Jumdi Khola Small Hydropower Project Electro-Mechanical Works Particular Technical Specification Section 13: Ancillary Equipments

Jumdi Power Pvt. Ltd.
MECHANICAL WORKS
Bidding Documents
ELECTROJumdi Khola Small Hydropower Project
JUMDI KHOLA SMALL HYDROPOWER PROJECT

ELECTRO-MECHANICAL WORKS
PARTICULAR TECHNICAL SPECIFICATION
SECTION 13: ANCILLARY EQUIPMENTS
Table of Contents
1.0 GENERAL
1.1
OVERHEAD TRAVELLING CRANE
1.1.1 SCOPE OF WORKS
1.1.2 SYSTEM DESCRIPTION, CHARACTERISTICS AND OPERATING CONDITION

2
1.1.3 QUALITY ASSURANCE
1.1.4 SUBMITTALS
1.1.5 PRODUCT COMPONENTS AND SUB-ASSEMBLIES
1.1.6 SPECIAL TOOLS AND SPARE PARTS
1.1.7 EXECUTION
1.2
DIESEL GENERATOR SET
10
10

10
1.2.4 SUBMITTALS
10
11
1.2.5 COMPONENTS - PRODUCTS AND SUB-ASSEMBLIES
11
13
1.2.7 EXECUTION
1.3
14
OIL PURIFYING AND HANDLING EQUIPEMENT
1.3.1 GENERAL
14
14
14
1.3.3 SYSTEM DESCRIPTION, CHARACTERISTIC S AND OPERATING CONDITION

15
1.3.5 SUBMITTALS
15
15
15
17
1.3.8 EXECUTION
1.4
17
FIRE FIGHTING SYSTEM
1.4.1 GENERAL
17
17
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18
1.4.5 SUBMITTALS
18
19
19
1.4.7 WATER FIRE FIGHTING SYSTEM
21
1.4.8 MOBILE DRY-TYPE FIRE EXTINGUISHERS
22
23
1.4.10
1.5
EXECUTION
23
TOOLS AND METERS24
1.5.1 MACHINE AND TOOLS
24
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ANCILLARY EQUIPMENTS
1.0
GENERAL
This section covers the design, manufacture, testing before shipment,

transportation to site, erection and commissioning and performance tests of the
followings:
One (1) Lot of overhead travelling crane;
One (1) Lot of diesel generator set;
Two (2) Lot of oil handling and purifying equipment;
One (1) Lot of fire fighting system;
One (1) Lot of tools and meters.
1.1
OVERHEAD TRAVELLING CRANE

The Contractor shall be responsible for the design, manufacture, delivery,
erection, site tests and shall provide the technical instructions for their operation
and maintenance. The standards, materials, material tests, working stress,
welding operation and other general technical requirements shall meet the
requirements specified in these documents.
One set of overhead travelling crane shall be installed in the powerhouse. The
crane shall be provided with main hoist and auxiliary hoist. The scope of works
shall include the followings:
One set of overhead travelling crane including hoisting appliances with a

main hook of 15 ton capacity and 5 ton auxiliary hook,
One crane runway with rail dampers, all fasteners and embedded parts,
One main contact conductor system along the crane runway,
Control equipment including mechanical and electrical operating

elements, protection elements and corresponding panelsOne lifting beam,
Tools and devices for the assembly, disassembly and maintenance of the
equipment,
Spare parts,
Submission of Documents.
Accessories not specifically outlined in this Section, but necessary for the
effective operation of the crane, shall be included in the Scope of Works.
The overhead travelling crane shall be of electrically-operated, suitable for 400volt, 3-phase, 50 Hz supply and shall be equipped with a single trolley having
both main and auxiliary hoists.
The crane shall be complete with bridge girder, main and auxiliary hoist,
shafting, gearing and complete electrical equipment including motors, control
gear, current collecting gear, trolley hoisting ropes, blocks and hooks, platforms,
guards and hand rails, spares, tools and spanners with rack, and other gear and
necessary accessories for its proper and efficient operation.
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The Bidder shall furnish the ISO 9002 or equivalent certificate of the Crane
Manufacturer along with its details of certifying agency (accreditation, validity
date etc.).
1.1.2 SYSTEM DESCRIPTION, CHARACTERISTICS AND OPERATING

CONDITION
1.1.2.1
General
The powerhouse cranes shall be used during erection and maintenance of the
turbines, main inlet valves, generators and other equipments. Normally, the
crane shall pick up equipment from the erection bay and transport it to the
generating units. The design shall be such that all movements take place
smoothly and positively. No slipping or creeping of the loads shall occur at any
time.
The design shall take into account the lateral stresses due to starting and
stopping the crane suddenly when carrying rated load.
The crane shall be designed for continuously repeated cycles up to a half-hour
total duration, starting with cold motors and brakes. Safety factors used in the
design except hoisting ropes shall in no case be less than four.
The Contractor shall indicate the quality of the materials with reference to
international standards and their mechanical and chemical properties. The
Contractor shall consider the most adverse conditions which will have to be
withstood by the equipment in operation or during manufacture, transport and
erection. The design calculations and loading conditions shall conform to
international codes.
1.1.2.2
Capacity
The crane shall be capable of easily handling, both during erection and
afterwards, the heaviest piece of plant covered by this Specification.
The lifting capacity of the main hoist shall be the heaviest assembled parts or
components of turbine or generator to be erected as one piece plus 25% extra
and that of the auxiliary hoist shall be 5 tons. The crane shall be capable of
travelling with its full load suspended in any position.
1.1.2.3
Dimension and Clearances
The span of the crane will be 10 m centre to centre of crane rails. Lifting height
of the main hoist and auxiliary hoist will be that necessary to reach the lowest
component of the equipment. The suitable provisions shall be provided so that all
parts of the turbine and generator can be lifted and assembled under the abovementioned conditions.
The trolley shall be so designed that in the extreme position of its traverse the
hook can plumb vertically as close as possible to the crane rail at either end. The
actual minimum possible distance of each crane hook from centre-line of rail at
each end shall be as stated in the Bid.
1.1.2.4
Speed
The various motions of the crane shall have not less than the following speeds
under full load conditions:
Bridge longitudinal travel
20
meters per minute
Trolley cross travel
10
meters per minute

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Main hoist
Auxiliary hoist
meters per minute
Creeping speed
10%
of the above speed.
1.25
meter per minute

1.1.3.1
Codes and Standards
The standards to be followed, but not limited to, shall be the ones mentioned
herein.
ASTM A 370, Standard Test Method and Definition for Mechanical Testing of
Steel Products
ASTM A 488, Standard Practice for Steel Castings, Welding, Qualifications of

Procedures and Personnel
ASME B 31.1 / ASTM A 488 / AWS D1.1, Structural Welding Code
NEMA Standards for Motors
ASTM A 325M (2005) Standard Specification for Structural Bolts, Steel, Heat
Treated, 830 MPa Minimum Tensile Strength (Metric)
Crane Manufacturers Association of America (CMAA) Specification No. 70,

