2A NTPC MTPP CHP Tech Spec Datasheet & Tender Drawings

KANTI BIJLEE UTPADAN NIGAM LTD.
(A JOINT VENTURE OF NTPC LIMITED AND BSEB)
MUZAFFARPUR THERMAL POWER PROJECT

STAGE-II (2X195 MW)
SECTION - VI
TECHNICAL SPECIFICATION
FOR
COAL HANDLING PLANT PACKAGE
BID DOCUMENT NO.: CS-0350-155(R)-2


STAGE-II (2X195 MW)
SECTION - VI
FOR

This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred,
reproduced or otherwise used for purposes other than that for which it is specifically issued.
TABLE OF CONTENTS
TABLE OF CONTENTS
PART SECTION NO TITLE
PART-A SUB SECTION- I PROJECT SYNOPSIS
IIA-01 INTENT OF SPECIFICATION
IIB-01 GUARANTEE TEST PROCEDURE
IIC-01 SPARES
PART-B MECHANICAL
IIIA-01 SYSTEM PARAMETERS AND OPERATION &

CONTROL PHILOSOPHY
IIIA-02 PADDLE FEEDER
IIIA-03 BRAKES & CLAMPS
IIIA-04 MONORAILS AND HOISTS
IIIA-05 CHUTES & HOPPERS
IIIA-06 BELT CONVEYOR SYSTEM
IIIA-07 DRIVE EQUIPMENT
IIIA-08 BELT SCALE
IIIA-09 DUST CONTROL & MISCELLANEOUS SYSTEM
IIIA-10 VENTILATION SYSTEM
IIIA-11 CHP BUILDING
IIIA-12 VIBRATING SCREENING FEEDER
IIIA-13 RING GRANULATOR AND VMS
IIIA-14 TRAVELLING TRIPPER & BUNKER SEALING

ARRANGEMENT
IIIA-15 INLINE MAGNETIC SEPARATOR AND

SUSPENDED MAGNET
IIIA-16 METAL DETECTOR
IIIA-17 COAL SAMPLING UNIT
MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATION

STAGE-II (2X195 MW) MAIN CONTENTS
COAL HANDLING PLANT PACKAGE SECTION-VI PAGE 1 OF 3
BID DOCUMENT NO. : CS-0350-155(R)-2
TABLE OF CONTENTS
IIIA-18 ELEVATOR
IIIA-19 STACKER CUM RECLAIMER
IIIA-20 WAGON TIPPLER
IIIA-21 APRON FEEDER
IIIA-22 SIDE ARM CHARGER
PART-B ELECTRICAL
IIIB-01 MOTORS
IIIB-02 LT SWITCHGEAR & BUS DUCT
IIIB-03 POWER CABLES
IIIB-04 CONTROL CABLES
IIIB-05 INSTRUMENTATION CABLES
IIIB-06 ILLUMINATION SYSTEM
IIIB-07 CABLING, EARTHING & LIGHTNING

PROTECTION
IIIB-08 TRANSFORMERS
IIIB-09 INSTRUMENTS
IIIB-10 HT LOAD BREAK SWITCH AND JUNCTION BOX
IIIB-11 BATTERY
IIIB-12 BATTERY CHARGER
IIIB-13 CONTROL PANEL
PART-B CIVIL
IIID-01 CHP SYSTEM - CIVIL & STRUCTURAL WORKS
IIID-02 FOUNDATION SYSTEM AND GEOTECHNICAL

DATA
PART-B QA & I SECTION
IIIE-01 TO E-17 QUALITY ASSURANCE AND INSPECTION

TABLE OF CONTENTS
PART-C GENERAL TECHNICAL REQUIREMENTS
PART-D ERECTION CONDITIONS OF CONTRACT
PART-E LIST OF TENDER DRAWINGS
PART-F LIST OF MANDATORY SPARES

PART - A

STAGE-II (2X195 MW) SECTION-VI
COAL HANDLING PLANT PACKAGE PART-A
PART - A
SUB-SECTION-I
PROJECT SYNOPSIS

CLAUSE NO.
PROJECT SYNOPSIS
PROJECT SYNOPSIS
1.00.00 BACKGROUND
A Memorandum of Agreement (MOA) was signed among Govt. of Bihar, Bihar State
Electricity Board (BSEB) and NTPC Limited on 26.12.2005 with an intent to promote
a joint venture company namely Vaishali Power Generating Company (VPGCL) with
the aim of taking over further reviving and operation of Muzaffarpur TPS (2x110
MW) and object of establishment, operation and maintenance of thermal power
project having an equity participation of NTPC 51% and BSEB 49%. VPGCL has
been incorporated with the Registrar of Companies, Delhi & Haryana on 06.09.2006.
Subsequently, the name of the company has been changed to Kanti Bijlee Utpadan
Nigam Limited (KBUNL) on 10.04.08. Further, as per MOA JV Company has taken
up expansion of Muzaffarpur TPS (MTPS) by implementing (2x195 MW) coal based
thermal power project at Kanti in Muzaffarpur district of Bihar state for meeting the
power demand of Bihar State and other willing customers after meeting the demand
of Bihar State.
2.00.00 LOCATION AND APPROACH
The project is located at village Kanti in Muzaffarpur district of Bihar State having
latitude and longitude of 260 11’ 40” N and 850 18’ 13” E respectively. The project is
situated on Muzaffarpur-Motihari section of National Highway No. 28 at a distance of
about 1.5 kms Kanti railway station on Samastipur-Motihari loop and about 13 kms
from Muzaffarpur Railway Station of East-Central Railway. The nearest town
Muzaffarpur is about 13 kms.
Airport
The nearest commercial airport is Patna at a distance of about 90 kms from the
project site.
The vicinity plan of the project site is placed at Annexure – 1
3.00.00 LAND
The project is planned to be accommodated within existing premises of MTPS.

