pump nozzles.
d. Loads on pedestal top due to installation and maintenance.
e. Any other forces/loads which equipment EPC Tenderer considers
applicable.
3.6.5
Analysis And Design

The analysis and design of machine foundations will be carried out to
ensure the following:
a) Compliance with the manufacturers requirements.
b) No resonance phenomenon of a disturbing nature to machine
operation should exist at the normal running speed.
c) Calculations to be performed for dynamic as well as static cases for
reinforced concrete block type pedestal.
3.6.6
Foundation Sizing
The outline plan dimensions of foundations will be given by the machine
EPC Tenderer. The height of foundation will be selected after taking into
consideration soil strata and operating level of the machine. The
eccentricity of common CG of machine and foundation with respect to the
centroid of base area/pile group should not exceed 3% of the
corresponding base dimensions of the foundation.
In order to reduce the horizontal amplitudes, the height of foundation
should be selected as small as possible. A larger base dimension should be
selected in the direction of rocking moment, if any, acting on the
foundation.
469
3.6.7
Compressor Foundation
The Compressor is a machine of reciprocating type. This is a low speed
machine and produces unbalance forces during operation, causing
vibration in the foundation. Excessive foundation vibrations may cause
settlement or damage to the foundation-machine system and also a feeling
of discomfort and uneasiness to the personnel. Compressor foundation
shall be isolated from the close slab and other foundations
Vibrations are also transmitted through the ground. Ground vibrations
may be minimized by providing trenches all around the foundation up to
a suitable depth.
3.6.8
Miscellaneous Machine Foundations

For the large variety of other types of machines there are numerous
foundation designs and the most suitable one will depend on the
particular application.
Foundations for pumps, etc. are usually in the form of solid block
foundations, resting on the undisturbed strata.
At machine supports supported on the finished floors, floor may be
thickened and extra reinforcements provided. Also, the machines, which
are almost vibration free and are very light to moderately heavy, may be
supported in the above manner. Rubber or neoprene pads may have to be
used under some of these machines to reduce transmission of vibrations to
the supporting floor.
470
3.7
GENERAL DESIGN CONSIDERATIONS

The design of various civil and structural works will be done as per relevant
Indian Standard and sound engineering practices to meet the system and
functional requirements.
Design Loads: Design loads for all structures will be determined according to the
criteria described below.
Dead Loads: - Dead loads will consist of the weights of the structure and all
equipment of a permanent or semi-permanent nature including tanks, wall
panels, partitions, roofing, piping, drains, electrical trays, bus-ducts. Dead loads
will be determined using the weight from IS-875 (Part -1).
Live Loads:- Live loads will consist of uniform live loads and equipment live
loads. Uniform live loads are assumed unit loads which are sufficient to provide
for movable and transitory loads, such as the weight of people, portable
equipment and tools, equipment, or parts which may be moved over or placed
on floors during maintenance operations. These uniform live loads will not be
considered on floor areas which will be permanently covered with equipment.
Equipment live loads are calculated loads based upon the actual weight and size
of the equipment and parts to be placed on floors during dismantling and
maintenance or to be temporarily placed on or moved over floors during
installation. Floors and supporting members which are subject to heavy
equipment live loads will be designed on the basis of the weight of the
equipment in addition to a uniform load of 500 kg/m, or specifically defined
live loads, whichever is greater. Each member in the floor which may carry these
loads will be designed for the heaviest piece or pieces of equipment arranged in
the most critical position. For loads caused by moving equipment over the floor
for installation, consideration will be given to the shoring of beams and floor
from floors below. When moving equipment over floors for installations are
considered, stress increases of 25 percent are permitted in beams and columns.
Wind Speed: The design wind speed will be based on IS: 875 (Part - 3). This
design wind speed will be used to determine wind loads for all structures.
Seismic Zone: As per IS: 1893-2002
471
3.7.1
Design Loads
a)
Dead Loads
Dead load will comprise of the following and will be computed as
per IS: 875 (Part-1). Following will be considered for evaluation of
dead loads:
i)
ii)
iii)
iv)
v)
vi)
b)
An uniform 150/200 mm thick RCC slab wherever concrete

floors are provided
An uniform floor finish of 50 mm laid over RCC slab
Other
area
flooring
will
consist
of
removable
grating/chequered plate or 50 IPS.
Beams & columns as per actual size
Wall/cladding loads
Self weight of supporting structure/facilities
Imposed Loads
Imposed loads will include minor equipment loads, cable trays,
small pipe racks/hangers (not exceeding 250 Kg/m ) and also
loads during erection, operation & maintenance.
Actual plant loads coming on the floor area occupied by the
equipment will be calculated and compared with the superimposed
loads given above. Higher of the two will be adopted for analysis
and design.
c)
Steam Piping Load

As per static/dynamic analysis for steam piping, the loads
superimposed on structure by piping hangers and at the restraint
points will be considered. However, pipe dynamic forces at hanger
location/restraint points will be considered not to act
simultaneously with seismic forces in that plane.
472
d)
Crane Loads
The frames will be analyzed for the maximum wheel loads when
the lifted weight is nearest to A row in one case and B row in
another load case. The impact factor for vertical load will be 25%
for crane girder and 10% for columns/foundations as per provision
of IS: 875 and lateral crane surge of 10% of lifted weight and trolley
weight will be considered in the analysis of the frame. The
longitudinal surge will be 5% of the static wheel load. Each of the
crane girders will be analyzed for the moving loads and for half the
total surge loads on each gantry girder.
e)
Wind Loads
The basic wind pressure will be taken as IS: 875(Part-III) and
combination of wind loads with other types of loading will be done
according to provision of IS:875 (Part-V). The basic wind speed of
50m/sec. up to height of 10metres above ground level.
f)
Earthquake Load
As per IS: 1893, the seismic zone and basic horizontal seismic
coefficient for this plant location will be decided. The importance
factor of not less than 1.50 will be used to calculate base shear
coefficient. The coefficient of soil-foundation interaction will be not
less than 1.0. Reduction in live loads is to be considered for analysis
according to IS: 875. In view of the asymmetrical nature of main
powerhouse, response spectrum method will be used for analysis.
g)
Temperature Loads
The effect of temperature loads will be considered for design of the
structural frames. For temperature loading calculation the total
temperature variation will be considered as 2/3rd of the average
annual variation in temperature. The structure will be designed to
withstand stresses due to 50% of the total temperature variation.
The structures will also be analyzed/checked for temperature
effects in the areas where the temperature rise is expected to be
high.
473
h)
Load Combinations
The following load combinations will be considered for finding out
the critical forces, moments and torsion on the structural elements.
i) DL + LL
ii) DL + LL + CLA + DLC CS
iii) DL + LL + CLB + DLC CS
iv) DL + LL + CLA + DLC CS TL
v) DL + LL + CLB + DLC CS TL
vi) DL + 0.5LL + K1(DLC) + K2(CLA)
vii) DL + 0.5LL + K1(DLC) + K2(CLB) + EL TL
vii) DL +LL + DLC + K3(CLA) K3(CS)+ WL1+TL
viii) DL +LL + DLC + K3(CLB) K3 (CS)+WL1+TL
ix) DL +LL + DLC + K3 (CLA) K3 (CS) WL2+TL
x) DL +LL + DLC + K3(CLB) K3(CS) WL2 TL
xi) DL +LL WL1 TL
xii) DL + LL WL2 TL
The following load combinations will be used for getting max.
tension at column base which will be used for the design of holding
down bolts
i) 0.9DL EL
ii) 0.9DL WL1
iii) 0.9DL WL2
i)
Nomenclature
DL
Dead load (comprising of only dead weight of structural
members, side cladding etc.)
LL
Live load (including imposed load, plant loads & equipment
loads)
TL
Temperature load
DLC Dead load of crane bridge with impact
CLA Crane trolley + lifted weight nearest to A row column with
impact
CLB Crane trolley + lifted weight nearest to B row column with
impact.
CS
Crane surge
EL
Earthquake load
WL1 Wind load with internal suction of 0.2p
474
WL2 Wind load with internal pressure of 0.2p

K1 (DLC)
Dead load of crane bridge without impact
K2 (CLA)
Crane trolley without lifted weight with impact or
(CLB)
K3(CLA)
Crane trolley + lifted weight with impact or (CLB)
K3(CS)
Crane surge for lifted weight.
3.7.2
Permissible Stresses
The permissible stresses will be as per relevant IS Code. An increase of
33.3% in permissible stresses will be made wherever wind or earthquake
load has been considered with dead load and appropriate amount of live
load. For secondary effects without wind or earthquake load, permissible
stress will be increased by not more than 25%.
3.8
DESIGN OF MISCELLANEOUS ITEMS

3.8.1
Cable Trenches
The cable trenches and pre-cast removable RCC cover (with lifting
arrangement) will be constructed using RCC/Masonry work. The cable
trench walls will be designed for the following loads:
1.
2.
3.
4.
Dead load of 155 Kg/m length of cable support and 75 Kg on one tier
at the end.
Triangular earth pressure + uniform surcharge pressure of 2T/m.
Cable trench covers will be designed for self-weight of top slab and
concentrated load of 200 Kg at center of span on each panel.
Cable trench crossing the road/rails will be designed for class AA
loading of IRC/relevant IS code and should be checked for
transformer loading.
Suitable drainage arrangement will be provided to drain water from cable

trenches. Cable trenches will not be used as storm water drains. The top of
trenches will be kept at least 50mm above the finished ground level.
Trench wall will not foul with the foundation. Suitable clear gap will be
provided.
475
A clear (vertical) space of at least 200-mm will be available for each tier in
cable trench. From trench bed to lowest tier, a minimum clearance of 150
mm will be available. The trench bed will have a slope of 1/500 along the
run and 1/250 perpendicular to the run. All the construction joints of
cable trenches i.e. between base slab to base slab, the junction of vertical
wall to base slab, from vertical wall to wall and all the expansion joints
will be provided with approved quality PVC water stops of approx. 230 x
5 mm size for those sections where the ground water table is expected to
rise above the junction of base slab and vertical wall of cable trenches.
Cable trenches will be blocked at the ends if required with brick masonry
in cement sand mortar 1:6 plaster with 12mm thick 1:5 cement sand
mortar.
3.8.2
Drains
Adequate surface drainage system will be provided within the plant area.
Design will be done with obtained rainfall data and the storm water
drainage system designed, (Culverts, ditches, drains etc.) to accommodate
the most intense rainfall that is likely to occur over the catchments area in
one hour period on an average of once per ten year. The surface of the site
will be sloped to prevent the ponding of water.
The maximum velocity for pipe drains and open drains will be limited to
2.4m/ sec and 1.8m/ sec respectively. However, minimum non-silting
velocity of 0.6 m/sec will be ensured. Longitudinal bed slope will not be
milder than 1 in 1000.
Invert of the drainage system will be decided in such a way that the water
can easily be discharged above the High Flood Level (HFL) outside
substation boundary at suitable location and approved by Owner. Pumps
for drainage of water (if required) will be provided.
476
3.9
ARCHITECTURAL CONCEPTS AND DESIGN

An Architectural Design Basis Report will be submitted to the Owner including
proposals for the following scheme components: shape, form, color, and basic
materials for interior and exterior architecture along with an appropriate
landscaping scheme. All schemes will be supported by architectural statement
explaining the factors considered in the design.
Exterior Architecture : General design criteria for the exterior architectural
systems will be as follows:
3.9.1
Wall/Cladding System
All external walls of the building shall be 230 mm thick brick walls and
internal walls 230/115 mm thick brick walls as per requirement in CM 1:5.
Internal plastering shall be 12 mm thick using CM 1:4 and external wall
with CM 1:4., 20/25 mm thick and/or sand faced plaster or any other
special finish if required, 115 wall shall be plastered with CM 1:3, 12 mm
thick. Ceiling plastering shall be 6 mm thick with CM 1:3. Damp proof
course 40 mm thick in PCC 1:2:4 using 6 mm down stone shall be
provided in the external brick walls at grade level.
In order to quickly erect / complete the Plant buildings, wall cladding
with Galvalume sheets may be examined above 5.0 m from ground level
and up to 5.0 m brick work can be adopted. Where ever advised, self
supported galvalume roofing could also be provided for the main plant
buildings and other non-plant buildings.
3.9.2
Roof
As per details given in relevant sections.
3.9.3
Flooring & Floor Finish

The floor slabs will be designed as cast-in-situ RCC slabs with removable
shuttering unless mentioned otherwise. The nominal thickness of RCC
slabs will be 150/200 mm.
477
Floor finish of 50mm thickness will be provided over the RCC Slab as per
finish schedule wherever applicable. Type of floor finish will be as per the
functional requirements of different areas and facilities.
3.9.4
Roof Water Proofing Treatment Above RCC Roofs