Specifications for Top Running Bridge & Gantry Type Multiple Girder Electric
Overhead Traveling Cranes, (Revised)
ASME B30.2 (2005) Overhead and Gantry Cranes (Top Running Bridge, Single
or Multiple Girder, Top Running Trolley Hoist)
1.1.3.2
Design Criteria
Design of crane, in general, shall be such that it is capable of performing all the
works requiring hoisting inside the powerhouse effectively and shall be of
requiring less maintenance.
1.1.3.3
Shop Tests and Inspection
The crane shall be completely assembled at Contractor's plant for the inspection
of functional tests. All parts shall be correctly doweled and match-marked to
facilitate assembly at the site. Two copies of the test reports shall be provided to
the Engineer.
In particular, the following tests shall be carried out before shipment:
Checking of the main dimensions,
Operation tests of all drives, including measuring of operating,
Function tests of the complete control system, measurement of stator

winding insulation resistance on all driving motors, voltage test and
insulation test on electrical installations.
Overloading test (125 per cent of the rated load).
Tests certificates for materials and equipment shall be provided to the Engineer,
which shall include the following:
Material tests and chemical analysis of steel and other principal used
metals.
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Welds shall be physically and radiographically or ultrasonically tested as

specified.
Insulation tests, operating tests, heating tests, load tests, etc. on electric
motors, starters, transformers, and other electrical and mechanical
components.
Load rope breaking tests.
All welding on the crane structure exposed to stresses shall be subject to nondestructive tests. The test equipment and instrumentation shall be provided by
the Contractor.
1.1.4 SUBMITTALS
All pertinent technical documents as well as the design and an explanation in
detail of the equipment operations shall be submitted to the Employers
Representative for approval.

1.1.5.1
Crane Bridge
The main bridge girders of the crane shall be constructed as box type girder or
plate girders and shall include the rails and end stops for the crane trolley. The
rails for the translation motion of the trolley shall be bolted to the girders. The
temporary deflection of the bridge structure under full load in any position shall
not exceed 1/1000 of the span.
After the welding, all welds of the bridge girders and cross girders shall be
subjected to 100% X-ray examination as applicable, complemented by a 100 %
ultrasonic test.
Bridge girders shall be mounted on equalizing type end trucks with buffer and
shall be rigidly attached to the trucks by machine fitted bolts. Heavy gusset
plates shall be attached to the bottom of the trucks to keep them square with the
main girders. The end trucks shall be designed so that the end reaction from the
bridge girders is divided equally between the wheels.
The end of the trucks shall be tied together to prevent spreading in the event
that the crane runs into the end stops. Trucks shall be bored to receive wheel
axles. Suitable stoppers shall be provided at the both ends on the rails.
The trolley frame shall be a rigidly fabricated steel structure to ensure uniform
distribution of the loads to all wheels without undue deflection. The trolley frame
shall be stress-relieved after fabrication.
1.1.5.2
Longitudinal Travel Rails
Suitable longitudinal travel rails shall be provided by the Contractor. The runway
rails and anchoring material shall be installed within the allowable tolerances
given in applicable standards. Foundation plates, anchor bolts, fasteners and end
buffers shall be included in the supply. The impact of concrete contraction joints
shall be adequately considered in the rail track design.
1.1.5.3
Axles and Wheels
Axles shall be of stationary-type, kept from turning in the truck or trolley frame
by means of a key plate fitted in a milled slot in the axle. They shall be made
from alloy-steel, heat-treated when necessary, and accurately machined and
ground to size to receive the bearing inner races.
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Wheels shall be made of cast, forged or rolled steel double-flanged of approved

contour to suit the longitudinal travel and bridge rails. They are to be accurately
ground to exact diameter and are to be provided with grease-lubricated
antifriction bearings.
1.1.5.4
Bridge and Trolley Driving Machinery
One pair of wheels in each end of the bridge shall be driven by an electric motor
driving a cross shaft through a helical, spur, or herring bone gear speed reducer
unit mounted near the centre of the bridge. The motor shall be coupled to the
reducer by a flexible coupling.
The cross shaft shall be supported on self-aligning bearings along the bridge.
Final drive pinions shall be mounted on shaft sections of shaft coupled to the
main cross shaft for convenience in assembly and replacement of parts.
The motor, speed reducer unit and brake shall be mounted on a common
structural steel base, supported from the bridge drive-side girder.
The trolley drives shall be generally as described for the bridge drive except that
gear head motors may be provided with direct drive to the wheel shafts.
All gearing, other than final drive gears at the wheels shall be enclosed in oil
tight gear cases designed for splash lubrication of the gears and bearings,
enclosed within the case. Adequate inspection openings shall be provided in
each case, together with an oil filler plug drain cock and oil level indicator or
dipstick.
1.1.5.5
Hoist
The lifting equipment on the trolley shall include two hoists, the main hoist for
main hook and the second hoist for the auxiliary hook. Hoists shall include rope
drums, journal bearings and geared motors. The hoist drums shall be of the twoway, opposite-groove type to yield vertical lifting of the load. The grooves shall
be machined. The drums shall be dimensioned to leave at least three complete
windings of lifting ropes in the grooves with the hook in the lowest position. It
shall also not be necessary to wind double layers when the hook is in its highest
position.
All movements shall be protected by limit type proximity switches which shall, if
activated, interrupt the power supply to the motor and activate the brake. In
addition to the holding brake for normal operation, a control brake shall be
actuated, for instance by a centrifugal switch. An overload-protection device and
slack rope contact shall also be provided.
Hoist drums shall be mounted on the trolley and located so that the hoisted load
will at all times be transmitted equally to the crane girders. Each drum shall be
dimensioned so as to receive the required amount of hoisting rope in one layer
with at least 1-1/2 turns to spare on each half of the drum with the hook in the
maximum raised position, and when the hook is in the lowest position at least
three full wraps of rope shall remain unwound on each half of the drum.
Hoist drums shall be fabricated or cast with adequate stiffening ribs to prevent
deformation and to minimize deflection under all operating conditions. Drum
diameters and rope grooves shall be in accordance with the recommendations of
the rope manufacturer. All surfaces to come in contact with the rope shall be
machined true to approved tolerances and surface finished to minimize wear and
prevent permanent deformation of the rope.
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1.1.5.6
Sheaves
The sheaves shall be of cast steel or fabricated steel properly dimensioned to

suit the recommendations of the rope manufacturer. The grooves as well as all
surfaces to come in contact with the rope shall be machined true to approved
tolerances and surface finish to minimise wear on the ropes. Sheaves shall be
mounted on bronze-bushed bearings. All sheaves shall be provided with guard
plates to retain slackened rope within the grooves. Ample means for lubricating
the bearing shall be provided in easily accessible locations.
1.1.5.7
Hook Blocks
The main hook shall be of double-type and the auxiliary hook shall be of single
standard type. Hooks shall be made of forged steel properly annealed after
forging and finish-ground.
Maximum stress at load test shall not exceed two third of the ultimate strength.
The hooks shall be load tested to 150% of rated load. The hook shall rotate freely
on sealed anti-friction bearings and be provided with safety latch. The design of
the lifting beam for transportation of the generator rotor, and of the lifting
attachment for the test block has to match the main hook dimensions. The lifting
beam design must be coordinated with the generator manufacturer.
1.1.5.8
Hoisting Rope
The wire ropes for the hoists shall be of twist-free design, preferably with a fibre
core. The wires shall be made of preformed, regular-lay extra-flexible hardened
and tempered steel. Rope stresses shall be calculated for maximum load
including the weight of the hook and the rope sheaves.
Hoisting ropes shall be designed so that the maximum working load including
hook block does not exceed one-fifth of the breaking strength of the rope.
Hoisting ropes shall be grease-impregnated during manufacture.
1.1.5.9
Lubrication
All bearings requiring grease shall be fitted with grease fittings easily accessible
from the crane walkways. A hand-operated grease gun of ample capacity shall
be supplied with all necessary extensions and fittings for greasing the bearings.
The Contractor shall advise the Engineer, in writing, as to the recommend type
and make of grease and other lubricating oils to be used. In addition, the
Contractor shall recommend a lubricating cycle to guide the Employer's
operating staff in their maintenance work. The Contractor shall provide the initial
lubrication for all the equipment, including the hoisting ropes.
1.1.5.10
Hand Operation
All electrically operated hoisting mechanisms shall be arranged such that hand
operation can be used if required in case of any emergency or during
maintenance. Provision shall be made for emergency hand operation of the
lowering motions of the main and auxiliary hoists. Engagement of hand gearing
shall embody a safety device, which will open power circuits to the motors. Hand
gearing shall be so arranged that the operating cranks cannot run away under
load.
1.1.5.11
Hoist Brakes
Each motor of any motions shall be provided with a separate spring-actuated