However, about 415 acres of land will be required for ash-pond and other corridors.
Govt. of Bihar has been approached for in-prrinciple clearance for availability of 415
acres of land vide letter dated 21.02.2008.
4.00.00 WATER
4.01.00 WATER SOURCE
Raw water is proposed to be used for meeting the complete water requirement of
the project. The source of raw water for the project is river Burhi Gandak which is at
a distance of about 4 kms from the plant boundary.
MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATIONS

CHAPTER-I
STAGE-II (2X195 MW) SECTION-VI PAGE
PROJECT SYNOPSIS
COAL HANDLING PLANT PACKAGE PART-A 1 OF 15
CLAUSE NO.
PROJECT SYNOPSIS
Water Requirement and Commitment
The make up water requirement for the project is about 1500 m3/hr with ash water
recirculation system and about 2000 cubic m3/hr with once through ash water
system.
Govt. of Bihar has accorded water commitment for availability of 45 Cusecs of

water vide letter dated 18.04.2008.
5.00.00 COAL REQUIREMENT, AVAILABILITY, QUALITY AND LINKAGE
Coal Requirement and Availability

Coal requirement for Stage-II of the project is estimated about 2.2 million
tones/annum corresponding to 90% PLF considering GCV of 3500 kcal/kg and 2500
kcal/kwh unit heat rate. SLC (LT) in its meeting held on 12.11.2008 accorded longg
term coal linkage and recommended Coal India Limited for issuance of Letter of
Award in accordance with New Distribution Policy for the project from mines of
Eastern Coalfields Ltd.(ECL).
Coal transportation
The envisaged mode of coal transportation from the coal mines to the power plant is
by Indian Railways rakes in BOX-N wagons.
6.00.00 COAL QUALITY
The coal quality to be considered for design of the system is mentioned in Table-1 of
this chapter.
7.00.00 RAILWAY SIDING
The railway siding required for MTPP, Stage-I (2x110 MW) is already available.
However, for meeting requirement of MTPP, Stage-II (2x195 MW) additional rail
facilities are required for receipt of materials and coal. In addition augmentation of
existing rail track is required for integration of Stage-I & Stage-II systems.
8.00.00 CONSTRUCTION WATER
The water requirement for construction purpose for Stage-II of the project would be
met from the existing network.
9.00.00 CONSTRUCTION POWER:
The requirements of the construction power supply for the project would be met from
the existing 6.6 KV station switchgear. Necessary 6.6/11 KV Transformers, 11KV
switchgear, 11 KV ring main /LT sub-stations etc shall be provided for the required
power plant area.

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
10.00.00 METEOROLOGICAL DATA
Important meteorological data from nearest observatory at Muzaffarpur is placed as

Annexure –II.
11.00.00 PLANT WATER SCHEME
The Plant water scheme is described below. Design Water Analysis is attached at
Annexure-III.
11.01.00 Condenser Cooling (CW) Water System
It is proposed to provide recirculating type CW system with cooling towers.
11.02.00 Equipment Cooling Water (ECW) System (Unit & Station Auxiliaries)
For scheme of Equipment Cooling Water System refer relevant tender drawings.
12.00.00 ASH WATER SYSTEM
It is proposed to provide ash water re-circulation system. Decanted water from ash
pond shall be led to the plant area by using pumps and the same shall be conveyed
through carbon steel pipes from ash dyke to plant area. . This water will be used
further in the ash handling system. Blow down of ash water from the system shall be
carried out to maintain the system scale free Normal make up to the ash water
system shall be from CW blow down water. However provision shall also be kept for
operating ash water system on “Once Through” mode During “Once Through” mode
operation, additional makeup shall be met from the plant raw water supply. Provision
to supply treated plant effluent from central monitoring basin to ash handling shall
also be kept.
13.00.00 OTHER MISCELLANEOUS WATER SYSTEMS
(a) The quality of Clarified water filtered (potable) water and DM water is given in
the enclosed Annexure-III to this Sub-section.
14.00.00 CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT
All structures and equipment of the power plant, including plant auxiliary structures
and equipment, shall be designed for wind forces as given in the Technical
Specifications on Civil Works.
15.00.00 CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT
All power plant structures and equipment, including plant auxiliary structures and
equipment shall be designed for seismic forces as given in the Technical
Specifications on Civil Works.

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
(SHEET 1 OF 2)
TABLE – 1
COAL CHARACTERISTICS
----------------------------------------------------------------------------------------------------------------
Sl. Description Symbol Design Worst Best Range of
No. Coal Coal Coal Adequacy Coal
----------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7
----------------------------------------------------------------------------------------------------------------
A. PROXIMATE ANALYSIS
(As received basis)
1. Total Moisture % 16.50 18.50 15.00 12.00-20.00
2. Ash % 43.00 46.00 34.00 30.00-50.00
3. Volatile matter % 17.00 15.00 20.50 22.00-14.00
4. Fixed carbon % 23.50 20.50 30.50 36.00-16.00
B. ULTIMATE ANALYSIS
(As received basis)
1. Carbon % 29.80 25.07 40.40 45.00-24.50
2. Hydrogen % 3.15 2.95 3.20 3.50 – 1.75
3. Nitrogen % 0.61 0.50 0.55 0.80 – 0.40
4. Oxygen % 6.68 6.71 6.64 7.00 – 6.00

(By difference)
5. Sulphur % 0.15 0.17 0.11 0.10 – 0.03
6. Carbonates % 0.08 0.06 0.07 0.05 – 0.10
7. Phosphorous % 0.03 0.04 0.03 0.07 – 0.03
8. Total Moisture % 16.50 18.50 15.00 12.00 – 20.00
9. Ash % 43.00 46.00 34.00 30.00 – 50.00
10. Gross Calorific KCal/Kg 2850 2450 3600 4000 - 2300

Value (as
Received basis)
11. Hard grove index 55 50 60 45 - 65

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
(SHEET 2 OF 2)
----------------------------------------------------------------------------------------------------------------
Sl. Description Symbol Design Worst Best Range of
No. Coal Coal Coal Adequacy Coal
----------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7
----------------------------------------------------------------------------------------------------------------
C. ASH ANALYSIS
1. Silica (SiO2)% 58.70 63.00 57.20 56.00 – 64.00
2. Alumina (Al2O3)% 25.80 28.50 25.00 25.00 – 31.50
3. Iron Oxide (Fe2O3)% 7.70 6.00 10.00 6.00 – 12.00
4. Titania (TiO2)% 1.30 1.10 2.00 1.00 – 2.20
5. Phosphoric (P2O5)% 0.63 0.25 0.70 0.20 – 0.80