Over the cast-in-situ roof slab, 50mm thick screed concrete (blended with
water-proofing admixture) will be laid. The final treatment will be heavyduty type with bitumen felts. For the provision of handling of equipment
on the roof and movement of personnel, tiles will be provided in place of
pea gravel.
Roof slope of 1 in 75 will be provided in one direction in A-B bay and
sloping towards A-row. For other bays, roof slope of 1 in 100 will be
provided in two directions.
For rainwater down comers, heavy duty UPVC pipes will be used.
Number and sizing will be as per the relevant Indian Standard.
3.9.5
Windows, Ventilators
Window and Ventilator frames will be made of extruded aluminium,
steel, or other tried and proven material as per the schedule given earlier.
Frames will have a minimum depth of 38 mm and a minimum thickness
of 3 mm. Ventilation sections will be compatible with the frames
providing a weather tight seal.
All aluminium windows shall be provided with MS grills of approved
design and all glazed windows to be provided with sun control film. All
steel windows to be provided with 12mm sq MS safety bars @ 100 mm c/c
All windows will be fully flushed and sealed for weather tightness.
478
3.9.6
Doors:
Pressed steel doors/ Aluminium doors will be provided as per the
schedule given earlier. Steel doors will be the hollow metal type, flush, 46
mm thick, insulated, with formed hollow metal frames. The doors will be
constructed from 1.3 mm steel with an internally reinforced, insulated
core. Frames will be constructed of 1.6-mm steel, welded, and ground
smooth. Both doors and frames will be factory galvanized or field painted.
Doors will have a glazed vision panel when required by door function.
Glazing will consist of tempered safety glass or wired glass.
Fire barrier doors, if any, shall be specifically designed steel doors with
required fire rating. The door, frame, and hardware will bear a
certification label for the class of opening and rating. Doors for fire exits
will be secured with panic bars.
Solid core flush doors with both side veneer finish to be provided for
housing and other non-plant buildings as advised and specified.
3.9.7
Equipment Access Doors:Large access exterior doors will be vertical lift rolling shutter type, with
weather seals and windsocks. Components will be formed from
galvanized steel, factory primed, and field painted. Doors at high traffic
areas will be motor-operated. Doors will be manually operated where
access is infrequent.
Interior Architecture: Interior architectural systems will conform to the
following general design criteria. Fire rated architectural system will be
provided when required by building or fire codes. All normal occupied
areas will be finished areas.
3.9.8
Painting:
Inside masonry walls and ceilings of all buildings will be provided with
white wash, color wash, oil bound distemper, acrylic emulsion paint as
per schedule given earlier. Steel structures, doors, windows, steel rolling
shutters, gangways, stairways railing, grating rain water pipes etc. will be
painted with synthetic enamel paint.
479
3.9.9
Sanitary Facilities:
Toilet and shower facilities will be provided for personnel in finished
areas of all major buildings and in other areas as determined by project
requirements. Sanitary facilities fixture types will be so selected to provide
a balance of local and Western fixtures. Towel and waste receptacles will
be recessed to the extent possible. Janitor closets and cleaning material
storage areas will be provided in finished areas of all major buildings. The
sewage from various locations will be collected in septic tank. The
capacity of the sewerage system, septic tank, required gutters, air vents,
PVC piping, etc. will be calculated based on manpower deployment of
500 personnel per shift.
All Architectural, Structural and RCC drawings and design calculations,
shall be supplied in triplicate to the Client and their Consultants,
minimum 15 days prior to construction of works at site, for approval
purposes and only after approval, the works shall be taken up at site. A
soft copy of all such drawings and designs, either by E-mail or by
CD/DVD, shall also be provided along with the hard copies of the same.
3.10 CONSTRUCTION
3.10.1 Concrete:
Reinforced concrete structures will be designed in accordance with the
latest version of IS: 456 Code of Practice for Plain and Reinforced
Concrete.
Water retaining RCC Structures will be designed in accordance to IS:3370:
Code of practice for concrete structures for the storage of liquids.
The grade of concrete for various structures will be as follows:
PCC below Foundations/Plinth Beams
1:4:8
PCC in base slabs for drains, water retaining structure etc. 1:3:6
PCC/RCC in grade slabs, pavements, plinth protection, etc M20
RCC in foundations and super structures
M20
RCC for liquid retaining structures
M25
RCC for T. G. Foundation
M20
480
Minimum cement content shall be as follows:

M15
:
324 kg/m
M20
:
360 kg/m
M25
:
400 kg/m
1:3:6
:
216 kg/m
1:4:8
:
216 kg/m
1:5:10
:
130 kg/m
a)
Grouting :
Non-shrink flowable grout shall be used for grouting below base
plate of columns. For grouting of base of machine foundation high
flowable strength ready mixed non shrink grout shall be sued.
Type and grade of grouting for structural columns and equipment
base shall be as indicated. Crushing strength of the grout shall
generally be one grade higher than the base concrete. Minimum
grade of grout shall be M30.
Nominal thickness of grouting shall be at least 50 mm for building
columns and pedestals of major equipments. For secondary posts,
stair & ladder base, etc, grouting shall not be less than 25 mm thick
b)
Reinforcing Steel:
Reinforcing steel will be High, Yield Strength Deformed bars

conforming to IS-1786 (Grade Fe 415).
Cement:- Cement used in all concrete mixes will be Ordinary
Portland cement/ Portland Slag cement 43-Grade unless
design requires a different type.
Aggregates: Fine aggregates will be clean natural sand.
Coarse aggregates will be crushed gravel or stone. All
aggregates will meet the requirements of IS:383 - 1970.
481
c)
Admixtures:
d)
Plasticizers and retarders will be used to control setting time

and to obtain optimum workability, if required.
Water: Clean water of potable quality will be used in all
concrete mixes.
Mixes: A table will be supplied with the Design Intent
Memorandum, which classifies the proposed mixes into a
general range of classes. The minimum cement provided in
concrete mixes will be as per the stipulations laid down in
IS: 456.
Secondary reinforcement : Polyester fibres will be used in
cement mortar, PCC, RCC, etc. to enhance / improve the
performance of mortar / PCC / RCC
Design Mix Tests:

Two sets of compression test samples, three samples per set, will be
made from each proposed concrete mix. One set of three samples
will be tested at an age of 7 days, and the other set will be tested at
an age of 28 days. Tests will be in conformity with IS:4031-1968.
Grade Slab: The existing earth fill will be thoroughly compacted,
and provided with 150 mm of boulder soling or brick aggregates,
interstices filled with small stones and sand. Floor paving will be of
100/150 mm thick in M-20 grade laid over the prepared surface.
e)
Finishing Formed Surfaces:

Fins and other surface projections will be removed from all formed
surfaces except exterior surfaces that will be covered with earth
back fill. Exterior surfaces that will be exposed above grade and all
interior surfaces, except those not usually exposed to view, will be
cleaned and rubbed. Rubbing will produce a smooth, uniform
surface free of marks, voids, surface glaze, and discoloration.
Rubbing will be done by hand with a carborandum stone using
only the mortar produced by the rubbing action and the application
of water.
482
Projecting ends of all form ties will be removed. The resulting

recesses will be cleaned, wetted, and filled with patching mortar.
Patches on rubbed surfaces will match the texture of the adjacent
concrete.
Plinth Protection: All buildings will be provided with 1000 mm
wide and 100 mm thick plain cement concrete paving all around on
the outside. The plinth protection will be laid over prepared subgrade and base formed with broken bricks or rubble laid to a
thickness of 75 mm.
f)
Structural Elements :
Minimum thickness of structural element to be as follows:
Suspended flow slab / roof slab / walkways
/ canopy slabs, etc
Ground floor slab (non-suspended)
Water retaining slab / walls
Cable / Pipe Trenches / Under ground pit /
Launder walls and base slab
All footing (including raft foundation)
Tapered footing
: 100 mm
: 150 mm
: 150 mm
: 100 mm
: 250 mm
: 150 mm
(Min. at edges)
Parapets / Chajjas
: 75 mm
Pre-cast louvers / fins
: 50 mm
Pre-cast trench cover slabs / floor slabs / : 75 mm
louvers
Paving
: 150 mm
Basement walls and base slab
: 150 mm
g)
Curing:
Concrete will be protected from loss of moisture for not less than 7
days after the concrete is placed. Trowelled surfaces, except those
that receive a separate finish or coating, will be cured with a
membrane curing compound. Float finished surfaces, except those
that receive a separate finish, may be cured with either a
membrane-curing compound or with water. Only water curing will
be used if the surface receives a separate finish.
483
Water Curing: Water saturation of concrete surfaces will begin as

quickly as possible after initial set of the concrete. Water curing will
begin within 12 hours in dry weather and within 24 hours in damp
weather. The rate of water application will be regulated to provide
complete surface coverage with a minimum of runoff The
application of water may be interrupted for surface rubbing. The
concrete surface will not be permitted to dry.
Damp proofing: Damp proof course in a thickness of 40mm and
consisting of cement concrete 1:2:4 with admixture of approved
water proofing compound, will be provided at plinth level for
masonry walls in super structure.
Waterproofing: A waterproofing seal will be provided for
structures where applicable. Water-proofing will be carried out by
a system duly approved by the Owner/Consultant.
3.10.2 Steel
a)
Structural Steel:Steel framed structures will be designed in accordance with IS:-800Code of Practice for Construction in steel adopting allowable stress
design and plastic design. In addition steel framed structures will
be designed in accordance with the criteria discussed in the
following subsections.
b)
Materials:
Structural steel shapes, plates, and appurtenances for general use
will conform to Indian Standards IS:800 with a minimum yield
strength of 250 MPa. Connection bolts will conform to IS:-1367.
Connections will conform to the latest version of the Specification
for Structural Joints. Welding electrodes will be as specified by the
AWS.
484
c)
Tests:
Mill test reports or reports of tests made by the fabricator will be
required certifying that all material is in conformance with the
applicable standards and specifications. In addition, the fabricator
will provide an affidavit stating that all steel specified has been
provided at yield stresses in accordance with the drawings and the
specification.
d)
Minimum Heights for pedestals of Steel Columns :

Top of RCC foundation (pedestals) shall normally be kept at a
height of 300 mm above the floor level.
Other Pedestals and Foundations
Stairs and ladder pedestal
: 200 mm above the finished

floor level
Equipment in open area
: As required (300 mm min.)
Equipment in covered area
: As required (150 mm min.)
Structures / Equipment : As per Tenderers data subject
to minimum as specified
supplied
above
In case the top of pedestal is kept at a lower level so that the
column base plates together with gussets and stiffener remains
below finished floor level (FFL), the column base as well as column
section shall be encashed in concrete above FFL as below:
Open area
Covered
: 300 mm above FPL / FGL, whichever is higher

: 150 mm above the FFL
485
3.10.3 Miscellaneous Metal Items

a)
Steel Grating:
Steel gratings will be pressure locked grating manufactured with
40mmx 5mm MS strips as longitudinal bearing strips (spanning the
supports) and 25mm x 3mm strips in transverse direction. The
grating will be provided with a 40mm x 5mm band all-round. The
grating will be designed for 500kg/m2 loading and spans up to
1500mm. Stair treads will also be made of steel grating with nosing.
b)
Guard rail /Handrail:

Guard rail will be a two-rail system with the top rail 1000 mm
above the walkway surface and the intermediate rail 500 mm below
the top rail. Guard rail post spacing will be proportioned to the
length of the protected horizontal opening, but will not exceed
1200mm centre-to-centre of posts. Guard rail will be shop
fabricated for specific locations and field welded or bolted to the
erected structural steel. Steel pipe will conform to IS-1151, Medium
grade.
c)
Anchor Bolts and Embedded Shapes:

Anchor bolts will conform to IS:-5624. Embedded shapes and plates
will be galvanized where required. Anchor bolt assemblies will be
galvanized where required. Steel, which is not galvanized and will
remain exposed, will be primed with a primer paint.
486
CHAPTER - 4
APPROVED LIST OF VENDORS, LIST OF SPARES AND LIST

OF DRAWINGS, DOCUMENTS
4.1
APPROVED LIST OF VENDORS

4.1.1
Major Equipment Suppliers

Steam turbine
AC generator
Steam generator
Diesel Engine
DCS
4.1.2
BHEL / Siemens / Shin Nippon / TDPS