solenoid-released electro-magnetic brake capable of rapidly decelerating and
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holding the full load. The brake control shall be so arranged to operate after a
time delay to ensure that the load is held by the drive motor before the brake is
released. There shall be no slipping of loads when the drive motor is stopped or
the electricity supply fails.
Main and auxiliary hoists shall be equipped with two independent brakes, an
electromagnetic holding brake and a control brake. The control brake shall
preferably be an electric brake controlled by frequency transformer.
The rubbing surface of brake drums shall be machined and free from defects.
Under operating conditions, the temperature of the rubbing surface of the brake
shall not exceed 100C with fabric lining or 200C with metal linings. Asbestos
will not be accepted. The brakes shall be designed for simple accessibility for
adjustment due to wear of the lining.
All brakes of any type shall exert a braking torque of at least 2 times the nominal
driving torque. The brakes shall be capable of operating 600 times per hour.
The hoist brakes shall be able to stop the nominal load at rated speed with a
maximum slip of 4 mm, and also maintain the load at rest without any slipping. A
failure of the motor coupling or gear box shall not cause the load to drop.
The trolley drive shall also have a spring-actuated solenoid-released brake
capable of rapidly decelerating the trolley to rest from full speed with full load.
Each brake shall be so arranged as to become automatically applied when power
is cut off and shall also be arranged to release automatically upon application of
power to the drive motor.
Each brake shall consist of a pair of shoes normally pressed against steel or cast
iron drums of ample diameter and width by adjustable helical springs in
compression. Each brake shoe shall have an ample thickness of renewable
friction lining. Brake drums shall preferably be on the input shaft of the gearbox
but where brake drums are on the motor shaft, they shall be so placed that they
can be readily removed to change a rotor and so as not to interfere with proper
access to the brushed and bearings.
In addition, the main and auxiliary hoists shall be provided with either:a) An electro-hydraulic thruster brake for lowering speed control in slow
operation. An overspeed safety device shall be incorporated in the hoist
controls to interrupt the power supply and operate the spring-actuated
solenoid-released brake to stop the hoist if over-speeding occurs, or
b) A multiple-disk, self-adjusting mechanical load brake, capable of sustaining
the load in the event of power failure and failure of the hoist electromechanical brake.
The bridge shall be provided with a friction brake of sufficient capacity to bring
the crane quickly to rest from full speed with rated load.
1.1.5.12
Control Equipment
The crane control system shall include all master switches, controls, resistors,
time or current relays, reversing contactors, overload relays, phase failure relays,
auxiliary relays, accelerating contactors, limit switches and accessories as
necessary for reliable operation.
The crane shall be equipped with control circuit transformers, motor starters and
thermal overload protections for each motor and trip for thermal sensors of the
motors.
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All hoists shall also be equipped with switch-off switches at loads exceeding the
rated capacity. The main hoists shall be equipped with additional contact
initiating automatic speed reduction for heavy loads.
1.1.5.13
Electrical Motors
The crane shall be supplied from power station low-tension switchgear cubicle
with 400-volt, 3-phase, 50 Hz current. The longitudinal travel drive, the cross
traverse drive, main and auxiliary hoist drives shall be operated by suitable
number of electric motors each of totally enclosed, wound-rotor, reversing, fancooled or self-cooled type with Class "B" insulation and suitably impregnated to
be non-hygroscopic and unaffected by conducting dirt or dust. Motor lead
insulation shall be Class H. Motor shall be a half-hour rated. Motor bearings shall
be ball or roller type mounted on the end covers.
1.1.5.14
Controllers
A separate reversing tramcar-type drum controller shall be provided for each

motor. Each controller shall be fitted with renewable contact fingers and tips on
the drum. Each controller shall be provided with arc shields of incombustible nonhygroscopic material. When in the "OFF" position, the controller shall isolate the
motor on all three phase. Each controller shall be provided with a dead man's
button or spring return to "OFF" position. Emergency stop buttons convenient to
controllers shall be provided.
1.1.5.15
Switchboard
A steel-enclosed switchboard with doors, suitable for working with controllers

shall be provided. The switchboard shall be equipped with circuit breakers,
contactors, protective relays, indicating instruments, transformers, fuses and
other necessary apparatus.
A main circuit breaker shall be provided to cut off all power to the crane and to
lock in the open position. Independent overcurrent, under-voltage and thermal
protection for each motor shall be provided. All controls, switches and
components shall be adequately labelled and numbered for easy maintenance. A
lighting and convenience outlet panel board shall be included on the
switchboard.
1.1.5.16
Safety Limit Switches
The crane shall be designed to prevent over winding of hoists, unreeling of wire
ropes from drums and overrunning of travel and traverse drives by means of
limit switches arranged for quick make and break of the motor circuits. The
upper main hoist limit switches shall be arranged to open by the rising hook
blocks without coming in contact with the rotating sheaves on the hoisting wire
ropes.
1.1.5.17
Wiring
The Contractor shall supply and install all wiring, cabling and conduit on the
crane taking the supply from the low-tension switchgear in the cubicle room. The
main runway contact wires and trolley conductors shall be of approved design
and shall be as per relevant standards and located on the outside of the bridge
girders to prevent interference with hoisted loads. The minimum size of
conductor used shall be 3.5 square millimetres.
All current collectors shall be of substantial construction with ample capacity and
designed to eliminate all sparking and flashing and to ensure continuous contact.
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The wearing parts shall be easily replaceable. Suitable guards or screens shall be
provided to comply with the safety requirements.