Anhydride
6. Lime (CaO)% 2.61 0.60 3.00 0.70 – 0.20
7. Magnesia (MgO)% 1.04 0.40 1.75 0.40 -2.00
8. Sulphuric (SO3)% 1.02 0.20 1.10 0.20 – 1.20

Anhydride
9. Alkalies (Na2O+K2O) (%) 1.20 0.70 1.40 0.60 – 2.00

(by difference)
NOTE: Na2O content in the above shall not be more than 0.1%
D. ASH FUSION RANGE Design Worst Best

(Under reducing atmosphere) Coal Coat Coal
a) Initial Deformation Temperature 1100 1100 1100

(IDT) °C
b) Hemispherical 1400 1350 1400

temperature °C
c) Flow temperature °C 1400 1350 1400
Oxidizing Atmosphere
d) Initial Deformation 1100 1100 1100

Temperature (IDT) °C
e) Hamispherical Temperature °C 1400 1350 1400
f) Flow Temperature °C 1400 1350 1400

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
TABLE - 2
FUEL OIL CHARACTERISTICS
Sl. Characteristics Heavy Furnace Low Sulphur Heavy

No. Oil IS-1953 Heavy Stock Petroleum Stock
1971 Grade HV (LSHS) (HPS)
1. Total sulphur content 4.5% Max. 1.0% Max. 4.5% Max.
2. Gross calorific value of the order of the order 9,500

(KCal/kg) of 11,000 of 11,000 (min)
3. Flash Point (Min) 66 deg C 75 deg C 75 deg C
4. Water content by 1.0% 1.0% 1.0%

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

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

weight (Max.)
7. Kinematic viscosity 370 180 500

in Centistokes at -
50deg C (Max)
8. Ash Content by 0.1% 0.05% 0.1%

weight (Max.)
9. Acidity (inorganic) Nil Nil Nil
10. Pour Point (Max.) 57 deg C 72 deg C
11. Sodium content — — 100 ppm
12. Vanadium content 25 ppm 25 ppm 25 ppm
13. Specific heat below 0.65

pour point (KCal/Kg °C)

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
TABLE - 3
LIGHT DIESEL OIL CHARACTERISTICS
AS PER IS 1460-1974 WITH AMMENDMENTS UPTO OCT. 85
Characteristics LDO
1. Pour Point (max) 12 deg.C & 18°C for Summer

and Winter respectively
2. Kinematic viscosity in centistokes at 2.5 to 15.7

38 deg.C
3. Waste content, percent by volume (max) 0.25
4. Sediment percent by mass (max) 0.10
5. Total sulphur percent by mass (max) 1.8
6. Ash percentage by mass (max) 0.02
7. Carbon residue (Rans bottom) 1.50

percent by pass (max.)
8. Acidity in organic Nil
9. Flash point (Min.) - Pensky Martens 66 deg.C.

Abel -
10. Acidity, total, mg of KOH/g (max.) -
11. Copper strip corrosion for 3 hours at Not worse

100oC than No. 2
12. Total sediment mg per 100 ml max. = 1.0 Not worse

than No.2

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -I
(Page 1 of 1)
VICINITY PLAN

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -II
(Page 1 of 2)
METEROLOGICAL DATA

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -II
(Page 2 of 2)
METEROLOGICAL DATA

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -III
(Page 1 of 5)
COOLING WATER ANALYSIS
Constituent as mg per litre
1. Calcium CaCO3 462
2. Magnesium CaCO3 297.5
3. Sodium CaCO3 297.5
4. Potassium CaCO3 35
5. Chloride CaCO3 252
6. Sulphate CaCO3 157.5
7. Carbonate & Bi-Carbonate CaCO3 682.5
8. Silica SiO2 2
9. Iron Fe Nil
10. pH Value -- 8
11. Turbidity NTU 40
Note : The C.W. system is expected to operate at aboutt 3.5 cycles of

Concentration.

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -III
(Page 2 of 5)
RAW WATER (MAKEUP TO ASH WATER SYSTEM) ANALYSIS
1. Calcium CaCO3 105.00
4. Potassium CaCO3 10.00
5. Chloride CaCO3 65.00
8. Silica SiO2 Nil
9. Iron Fe Nil
10. pH Value -- 7.20
11. Turbidity NTU 10

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -III
(Page 3 of 5)
CLARIFIED WATER ANALYSIS
8. Silica SiO2 Nil
9. Iron Fe Nil
10. pH Value -- 7.50
11. Turbidity NTU 10.00
Note : At the outlet of clarifier of PT Plant.

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -III
(Page 4 of 5)
FILTERED WATER ANALYSIS (DRINKING WATER)
8. Silica SiO2 Nil
9. Iron Fe Nil
10. pH Value -- 7.50
11. Turbidity NTU 10.00

CHAPTER-I
PROJECT SYNOPSIS
CLAUSE NO.
PROJECT SYNOPSIS
ANNEXURE -III
(Page 5 of 5)
ANALYSIS OF DM WATER TO BE USED

FOR
MAKE-UP WATER TO CONDENSER
S.No. Characteristics Value
1. Silica (Max.) - 0.02
2. Iron as Fe - Nil
3. Total hardness - Nil
4. pH Value - 6.8 -7.2
5. Conductivity - Not more that 0.1