Francotosi / Skoda / GEC
BHEL / Siemens / TDPS / Jeumont /
WEG / Cummins
BHEL / Thermax / IJT / WIL Foster
Wheeler / CVL
Cummins / Greaves Cotton / MAN /
Kirloskar / Wartsila / Powerica
Emerson / Yokogawa / Honeywell / ABB
/ Siemens
Mechanical
Air Conditioning System Blue-Star / Voltas / Carrier / Daiken / LG
Condenser
GEI Godavari / Siemens / BHEL / L&T
Bearings
SKF /FAG / ZKL
Bellows
Flexicon / Lone Star / Metallic Bellows /
Instrumentation Ltd. / Cori Rubber
Belt Weigh Scale
PBL / IPA / Avery
Blow down valve
Levcon/BHEL/Hopkinson / Keystone
Boiler Feed Pumps
KSB / Kirloskar Ebarra / Sulzer
Butterfly valves
KSB / Audco / BDK / Instrumentation
CBD & IBD Valves
BHEL / Hopkinson / Fainger Laiser /
Forbes Marshall
Chains /Sprockets
Diamond / Rolcon / Swajit
Condensate Extraction Sulzer / Mather and Platt / KSB / Sigma
Pumps
Lutin
Conveyor Belt
Dunlop / Andrew Yule / Ravasco / MRF
487
Couplings (Tyre Type)

De-aerator
Fenner / Unique
Thermax / BDT / GEA / BHPV / BHEL /
L&T / Tri-power
Dust Extraction System
Rajdeep / Ecomak / Duvent
Ejector
Mazda / New Field / BHEL
ESP
Thermax / BHEL / ETS-Elex / Alstom /
VT Corp / CVL / Rieco / Him-Enviro
Fire Hydrants / Fire Fireflex / Minimax / Minimak / Alert /
Extinguishers
Kafex / Safex
Fire Protection systems New Fire / Vijay / Agni Heavy Ind/
(CO2)
Mather & Platt
Gate, Globe & Check Audco / BHEL / KSB / Fouress
Valve CI 600 and above
Gate, Globe & Check BDK / Audco / BHEL / KSB / Valtech
valves
Turbine Gear Box
Lufkins / Flender / Skoda / Mitsubishi /
Maag / Osaka / Hitachi
Gear Box
Radicon / Elecon / Shanti
Governor
Woodward 505 E
GVC
Eskay / Patel Air Temp / Mazda / TEMA
HP & LP Dosing system Metapow India / Asia LMI / Enpro / PSI
Engineering
HP heater
BHEL / L&T / GEI Godavari / TEMA /
Patel Engg
ID, FD and SA Fans
AYL / ABB / BHEL / Batliboi / Reitz
Turbovent / Flakt
Insulation
Lloyds / Minwool / Orient
LRSB Soot blowers
BHEL / Hopkinson / RR
Lube oil purifier
Alfa Laval / Pennwalt
Magnetic Separator
Electromag / Sterling / MCI
Misc.
valves
& Fouress / Audco / KSB / Crescent /
specialties
Non IBR valves
BDK / L&T / KSB
NRV
BHEL / Hopkinson / KSB
Oil coolers
Eskay / Reynolds / Southern Lubricants
Oil filters
Industrial
Enterprises
/
Southern
Lubricants / Enpro
Oil Pumps
Delta / Sigma Lutin / Prakash
Pumps
KSB/Khimline / Sulzer / Beacon Weir
488
Refractory
Relief valves
Rotary Soot Blowers
Rupture disc
Safety Switches
Safety valves
SJAE
Spring hangers
Welding Electrodes
4.1.3
Parshuram / ACC / KFS / Furnace

Fabrica
BHEL / L&T / JNM
RR Tech / Hopkinson / BHEL / Sitson
FMC Sanmar / Eagle / Burgmann
AG / Jayshree / AE
BHEL / L&T / TYCO Sanmar
BHEL / Newfield / Thermal Systems
BHEL / L&T / Sarathi / Myricks
Advani Oerlikon / Esab / Hannover /
Lincoln
Electrical
Air Circuit Breakers
Analog Meters
Annunciators
Auto Excitation
Regulation System
(Digital)
Auto Synchroniser
Battery
Battery Charger
Busduct
Capacitor Banks
Comprehensive
Transformer Protection
Relays
Control panel
CTs & PTs
DC Distribution Board &
EOP starter
DC Motors
ABB / GE Power / L&T/ Siemens /

Schneider
AE / IMP / Rishab
IEC / Minilec / Procon / Alen / Sun Auto
Basler / BHEL / Elin / GE / Siemens /
ABB
Alstom / AVK-SEG / L&T / Siemens /
Woodward
Amara Raja / Exide / Universal (BUI) /
Panasonic
Amara Raja / BCH / Tritech / Chhabil /
Sab Nif / Universal / Masstech
C&S / Elpro / Power gear / General /
Stardrive / Suman Control / BHEL
Ductail / L&T / Malde / Siemens / CGL
ABB / Alstom / Easun Reyrolle / GE /
Multilin / Siemens / Alstom
Auto Con, Logix, Future Electronics
ABB / AE / CGL / Prayog / Pragati /
KAPPA
Alstom / GE Power Controls / L&T /
Siemens / ICA / BCH / BHEL
IEC / KEC / Crompton Greaves
489
df/dt Relay
Alstom / L&T / AVK-SEG
Digital Meters
AE / Enercon / L&T / Siemens
Distance Protection Relays ABB / Alstom / Easun Reyrolle / GE /
Multilin / Siemens
EHV XLPE Cables
Nicco / RPG / KEI
FD, TPN SFUS
L & T /Schneider /Siemens/ABB
Feeder Protection (11kV
ABB / Alstom / Easun Reyrolle / GE /
Relays)
Multilin / AVK-SEG
Fuse Bases and HRC
L & T /Siemens/ABB
Fuses
Generator Protection
ABB / Alstom / Beckwith / GE Multilin /
Relays
Siemens
HT Breaker Panels
ABB / BHEL / Siemens / Alstom/CGL
Illumination System
Bajaj / CGL / Philips / Wipro
Indicating Lamps
Technic/Siemens/ L & T /Vaishno
Instrument Transformers
AE / Intrans / Kappa / Pragati / Prayog /
11kV & 415V)
Silkans
Insulators
IEC / Jayashree / Modern / WS
Isolators
Bimco / Elfab / GR Power / Kausik / PEI
/ SMC / S&S / Versatek / ABB / Kiran
Universal / Pactil
LAVT & Terminal
C&S / Elpro / Enpro / Power Gear /
Cubicles
Rajarajan / Suman Controls
Lighting fixtures
Bajaj/Crompton Greaves/Wipro
Lightning Arrestors
IGE / Elpro / Lamco / Oblum / WS
LT Motors
ABB / CGL / Siemens / KEC / NGEF
LT Panels
ABB / Alstom / GE Power Controls / L&T
/ Siemens / CPRI approved
LT Switchgear
ABB / GE Power / L&T / Siemens
Components
Master Trip & Auxiliary
ABB / Alstom / Easun Reyrolle
Relays
MCB
MDS Legrand /Indokopp/Groupe
ELCB
Schneider
MCB Distribution Boards L&T / MDS / Siemens / Datar / CPRI
approved
MCCB
Siemens/ABB/ L & T
Microprocessor Based
Alstom / Siemens/ Schneider
490
Motor Overload Relays

NGR Panel
Outdoor Circuit Breaker
Power & Control Cables
Power Quality Meters
Pressure Gauges
Protection, Metering,
Synchronising & Control
Cubicle
Protective Relays
Push Buttons
Relays
Rotor Earth Fault &
Sensitive Directional Earth
Fault Relays
(Microprocessor /
Numerical Version)
RELAYS
Selector Switches
Semiconductor Fuses
SF6 Breakers
Surge capacitor
Temperature Scanner
Ampcontrols / Narkhede / Essen /

National switch gear
ABB/Crompton Greaves/ Areva /
Kirloskar
CCI / FGIL / Incab / Nicco / RPG / RR /
Torrent / Universal / Finolex
GE Multilin / L&T / Enercon / Conserv
Bells / GIC / H. Guru / Waree
ABB / Alstom / Easun Reyrolle / Elpro /
Enpro
Areva / Siemens / L & T /SEGC/ABB
L & T /Siemens/Technic/Vaishno
Siemens/ Group Schneider/ABB/L &T/
Alstom / AVK-SEG
ABB / Alstom / AVK-SEGC
Kaycee/Salzar / AE
Feroz / GE Power / Siemens
ABB / Alstom / BHEL / CGL / Siemens
Madhav / Narkhade / Vee Vee
ABB / Massibus / Yokogawa Bluestar /
Sun
Transducers
ABB / AE / Siemens
Transformers
Kirloskar / Crompton / Emco / Voltamp /
Areva / Indo Tech / Siemens / Bharat
Bijlee / PETE
Trivector Meters
ABB / L&T / Allen Solly / Sun
Variable Frequency Drives ABB / GEC / Siemens / TB Wood / L&T
XLPE Cable Termination
3M Birla / CCI / M-Seal / Raychem
Kits
491
4.1.4
Instrumentation
Air filter regulators
Analysers
Control valves
Desuperheaters
Draft Gauges
Flow nozzles / Orifice
IP converters
Oil Centrifuge
Power cylinders
Pressure gauges
Pressure switches
Steam traps
Strainers
SWAS
Temperature Gauges
Thermocouples
Transmitters
UPS
Ventilation system
Vibration system
Shavo-Norgon / Placka
ABB / Rosemount / Yokogawa / Emerson
MIL / ARCA / Fouress / IL / ABB /
Dresser / Fisher
ABB Introl / Chemtrol Forbs Marshal /
Key Stone / Fisher
Switzer / Bells / Levcon
Micro precision / Hydro pneumatics /
Fairflow / IL / General instruments /
Gurunanak / Placa
Bells / Rosemount / JNM / ABB / MIL /
Moore / MTL
Alfa Laval / Pennwalt
Bells control / IL / Chemtrols
H. Guru / GIC / Bells / Waree
Switzer / Danfoss / Infoss / Verma
Spirax Marshall / Pennant / Greaves
Cotton
Spirax Marshall / Triveni / Bhatia /
Strainwell
ABB / JNM / Foxboro / Rosemount
H. Guru / GIC / Bells / Wica / Waree
General Instruments / Pyroelectric / Altop
/ Toshniwal
Rosemount / Honeywell / Yokogawa /
Bells / Moore / E&H
APC / DB / Emerson
ABB / C-Doctor / Crompton / GEC /
Voltas
Bently Nevada / Shinkawa / Provibtech
(USA) / B & K Holland
Note: If the eligible EPC Tenderer is a manufacturer of any sub-components, the same
will be acceptable. The Tenderer may request for additional approvals during the
technical pre-bid meeting.
492
4.2 LIST OF SPARES

4.2.1
List of Spares for steam generator

Sr.
No.
A.
B.
1.
2.
3.
4.
5.
6.
Item
Unit
Quantity
Pressure Parts
a) Gaskets for drum manhole
b) Pressure part bends
No.
No.
2
10
No.
No.
No.
1
2
1
No.
No.
No.
1
1
1
Set
Set
Set
1
1
1
Set
Set
Set
Set
Set
1
1
Set
Set
No
1
1
2
Non Pressure Parts

Spares for drum safety valve
a) Valve disc
b) Adjusting rings
c) Spindle
Super-heater safety valve
a) Valve disc
b) Adjusting rings
c) Spindle
Isolating valve for main steam
a) Gland packing for main steam
b) Gasket
c) Packing
Feed water isolating valve
a) Glands packing for isolating valve
for feed water
b) Gasket
Packing ring isolating valve for
Attemperator
a) Gland packing for isolating valve of
attemperator
b) Gasket
c) Packing ring
Feed water control valve
a) Gland packing
b) Seal ring
c) Body bonnet gasket
493
Sr.
No.
7.
8.
9.
10.
Item
SH Spray Control Valve
a) Gland packing
b) Seal ring
c) Body bonnet gasket
Fans
a) ID fan bearing
b) ID fan rotor
c) SA fan bearing
d) FD fan bearing
Rotary Feeder
Feeder valves
Steam generator feed pump spares
(like seals, gaskets, etc.)
Valves (high pressure)
a) 25 NB
b) 50 NB
c) 100 NB
d) 200 NB
e) Push buttons & indicating
f) Fuses
g) Gaskets
11.
Description
a) Thermocouples
b) Temperature monitors
c) Feeder rotor
d) Annunciator lamps
e) Fuses
f) Relays
g) Pressure gauges shatter proof glass
h) Temp. gauges shatter proof glass
i) Level gauge toughened glass
Unit
Quantity
Set
Set
Nos.
1
1
2
No.
No.
Set
Set
2
1
1
1
Nos.
Set
2
2
2
2
3 nos. of
each
2 nos. of
each type
2 nos. for
each high
pressure
flange
2
2
2
5
5
5
2
2
1
494
Sr.
No.
Item
Unit
j) Slight glasses
1spare
each
1
4
k) Alarm annunciator card

l) Pressure gauges
12.
4.2.2
Quantity
Tubes : 5% (to nearest figure) of all profiles for furnace, water

walls, Eco, APH & SH
List of Spares for steam turbine generator

Sr.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Description
Set of radial and thrust bearing pads
Front bearing supporting plates
Rods for grid valve actuator
Oil retaining rings
Fuses
Oil ring
RTDs
Gear box bearings, both high & low side
Oil filter element for control and lube oil
Spare vibration probes
Spring for over-speed trip device
Gaskets for governor valve and emergency
stop valve
Sheet packing for Condensers
Tube for Condensers
Sheet packing for Air Ejector
Tubes for Air Ejector
Gland Packing for CEP
Bearing for CEP
Cooling tubes for air cooler
Sheet packing for air cooler
Oil seal for main oil pump
Oil seal for Aux. Oil pump
Oil seal for emergency oil pump
Quantity
1 set
1set
2 nos.
1 set of each type
1 of each type
2 of each type
1 of each type
1 set
2 sets of each
2 sets
1 no.
1 set each
1 set of each
20 pcs.
1 set of each
4% of total tubes
1 set of each
1 set of each
8% of total tubes
1 set of each
2 sets of each
2 sets of each
1 set of each
495
Sr.
No.
24.
25.
26.
27.
4.2.3
Elements for Control Air Filter