1.1.6.1
Special Tools
One complete set of all special tools and devices necessary for the assembly,
disassembly and maintenance of the crane including rope slings shall be
provided.
The following accessories shall also be provided:
Lubricating oil, grease, machine oil
1 lot with 50% spare
Hand-operated grease gun
1 set
Wrenches and tools for maintenance
1 lot
1.1.6.2
Spare Parts
The special spare parts listed below shall be included and quoted separately from
the main equipment in the Bid.
One set of brake parts subject to wear, per brake
Two sets of limit switches of each type
Two sets of fuses of each type
One set of brush holders with two sets of carbon brushes for each slip-ring
motor
One set of bearings of each type
One complete assembly set of switches, contactors, relays, etc.
Two sets of carbon brushes for motors, fuses and lamps
One set of brake shoes of each type
1.1.7 EXECUTION
1.1.7.1
Field Installation and Tests at Site
After complete assembly at site, the Contractor shall conduct the following
commissioning tests to ensure that the equipment has been correctly installed,
all necessary adjustments and settings been made, and that it is in sound and
safe condition to operate. The contractor shall furnish 'Crane clearance diagram'
giving all the dimensions, clearance required, dead weight of crane, wheel loads
(including and excluding impact), instruction and operation and maintenance
manuals, general assembly drawings, crane rail fixing details, power supply
conductor fixing details, calculations for motor ratings, wheel load details, etc .
The Contractor shall conduct the commissioning tests to ensure that the
equipment has been correctly installed, all necessary adjustments and settings
been made, and that it is in sound condition to operate. Rail-track position shall
be checked before and after its definite setting and clamping. During no-load test
the following items shall be checked:
Correct operation and efficiency of brakes and limit switches,
Vertical and horizontal travelling distances and approach measurement,
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Operating speeds,
As far as possible, the Contractor shall carry out the load tests under the worst
operating conditions under which the hoisting equipment will be operated. All
measuring equipment, including test loads, test load carrying structures, ropes
etc. shall be provided by the Contractor.
With the handling mechanism in a fixed position, the hoisting equipment shall be
tested under an overload 25% greater than its rated load. This load shall be
maintained for one hour. The load shall then be relieved gradually. No defect or
permanent deformation shall remain after complete removal of the load.
After satisfactory completion of the static test, the testing load shall be
decreased to a value 20% greater than that of the rated load of the hoisting
equipment. Under these conditions, all the lifting and lowering operations shall
be carried out successively for a period of fifteen minutes of effective operation,
without vibration, deformation or detrimental temperature rise. Transversal
movements of the handling mechanism shall be tested under the same
conditions as above.
The crane shall be loaded to its rated load and the following shall be checked:
The deflection;
The horizontal and vertical travel distances;
The operating speeds;
The lifting and lowering movements, which shall be made in a continuous

smooth manner so that all manoeuvres shall be possible with adequate
accuracy;
After successful completion of all commissioning tests, the bridge crane and the
associated equipment shall be subject to a Trial Operation Period. The Trial
Operation shall be carried out under supervision and responsibility of the
Contractor.
1.2
DIESEL GENERATOR SET

One 50 kVA diesel engine generating set complete with the necessary switchgear
and accessories shall be provided to supply emergency electric power for
operation of cooling water system, governor oil system, battery charger,
communication facilities, powerhouse lighting and ventilation system, black
starting of the units and for any other system as deemed necessary.
The Bidder shall furnish the ISO 9002 or equivalent certificate of the Diesel
Engine Generating Set Manufacturer along with its details of certifying agency
(accreditation, validity date etc.). The technical specification submitted with bid
shall be in English language.
The location of diesel engine generating set shall be in the vicinity of the
powerhouse and will be finalised during contract negotiation.
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CONDITION
1.2.2.1
Operating Principles
Each diesel generating set shall be designed to start up automatically in the

event of a general power failure on the bus bars of main distribution board
(MDB). Once main voltage is restored, the set shall be automatically shut down
after a time lag of about 5 minutes.
It shall also be possible to start up each DG-set manually for periodical checks.
The starting and operation of the each emergency diesel generator set shall be
independent of any common auxiliary sources of the power station; in order to
be able to start the turbine-generator units in case of lack of all outside electrical
sources (black start).

1.2.3.1
Reference Standards
ISO standards for each of the diesel engines, especially:
ISO 3046-1 and 3046-3: Reciprocating internal combustion engines Performances
ISO 10816-1: Mechanical vibrations
IEC 60034-1: Rotating electrical machines - Part 1: Rating and performance
1.2.3.2
Design Criteria
Each diesel engine shall be capable of: Driving the respective AC generator at full
load with a 0.8 power factor.
1.2.3.3
Workshop Tests
The following tests shall be carried out on the combined engine and generator
before shipment at contractor's plant:
Starting test
Load test including temperature rise and fuel and lubrication oil
consumption measurement
governor test
Overspeed test (120% for one minute)
1.2.4 SUBMITTALS
Overall dimensions and civil work guide drawings of each DG set.
Installation drawings for each unit.
Control diagrams of each unit.
Test certificates for each of the units.
Operation and maintenance manuals.
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1.2.5 COMPONENTS - PRODUCTS AND SUB-ASSEMBLIES

1.2.5.1
Diesel Engine
The diesel engine shall be of the full compression ignition with V-configuration,
single-acting, 4-cycle, solid injection, radiator-cooling type. Engine cylinder liners
shall be of the full length replaceable type. The diesel engine and generator shall
be placed on a common bedplate. The engine shall be provided with jacketed
water heater suitable for cold-weather starting.
Continuous output of diesel engine generating set shall be guaranteed to be 50
kVA at generator's terminal, under the climatic conditions of the project site. The
diesel engine shall be designed to use high speed diesel oil, which should be
easily available in Nepal.
The diesel engine shall be capable of manual and/or automatic starting on mains
failure. The starting shall be selected by key-operated test/manual/auto switch.
While in auto, the generator shall automatically start on detection of the mains
failure. The generator shall also be capable of starting from the centralized
control room by the operator. The generator shall be self-supervised and changeover circuit breakers shall be provided to change all the auxiliary power supplies
and essential loads to the generator automatically.
The diesel engine generator shall be stopped automatically when the normal
main supply resumes. However, it may continue running for set period of time at
no load, so that it can take the auxiliary supply load immediately if the main fails
within that time period. The revolution per minute of engine shall be 1500.
In addition, the following items shall be supplied for the engine.
A fuel oil tank with float level gauge for minimum eight running hours.
Pumps for lubricating oil and fuel oil injection. The forced lubrication
system shall cover main bearings, crank pin bearings, piston pins, timing
gears, camshaft bearings, valve rocker mechanism and governor;
Filters for fuel oil and lubricating oil, Thermometers for cooling water and
lubricating oil;
A tachometer;
A lubricating oil cooler;
Foundation bolts and nuts;
Reamer bolts with nuts, for coupling up with generator;
Alarm and automatic shut-down devices in the event of lubricating oil

pressure drop, cooling water high temperature and over-speed;
Panel for safety device with alarm, associated with the generator control
panel;
Pressure gauge for lubricating oil:
All piping materials with valves and cocks;
Air suction strainer, cleanable-type to avoid frequent replacements;
Expansion or flexible joint for exhaust pipe;
Maintenance tools;
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Silencer and exhaust pipe to atmosphere;
Any additional accessories as recommended by the manufacturer.
1.2.5.2
Generator
The generator shall be 3-phase, 4-wire, revolving field type with damper winding,
self-excited, self-ventilated open-type single-bearing synchronous alternator. The
rating of the generator shall be 400 V, 50 Hz, 0.8 lagging power factor, 50 kVA
maximum continuous output and shall be directly connected and flange mounted
to engine. Insulation shall be Class "B" or higher class.
The excitation current shall be controlled by both voltage and current of the
generator through rectifiers to have compound characteristics. The automatic
voltage regulator shall be provided for the excitation system capable of
controlling voltage within 2% from no load to full load. The neutral point of
armature winding will be connected to neutral bus of the low tension switchgear
and solidly grounded.
The maximum temperature rise of the generator shall not exceed the following:
Stator winding (by thermometer)
70 0C
Rotor field winding (by resistance)
80 0C
Iron core and other parts (by thermometer) 800C
Generator control cubicle shall be of sheet metal dead front, indoor type, floor
mounted and self-standing or wall mounted. The panel-mounted equipment and
devices shall include, but not be limited to, the following:
One 100A moulded-case circuit breaker
One A.C. ammeter with selective switch
One A.C. voltmeter with selective switch
One frequency meter
One wattmeter
One watt-hour meter
One power factor meter
One frequency meter
One regulating switch for governor motor
One group annunciator
One group of annunciator alarm
One rheostat for AVR voltage setting
One set of cable terminals, back wiring and terminal boards and
nameplates
One over-voltage relay
One over-current relays
One set of connections for fault indication of excessive temperature rise of