excluding the effects
of free CO2

CHAPTER-I
PROJECT SYNOPSIS
PART - A
SUB-SECTION-IIA-01
INTENT OF SPECIFICATION

CLAUSE NO. SCOPE OF SUPPLY & SERVICES
1.00.00 INTENT OF SPECIFICATION
This specification is intended to cover the following activities and services in respect
of all the equipment of Coal Handling Plant to be installed for Muzaffarpur Thermal
Power Project Stage-II (2x195 MW), completely covering the following activities and
services in respect of all the equipment specified and covered under the
specifications and read in conjunction with “Scope of Supply & Services”, Sub-
section-III, Part-A, Section–VI of Technical Specification.
(a.) (i) Detailed design and engineering of all the equipment and equipment
system(s).
(ii) Complete manufacture including shop testing/ type testing.
(iii) Providing engineering data, drawings, Commissioning procedures

and O & M manuals, etc. for the Employer’s review, approval and
records.
(iv) Packing and transportation from the manufacturer’s works to site

including transit insurance, customs clearance/ port clearance, if
required.
(v) Receipt, unloading, storage, preservation, conservation and

insurance of equipment at site.
(vi) Fabrication, pre-assembly, (if any), erection, testing and putting into
satisfactory operation of all the equipment including successful
completion of facilities.
(vii) Associated civil, structural, architectural and electrical works.
(viii) Commissioning and completion of facilities and Performance

Guarantee Tests after successful completion of initial operation.
(ix) Furnishing of spares on FOR site basis and handing over to NTPC
stores.
(x) Reconciliation with custom authorities, if applicable.
(xi) Satisfactory completion of the contract.
(b.) The equipment and services to be furnished and installed as required in this
Technical Specification shall also meet all the requirements as stated in
“General Conditions of Contract” (GCC), “ Special Conditions of Contract”
(SCC) and “Bid Form & Procedures” which shall be considered as a part of
this technical specification as bound herewith.

TECHNICAL SPECIFICATIONS SUB-SECTION-IIA-01
STAGE-II (2X195 MW) PAGE
SECTION-VI INTENT OF
COAL HANDLING PLANT PACKAGE 1 OF 28
PART-A SPECIFICATION
(c.) The Bidder shall be responsible for providing all materials, equipment and
services, specified or otherwise (unless specifically excluded) which are
required to fulfill the intent of ensuring operability and the reliability of the
complete system covered under this specification.
(d.) It is not the intent to specify completely herein, all aspects of design and
construction of equipment. Nevertheless, the equipment shall conform in all
respects to high standards of engineering, design and workmanship and
shall be capable of performing in continuous commercial operation.
(e.) Whenever a material or article is specified or described by the name of a

particular brand, manufacturer or trade mark, the specific item shall be
understood as establishing type, function and quality desired. Other
manufacturer’s products may also be considered provided sufficient
information is furnished so as to enable the Employer to determine that the
products are equivalent or superior to those named.
(f.) Bidder is requested to carefully examine and understand the specifications

and seek clarifications, if required, to ensure that they have understood the
specifications. Such clarifications should reach Employer at least 15 days
before the scheduled date of the opening of the bids. The Bidder’s offer
should not carry any sections like clarifications, interpretations and/or
assumptions.
(g.) If the Bidder feels that, in his opinion, certain features brought out in his offer
are superior to what has been specified, those may be highlighted
separately.
The Bidder may also make alternative offers provided such offers are
superior in his opinion. In which case, adequate technical information,
operating feed back, etc. shall be enclosed with the offer, to enable the
Employer to assess the superiority and reliability of the alternatives offered.
In case of each alternative offer, its implications on the performance,
guaranteed efficiency, auxiliary power consumption etc. shall be clearly
brought out for the Employer to make an overall assessment. In any case,
the base offer shall necessarily be in line with the bidding documents/
specifications.
Under no circumstances the equipment / system specification in Technical

Specification shall be brought out as alternative offer.
(h.) Any deviation or variation from the scope, requirement and/or intent of this
specification shall be clearly defined by the Bidder in “Attachment-6
Deviations” of Section-VII of bid documents irrespective of the fact that such
deviations/ variations may be standard practice or a possible interpretation of
the specification by the Bidder. Except for those deviations/ variations

covered under Attachment-6, which are accepted by the Employer before the
award of the Contract, it will be the responsibility of the Bidder to fully meet
the intent and the requirements of the specification within the quoted price.
No other deviation whatsoever from this specification, except for the declared
deviations submitted by the Bidder with his proposal under “Attachment-6
Deviations” shall be considered. Bids not complying with this requirement
shall be treated as non-responsive and hence liable for rejection. The
interpretation of the Employer in respect of the scope, details and services to
be performed by the Bidder shall be binding unless specifically clarified
otherwise by the Employer in writing before the Award of the Contract.
(i.) Before submitting his bid, the Bidder should inspect and examine the site and
its surroundings and should satisfy himself as to the nature of the ground and
subsoil, the quantities and nature of work, materials necessary for completion
of the work and their availability, means of access to site and in general shall
himself obtain all necessary information as to risks, contingencies and other
circumstances which may influence or affect his offer. No consequent extra
claims on any misunderstanding or otherwise shall be allowed by the
Employer.
(j.) For all the related buildings and facilities in Employer’s scope and not
covered under the scope of this package, the bidder shall furnish all the
related input data/ details for preparation of Mechanical/ Electrical/ Civil
Drawings within 45 days of award of contract.
(k.) The sizes of various buildings/conveyor galleries indicated in the tender

drawings and the parameters of equipment indicated in various sections of
technical specifications are the minimum requirements of the employer. Any
increase in these sizes or the parameters, if required to meet the
system/maintenance/operational requirement shall be supplied by the bidder
without any extra cost implication to the employer.
(l.) Bidder shall take all necessary precautions to protect all the existing
equipment, structures, facilities and buildings etc. from damage. In case any
damage occurs due to the activities of the bidder on account of negligence,
ignorance, accidental or any other reason whatsoever, the damage shall be
immediately made good by the bidder at his own cost to the satisfaction of
the Employer. The bidder shall also take all necessary safety measures with
specific reference to excavation in rock, at his own cost, to avoid any harm or
injury to his workers and staff from the equipment and facilities of the power
plant.
(m.) Bidder should note that the existing rail lines within the plant area are
operational with rail traffic of coal and liquid fuel rakes. Bidder shall take all
precautions to ensure the safety of existing rail tracks and other associated
facilities as well as the safety of his men, material and equipment from the