Packing for control filter
1 set of rotating diodes
Bearing for AC Generator
Quantity
4 sets of each
4 sets of each
1 set
1 set of each
List of Spares for cooling tower

Sr.
no.
1.
2.
3.
4.
5.
6.
7.
4.2.4
Description
Description
Unit
Quantity
Motor bearings DE / NDE

Set of oil seal
Bolt, nut and rubber bush
Sprayers / nozzles
End flush valves
Bearing for gear box
Nozzles
Set
Nos.
Set
Set
Set
Set
Nos.
1
2
2
50
5
1
20
List of spares for WTP

Sr.
No.
1
2
3
Description
Degassed Water Pumps
Set of bearings (drive end)
Set of bearings (non drive end)
Set of gaskets
Set of oil seals
Effluent Disposal Pumps
Bearing set , both ends
Lobe Type / Roots Blowers
Air Scouring Blowers
Bearings, both ends
Degasser Blower
Complete rotor assembly including
impeller, wheel, hub, nuts bolts and shaft
Unit
Quantity
Nos.
Nos.
Nos.
Nos.
1
1
1
1
Nos.
Nos.
Set
496
Sr.
No.
5
10
Description
Unit
Quantity
Strong Acid Cat-ion Exchanger

Resin
Strainers
Resin trap element
LTR
Dozen
Nos.
50
5
1
Strong Base Anion Exchanger

Resin
Strainers
Resin trap element
LTR
Dozen
Nos.
50
5
1
Mixed Bed Unit

Resin
Strainers
Resin Trap Element
LTR
Dozen
Nos.
10
5
1
KG
KG
Nos.
50
50
10
Nos.
Nos.
Nos.
2
2
2
Nos.
Nos.
Nos.
Nos.
Nos.
2
2
2
2
2
Activated Carbon Filter

Activated Carbon
Filter bed material
Strainer
PP Ball Valves
15 NB
25 NB
40 NB
Rubber Lined Diaphragms Valves
20 NB
25 NB
40 NB
50 NB
80 NB
497
4.2.5
List of Spares for Electrical Evacuation

Item
No.
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
4.5
Description
Battery charger & DCDB
AC fuses of each rating
DC fuses of each rating
Bridge protection fuses of each rating
Control fuses of each rating
DCDB fuses of each rating
SCR bridges of each rating
Indicating lamps
HT Switchgear
Breaker closing coils
Breaker tripping coils
Indicating lamps
HT fuse for PT
LT fuses
HT Bus Duct
Neoprene rubber gaskets
Seal off bushings
TPN set of Cu flexible for SWGR end
TPN set of Cu flexible for TRAFO end
AL expansion joint TPN
Control fuse for space heater
LT Bus Duct
Seal off bushings
TPN set of Cu flexible for SWGR end
TPN set of Cu flexible for TRAFO end
AL expansion joint TPN
Control fuse for space heater
Unit
Quantity
Nos.
Nos.
Nos.
Nos.
Nos.
Set
Nos.
2
2
2
2
2
1
2
Nos.
Nos.
Nos.
Nos.
Nos.
2
2
2
2
2
M
Set
Set
Set
Set
Nos.
10
1
1
1
1
2
Set
Set
Set
Set
Nos.
1
1
1
1
3
498
4.2.6
List of Spares for DCS

Item
No.
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
4.2.7
Description
Unit
Quantity
DCS
Analog control I/O module card
Digital input module card
Temperature (T/C) input module card
Temperature (RTD) input module card
Terminal boards
Input signal conditioning card
Output signal conditioning card
Signal distributor
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
Nos.
1
1
1
1
1
1
1
1
List Of Spares For Balance Of Plant Equipments

Sr.
no.
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
2.4
Description
EOT Crane
Brake linings with necessary rivets /
screws / fixtures for EHT Brake
Overload relay for each motor
Coil for limit switch delay relay
Limit switch
HRC fuse links for all motors and for
control circuit
Seals for each thruster brake
Indicating lamp of each type
Plant Air Compressors
O ring
Sight flow glass
Oil Filters
Gasket bearing. Housing Drive side
Unit
Quantity
Set
Set
Nos.
Set
Set
1
2
1
1
Set
Set
1
1
No.
No.
No.
No.
1
1
1
1
499
4.2.8
List Of Spares for Fuel & Ash Handling Plants

Item Description
No.
Fuel Handling Plant
1
Belt Conveyors
1.1
Idler Rollers for each belt width
1.1.1 Carrying
1.1.2 Impact
1.1.3 Return
1.2
Skirt Rubber
Unit
Quantity
Nos.
Nos.
Nos.
M
10
10
10
10
2.1
2.1.1
2.1.2
2.1.3
Ash Handling System

Belt Conveyors
Idler rollers for each belt width
Carrying
Impact
Return
Nos.
Nos.
Nos.
3
3
1
3
3.1
Screw Conveyor
Hanger bearing bush
Nos.
2.
500
4.3
LIST OF DRAWINGS & DOCUMENTS
4.3.1
General
All I.B.R. test certificates required to be submitted to the Boiler directorate/chief
inspector of Bihar and all approvals to be obtained by the Tenderer. It shall be
the responsibility of the Tenderer to provide all necessary information /
documentation / follow up and arrange inspection of the Boiler Inspector. The
responsibility of the steam generator Tenderer regarding IBR shall be only to be
completed after handing over of P.O. and steam (Safety Valve) test certificate
from the Boiler Inspector, along with required documents & drawings.
Single line drawing to be provided by Tenderer will inter-alia include: 3 element
drum level control, de-aerator level and pressure control, furnace draft control,
steam temperature control etc. Tenderer will provide P & I drawings for feedwater system, de-aerator cum storage tank, blow-down tank, combustion control,
LP & HP dosing, sample coolers arrangement, steam line, air line, fuel feeding,
GA, plot plan, etc. Detailed list of drawings for information / approval to be
freeze during kick-off meeting.
All the drawings shall be approved and vetted by the Owner /their Consultants.
All drawings which are to be approved and finally approved drawings,
instruction and maintenance manuals of all equipments and other details will be
handed over as under before commissioning.
(a)
6 sets for the Owner including soft copy on CD.
(b)
2 sets for the consultants to the Owner including soft copy on CD.
The Tenderer shall submit all major drawings for approval, as well as a
drawing list from which the Owner/Consultant will select those drawings which
they consider necessary for completion of drawing approval. Before starting
manufacturing of the equipment, the Tenderer shall have to take approval of the
design drawings from the Owner/Consultant. Any manufacturing done prior to
approval of the drawings shall be rectified in accordance with approved
drawings by the Tenderer at his own cost, if any discrepancy arises and the
equipment shall be supplied within stipulated period.
501
General Arrangement drawing shall be submitted for approval to the

Owner/Consultant prior to the commencement of detailed engineering by the
Tenderer. These drawings shall show to scale, location and size of building
facility and all major equipment including electrical. Equipment and building
outlines and overall dimensions as well as tie-in dimensions and clearances shall
be clearly indicated.
The Tenderer will be required to furnish all the necessary drawings data, etc. of
the plant/equipment with appropriate status stamp in adequate number of
copies as indicated below.
Sr.
No
1.
2.
3.
6
7
Status
of
the
drawing/ document
etc.
Reference/informati
on
For approval
Final & certified
duly signed
No. of copies for No. of copies for

Owner
Consultant
2 prints
2 prints
4 prints & 1
reproducible
tracing/ sepia &
soft copy in CD
& 3 copies + CD
Operation
maintenance
manual
Performance
& 2 copies
acceptance
test
procedure
All other documents 3 copies
As built drawings 3 copies
for the entire project
2 prints
3 prints
2 prints
1 CD
2 copies
2 copies
1 copy
Within a period of ten (10) days after the receipt of those drawings/document,
the Owner/Consultant shall signify his approval or otherwise. The Tenderer
shall submit copies of all drawings which are required to be approved by the
Owner/Consultant. The drawings which are approved by the
Owner/Consultant shall not be deviated from.
502
The drawings submitted by the Tenderer for approval shall contain all
information regarding the manner in which equipment is going to be located and
all the loading data for the Owner/Consultant to design suitable civil
foundation. The drawing should show details of piping and electrical
connections to be made by the Owner/Consultant for connecting the Tenderers
equipment in the system.
The operating & maintenance instruction and the erection procedures together
with drawings of the equipment as completed shall be in sufficient detail to
enable to Owner to properly erect/install the equipment, to maintain, dismantle,
reassemble and adjust all parts of the equipment.
The manuals shall give stop-to-step procedures for all operations likely to be
carried out during the life of the plant/equipment including during erection,
commissioning, testing, operation & maintenance, dismantling and repair.
The manuals shall also contain copies of approved drawings as well as the
performance/rating curves and copies of test certificates, if applicable. The
maintenance instructions shall include the lubrication procedures, periodicity of
lubrication as well as the brands of Indian lubricants to be used to ensure trouble
free operation.
Indicative list of drawings to be submitted are given below. The final list
including classification for information / approval will be freezed during the
kick-off meeting. Apart from the below list, overall plant GA, overall electrical
SLD, fire fighting scheme, integrated plant piping, chimney height & diameter
calculations, P & IDs for raw water, treated water, compressed air & cooling
water, design basis of all civil structures, design of main boiler steel columns, etc.
will be submitted for approval.
503
4.3.2
Tentative list of Drawings / documents to be submitted for steam generator

Sr. No.
1)
2)
3)
Item
P & I Diagram Steam and water system
P & I Diagram Plant steam system
P & I Diagram De-aerator, FWPS & Dosing System
4)
5)
P & I Diagram Air & Flue gas system

P & I Diagram for HP Heater
6)
7)
8)
9)
Boiler performance data sheet

Sizing Calculation for Boiler feed pump (for both capacity &
head)
Sizing Calculation for Boiler feed water transfer pump
Main steam line pressure drop calculation
10)
11)
12)
13)
Piping line list

Thermal insulation schedule (for piping & boiler)
Valve Schedule
Technical specifications for FD Fan
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
30)
31)
Technical specifications for SA Fan

Technical specifications for ID Fan
Technical specifications for Boiler feed pump
Technical specifications for Boiler feed water transfer pump
Technical specifications for ESP
Technical specifications for Soot Blowers
Technical specifications for CBD valve
Technical specifications for IBD valve
Technical specifications for Boiler safety valve ( Drum & SH)
HP dosing system
LP dosing system
Control valve Data Sheet
Gate, Globe, Check valves
Drum level gauge
GA Plan (Combined with elevation)
Main foundation Drawing
Auxiliary foundation Drawing
Terminal point drawing
504
Sr. No.
32)
33)
34)
35)
36)
37)
38)
39)
40)
41)
42)
43)
44)
45)
46)
47)
48)
Item
Design basis for boiler structural
De-aerator Assembly
General Arrangement Drawing of Piping
EQUIPMENT GA DRAWING
a) ESP with loading data
b) FD Fan
c) SA Fan
d) ID Fan
e) LRSB
f) Rotary Feeders
g) Boiler feed pump
h) Feed water transfer pump
i) De-aerator
j) Feed water tank
k) CBD tank
l) IBD tank
ELECTRICAL & INSTRUMENTATION
Single line diagram of boiler
Single line diagram of ESP feeders
Power & Control wiring for different types of feeders
Cable tray & trench layout for the boiler
Cable tray & trench layout for the ESP system
Earthing layout drawing for the complete equipment in scope
MCC Panel Specification
GA, schematic and wiring diagrams of VFD panels
Logic diagrams for drives
Control schematics
Hook up drawings
Logic diagrams for soot blower system
49)
50)
51)
52)
53)
54)
Instrument cable tray routing drawing