cooling water, pressure drop of lubricating oil and overspeed
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The following accessories shall be supplied:
Indicating lamps
Local starting stand with starting switch
One set of cabinet type static exciter with automatic voltage regulator and
necessary accessories
Battery and charger for a starter motor
Foundation bolts and nuts
Other necessary accessories as recommended by the manufacturer

1.2.6.1
Special Tools
Special tools for erection and maintenance
1.2.6.2
Spare Parts
The spare parts listed below shall be included and quoted separately from the
main equipment in the Tender.
Fuses and lamps
Fuse and protection for rotating diode
Contactors, relays
Filter elements for fuel, lubrication and air
Electrical spares like contactors, coils, resistors, rectifiers,
100%
100%
1 set of each type
rheostats, transistors, capacitors, etc.
1 set of each type

1 set
1.2.7 EXECUTION
1.2.7.1
Tests
The following field tests shall be performed:
General inspection;
Insulation resistance measurement;
Dielectric test;
Sequence and operation test;
Trial operation for 12 hours.
1.3
OIL PURIFYING AND HANDLING EQUIPEMENT
1.3.1 GENERAL
The oil purifying and handling equipment shall be two (2) sets of mobile oil
treatment system for the powerhouse. One system shall be used for the
treatment of the bearing lubricating oil of turbine/generators and governor
pressure oil. The second one shall be used for the treatment of the transformer
oil.
The Bidder shall furnish the ISO 9002 or equivalent certificate of the oil purifying
and handling equipment manufacturer along with its details of certifying agency
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(accreditation, validity date etc.). The technical specification submitted with bid
shall be in English language.

This specification covers the supply, delivery and tests of the oil treatment
system.
The Scope shall include the following supply and services:
Two (2) sets of oil treatment system with all necessary accessories, each
set consisting of:
One (1) mobile transfer pump.
One (1) mobile oil purifier
One (1) set of piping, valves, flexible hoses, controls and instrumentation
One (1) set of special tool required for the maintenance and operation of
the system.
One (1) set of instruments including:
Instruments to measure
dielectric capacity of oil
acidity index
water content of oil
Calorimeter
Viscosity meter
One (1) set of spare parts
1.3.3 SYSTEM DESCRIPTION, CHARACTERISTIC S AND OPERATING

CONDITION
1.3.3.1
Performances
The oil purifier shall be able to remove all particles above 10 microns. Under the
assumption of an initial water content of 50 ppm, the final water content of oil
after only one passage in the treatment system shall not be above 10 ppm. The
oil purifier for bearing oil shall be able to process 500 l/h that for transformer oil
shall be able to process 1000 l/h.
Transfer pump for bearing oil shall have capacity of 500 l/h. That for transformer
oil shall have capacity of 1000 l/h.

Design Stress
Under usual loading, the maximum equivalent stress shall not exceed 50%
of the yield strength.
Under unusual loading and hydrostatic test pressure, the maximum

equivalent stress shall not exceed 75% of the yield strength.
1.3.5 SUBMITTALS
The Contractor shall submit the following documents:
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Piping and Instrumentation Diagram (P&ID) for the oil filtration system.
Component lists.
Logic diagrams.
Operation & maintenance manual.

1.3.6.1
Oil Transfer Pump and Strainer
The oil transfer pump shall be of self-priming positive displacement type and be
able to handle the most viscous oil at the lowest average daily ambient
temperature. The pump shall be provided with safety relief valves and high
temperature shutdown. A pressure gauge shall be attached to the pump
discharge line and shall be fitted with filter-pulsation damper.
The pump pressure rating shall include an allowance for the hoses, connecting
pipes and filter. The pump shall be provided with a relief valve connected to
discharge to the pump suction and set to protect the pump from overpressure.
A pressure gauge shall be attached to the pump discharge and shall be fitted
with a filter-pulsation dampener. The pump shall be driven by an electric motor.
The available power supply outlets are for 400 V, 3-phase, 50 Hz.
The transfer pump and strainer shall be mounted on a mobile cart. The cart shall
be provided with oil resistant tired casters, lifting lugs and pull bar. Racks shall be
provided on the cart for storing hoses and the electrical power cable.
Suction and a discharge oil-resistant hose shall be provided, each about 10
meters in length for connections. These hoses shall also be used for connecting
the oil purifier to the sump or transformer. All hoses connections shall be of the
swivel coupling type and corresponding adaptors and coupling halves shall be
provided on each sump fill and drain connection.
The strainer shall be mounted on the mobile cart and shall be rated for the
transfer pump discharge at corresponding viscosities. The strainer shall be fitted
with a differential pressure gauge and the body shall be rated for the pressure
setting of the pump relief valve. The filtering medium shall be of non-corroding
metal or synthetic fibre and shall be cleanable. The strainer body shall have a
suitable drain, supports and easy means of access to the filter element. A
suitable flexible connection shall be provided between the pump and strainer.
1.3.6.2
Vacuum Oil Purifier
A vacuum oil purifier shall be provided to dehydrate, de-aerate, purify and filter
the bearing lubricating oil and governor pressure oil.
The oil purifier shall be provided with:
Centrifugal separator
Filter press
Vacuum dewatering,
Direct heating,
Vacuum and circulating pumps, controls and instrumentation.
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The purifier shall have all components, controls, valves, thermostats, pump
drives, motors, starters, relays, filters etc., required to ensure the performance
stated in 1.3.3.1.
The oil purifier shall be of the closed circuit operation type and shall not need oil
transfer into a tank. The oil treatment system shall be able to extract oil by
suction from the equipment for treatment and return it by gravity after treatment
or vice versa.
Oil treatment shall include:
Filtration or centrifugal separation
Dewatering
If the purifier uses disposal filtering or oil dispersion material, the Contractor
shall supply with the unit not less than 5 years supply of such material. The
quantity of filtering material shall be sufficient to allow changing the filtering
media after an annual treatment of the oil in each of the bearing sumps and
governors. The filtering media shall be changed after the treatment of the
quantity of oil in each sump or system.
The purifier shall be movable and provided with all attachments appropriate to
obtaining easy manoeuvrability and to locating the purifier adjacent to the oil
container on the generating unit. The purifier shall be rated for the 400/230 volt
A.C. power.
The purifier shall have two flexible hoses: one of them to be connected to the oil
sump drain line or to be inserted through the filling opening of the oil sump, and
able to reach the bottom of the sump. The return flexible pipe shall be connected
to a refill line or be inserted in the filling opening.
The purifier shall be provided with its own electrically driven transfer oil pump
and electric supply cable. The purifier system shall be mounted on an easily
manoeuvrable trolley, provided with lifting lugs and a sling.
1.3.6.3
Oil Tester
A portable dielectric oil tester shall be provided. The rating shall be 1 kVA, with
maximum capacity of a test voltage of 70 kV. The test voltage shall be adjustable
by the voltage regulator. The unit shall be complete with switches, instruments
and accessories.
1.3.6.4
Miscellaneous
The Contractor shall furnish all necessary piping, valves, hoses, connectors, pipe
supports and other accessories.