operating rail traffic. The bidder shall plan and make all arrangements to
ensure that disruption to the existing rail traffic is minimum and shall follow
the instructions of the Employer in this regard. Further, bidder shall plan and
co-ordinate all his activities considering restrictions, if any, on free access to
his work areas due to the rail traffic.
(n.) After award of work, before finalising his layout especially the layout / levels
of conveyors, cable / pipe routes and other services, the bidder shall carry
out a site survey to identify the location & details of existing facilities that may
interfere with his proposed facilities. The bidder shall suitably modify his
layout / levels to prevent dislocation of existing facilities and any cost / time
implication arising out of such modifications will be to his account. Bidder
shall also be responsible to determine and obtain the necessary details at
site as required for interfacing and interconnection with the existing system /
facilities.
If during the execution of works it is found that there is interference with the
existing facilities / structures, the bidder shall revise his design / detailed
drawings to clear the interference and shall provide all necessary measures
for the safety of existing structures. No claim in terms of cost or relaxation in
time shall be entertained for any redesign, rework and for safety measures
provided. If at any stage of work, any dismantling or modification or
relocation of any existing facility is required to be done to complete the work
in bidder’s scope and which has been agreed by the Employer, the same
shall be done by the bidder at no extra cost or time implication to the
Employer. All such changes will be as per drawings and work plan approved
by the employer.
(o) Bidder’s Office & Store Buildings
For his site office and covered store buildings, the bidder shall adopt pre-
engineered / pre-fabricated constructions made of steel with single / double
skin, insulated or uninsulated roof and wall coverings (fabricated out of
permanently color coated metal sheets). Alternatively, bidder can adopt
readymade ‘Portacabin’ or similar construction. Bidder shall ensure that all
such constructions are well engineered, neatly constructed and overall
present a pleasing look.
(p) Use of ash and ash based products
In line with Gazette Notification on Ash Utilisation issued by MOEF and its
amendment thereafter, bidder shall use ash and ash based products in works
as specified in these specifications, drawings and as per instructions of the
Engineer. He shall also use ash and ash based products in construction of
his offices, stores, staff quarters and labour huts etc. He shall furnish a

compliance report along with all details of use of ash and ash based products
along with each bill.
(q) Repair & Maintenance Facilities by the Bidder
Bidder shall establish/set up at site suitable repair facilities for construction

plant, equipment and machinery (like piling rigs, cranes batching plant,
dewatering pumps etc.) In case of piling rigs, cranes, batching plant etc. he
will also make arrangements/tie up with equipment manufacturers / suppliers
for periodic overhaul/maintenance and for major breakdown, if any. He shall
also keep adequate stock of spares at site for various plant, equipment and
machinery to meet day to day requirements as recommended by the
equipment manufacturer/suppliers or as instructed by the Engineer. Bidder
shall deploy dedicated qualified, full time mechanical/electrical
foreman/supervisors for manning the repair facilities as specified above.
1.02.00 Equipment and services covered under COAL HANDLING PLANT package are
described in the following sub-sections :
MECHANICAL
III-A-01 : System parameters and Operation & Control Philosophy
III-A-02 : Paddle Feeders
III-A-03 : Brakes and Clamps
III-A-04 : Monorails and Hoists
III-A-05 : Chutes and Hoppers
III-A-06 : Belt Conveyor System
III-A-07 : Drive Equipment
III-A-08 : Belt Scales
III-A-09 : Dust Control & Miscellaneous Systems
III-A-10 : Ventilation System
III-A-11 : CHP Buildings
III-A-12 : Vibrating Screening Feeder
III-A-13 : Ring Granulator & VMS
III-A-14: Travelling Tripper and Bunker Sealing Arrangement

III-A-15 : Inline Magnetic Separator and Suspended Magnet
III-A-16 : Metal Detector
III-A-17 : Coal Sampling Unit
III-A-18 : Elevator
III-A-19 : Stacker cum Reclaimer
III-A-20 : Wagon Tippler
III-A-21: Apron Feeder
III-A-22: Side Arm Charger
ELECTRICAL
IIIB-01: Motors
IIIB-02 : LT Switchgear & Bus Duct
IIIB-03 : LT Power Cables
IIIB-04 : Control Cables
IIIB-05 : Instrumentation cables
IIIB-06 : Illumination System
IIIB-07 : Cabling, Earthing & Lightning Protection
IIIB-08 : Transformers
IIIB-09 : Instruments
IIIB-10 : HT Load Break Switch and Junction Box
IIIB-11 : Battery
IIIIB-12 : Battery Charger
IIIB-13 : Control Panel
CIVIL
III-D-01 : CHP System- Civil and Structural Works
III-D-02 : Foundation System and Geotechnical Data

QUALITY ASSURANCE
III-E-01 to E-17 : Quality Assurance and Inspection
1.03.00 In addition to the specifications of equipment / system indicated in various sections

as above and General Technical Requirement attached at Part-C of the
Specification and Erection Conditions of Contract attached at Part-D of the
Specification shall also form part of this Technical specification.
1.04.00 TENDER DRAWINGS
The drawings listed in the specification at Part-E, form part of the specification and
shall supplement the requirements specified herein. The scope and terminal points
for the equipment to be furnished under this package shall be as identified in these
drawings and read in conjunction with the text of these specifications. These
drawings are preliminary drawings for bidding purpose only and subject to changes
that may be necessary during the detailed engineering.
1.05.00 In case of any conflicts / contradiction among various volumes / sections / annexures
/ chapters / appendices / tender drawings of bid documents, the same shall be
referred to the Employer for clarifications whose decision shall be final and binding.
No extra claims shall be allowed on this account.
1.06.00 SCOPE
1.06.01 The scope of Coal Handling Plant to be furnished, erected and commissioned under
this specification shall be as detailed hereinafter. The Bidder shall be fully
responsible for system and detailed design, engineering, manufacture, shop
fabrication, assembly, testing and inspection at manufacturer’s works, packing,
dispatch, transportation, transit insurance, custom clearance etc. as applicable,
delivery to site, unloading, handling and storage at site, insurance during storage,
construction, erection, including erection supervision, testing, inspection,
commissioning and handing over to Employer and Guarantee testing including all
associated electrical, civil, structural & architectural works as specified, unless
specifically excluded as per Section-Terminal Points & Exclusions.
1.06.02 The scope of the bidder shall be deemed to include all such items which although
are not specifically mentioned in the bid documents and/or in Bidder’s proposal but
are needed to make the system complete in all respects for its safe, reliable, efficient
and trouble free operation and the same shall be furnished and erected unless
otherwise specifically excluded as per Section Terminal Points & Exclusions. The
general description of the proposed system and the broad scope of work under the
specification shall include but not be limited to as elaborated below.