Electrical load list
Cable schedule
Instrument schedule (List only)
DCS I/O list
Alarm set point list
505
4.3.3
Sr. No.
55)
56)
57)
58)
59)
60)
61)
62)
63)
64)
65)
Item
Write up for control schematics
JB schedule
Sizing calculations for flow elements
Motorized Valve Data Sheet.
Actuator specs
Instrument erection hardware details
Flow elements
Contract co-ordination procedure
L2 Schedule
Milestone activities
Utility Requirement data
66)
67)
Specification for Motorized valves

Electrical Motor Selection
Tentative list of drawings / documents to be submitted for Steam turbine

generator.
Sr. No.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
Item
Specification For Control Valves
Specification For Safety & Thermal Relief Valves
BOM For Lube Oil System
P&I Diagram For Lube Oil System
GA With Foundation Plan For Lube Oil System
GA Drawing For Duplex Lube Oil Cooler
GA Drawing For OHT
No-Load Mechanical Running Procedure
Technical Specification For Steam Turbine
Rust Prevention And Painting Procedure
Test & Inspection Procedure
Instrument List Of TG Auxiliaries
Specification For CEP
Allowable Nozzle Force And Moment
P&I Diagram For Steam Line
P&I Diagram For Oil Line
Layout
506
Sr. No.
18)
19)
20)
21)
22)
23)
24)
4.3.4
Item
P&ID For Vibration And Temperature Monitoring
Generator Data Sheet
Steam Flow V/S. Power Curves
Specifications, GA & SLD Of AVR Panel And Breaker Cum
Relay & Metering Panel
Specifications, GA & SLD Of Battery Charger Cum DCDB
Overall GA
Powerhouse Plans
Tentative Drawings / documents to be submitted for Fuel & ash handling

Sr. No.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Item
Material of construction for all components
Make, type and details for bought out items
Overall assembly drawings for the equipment
Layout for the handling system
Equipment Size / Power / Belt Selection Calculation
Overall assembly drawing showing the drive arrangement, etc.
for each equipment
Calculations for the select structure
Copy of material certificates/ inspection reports
Logic diagram / wiring diagram
Layout drawings for the total fuel & ash handling system and
for the equipment supplied
507
4.3.5
Drawings and documentations for Electrical evacuation

The drawings and documents to be furnished by the select vender shall include
but not limited to the following
Sr.
No.
I
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Item
General
Detailed bar chart for the design, manufacture, delivery,
erection, testing and commissioning period with critical
milestone activities
Duly filled technical data sheets
Single line diagram for the complete system, including 110 V,
DC power distribution system
Proposed hook-up arrangement drawings for plant, with
layout plan and sections
Physical installation layout of the complete plant, to show all
electrical equipment in scope
Earthing layout for the Cogen plant
Earthing connection details
Earthing sizing calculations
Lightning protection calculations, for the buildings and
structures
Cable schedule and inter connection chart for complete
cabling in scope
Cable tray / trench layout drawings, duly marking all the
cables with identification details
Cable tray and support arrangement drawings
Relay co-ordination chart and calculations for the complete
equipment and systems in scope
GA drawings, catalogues and wiring diagrams, as applicable,
for the items like capacitor banks, lighting fittings, lighting
poles, junction boxes, receptacles, lighting and small power
distribution boards, safety appliances, etc.
Any other drawings / details, as required for CEIG and other
statutory authorities
Quality Assurance Plan
List of manufacturers and specifications of all standard
equipment
Approval of
Category
Approval
Approval
Approval
Approval
Information
Approval
Approval
Approval
Approval
Approval
Approval
Information
Approval
Information
Information
Approval
Approval
508
Sr.
No.
18.
19.
20.
II
1.
2.
3.
4.
5.
III
1.
Item
Test certificates and inspection reports of all equipment
Erection manuals and installation procedures for all
equipment
Operation and maintenance manuals for all equipment and
systems
As-Built drawings
Switchyard Equipment
Layout, with plan and sections for switchyards at plant end
and sub-station end
Dimensional General Arrangement Drawings, wiring
diagrams, name plate details, terminal details, cable box /
bushing details and drawings, for all equipment in
switchyard
Design calculations for the following
- Equipment supports and structures
- CT, PT burden calculation
- Earth mat design calculations
- Lighting calculation, for switchyard illumination
- Bus bar sizing calculation
- Support structure design calculations
- Bus support insulator cantilever strength calculation
- Switchyard lightning protection calculations
Construction drawings to include
- Equipment supports / load data
- Switchyard foundation arrangements
- Transformer foundation arrangement drawings
- Cable trench and tray drawings
- Oil soak pit drawings
- Oil drain arrangement drawings
- Details of equipment earthing
- Structure drawings
Junction box / marshaling box details
Transformers
General out line drawing, showing front side elevations and
plan views of the transformer and all accessories and
external features with detailed dimensions, weights, crane lift
for untanking and for erection / removal of bushings, size of
lifting lugs and pulling eyes, HV and LV terminal clearances,
Approval of
Category
Information
Information
Information
Information
Approval
Approval
Approval
Information
Information
Approval
509
Sr.
No.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
IV
1.
2.
3.
4.
5.
6.
Item
live terminal to ground clearance, quantity of insulating oil,
dimensional details for foundation
Assembly drawings of HV, LV and Neutral groundings
Schematic control and wiring drawings and drawings
showing temperature indicator circuits and control system
for cooling equipment
Drawing showing construction and mounting details of
marshalling box
Drawing, giving details of name plate, terminal marking and
connection diagram
Drawing on tap changer gear assembly
Remote tap changer control panel
Remote tap changer control circuit
The magnetization characteristic curves of the bushing
current transformers, indicating the knee point voltage
excitation current and secondary resistance
Drawing on terminal clamps
Core saturation curves
Final drawings shall be supplied for the transformer,
sufficiently before the actual dispatch of the equipment
All bulletins, complete instruction manuals for the erection,
operation and maintenance of the transformer are to be
supplied before they are dispatched
11KV and LT switchgear panels and VFDs
Design calculations for bus bars for short circuit and and
temp rise
Connection diagram for all units (like incomer, outgoing
feeders, breaker wiring diagrams, starter wiring diagrams,
etc.)
Schematic diagram for the complete switch board
Terminal connection diagram of the main terminal boards
Sketches of the overall dimensions of the board / bus duct
Plan, elevation and section views clearly showing the bus
size
Typical internal arrangement drawings for all types of
feeders, showing clearly the dimensions of components /
devices and clearances
Approval of
Category
Information
Information
Information
Approval
Information
Information
Information
Information
Information
Information
Information
Information
Approval
Information
Approval
Information
Approval
Information
510
Sr.
No.
7.
8.
9.
V
1.
2.
3.
4.
VI
1.
2.
Item
Brand names of all components incorporated like, circuit
breakers, relays, contactors, pilot device, pilot lamps, current
transformers, HRC fuse fittings / links, terminal blocks,
wirings, cable sockets, meters, selector switches for
instruments, instrument fuse fittings / links etc.
Guaranteed technical particulars for the critical components
Certificates of tests giving the results of tests conducted as
per the appropriate standards on similar switchboard and
interior components
Bus ducts
General arrangement and routing drawings to show the
support arrangements
Cross section of the bus duct, to show bus bar support
details, space heaters, breathers, flexible, joints, bends,
bellows, seal off bushings, etc.
Calculations for sizing and temp rise
Type test certificates
Protection, Metering and Control Panels
General arrangement drawings showing front, rear and side
views, inter connection and wiring diagram as well as other
drawings which may be deemed necessary by the Owner.
Approval of the GA drawing is required before the
fabrication of panel starts. Approval of wiring and inter
connection drawings is required before the manufacturer
proceeds with the panel wiring
The following drawings, dimensioned and drawn to scale :
- Layouts of front and rear cubicles complete with
identification markings for all mounted devices and
complete list
- General construction showing section views, details and
framing
- The above drawings shall incorporate the following details :
- Power and control systems run ways
- Outline including shipping dimensions
- Mounting holes
- Foundation details
- Sufficient details to demonstrate accessibility of equipment
for operation and maintenance
Approval of
Category
Information
Information
Information
Approval
Approval
Information
Approval
Information
511
Sr.
No.
3.
4.
5.
6.
7.
8.
VII
1.
2.
3.
VIII
1.
2.
3.
4.
Item
- Details of emblems, escutcheon and name plates (with
exact lettering)
- Panel cutouts
- Total weight of each panel section
- Size and location of ground bus
- Location and size of internal lights, heaters, etc. maximum
load (kW)
Bill of material shall correlate components to outline
drawings and diagrams. Components may be identified by
the manufacturer and his catalogue numbers
Each device designation correlated to outline and wiring
diagrams. Contact development diagrams of control,
selector, etc., switches push buttons
Following schematic & wiring diagrams shall be furnished :
- Each type of device internal wiring diagram
Control power supply circuit voltage and source requirement
for un-interruptible or interruptible. Each control circuit
breaker size and trip rating. Control supply one line
diagrams (AC, DC and un-interruptible AC)
Cubicle internal connection wiring diagrams shall show
identification of devices, terminals and connecting wires
Interconnection schedule, to show clearly any connections to
be made in field (because of shipping sectionalizing)
DC System
GA and wiring diagrams of Battery Charger
Battery sizing calculations
Dimensional details of battery banks
Illumination System
Lighting layout to show main lighting distribution board,
lighting transformers, sub distribution boards, MCB
distribution boards and lighting fittings with identification
numbers
Single line diagram with identification details for all lighting
fittings
Lighting calculations for the complete system
Typical drawings for poles, towers and other mounting
arrangements
Approval of
Category
Approval
Information
Approval
Approval
Approval
Information
Approval
Approval
Approval
Approval
Information
Approval
Approval
512
CHAPTER - 5
DATA SHEETS
5.1
STEAM GENERATOR & AUXILIARIES

Sr. no.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Parameters
Value
M.C.R with 100% bagasse (TPH)

Capacity with biomass(TPH)
Pressure at turbine inlet valve kg/cm2
Temperature at turbine inlet valve
Pr. at boiler MSSV
Temp. at boiler MSSV
Feed water temperature at deaerator inlet 0C
(minimum) (required minimum of 45C)
Feed water temperature at deaerator outlet 0C
Feed water temperature at eco inlet / HP heater no.2
outlet 0C
Excess air % theoretical air (maximum)
Temperature of flue gases at the boiler outlet with
100% MCR on bagasse
Steam generator thermal efficiency on bagasse &
biomass
Bagasse consumption at MCR condition, kgs/kg
Auxiliary power consumption, KW at 100% MCR
with bagasse
Steam Drum
Material Specification
ID mm
Plate thickness mm
Length mm
Holding capacity m3
Furnace Water Wall tubes
Tube OD mm
Thickness mm
Pitch mm
Material specification
Heat transfer area m2
513
Sr. no.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
Parameters
Value
Boiler Bank Tubes

Arrangement
Tube OD mm
Material
Heating surface m2
Boiler headers
Diameter OD mm
Thickness mm
Material specifications
Superheaters
Type of superheater arrangement
Location of superheater
Superheater elements OD
Superheater elements thickness
Material
Heat transfer area
Type of attemperation
No. of stages
Turndown ratio
Furnace (effective)
Length of furnaces
Width of furnaces
Furnace area
Heat release rate
Material of grate bars
Economiser
OD of coil tube
Thickness of coil tube
Heating surface
Precautions for erosion
Air Preheater
Air preheater tube dia
Air preheater tube thickness
Tube material specification
Total heating surface
Precautions for erosion
Provision of Corten Steel
514
Sr. no.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
Parameters
Total HTA (m2)
Pressure parts (effective)
HRU
Fans technical parameters
Nos. of fans per steam generator nos.
Capacity of the fan cu.m/sec(each)
At MCR kW(each motor)
Recommended drive motor kW
Electrical driven FWP
Nos. of pumps
Capacity
Head
Drive power kW
Deaerator Flow rate(m3/hr)
Deaerator storage tank (m3 )
ESP
Inlet dust concentration
Gas flow
Outlet dust concentration
No. of fields
VFD for fans
VFD for fuel feeders
Gas Velocity
- Furnace
- Boiler bank
- Superheater
- Economiser
- Airpreheater
- ESP
No. & type of soot blowers
Pressure & temperature of steam to soot blowers
Capacity of bagasse silo
Inclusion of SWAS
Hot / cold ducting thickness
Hot air / flue / cold air velocity, m/sec
Inclusion of blow down flash recovery
Aluminium cladding thickness
Value
ID
FD
SA
515
Sr. no.
101.
102.
103.
104.
5.2
Parameters
Value
Inclusion of steam flow meter