1.3.7.1
Special Tools
Special tools for maintenance
1.3.7.2
Spare Parts
main equipment in the bid.
Two (2) sets of oil filters.
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Two (2) sets of seals and gaskets for pumps and valves of the oil purifier
and transfer pump of two different capacities.
One (1) set of bearing or bushings, including one of each size and type
used in the pumps, motors, wheels or other rotating component of the
equipment supplied under this item.
One (1) set of components for the control equipment associated with the
equipment supplied under this item, such as, contactors, relays,
thermostat, pressure switch, etc.
1.3.8 EXECUTION
1.3.8.1
Site Tests
The equipment to be supplied shall be tested as per recent international

standards and codes at Contractor's plant before shipment. Site test shall be
carried out on at least one oil sump to check the system ability to suck oil from
the sump.
The Contractor shall provide the descriptive documents, the operating and
maintenance instructions of the oil treatment systems and associated
instruments as well as the operating and maintenance manuals of all machines
and instruments.
1.4
FIRE FIGHTING SYSTEM
1.4.1 GENERAL
The Contractor shall be responsible for design, manufacture, supplys, erection,
site testing and commissioning of the fire fighting system at the powerhouse.
The supply shall include the fire fighting equipment comprising fire hydrant
pump, fire hoses and piping system, fire detection and alarm system, portable
CO2 and dry chemical extinguishers. All internal alarm/control cables are part of
the supply.
The powerhouse will be equipped with an independent fire alarm system based
on smoke detectors and heat detectors. The fire alarm system as well as control
cables between local control units will also be supplied.
The permanent fire fighting system for the powerhouse shall be based on the
following type of equipment:
Fire hoses with nozzles at each of the powerhouse floors in the vicinity of
stairs and entrances.
Dry chemical extinguishers and carbon-dioxide (CO 2) extinguishers located

throughout the powerhouse area.
The equipment shall be supplied from a reputable manufacturer according to

approved standards. The quality and type of equipment shall be illustrated and
documented in the bid by brochures.
The Contractor shall submit detail drawings and all pertinent technical
documents as well as the design and an explanation in detail of the equipment
operations of the fire fighting system to the Engineer for approval.

The scope of work shall include, but not necessarily be limited to, the followings:
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One (1) set of main fire hydrant pump with motor and other accessories.
One (1) complete galvanized steel piping system for water supply to fire
hoses and deluge equipment from the header pipe of fire hydrant pumps,
complete with all the required valves, flanges, drains, gaskets, brackets,
anchors, bolts, screws, and electrical controls.
One (1) complete set of fire detection and alarm system.
Ten (10) portable dry chemical extinguishers, 4.5 kg each.
Ten (10) portable CO2 extinguishers, 4.5 kg each.
One (1) cabinet-mounted fire hoses with auxiliary equipment.
One (1) set of all tools, special keys, spanners, etc. for the repair, servicing
and maintenance of the supply, all kept in a metallic cabinet with lock.
All components, accessories, items and equipment not specifically

mentioned above, but necessary for the safe and proper erection,
successful operation, and maintenance of the supply.

CONDITION
1.4.3.1
Fire Alarm System
The fire alarm installed shall detect the fire, send warning signal and ultimately
signals for fire fighting through automatic system activation. The fire alarm
system shall consist of various types of detectors looped in protected areas
through fire control panel, and which shall also be connected to manual alarm
tripping loops using fire rated cables and accessories.

The installation and equipment shall comply with current edition of:
IEC 60839: Alarms systems
NFPA: National Fire Protection Association.
Where discrepancies occur they shall be referred to the Employer for his
approval.
1.4.5 SUBMITTALS
All pertinent technical documents as well as the design and an explanation in
detail of the equipment operations shall be submitted to the Employers
Representative for approval. The Supplier/manufacturer shall conduct all
approval procedure in order to get the Operation Licence from the concerned
authorities of Fire Fighting Department (Nepal).

1.4.6.1
Fire Detection and Alarm System
The fire detection and alarm system shall be used for early detection of fire,
warning and sending of signal for fire fighting automatic system activation. It
shall consist of various types of detectors installed in rooms or areas to be
protected and control panel, to which are connected the detection loops, manual
alarm tripping loops in closed circuits, cables and accessories.
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The system shall consist of control annunciator, network control system, graphic
mimic panel, central alarm control panel and power supply. All status information
of equipment shall be displayed and recorded on the central alarm control panel
in the control room of the powerhouse.
1.4.6.2
Detectors
Automatic fire detection system shall cover the fire detectors, which shall be
installed in all required areas to provide early detection of any fire which might
occur. The Contractor shall be responsible for determining the most appropriate
type of detector on the basis of a fire risk analysis and appraisal of
environmental conditions. The detectors shall be of the draw-out type on the
standard base, so that the type may be changed at any time.
Smoke detectors shall be ionic detectors, reacting to visible and invisible
combustion products. They shall be equipped with a self-compensating system
against temperature, humidity and atmospheric pressure variations.
Heat detectors shall be thermostatic detectors, responding to a rapid rise in
temperature and to an abnormally high temperature.
The detectors shall be provided with a built-in alarm indicator.
Smoke detector:
Principle
: Optical
Setting time
:1s
Protection area at 4 m height
Threshold
Working temperature
: 100 m2
: smoke concentration 15% volume
: 0C to 70C
Thermal detector:
Principle
: temperature rise and fix temperature
Threshold
: 70 C or temperature rise 15 C/min
Protection area at 4 m height
: 40 m2
Working temperature
: 0C to 70C
1.4.6.3
Alarm call boxes
In case personnel are present, it shall be possible to activate the alarm manually
by means of special alarm call boxes installed throughout the different buildings
and accesses to be covered. They shall be wall-mounted and of the type, in
which a frangible glass cover plate is smashed releasing a switch, which initiates
an alarm without further action by the user. They shall be coloured red, with the
words "FIRE ALARM" in white either on or immediately adjacent to the body of
the Call Point.
Alarm call boxes
Waterproof type (IP65) for outdoor and IP54 for indoor
Operating voltage
Working temperature
: 24 VDC
: 0C to 70C
Alarm bell:
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Cover by aluminium alloy
Operating voltage
: 24 VDC
Audibility
: 90 dB/1m
Working temperature
1.4.6.4
: 0 C to 70 C
Central Alarm Control Panel
Enclosure of the control panel shall be made of steel plate 1.2 mm or thicker with
such a construction as the internal equipment can be easily inspected. When the
fire alarm signal is received from a detector or manual alarm station, the control
panel shall clearly indicate the place where a fire has broken out by illuminating
the zone indicator and sounding the main alarm bell in the panel.
When an alarm is initiated, the alarm condition shall remain until reset switch of
the panel is operated.
The control panel shall have the reporting function. The following devices shall
be provided, but not limited to, on the control panel:
Main alarm and Local alarm bell silence switch,
Fire reset and test switch,
Fire alarm and local alarm lighting,
AC/DC power source lighting.
1.4.6.5
Cables and Conduits
The fire detection system cable installation shall be of copper wire type, PVC
insulated, aluminium shield. Identification markers shall be fitted to the ends of
all cables in accordance with relevant standards raceways.
Conduit shall be made by zinc plated steel. All conduits shall be grounded.
1.4.7 WATER FIRE FIGHTING SYSTEM