2.00.00 DESCRIPTION, SCOPE AND TERMINAL POINTS
2.01.00 BRIEF DESCRIPTION OF PROJECT
2.01.01 Muzaffarpur Thermal Power Project Stage-II (2x195 MW) consists of two (2) nos.
generating units each of 195 MW capacity. An independent coal handling plant is
proposed to cater to the two (2) units of 195 MW. Coal handling plant consisting of
one (1) no. track hopper, 1200 MTPH coal conveying system (with 100 % standby
parallel stream) along with paddle feeders, crusher house, trippers etc., one (1) no.
stacker/reclaimer and two (2) nos. wagon tipplers along with associated reclaim
conveyors are proposed to be installed alongwith their auxiliaries and other facilities.
2.01.02 Brief description of proposed Coal handling Plant.
This shall be read in conjunction with Coal Flow Diagram and the CHP layout
enclosed else where in the specification.
(i) Coal rakes consisting of bottom discharge BOBR wagons / Box-N wagons
shall transport coal to the power plant. The coal received from BOBR wagon
shall be unloaded in under ground R.C.C. Track hopper. The coal received
from Box-N wagons shall be unloaded in underground RCC hoppers by
means of Rota side wagon tipplers. Each wagon tippler hopper shall have a
loading capacity of minimum three (3) wagons loads of coal i.e. 300 Te. Two
(2) such Rota side wagon tipplers (WT-3 & WT-4) are to be employed for
unloading IR Coal rake. Side arm chargers are envisaged for placement of
wagon on the tippler table & removal of empty wagon from tippler table after
tippling. Clear access shall be provided for movement of pay loaders/
bulldozers on the hopper grating of wagon tipplers. Gratings over wagon
tippler hopper shall be placed and designed accordingly. Apron feeders are
employed under each wagon tippler for extracting coal from wagon tippler
hopper and feeding onto underground reclaim conveyors.
(ii) Four (4) number paddle feeders (PF-1, PF-2, PF-3, PF-4), each of 900MTPH
rated capacity shall be installed at the bottom of the Track hopper to scoop
the coal from track hopper and feed coal on to the underground conveyors
1A/1B. Suspended magnets (SM-1 and SM-2) shall be provided on Conveyor
1A/1B at pent house-I for removal of tramp Iron pieces. The rated capacity of
each conveyor in coal handling plant shall be 1200 MTPH .
(iii) Conveyor 1A shall transfer coal on to conveyor 2A/2B and conveyor 1B on

conveyor 2A/2B at TP1. Coal shall be moved on to conveyor 3A/3B at TP2.
Metal detectors MD-1 and MD-2 shall be provided on Conveyors 1A/1B to
detect non-magnetic metallic materials present in the “as received” coal.
Two numbers Belt Scale (BS-1 & BS-2) shall also be provided, one each on
Conveyor 1A and 1B for measurement of coal flow rate. Further Conveyor
1A/1B shall have facility for manual stone picking, at a suitable location after

PH-1. Two (2) nos. In line magnetic separators (ILMS-1 & ILMS-2) shall be
provided at discharge end of Conveyor 1A/1B for removal of metallic ferrous
tramp from “as-received” coal. Conveyor 3A/3B shall transfer coal on to
crusher house (CH). A passenger cum goods elevator (EL-1) as specified
elsewhere shall be provided in Crusher House (CH).
(iv) In Crusher house (CH), conveyor 3A & 9B shall transfer coal on to Belt
feeder-1 (BF-1) and conveyor 3B & 9A shall transfer coal on to Belt feeder-2
(BF-2). Coal from Belt feeder-1 shall pass through two (2) numbers
(dedicated) Vibrating Screening Feeder (VSF-1 & VSF-2) and two (2)
number (dedicated) crushers (CR-1 & CR-2) respectively. Similarly coal from
Belt feeder-2 shall pass through two (2) numbers (dedicated) vibrating
screening feeders (VSF-3 & VSF-4) and two (2) numbers (dedicated)
crushers (CR-3 & CR-4) respectively. Each dedicated stream shall have a
set of Rod gates and Rack & Pinion Gates before Vibrating Screening
Feeders to permit maintenance of equipment, hoppers and chutes in one
stream without affecting the operation of other stream. Coal sampling unit
(CSU-1) shall be provided to sample the coal of (-) 250mm size.
(v) Each of the four (4) Vibrating Screening Feeders shall be of 660 TPH
guaranteed capacity. Each of the four (4) crushers (ring granulator) shall be
of 660 MTPH guaranteed capacity which shall crush coal to (-) 20mm size.
Both the screened coal below 20mm size and crushed coal shall be
discharged on to dedicated set of Reversible Belt Feeders (RBF-3, RBF-4)
placed below the crusher floor. RBF-3 shall have provision to drop coal on
either conveyor 4A/4B when operating in one direction or on conveyor
10A/10B when operating in another direction. Similarly RBF-4 shall have
provision to drop coal on either conveyor 4A/4B when operating in one
direction or on conveyor 10A/10B when operating in another direction.
(vi) At TP-3 conveyor 4A/4B shall drop coal on to conveyor 5A/5B. In line
magnetic separators (ILMS-3 & ILMS-4) shall be provided at discharge end
of Conveyor 4A/4B for removal of metallic ferrous tramp from “as fired” coal.
At TP-4 conveyor 5A/5B shall drop coal on to either conveyor 6A/6B or
conveyor 14. Metal detectors MD-3 and MD-4 shall be provided on
Conveyors 5A/5B to detect non-magnetic metallic materials present in the
“as fired” coal. Two numbers Belt Scale (BS-3 & BS-4) shall also be
provided, one each on Conveyor 5A and 5B for measurement of coal flow
rate.
(vii) Conveyor 6A/6B shall drop coal onto Bunker conveyor 7A or 7B at transfer
point TP-5. Coal sampling unit (CSU-2) shall be provided to sample the as
fired coal of (-) 20 mm size.