Inclusion of cinder re-injection
Make of travelling grate
Inclusion of performance test as per ASME PTC 4.1,
indirect method
STEAM TURBINE GENERATOR & AUXILIARIES

Sr. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Parameters
Capacity, KW
Inlet steam parameters, kg/cm2 , Deg C
Steam flow to condenser in season to generate 20
MW at given steam flows to process in this tender
HBD, TPH
Specific steam flow in off-season to generate 20
MW, kg/kW
No. Of Bleeds (Uncontrolled extraction)
No. Of Pass out (internally controlled extraction.)
Electronic over-speed trip.
No. of nozzle control valves
Make and model of governor.
Pneumatically operated quick acting Non-return
valve for
a) Bleed lines
b) Controlled extraction line
Gland sealing system.
No. of steam vent fans in gland condenser.
Flash vessel for drain.
Lagging and cladding.
Temperature monitoring system.
a) All bearings (Turbine, Gear box, and Generator)
Nos.
b) Turbine casing Nos.
Make & model of vibration monitoring system.
Non-contact type vibration transducers for each
bearing.
Value
516
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Displacement transducer
- Turbine thrust bearing (Dual Type)
- Turbine casing expansion.
High speed coupling type.
Provision of coupling guard.
Type of gear box and service factor
Gear Box input /output speed
Gear ratio.
Type of main oil pump.
Barring arrangement.
Motor rating.
Type of coupling.
Auto engagement and disengagement provision.
Facility for manual barring.
Low speed coupling type.
Provision of coupling guard.
Inclusion of MOP
Inclusion of AOP
Inclusion of EOP
Oil cooler
- Nos.
- MOC
Oil reservoir capacity as holding time
Oil centrifuge system as % of total lube + control oil
Capacity of OH oil tank in terms of coasting down
time
Provision of Duplex oil filter (Lubricating)
Provision of Duplex oil cooler (Control)
Differential oil pressure switch / Alarm across filter
for lube / control).
No. of oil vapour extractor.
Alternator
Rating, KW
Voltage, KV
Speed, RPM
Class of insulation
Cooling
Efficiency at 100%, 80%, 60% capacity rating
Rated frequency
517
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
Power Factor.
Overload Capacity
Applicable Standard.
No. of bearings.
Insulation Class for Rotor, Stator and Exciter F
Temperature rise class B
Excitation system (Brush less with PMG)
Short circuit ratio.
Location of water cooler
Capacity of cooler (2 x 100%)
Provision of water leakage detector.
Provision of Rotor earth fault detector.
No. of RTDs.
- In stator (2 per phase min.)
- In cold air circuit (min 2)
- In warm air circuit (min 1)
- In each bearing (min 2 nos.)
Provision of modes in AVR.
No. of Auto modes (min 2)
No. of Manual mode (min 1)
Provision of rotating diode failure detector.
Metering Panel including amps, voltage, kw, kvar,
kva, kwh
Provision of TVM with output signal to monitor &
record all electrical parameters
NGR to restrict fault current to 100 A for 30 Sec.
LA and VT panel
Rating of station class lightening arrestor (10 kA, 12
kV)
Rating of station class surge capacitor (0.25 micro
farad, 11 kV)
Synchronization panel
Auto synchronizer
Details of temperature scanner
Make of auto synchronizer
Inclusion of external PRV, mating flange, pressure
& temperature gauge, flow transmitters, safety
valve, DSH and QCNRV for bleeds
518
73.
74.
5.3
Inclusion of QCNRV mating flange, pressure &

temperature gauge, flow transmitters and safety
valve for controlled extraction
No. of turbine stages
WATER TREATMENT PLANT & AUXILIARIES

Sr. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Parameters
Piping from raw water reservoir
Clarifier / Clarifloculator / tube settler
Inlet well, flash mixer, floculator etc.,
Dosing System
Dosing Tanks
Dosing Pumps
Plant Instrumentation
a)
Pressure gauges
b)
Measuring / metering devices
c)
Flow meters
d)
Water meters with totalliser
Any other miscellaneous instruments
e)
Clarified water pumps, capacity & head
Settled water tanks in 2 parts (Clarified water
storage tanks RCC)
Basket strainers for clarifier water pumps
All valves, fittings, piping etc.,
Pressure Filters
2 nos. multi-grade vertical pressure filters, as per
design, dished ends, air valve, pressure gauges,
media mounted on RCC saddles, piping, headers,
washing devices, delivery end, flange and sluice
valves for working pressure as required by
UFROMB unit and softener unit (minimum 40 M
head) and all piping (Epoxy / MS)
Activated carbon filters for UF RO + MB Unit
UFRO Unit 1 stream - capacity
Basket Filter MOC MSRL / SS
RO feed pumps
MOC SS 304
Mixed Bed Unit
Value
519
Sr. No.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
Parameters
Value
Degasser Tower
All internals exposed to vapour / gas should be
MSRL
Blower for degasser Nos.
Degasser Tank / Sump
Degasser Water Transfer Pump
No. of pumps
Acid Measuring Tank
MOC
No. of Blowers
Instrumentation
Conductivity meters
Flow meter
Pressure Gauges
Hydraulic ejectors
Morpholine / Hydrazine dosing tank
Metering pump
Softener Plant
Activated Carbon Filters (Softener)
MOC
Thickness of shell plate
Softeners
Flow rate m3 / hr
Average
MOC
MOC
Brine Measuring Tank
Filtered Water (Service Water) scheme
Specification of chemical storage & water storage
tanks
Hydrochloric Acid one tank
Level Indicator
MOC
Caustic Lye Tank
Cylindrical vertical tank with flat bottom and top
520
Sr. No.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
Parameters
end covers to hold 15 m3 of 50% caustic lye
Level Indicator
MOC
Storage Tank for DM water
MOC
Level Indicator
To provide float and scale device to increase the
quantity of water in the tank and level transmitter
with output to DCS
Storage Tank for Soft water
Level Indicator
MOC
Filtered water (service water) Tank
MOC
Level Indicator
Potable Water Storage Tank including chlorination
Specification of pumps General
Pumps for Hydrochloric acid, as per design
Pumps for raw water
Fire Hydrant Pumps
(As per relevant standards)
Header and other details as per relevant standards.
Clarified Water Transfer Pumps
DM water transfer pumps
Service water (filtered water transfer pumps)
Potable Water Pumps
Hydrochloric Acid & Caustic Lye
Value
521
5.4
COOLING TOWER
1.
2.
3.
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
Design
&
Operating
Conditions
:
Total tower capacity, m3/hr
:
No. of cooling towers, Nos
:
Cells per tower, Nos
:
Cells operating, Nos
:
Flow per cell, m3/hr
:
Type of tower
0
:
Hot/re-cooled water temp., C
:
Design inlet wet bulb temp
(without
recirculation
0
allowance), C
:
Tower operation
:
Type of water handled
Constructional features
:
:
Fan blade construction
:
Type of fill
:
Basin type
Cold water (outlet) temp. :
indicator
Duty conditions
Total design capacity
Flow per cell
Hot water inlet temperature
Re-cooled water temperature
Design inlet wet bulb temperature
Design approach
Total no. of cells/tower
Number of cells operating
m3/hr
M3/hr
Deg. C
Deg. C
Deg. C
Deg. C
522
5.5
FUEL & ASH HANDLING
5.5.1
Belt Conveyor (To be filled up for all conveyors)

S No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Description
Conveyor No
Conveyor Type
Profile Centers
Material handled
Bulk density
Capacity
Volumetric capacity
Belt Speed
C-C distance
Lift
Belt
Width
Material
Construction/Grade
Cover Grade
Factor of Safety
Gear Box
Type
Reduction Ratio
Service Factor
Coupling
Type
Head Pulley
Head Pulley D X L X T
Shaft Diameter
Rubber Lagging
Tail Pulley D X L X T
Take Up Pulley D X L X T
Idlers
Idler Classification
Unit
Value
TPH
Cu. m
/sec
m/sec
m
m
mm
mm
mm
mm
mm
mm
523
S No
16.
17.
18.
19.
20.
21.
22.
23.
24.
Description
Carrying Idler
Type
Pipe Dia / Length
Spacing
Idler Housing
Shaft diameter
Impact Idler /Transition Idlers
Type
Pipe Dia / Length
Spacing
Idler Housing
Shaft diameter
Rubber Rings Dia /Material
Return Idler
Type
Pipe Dia / Length
Spacing
Idler Housing
Shaft diameter
Take Up Type
Bearing Type / make
Belt Cleaners
Internal
External
Hold Backs / Brakes
Coasting Time
Skirt Board
Type / Location
Material Thickness
Rubber Skirt
Skirt Length
Deck Plate
Location
Material Thickness
Hood
Type
Hood plate thickness
Guide rollers
Unit
Value
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
Sec
524
S No
25.
26.
27.
28.
29.
30.
5.5.2
Description
Unit
Value
Unit
Value
Spacing
Conveyor Frame type
Short Support
Discharge chute
Plate Thickness
Drive Base Frame
Gallery
Walk-way
Safety Switches
Zero speed/ Pull Cord /Belt
Sway
Contact
Protection
Chain Conveyor
S No
Description
Conveyor No
Conveyor Type
Profile Centers
Material handled
Bulk density
Capacity
Volumetric capacity
Chain Speed
C-C distance
Lift
Chain
Pitch
Material
Roller Diameter
Pin Material & Diameter
Factor of Safety
Make
Gear Box
Make
TPH
Cu. m
/sec
m/sec
m
m
mm
mm
mm
525
S No
Description
Type
Reduction Ratio
Service Factor
Coupling
Type
Drive Sprocket
Diameter
No of teeth
Shaft Diameter
Non driven Sprocket
Diameter
No of teeth
Slats
Width
Thickness
Pitch
Take Up Type
Bearing Type / make
Hold Backs / Brakes
Coasting Time
Skirt Board
Type / Location
Material Thickness
Rubber Skirt
Skirt Length
Deck Plate
Location
Material Thickness
Hood
Type
Hood plate thickness
Conveyor Frame type
Short Support
Discharge chute
Plate Thickness
Drive Base Frame
Gallery
Unit
Value
mm
mm
mm
mm
mm
mm
mm
mm
mm
Sec
mm
mm
mm
mm
mm
526
S No
Description
Unit
Value
Unit
Value
Walk-way
Safety Switches
Zero speed
5.5.3
SUBMERGED BELT CONVEYOR

S No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Description
Conveyor No
Conveyor Type
Profile Centers
Material handled
Bulk density
Capacity
Volumetric capacity
Belt Speed
C-C distance
Lift
Belt
Width
Material
Construction/Grade
Cover Grade
Factor of Safety
Make
Gear Box
Make
Type
Reduction Ratio
Service Factor
Coupling
Type
Head Pulley
Head Pulley D X L X T
Shaft Diameter
Rubber Lagging
Tail Pulley D X L X T
TPH
Cu. m
/sec
m/sec
mtrs
mtrs
mm
mm
mm
mm
mm
527
S No
15.
Description
Shaft Diameter
Snub / Bend Pulley D X L X T
Shaft Diameter
Take Up Pulley D X L X T
Idlers
Idler Classification
Carrying Idler
Type
Pipe Dia / Length
Spacing
Idler Housing
Shaft dia
Impact Idler /Transition Idlers
Type
Pipe Dia / Length
Spacing
Idler Housing
Shaft diameter
Rubber Rings Dia /Material
Return Idler
Type
Pipe Dia / Length
Spacing
Idler Housing
Shaft diameter
Unit
mm
mm
mm
mm
mm
Value
mm
mm
mm
mm
mm
mm
mm
mm
mm
16.
17.
18.
19.
20.
21.
Take Up Type
Bearing Type / make
Belt Cleaners
Internal
External
Hold Backs / Brakes
Coasting Time
Skirt Board
Type / Location
Material Thickness
Sec
mm
528
S No
22.
23.
24.
25.
26.
27.
28.
29.
30.
5.5.4
Description
Rubber Skirt
Skirt Length
Deck Plate
Location
Material Thickness
Trough
Type
Size width X Length X Height
Guide rollers
Spacing
Conveyor Frame type
Short Support
Discharge chute
Plate Thickness
Drive Base Frame
Gallery
Walk-way
Safety Switches
Zero speed/ Pull Cord /Belt
Sway
Contact
Protection
Unit
Value
mm
mm
mmxmm
xmm
mm
mm
Screw Conveyor (To be filled up for all the screw conveyors)

S No
1.
2.
3.
4.
5.
6.
7.
8.
9.
Description
Conveyor No
Conveyor Type
Profile Centers
Material handled
Bulk density
Capacity
Volumetric capacity
Tip Speed
C-C distance
Unit
Value
TPH
Cu. m
/sec
m/sec
mtrs
529
S No
10.
11.
12.
13.
5.5.5
Description
Lift
Screw
Diameter
Pitch
Material of Construction
Gear Box
Make
Type
Reduction Ratio
Service Factor
Coupling
Type
Unit
mtrs
Value
mm
mm
Structural Steel Work (CONVEYOR GALLERIES)