The system shall be used to protect all structures at powerhouse and switchyard
including from fire. It shall consist of one pumping plant with distribution supply
system and stop, control and fire fighting fittings.
The water used for the fire fighting system shall be drawn from the sump
connected to tail race and used for drawing water for cooling water system. So
the pumps for fire fighting shall be installed in the same room as used for cooling
water system. The system includes the water deluge system and the water to
the fire hoses.
The system shall be designed for pumps capacity equal to simultaneous fire
fighting of a transformer and external fire fighting.
Water supply for the system is taken from the fire pumping plant.
1.4.7.1
Fire Hydrant Pump
The system shall consist of a main fire hydrant pump of centrifugal-type directly
coupled with motor with all necessary accessories such as valves, operation
panel, meters, piping, pipe joints, pressure gauges and other necessary devices
in the steel frame. The pump shall be of such a construction as to operate with
low noise and vibration.
Main part of the pump shall be as following:
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Casing
Impeller
: Bronze or stainless steel.
Shaft
: Stainless steel.
Rated speed
: 3000 rpm
Starting mode
: Star/Delta
Power supply
: 380 VAC/3phase/50Hz
1.4.7.2
: cast iron or stainless steel
Control panel
Control panel of each pump unit shall have the minimum following function and
devices:
Switches
OFF.
: Push button switch ON-OFF with buzzer ON-
Signal lamp
: Power-Operation-Over-current of motor.
Meters
: Voltage, Current
Buzzer
: Over-current of motor
Automatic start by receiving signal from pressure switch or remote

starting signal such as push button and/or detector.
1.4.7.3
Hydrant box
The hydrant box shall consist of hydrant valve, horse rack, horse and nozzles.
The box shall be constructed of steel plate 1.6 mm thick, shop-coated with oil
paint. The door shall be a steel flush door.
The box shall be surface mounted or flush mounted type depending on the
places.
The hose rack shall be of cast bronze construction, chromium-plated, swing-out
type.
The hose shall be of cotton or linen rubber lined hose treated to prevent mildew,
rated for 4.5kg/cm2 water pressure. The hose shall have 65 mm diameter and 20
m length and shall be provided with suitable couplings for connection to the
hydrant valve and nozzle.
The nozzle shall be of bronze construction, stream water discharge-type.
1.4.7.4
Piping System and Accessories
The material of pipe shall be black steel for diameter greater than 80 mm and
zinc-plated steel for diameter up to 80 mm. The whole assembly of pipes and
supports shall include all necessary flanges and bolting to allow rapid
dismantling in case to be removed for maintenance. The tank, collectors, water
spray distribution pipes, valves, supports shall be galvanized.
1.4.7.5
Fire Hose System
The fire hose system shall consist of fire hose cabinets and piping. Required
numbers of fire hose cabinets shall be installed in the powerhouse. The cabinets
shall be of stainless steel construction. They shall be of the wall recessed type,
wire-glass door style with door hinges and provided with door handles with lock.
The cabinets shall be suitable for outdoor installation and shall include a valve.
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The nozzle shall be of the fog type, suitable for all types of fire. Pipe headers and
risers shall be provided for the fire hoses. From the risers, a branch shall be
provided at each floor to each hose cabinet. The supply shall include all valves
and necessary equipment.
1.4.8 MOBILE DRY-TYPE FIRE EXTINGUISHERS

The mobile dry-type fire extinguishers shall be applied for initial fire fighting at
specified zones in the powerhouse.
The fire extinguishers shall consist of a bottle and carrying assembly, pressure
reducing valve and medium pressure hose. The bottle shall supply sufficient
extinguishing agent for one man to operate at a medium to heavy rate for one
hour. The carrying assembly shall be lightweight, made of fire resistant material
and shall be of robust construction and incorporate a pressure gauge graduated
in MPa and kg/cm. The fire extinguisher medium shall be of dry chemical, heavy
duty, ABC and CO2 contained in the steel bottle as following:
Dry Chemical Extinguishers
The dry chemical extinguishers shall be designed for fighting of fires in solids, oil
and electrical equipment (ABC type). Each of the portable units shall be complete
with short flexible tube, pistol nozzle, and wall bracket.
Extinguishing agent
ABC quantity in container
: 4 kg and 8 kg
Container pressure
: 12 kg/cm2
Equipment:
: lever plunger, diffuser with grip
: ABC powder
CO2 Fire Extinguishers

The CO2 units shall be designed for fighting of fires in oil and electrical
installations (BC type). Each of the portable units shall be complete with short
flexible tube with diffuser made of dielectric material, operating lever protected
against unintended utilization, carrying handle and wall bracket.
The extinguishers for the diesel generator unit shall be housed in a weather-proof
metal cabinet on the outside wall of the unit housing.
Extinguishing agent
CO2 quantity in container
: 5 kg
Discharge duration
:9s
Discharge distance
:2m
: carbon-dioxide

1.4.9.3
Special Tools
One complete set of all special tools, necessary for the assembly,
disassembly and maintenance of the Oil filtration plant shall be provided.
1.4.9.4
Spare Parts
main equipment in the bid.
One (1) fire detector of each type.
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10% of each type of switch, solenoid and relay used, but minimum one of
each type.
Two (2) sets of all lamps, fuses, indicators of each type used.
Two (2) sets of all gaskets.
1.4.10
EXECUTION
1.4.10.3
Tests
The equipment to be supplied shall be tested as per recent international

standards. After installation, the fire detection system shall be tested. The test
shall include testing of all items of equipment and audibility tests. Each detector
shall be tested with specific equipment recommended by the Manufacturer.
After completion of erection random tests of one dry chemical extinguisher unit
and one CO2 unit shall be carried out by the Engineer to prove correct operability.
The tested units shall be recharged by the Contractor.
The deluge system tests shall include the followings:
Operation of the water deluge systems with actuation by the automatic

detection system, alarm system and manual release.
Pipe shall be flushed clean and hydrostatic pressure tested.
The embedded pipes in the ground shall be painted with 2 layers of anti-erosion
and 2 layer of bitumen with thickness not less than 2 mm.
The exposed pipes shall be painted with 2 layers of anti-erosion and 2 layer of
coating (red colour for water fire fighting pipe and blue for CO 2 pipe). The
painting thickness of each layer shall not be less than 50 microns. The treatment
method before painting shall be submitted to Engineer for approval.
The pipe lines shall be pressure tested by clean water at pressure of 1.5 time of
rated system pressure and ensure that the pressure drop shall not exceed 5% of
testing pressure after 12 hour without any addition of water to the system.
1.5
TOOLS AND METERS
The machines, tools and meters, as listed, with necessary accessories and spares
shall be supplied under the contract. These may be used by the Contractor
during construction with the approval of the Engineer and shall be returned in
good repair after completion of the works. The electric source for following
apparatus is 400 V, 3-phase, 400 V or 230 V, single phase, 50 Hz.
The contractor shall furnish the details of tools and meters with catalogues or
leaflets during contract negotiation. The contractor shall furnish set of
viewgraphs with overlays to explain machine operation, wall chart, machine
manual in English language, overall dimensioned diagram, foundation details
and list of standard spare parts for the tools and meters to be supplied under this
contract.
The bidder shall furnish the ISO 9002 or equivalent certificate of the tools and
meters manufacturer along with its details of certifying agency (accreditation,
validity date etc.). The technical specification submitted with tender shall be in
English language.
The location of powerhouse workshop, where all the tools and meters will be
placed, shall be in the vicinity of the powerhouse and will be finalised during
contract negotiation.
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1.5.1 MACHINE AND TOOLS