(viii) At TP-7, conveyor 10A/10B shall drop coal on to yard conveyor 11. Yard
conveyor 11 shall convey coal on to Stockyard (Coal stock pile-1 and coal
stock pile-2) and shall run in conjunction with Stacker Reclaimer SR-1.
(ix) One (1) number Stacker cum Reclaimer (S/R-1) machine of 1200/1200
MTPH rated capacity shall be provided on yard conveyor 11. The Stacker
Reclaimer machine shall operate on rails for stacking/reclaiming the coal in
the stock yard area. During reclaiming operation the reclaimed coal shall be
conveyed to the yard conveyor 11 by the boom conveyor of the Stacker
Reclaimer machine (S/R-1).
(x) The reclaimed coal from Yard Conveyor 11 can be fed on to either conveyor
12A or 12B at TP-8. From TP-8, the reclaimed coal can be conveyed to the
raw coal bunker by conveyor 12A/12B, 5A/5B, 6A/6B, 7A/7B onwards to the
desired row of bunkers. One (1) no. In line magnetic separators (ILMS-7)
shall be provided at discharge end of yard Conveyor 11 for removal of
metallic ferrous tramp from crushed coal.
(xi) One (1) number Traveling Tripper is mounted on each of the Bunker
Conveyors 7A/7B (i.e. total two (2) nos. of traveling trippers) to feed coal into
Raw coal bunkers of the boiler units (unit no. 3 & 4).
(xii) Two (2) nos. Wagon tipplers (WT-3 & WT-4) along with apron feeders (AF-1
& AF-2) shall be provided to unload coal from Box-N wagons. Apron feeder
AF-1, receiving coal from WT-3, shall drop coal on to conveyor-8A. Apron
feeder (AF-2), receiving coal from WT-4 shall drop coal on to conveyor 8B.
Apron feeder AF-1, AF-2 shall be of 1200 MTPH capacity.
(xiii) At transfer point TP-6, conveyor 8A shall drop coal on to either conveyor 9A
or 9B and conveyor 8B shall drop coal on to either conveyor 9A or 9B. Two
(2) nos. In line magnetic separators (ILMS-5 & ILMS-6) shall be provided at
discharge end of Conveyor 8A/8B for removal of metallic ferrous tramp from
crushed coal.
(xiv) Conveyor 9A/9B shall drop coal onto Crusher House (CH) via Pent house
PH-2. Metal detectors MD-5 and MD-6 shall be provided on Conveyors
9A/9B to detect non-magnetic metallic materials present in the “as received”
coal. Two numbers Belt Scale (BS-5 & BS-6) shall also be provided, one
each on Conveyor 9A and 9B for measurement of coal flow rate. Further
Conveyor 9A/9B shall have facility for manual stone picking, at a suitable
location after PH-2. Two (2) nos suspended magnets (SM-3 & SM-4) shall be
provided on conveyor 9A/9B at Pent House-2 for removal of tramp iron
pieces.
(xv) Interconnection from Stage I coal handling plant to Stage II Coal Handling
plant is envisaged at existing TP-2A of Stage I and TP 4A of Stage II. At

existing TP-2A of Stage-I, existing conveyor 8A/B is presently feeding coal

onto existing conveyor 9A/B. By providing necessary chute work and flap
gates including all associated electrical works, along with necessary
modifications in existing chute work of conveyor 8A/B, coal from existing
conveyor 8A/B shall also be fed onto conveyor 13 (proposed for stage-II coal
handling plant) at existing TP-2A. Coal from conveyor 13 shall feed the
conveyor 6A/B at TP-4A of stage-II. Metal detector MD-7 shall be provided
on Conveyor 13 to detect non-magnetic metallic materials present in the “as
fired” coal. One (1) number Belt Scale (BS-7) shall also be provided on
Conveyor 13 for measurement of coal flow rate. One (1) number In-line
magnetic separator (ILMS-8) shall be provided at discharge end of conveyor
13 at TP-4A for removal of metallic ferrous tramp from “as fired” coal.
(xvi) Interconnection from Stage-II coal handling plant to Stage-I Coal Handling
plant is envisaged at TP-4 of Stage-II and TP-9 on existing Stage-I conveyor
8A/B. Conveyor 14 (proposed for interconnection from stage-II to stage-I)
shall feed the coal onto existing Stage-I conveyor 8A/B at TP-9.
(xvii) Transfer point TP-9, is proposed on existing operating conveyor 8A/B of

Stage-I coal handling plant. The construction and erection of TP-9 should be
planned in a manner so as to have minimum requirement of shutdown for
conveyor 8A/B.
2.02.00 DETAILED SCOPE
2.02.01 Underground RCC track hopper, underground wagon tippler hoppers, machinery
hatches at each end of track hopper, underground transfer point TP-6, underground
tunnels and pent houses PH-1& PH-2 complete with civil, structural, architectural
and electrical works including over ground structural shed for entire length of track
hopper and machinery hatches, steel grating (over hopper portion), removable
chequered plate covers over openings in machinery hatches for handling
underground equipment in Track Hopper, wagon tipplers and for all buildings,
equipment handling facilities for paddle feeders inside track hopper and feeders
below wagon tippler and shed over machinery hatches and other
equipment/systems such as DS system, ventilation system, drinking water system,
drainage system etc. as specified elsewhere in the specification. However, rails and
its fixing over track hopper is excluded from Bidder’s scope but rail foundation with
necessary pocket details for fixation of rails over track hopper and fixation of rails
near wagon tippler table is in coal handling plant Bidder’s scope. Cat walk of 1000
mm wide with handrails on one side all along track hopper for maintenance and
approach to wagon is also in the scope of the bidder.
2.02.02 Four (4) Nos. Paddle feeders, complete with all electrical, rails, supporting
structures, end stops, cable reeling drums, trailing cables, and necessary
arrangement for cabling on floor of track hopper along with accessories.