Sr No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Description
Conveyor Galleries ( Conveyor
wise)
Overall Dimensions
Type of Gantry
Maximum slope on walkway
No of approaches per conveyor
Width of walkways / staircase
Head room
Provision of anti slip strips
Live load for platforms and
walkways
Dynamic load factor considered
for design
Cladding material
Handrails type
Toe plate size / thickness
Walk-way / platform grating type
Unit
Value
mmxmm
mm
530
5.6
EOT CRANE
Location
Power Supply
Control Voltage
Duty class / Spec.
Mechanism
Capacity (t)
Speed (m/min) - Main/Micro (VVVF)
No. of Falls
Diameter (mm)
Wire
Construction/Factor of safety
Rope
Type
Make
Bkg. Strength (T)
Qty.
Type
Frame size
Motor
Frame kW
Duty
No. of poles
Make
Brake
Qty.
Type
In Door (TG Building)
MAIN HOST
AUX. HOST
CROSS TRAVEL LONG TRAVEL
531
Make
Brake Size
Qty.
Size
Gear Box
Make
Ratio
Qty. Total / Driving
Thread Dia. (mm)
Rail Size
Wheel
Girder dimensions &
Construction
Max. Load (t)
Limit Switch (WMI)
Trolley Height (t)
Crane Weight (t)
Lubrication
532
5.7
ELECTRICAL EVACUATION
5.7.2
Distribution Transformer
a.
Rating (KVA)
2000 KVA
b
c.
d.
e.
f.
:
:
:
:
:
11 KV / 433 V
Dyn11
2Nos. 2000 KVA
ONAN
45 C
g.
Voltage ratio
Vector Group
Quantity
Type of cooling
Temp. rise over an ambient
of 50 C in oil by thermometer
Tapping on HV winding
7.5 % through off circuit

tap
changer in steps of 2.5 %
h.
i.
Ref. Standard
Winding connection
:
:
IS 2026 part I to IV
Dyn11
j.
Transformer losses
(max. value without positive
tolerance)
No load at Rated Voltage and :
Frequency
Load Losses at 75C and Rated :
Current at 0.8 p.f.
:
Impedance
k.
l.
2.5 KW
20 KW
>6.25 %
The various fittings for the transformer will be as below :

- Rating and diagram plate along with labels. wherever necessary
- Earthing terminals
- Lifting lugs for complete transformer
- Air release plug on tank cover
Dehydrating breather 0 1 No silica gel type with oil seal and
connecting pipe.
150 mm dial Magnetic type oil level indicator with one set of
contacts, for low oil level alarm - 1 No for the transformer
conservator
150 mm dial oil temperature indicator with maximum reading
pointer and electrically separate contacts for trip and alarm.
5.7.3
150 mm dial winding temperature indicator with maximum

reading point and electrically separate contacts for trip and alarm
Oil filling hope with cap, on conservator
Oil conservator with drain valve and plug
Drain valve with plug
Filter valve with plug
Sampling valves
Explosion vent with double diaphragm and pressure equalizer
pipe connection
Thermometer pocket
Double float type Buccholz Relay with two sets of contacts and
one shutoff valve on either side of the Buccholz Relay
Jacking lugs and hauling holes
Marshalling box with wiring according to our standard practice
Disconnection Chamber for H.V. Cable
Neutral CT for REF
Main Unit Transformer for cogeneration plant : 1 No.
a.
b.
c.
d.
e.
f.
g.
h.
Rating
Primary voltage
Secondary Voltage
Vector Group
Impedance
Frequency
Type of cooling
Application
:
:
:
:
:
:
:
:
i.
j.
Duty
Tapping
:
:
k.
Terminal arrangement
HV Terminal
LV Terminal
:
:
Ref. Standard and
l.
20/25MVA
11 KV
132 KV
YNd1
10% on basis of 20MVA
50 Hz
ONAN / ONAF
Generator transformer used for
power export to grid at 132KV
system
100 % continuous
OLTC with RTCC and AVR
Panel with tap range of + 10%
to 10% in steps of 1.25 %
Suitability for Bi-directional
power flow required.
Bushing
Cable box suitable for XLPE
cables
IS 2026 part I to IV
534
j.
m.
Basic Insulation level to

BIL 650 KVp
be considered
Transformer losses at
25 MVA ONAF rating
(max.
value
without
positive tolerance)
20KW
No load at Rated Voltage :
and Frequency
Load Losses at 75C and :
110KW
Rated Current at 0.8 p.f.
:
Aux. Losses in ONAF
3KW
The various fittings for the transformer will be as below :
- Rating and diagram plate along with labels. wherever necessary
- Earthing terminals
- Lifting lugs for complete transformer
- Air release plug on tank cover
Dehydrating breather 0 1 No silica gel type with oil seal and
connecting pipe.
150 mm dial Magnetic type oil level indicator with one set of
contacts, for low oil level alarm - 1 No for the transformer
conservator
150 mm dial oil temperature indicator with maximum reading
pointer and electrically separate contacts for trip and alarm.
150 mm dial winding temperature indicator with maximum
reading point and electrically separate contacts for trip and alarm
- Oil filling hope with cap, on conservator
- Oil conservator with drain valve and plug
- Drain valve with plug
- Filter valve with plug
- Sampling valves
- Explosion vent with double diaphragm and pressure equalizer
pipe connection
- Thermometer pocket
- Double float type Buccholz Relay with two sets of contacts and
one shutoff valve on either side of the Buccholz Relay
- Jacking lugs and hauling holes
- Marshalling box with wiring according to our standard practice
- Disconnection Chamber for L.V. Cable
- 2 Core Neutral CT for Stand by Earth Fault and REF
protection
535
i.
132 KV Switchyard equipments :

a)
132 KV Isolators
a. Type
b. Quantity
c.
d.
e.
f.
g.
h.
:
:
:
:
:
:
Rated Voltage
Highest system voltage
Fault level
Continuous Rating
No. of Poles
Material of Moving
silver plated Contact
i. Auxiliary Contacts
j. Control Supply
k. Type test certificate:
l. Type of Mounting
:
:
:
:
m. Creepage Distance
Motorised,
Horizontal
Centre Rotated,
Double Break, Out
Door type
1 No. with Earth
Switch 2 Nos.
without Earth
Switch
132 KV
145 KV
40KA for 3sec.
1250 A
3
Copper tinned /
6 No + 6 NC
110V DC
To be furnished
On fabricated
outdoor Structure
31 mm/KV
536
b)
c)
132 KV Lightning Arrestor

a. Type
b.
c.
d.
e.
f.
g.
h.
i.
:
:
:
:
:
:
:
:
Quantity
Rated Voltage
Nominal discharge current
Fault level of system
Discharge Class
Surge Counter
Type test certificate
Creepage Distance
Station Type, Out

door
2 sets
120 KV
10 KA
40 KA for 1sec.
3
Required
Required.
31 mm/KV
145 KV SF 6 Circuit Breakers

1.0
Functional requirements :
1.1
Reference Standards
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Type
Installation
Nominal system Voltage
Highest system Voltage
Basic Insulation Level
Cont. Current Rating
System Earthing
Type of operation
1.10
1.11
1.12
a. IS 2516 Specifications of
Outdoor
Circuit Breakers
b. IEC 56 Specifications of
Outdoor
Circuit Breakers
SF 6 Gas insulated
Outdoor
132 KV (rms), 3 Ph., 50 Hz.
145 KV (rms)
650 KVp
1250 Amps.
Neutral solidly earthed
Three single poles gang
Operated.
Rated
Operating
Duty 0 - 0.3 sec - CO - 3 min. - CO
cycle
as per IEC 56
Maximum Closing time
150 m sec
Maximum Breaking time
at rated breaking capacity 60 m sec.
537
1.13
1.18
One min. Power Frequency

withstand Voltage
1.2/50 micro sec Impulse
Test Voltage
Short Circuit Current for
3 secs.
Maximum
permissible
temperature
Minimum Clearances
in
air
Mounting
2.0
2.1
Other Particulars :
Mechanism
1.14
1.15
1.16
1.17
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
275 KV
650KVp
40 KA.
90C
As
per
Manufacturers
design
On GI structure supplied
by CB manufacturer.
Motor
Charged
spring
Operating mechanism
Mechanism housing
Weather proof
enclosure
with IP 55 construction as
per IS 2147
Porcelain Housing
Single
piece, vitreous,
homogeneous
porcelain
material
having creepage
distance of 31mm/KV.
Termination
Incoming
and
outgoing
terminal pads shall have
max current density of 1.6
A/sq. mm
Control voltages
110 V D.C. for breaker
closing, opening and spring
charging motor.
Voltage Tolerances for
85% to 110% of
rated
closing coil
control voltage
Voltage Tolerances for
70% to 110% of rated
Tripping coil
control voltage
Aux. Contacts
Min. 10 NO + 10 NC aux.
Contacts with contact rating
of 10Amp.
Control
/
indications a. Local Remote Selector
required
Switch
538
3.0
d)
b. Manually
Operated
Emergency Trip
Push
Button
c. Anti Pumping device
d. Mechanical indication of
Breaker ON
e. Mechanical indication of
Breaker OFF
f. Operation Counter
1 No.
Quantity
132 KV Current Transformers

1.0
1.1
Functional
requirements :
Reference Standards
1.2
Type
1.3
1.4
Installation
Nominal
Voltage
for
3 sec.
System Earthing
Core applications
Core Details
C.T. Ratio
Rated cont. Terminal
current
1.5
1.6
1.7
1.8
1.9
1.10
1.11
a.
IS 2705 Specifications of
Current
Transformers
b. IS 2099 Specifications of
Bushings
for
voltages
above 10 KV
c. IS 3347 Specifications for
porcelain
transformer
bushings
Single phase, Dead Tank, Oil
filled
and
Hermetically
sealed
Outdoor
system 132 KV (rms), 3 Ph., 50 Hz.
145 KV (rms)
650 KVp
Solidly Earthed system.

As given in SLD
As given in SLD
As given in SLD
400 Amps on primary and
10 Amp on secondary side.
539
1.12
1.13
1.14
1.15
1.16
1.17
1.18
e)
One
min.
Power
Frequency
withstand
Voltage
Test Voltage
Short Circuit
Current
for
1 sec.
Maximum
permissible
temperature
Creep age distance
Mounting
Quantity
275 KV rms
650KVp
40 KA.
90C
31mm /KV
On GI structural support.
3 Nos. - 5 core in 20/25MVA
Trafo. bay
3 Nos. - 1 core in Switchyard
Incoming
bay for check
Metering
Incoming
bay for tariff
metering
132 KV Potential Transformer

1.0
1.1
Functional
requirements :
Reference Standards
1.2
Type
1.3
1.4
Installation
Nominal
Voltage
a. IS 3156 Specifications of
Potential Transformers
b. IS 2099 Specifications of
Bushings
for
voltages
above 10 KV
c. IS 3347 Specifications for
porcelain
transformer
bushings
Single phase, Oil filled and
Hermetically sealed
Outdoor
system 132 KV (rms), 3 Ph., 50 Hz.
540
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18

for
3 sec.
System Earthing
Core applications
Core Details
P.T. Ratio
Rated Voltage Factor
One
min.
Power
Frequency
withstand
Voltage
Test Voltage
Short Circuit
Current
for
1 sec.
Maximum
permissible
temperature
Cree page distance
Mounting
Sec. Terminal
Box
Details
1.19
Primary connection
1.20
Quantity
145KV (rms)
650 KVp
Solidly Earthed system.

As given in SLD
As given in SLD
132KV/V3/110V / V3
1.9 for 30 sec.
275 KV rms
for primary
winding
2 KV for secondary side.
650KVp
40 KA.
90C
31 mm per kV
On GI structural support.
Weather proof terminal box
with
H.R.C.
Fuses
and
removable glad cover.
Neutral end
of
primary
winding shall be connected
to earth through removable
link.
3 Nos.
3 core
in
20/25MVA Trafo. bay
Incoming
bay for check
metering
Incoming
bay for Tariff
metering
541
5.7.4
Busbar Trunking Sr.

No.
1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
2.6
3
3.1
5.7.5
Particulars
General
Location Indoor/Outdoor
Reference Ambient Temperature
Climatic Conditions
Power System
A) Voltage, Phase, Wire,
Frequency
B) Short Circuit Level
C) Neutral Earthing
Type of Bus Duct
Bus Bars
Material
Rated Voltage and Continuous
Current
Short Time Current & Duration
Dynamic Current Rating
Air Clearance
A) Phase To Phase
B) Phase To Earth
Insulator Creep age Distance
Enclosure
Degree Of Protection Provided
Specific Data
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
L.T. Panels:
1.0
1.1
1.2
1.3
1.4
1.5
Switchgear Cubicle & Busbars

Type of switchgear
Rated Voltage and Frequency
P.F. withstand Capacity for
1min.
Short
Circuit
Withstand
:
:
:
:
:
542
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
Design Ambient. Temp.