Sufficient machine and tools with accessories to fully equipped a maintenance
machine shop and sufficient meters for inspection and maintenance of the major
and ancillary equipment installed in the power plant shall be supplied.
The machines and tools shall include, but not be limited to, the following:
1. Bench Drilling Machine
The machine shall be bench-type, drilling head to be raised and lowered on
column, spindle with adjustable speed, spring-balanced drilling spindle,
adjustable depth stop with millimeter scale, built-in machine light, etc.
Approximate Specification
S.No.
Items
1.
Specification
Drilling capacity in steel
2.
15 mm
Drilling depth
3.
90 mm
Diameter of column
85 mm
2. Power Hacksaw
The machine shall be of heavy duty type with hydraulic saw frame control,
automatic blade lift on return stroke, adjustable cutting pressure, adjustable
length of stroke, automatic stop at end of cut, swivelling vice and complete with
coolant pump.
S.No.
Items
Specification
1.
Length of blade
450 mm
2.
Cuts round
150 mm
3.
Cuts square
100 x 100 mm
4.
Max. length of stroke
150 mm
3. Bench Grinding Machine

The machine shall be double-ended bench type, totally enclosed, complete with
electric motor with ball bearings, adjustable tool rests for grinding of tools,
detachable wheel guards and eye shields, complete with two grinding wheels,
one fine and one coarse.
S.No.
Items
Specification
1.
Wheel size
300x50x25 mm
2.
Distance between wheels
600 mm
3.
Electric motor
2 kW, 3000 rpm
Accessories required shall be:

Grinding wheel, straight, 40 grit, 300x50x25 mm
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4. Welding Transformers
The machines shall be of built-in transformer and rectifier type with preferably
current control, portable on wheels.
S.No.
Items
Specification
1.
Primary current (Adjustable)
2.
Secondary current rectified
300 Amps, 50 V
3.
Insulated electrode holders
2 nos.
4.
Ground lead
5.
Electrode lead
30 m
6.
Welding helmet
2 nos.
7.
Leather apron
2 nos.
8.
Leather gloves
2 pairs
9.
Wire scratch brush
2 nos.
10.
Chipping hammer
11.
Earthing clamps
40 Amps, 380 V
30 m
2 nos.
2 nos.
Welding transformer shall be specially designed for continuous-duty welding

purposes. Its cores shall be constructed of high quality. The steel shall be of thin
lamination. Both sides of each steel plate should be insulated with durable
insulating material. It should have minimum vibration.
The complete assembly of core and coil shall be dried in a vacuum sufficient to
ensure elimination of air and moisture within the insulating structure. Coil should
be made of copper.
The transformer shall be designed and constructed to withstand without injury
the thermal stresses produced while working on the max. current of 310 Amps.
Its primary nominal voltage shall be 220/400 V, AC. The secondary voltage shall
be rectified and welding Transformer shall be used as direct current source of 50
V.
5. Air Compressor
Air compressor shall be reciprocating, air-cooled, single/double acting and multi
stage-type complete with drive motor, drive arrangement, suction air
filter/silencer, unloader, high outlet air temperature switch, coolers and an
integral air receiver of 400 liters capacity. Air receiver shall be designed in
accordance with international standards and shall be tested hydrostatically to a
pressure of 1.5 times the design pressure.
The compressor shall have over-load protection and shall require minimum
maintenance work. Its interval of maintenance should be greater than or equal to
1000 working hours. Air receiver shall be complete with supporting stand, fixing
bolts and nuts, hand hole for inspection, safety valve, pressure gauge and other
necessary accessories.
The compressor shall have auto reclose pressure switch closing at 8 bar and
opening at 10 bar and a running hour meter. A suitable high pressure hose of 50
m. long shall be included.
Ancillary Equipment
- 26 -

MECHANICAL WORKS
Bidding Documents
6. Hand Drill
The item shall be having variable speed and reversible rotation control. It should
be supplied complete with drill chuck, key and cable with plug.
S.No.
Items
1.
Drilling capacity in steel
2.
Specification
13 mm
Rated voltage
3.
phase
220 V
Supply details
AC, 50 Hz, single

A set of drills from 0-4,5,6,7,8,9,10,11,12,13 mm
Catalogue and operation and instruction manual.
7. Hand Grinder
The grinder shall be used for weld dressing work, general grinding work and for
cutting off purposes. It shall be useful for fast cutting work too.
Approximate specification
S.No.
Items
Specification
1.
Grinding wheel diameter
178 mm
2.
Grinding wheel thickness
5 to 10 mm
3.
50Hz.
Power supply details
220 VAC, single phase,
Grinding wheels with different shapes suitable to be used in them. (Each

single quantity)
Catalogue with internal drawing and instruction manual
8. Tools
Item
Description
Specifications
Anvil
100 kg
Swage block
55 kg
Leg vise
150 mm (6")
Allen keys
1.5mm to 10 mm each
12mm to 24mm each
5 ton
3 ton
Chain block
Quantity
Ancillary Equipment
- 27 -

MECHANICAL WORKS
Bidding Documents
Hydraulic type jack
10 and 25 ton
Portable electric blower
1/4 HP motor driven
Die stock with ratchet
13 mm - 50 mm (1/2" - 2")
Pipe cutter
13 mm - 57 mm (1/2" - 21/4")
10
Micro-meter calliper
0.1 - 25 mm
11
Extensible
micrometer
12
inside 50 - 1,000mm
Iron bench level
450 mm (18")
13
Vernier Calliper
0-250 mm
14
Wire rope
12mm (1/2") diameter
50 m
18mm (3/4") diameter
50 m
Description
Quantity
9. Meters
The following meters shall be supplied:
S. No.
Item
Tong tester
0-600V, 0-1000A clip on

voltmeter and ammeter
Insulation tester
2,000V, 5,000 mega-ohm
Phase
indicator
Frequency meter
rotation 50-500 V
Portable type,
45-65 Hz, 0.2 Hz step,

120-240V
5
Digital Multimeter
Portable
0-1000V AC
0-750V DC
0-2/10A AC
0-100mA/DC
0-200A/1K/20K/1M
Ancillary Equipment
- 28 -

MECHANICAL WORKS
Bidding Documents
Calibrator
Portable Precision
Inject 0-200mA DC
0-200mV/20V DC
Measure 0-20/200mA DC
0-200mV/20V DC
Each equipment shall be tested in accordance
standards at the manufactures shop.
with applicable
code
and
The Employer shall be given the opportunity to witness all the tests according to
approved test plan. All test report shall be certified by the Contractor whether
witnessed or not.
Ancillary Equipment
- 29 -

Jumdi Khola Small Hydropower Project Electro-Mechanical Works Particular Technical Specification Section 13: Ancillary Equipments

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