Cont. Current
Rating
of
Busbar
Max. Temp. at cont. Operating
Current
Applicable Standard
Doors, Removable
covers,
Partitions
:
:
:
:
:
:
:
:
:
5.7.6 L. T. Capacitors
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
Designation
Quantity and Output In KVAR
Rated Voltage
Ref. Standard
Upper Limit of Temperature
Category as per IS:2834
Location of Capacitors
Connection and Switching
Device
through FSU and Contactors
Size And Material Of Earth Bus
Air Clearances for Live Parts
Phase-Phase
Phase-Earth
Type Of Dielectric Material
:
:
:
:
:
:
:
:
:
:
:
543
5.7.7

1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7

Type of switchgear
Metal Clad, Indoor, Draw
out type
Rated
Voltage
and 11KV, 3Ph., 50 Hz.
Frequency
12 KV, Indoor switchgear
P.F. withstand Capacity for 28KV (r.m.s.) for 11KV,
1min.
2.5 KV for 415 Volts
Impulse Withstand Voltage
75 KV peak
Short
Circuit Withstand
40 KA for 3 sec.
Design Amb. Temp.
50 C
Cont. Current Rating of 2000 Amp.
Busbar
Max. Temp.
at
cont.
Operating Current
As per IEC 694
Applicable Standard
As per IS 13118
CRCA sheet steel
10 SWG
Doors, Removable
covers, 14 SWG
Partitions
IP 4X as per IS 2147
Color of Finish shade
Light Gray Semi glossy
finish as per Shade 631 of
IS 5 for Exterior and
Brilliant White finish for
interior
Bus bar Material
Electrolytic
Aluminum
with
Heat
Shrinkable
Sleeves
Earthing Bus bar Material
Copper
Flat 50 x 6 mm
min or Equiv. Al.
Minimum Clearance in Air
150 mm between phases
80 mm between phase and
earth
544
2.8
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
4.0
4.1
4.2
4.3
4.4
4.5
5.0
5.1
5.2
Cable Entry
Circuit Breaker Details
Type
Rated Operating Duty
Rated Current at amb. Temp.
Bottom
Vacuum Circuit Breaker

0-3min.- CO - 3min - CO
As per feeder details
given
Rated Breaking Capacity
40KA for 3 sec.
Rated Making Capacity
100KAp
Total Opening Time
2.5 to 3 cycles
Total Closing Time
3 to 3.5 cycles
Type
of
operating a.
Motorized
spring
mechanism
charging mechanism
with
mechanical trip
facility
b. Trip free
and
anti
pumping mechanism
Required.
Min. No.
of
auxiliary 4No + 4 NC for Owners
contacts
use.
110V, D.C. for Closing
Auxiliary Control Voltage
tripping, protection
and
indication circuit
230 V, A.C. for Spring
Charging motor and space
heater circuits.
Current Transformers
Type
Cast Resin
Class of insulation
Class 'E' or better
Winding Material
Copper
Accuracy Class
Class 0.5 for metering
Class 5P10 for protection
and
Class PS
for
diff.
Protection
Applicable Standard
IS 2705
Voltage Transformers
Type
Single phase , Cast Resin
Rated Voltage
11000 V / V3 for Primary
and
110 V / V3 for secondary
545
5.3
5.4
5.5
5.6
5.7
5.6
6.0
5.7.8
Star / Star
As per SLD
Class 1
1.2 Cont. / 1.9 for 30 Sec
Class 'E' or better
IS 3156
in As per SLD
Data Sheet for Air Circuit Breaker

1)
2)
3)
4)
5)
6)
7)
8)
5.7.9
Connection
Burden
Accuracy Class
Rated Voltage Factor
Class of insulation
Applicable Standard
Feeder
Details
Switchboard
Type
Make
Rated Voltage
Rated frequency
One second short time current rating
Momentary current rating
Maximum temperature rise over ambient
temperature
Type of Tripping mechanism
:
:
:
:
:
:
:
:
Data Sheet for Indicating Instruments
1)
2)
3)
4)
5)
VOLTMETER
Make
Type
Standard applicable
Accuracy Class
Voltage coil burden
:
:
:
:
:
1)
2)
3)
4)
5)
AMMETER
Make
Type
Applicable standard
Accuracy Class
Current coil burden
:
:
:
:
:
546
1)
2)
3)
4)
1)
2)
3)
1)
2)
3)
4)
1)
2)
3)
4)
5)
6)
1)
2)
3)
4)
5)
1)
2)
3)
4)
1)
2)
3)
WATTMETERS
Make
Type
Applicable standard
Current coil burden
POWER FACTOR METER
Make
Type
Applicable standard
PROTECTIVE RELAYS
Make
Type
Applicable standard
Burden
CONTACTORS
Type
Make
No. of poles
Aux Contacts
Coil Voltage
Class of insulation of coil
OVERLOAD RELAYS
Type
Make
Setting range
Voltage rating
Burden
PUSH BUTTONS
Make
Type
Number of Contacts
Contact rating
INDICATING LAMP
Make
Type
Voltage
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
547
5.7.10
Battery / Battery Charger

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
5.7.11
Type
Make
Applicable Standard
DC system voltage
Rated Voltage
Capacity
Rated Current
Expected life
Floating charge voltage
Floating charge current
:
:
:
:
:
:
:
:
:
:
Lighting Fixtures
1)
2)
3)
4)
5)
6)
7)
8)
Type
Make
Applicable Standard
Rating
Type of Reflector
Type of Filament
Type of Control Gear
Accessories
:
:
:
:
:
:
:
:
5.7.12 Lighting Poles

1)
2)
3)
4)
5)
Type
Make
Dimension Height Diameter Size of
base plate
Applicable Standard
Accessories
:
:
:
:
:
548
5.8 DCS
Particulars
Sr. No.
1.
Scan time for critical loops
2.
Scan time for non-critical loops
3.
Future expandability
4.
Communication from CPU to OS
5.
Communication from CPU to Cards
6.
Engineering Workstation
7.
Operator Workstation
8.
Online UPS parallel, redundant

configuration with 30 min back-up
9.
Printers
10.
LAN & Accessories
11.
Controller subsystem
12.
System Cabinet
13.
SOE System
14.
Type of network
15.
Training
Details
549
5.9
Building Dimensions
Sr.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
5.10
Particulars
Value in m
Powerhouse width
Powerhouse length
Area for steam generator & auxiliaries
Water treatment plant building width
Water treatment plant building length
Water treatment plant building height
Cooling tower width
Cooling tower length
Cooling tower height
Covered bagasse shed width
Covered bagasse shed length
Covered bagasse shed height
Performance Guarantee Data Sheet

Sr.
No.
1.
2.
3.
4.
5.
6.
Parameters
Value
Time period from notice to proceed up to

commissioning trials
Guaranteed power generation in sugar
season for the required process steam
flows, as per enclosed HBD
Guaranteed power generation in sugar
off-season for the required process steam
flows, as per enclosed HBD
Guaranteed
auxiliary
power
consumption in sugar season with
process steam flows, as per enclosed HBD
Guaranteed
auxiliary
power
consumption in sugar off-season with
process steam flows, as per enclosed HBD
Cogeneration plant steam rate (kgs/kW)
at given process steam conditions for
season, as per enclosed HBD
550
Sr.
No.
7.
8.
9.
10.
11.
12.
13.
14.
Parameters
Cogeneration plant steam rate (kgs/kW)
at given process steam conditions for offseason, as per enclosed HBD
Performance test code for steam
generator & auxiliaries
Performance test code for steam turbine
generator & auxiliaries
Performance test code for cooling tower
& auxiliaries
Performance guarantee will need to be
provided for total water consumption for
design season & off-season basis.(makeup to reservoir)
Performance guarantee for boiler feed
water treatment
Value
+ 5% of guaranteed figures
to be measured for 8 hours
during the PG test.
The boiler feed water

samples will be analysed by
the
Tenderer
at
an
approved laboratory of
CPCB / BPCB / MoEF for
all relevant parameters and
they
will
necessarily
confirm or better the
requirements.
Performance test code for all other As per relevant IS codes for
equipments, including air compressor, specified
capacity,
material handling, fire fighting, water turndown,
guaranteed
treatment, DG sets, etc.
auxiliary
consumption,
noise levels and specified
output qualities
Average annual availability, where
(1- (B+D+P)) x 100%
B = MW hours lost due to full breakdown
(DNC x PH)
D = MW hours lost due to de-rating
excluding evacuation restrictions
P = MW hours lost due to planned
maintenance
DNC = Declared Net Capability or the
full load MW output of the unit
PH = Period in Hours (8760 / year)
551
Sr.
No.
15.
16.
5.7
Parameters
Value
Design margins, redundancy and buffer

storage shall be incorporated as necessary
to achieve the assured availability
Duration of performance test (to be
carried out by the Tenderer with
calibrated instruments within 3 months of
commissioning)
Individual equipment will

undergo performance test
as per relevant standard
and in the minimum to
document the continuous
Tenderer to submit HBD for normal availability of rated output
season and off-season conditions.
and
efficiency.
The
cogeneration power plant as
a complete system will
undergo performance test
for a period of 7 continuous
days to prove reliability and
capacity of all sub-systems.
Within
this
period,
individual PG tests of main
power island will be carried
for a minimum period of 8
hours, as per relevant code.
PG
test
will
also
demonstrate the plant heat
rate and auxiliary power
consumption.
Station heat rate
(GCV of Fuel x Hourly fuel
Consumption
-Energy
Supplied to process) / kWh
LIST OF TECHNICAL DEVIATIONS

Clause no. & Page Details as per
no,
tender
Deviation
required by
Tenderer
Reply on sought
deviations by
Consultant to all
tenderers
552

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ENGINEERING, PROCUREMENT & CONSTRUCTION

20 MW Cogeneration Power Plant

Technical Basis And Specifications

Hindustan Petroleum Corporation Ltd. (HPCL)

MITCON Consultancy Services Ltd. (MITCON)

EPC BID DOCUMENT

TABLE OF CONTENTS (contd..)

APPROVED LIST OF VENDORS, LIST OF SPARES AND

TABLE OF CONTENTS (contd..)

SITE LOCATION MAP

PROXIMATE & ULTIMATE ANALYSIS OF BIOMASS FUELS

TYPICAL TG HALL LAYOUT

PROPOSED MASTER PLAN DEMARCATING COGEN

TYPICAL SCHEMATIC PLANT STEAM SYSTEM

TYPICAL SCHEMATIC FOR HP HEATER

TYPICAL SCHEMATICS COOLING WATER SYSTEM

TYPICAL SCHEMATICS PLANT WATER SYSTEM

TYPICAL BOM, FIRE FIGHTING

TYPICAL SCHEMATICS SYSTEM CONFIGURATION,

EVACUATION & DISTRIBUTION SYSTEM

PIPING MATERIAL SPECIFICATIONS

CODES & STANDARDS

TYPICAL PAINTING SUMMARY

ELECTRICAL SYSTEM REQUIREMENTS FOR MOTOR

RAW WATER ANALYSIS

HEAT & MASS BALANCE DIAGRAM

TERMS & CONDITIONS FOR ERECTION &

DESIGN BASIS, SCOPE OF WORK, TERMINAL POINTS

Season operation, days

Off season operation, days

Fuels used for season operation

Fuels used for off season operation

: Saved bagasse, Cane Trash,

Feed water temperature, C

Captive power consumption, % of : 8.5 during season & 9

Key performance parameters

Steam Generator efficiency, %

: 702 on bagasse / biomass

Steam to Fuel Ratio,

Note: The estimated HMBD is provided in Appendix XVII. However, the

Design Wind Velocity

: As per IS: 1893-2002

Design & Guarantee Fuels

The Following gives the Ash Analysis for Bagasse:

Plant Design Criteria

Bagacillo / handling loss,% cane (TPH)

Bagasse available for boiler, % cane (TPH)

Bio-gas available from distillery as fuel

Turbine size & configuration

Main Plant And Equipments

Steam Generator & Auxiliaries

Turbo-generator & Auxiliaries

Part of the generated power will be supplied to the sugar factory

0.1 (in off-season)

Required with BSEB grid

The turbo-generator system should be designed in such a way that

Load set point shall remain unaffected for the variation

The turbine inlet steam pressure shall be maintained at

The Turbine extraction which provides the Medium Pressure

Fuel & Ash Handling

Bagasse from sugar mill elevator & yard,

Cooling Tower & Pumps