2.02.03 Conveyors 1A/1B ,8A/8B,9A/9B complete with tunnel, conveyor gallery along with its
supporting structures, short supports, stringers, deck-plate, seal-plate, conveyor
foundations, drive motors, pulleys, idlers, gravity take ups, take up structure, internal
and external belt cleaners, pull chord switches, belt sway and zero speed switches,
electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and
architectural works for tunnel, conveyor gallery, gallery supporting trestle and their
associated foundation etc. Conveyor 1A/1B & Conveyor 9A/9B shall have
arrangements for manual stone picking arrangement at an appropriate location after
the pent house-1&2 (PH-1,PH-2) respectively.
2.02.04 Belt Conveyors 2A/2B to 6A/6B, conveyor 7A/7B (Between TP-5 and Bunker
Building), 10A/10B, 12A/12B, 13,14 complete with conveyor galleries, conveyor
supporting structures, short supports, stringers, deck plate, seal plate, conveyor
foundations, drive motors, drive units, pulleys, idlers, gravity take ups including
guides, pits etc., internal and external belt cleaners, pull chord switches, belt sway
and zero speed switches, electro-hydraulic thruster brakes, all electricals etc.
including all civil, structural and architectural works for conveyor gallery, gallery
supporting trestles and their associated foundations.
2.02.05 Bunker Conveyors 7A/7B in the bunker building complete with conveyor supporting
structures, short supports, stringers, short support mounting stools and its fixing,
inserts (if any), deck plate, seal plate etc. drive motors, drive units, pulleys, idlers,
gravity take-ups with guides upto ground, internal and external belt cleaners, pull
chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes
including all electrical works etc.
2.02.06 Yard conveyors 11 complete with conveyor supporting structures, short supports,
stringers, deck plates, conveyor foundations, drive motors, drive units, pulleys,
idlers, take-ups, take-up structure, internal and external belt cleaners, pullchord
switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all
electrical, etc. including all civil, structural and architectural works and their
associated foundations.
2.02.07 One (1) numbers crusher house (CH) complete with all civil, structural, architectural
and electrical works etc accommodating two (2) nos. belt feeders, four (4) nos. ring
granulator and associated vibrating screening feeders (VSF), two (2) nos Reversible
belt feeders, R&P & rod gates etc., goods cum passenger elevator, conveyors, chute
work alongwith actuator operated flap gates, monorails & hoists, hoist maintenance
platform, external and internal staircases, hand rails and other equipments such as
coal sampling unit, dust suppression, dust extraction system, elevator, etc as
specified elsewhere.
2.02.08 Four (4) nos. Vibrating screening feeders (in crusher house) to feed the coal to
crushers complete with drives, dust hood, all mechanical, electrical accessories and
supporting structures etc.

2.02.09 Four (4) nos. ring granulators complete with drives, accessories all mechanical,
electrical civil & structural works, including crusher supporting foundations, vibration
isolation system with springs & viscous dampers, vibration monitoring system etc.
2.02.10 Four (4) sets of Gates each comprising of one rod gate and one actuator operated
rack & pinion gate at inlet to each of the vibrating screening feeder feeding coal to
crushers complete with drives, all mechanical, electrical, structural works etc.
2.02.11 Transfer points TP-1, TP-2, TP-3, TP-4, TP-4A, TP-5, TP-7, TP-8, TP-9 and TP-6
(along with under ground RCC structures), tunnel complete with all civil, structural,
architectural and electrical works including chutes, monorails, hoists/chain pulley
blocks, hoist maintenance platforms, external staircases, dust debris chutes etc. All
transfer points shall have separate debris disposal chute up to the ground floor.
Underground transfer point TP-6 shall be provided with suitable structural shed,
removable chequered plate covers over openings in matching hatches for handling
under ground equipment.
2.02.12 One (1) no. Stacker cum Reclaimer machine having rated stacking and reclaiming
capacity of 1200TPH/1200 TPH complete with all equipment and conveyors,
structural, electrical, cable reeling drums, all trailing cables cable trays and
accessories, rails, rail foundations, boom resting and maintenance platform, boom
tie arrangement, lighting towers (with foundations), end buffer structures, provision
of retaining wall in between machine foundation and stockyard, grade slab, drains,
cable pit, cable trench/cable supporting pedestals, pipe support pedestals, fixing and
grouting of rails along with all associated civil & structural works to operate in
conjunction with yard conveyor 11.
2.02.13 Complete chute work along with chute block switches and actuator operated flap
gates, mobile discharge pulleys (as applicable) and belt feeders in all Transfer points
and crusher house between various conveyors.
2.02.14 Two (2) Nos. passenger – cum – goods elevators with drives, all electrical,
mechanical, civil, structural & associated foundation works, accessories and
electrical to serve various floors of the crusher house (CH) and TP-5.
2.02.15 Two (2) Nos. motorised traveling Trippers, each of 1200 TPH capacity one (1) no. on
each conveyor 7A and 7B. Trippers shall be complete with all mechanical, electrical
equipment, rails, chute work, rail supporting structure (along with structural stools, as
required), cables with cable festooning arrangement, thruster brakes, rail clamps,
electric hoist, actuator flap gates etc. Bunker sealing and Grid/grating over the entire
length of bunker slot on tripper floor.
2.02.16 Adequate number of ventilation equipment for ventilating the track hopper, wagon
tippler hopper, underground tunnel of Conveyor 1A/1B, Conveyor 8A/8B and 9A/9B,
underground transfer point TP-6 and bunker bays (housing tripper conveyors)

complete with all mechanical, electrical, civil and structural works and associated
foundations.
2.02.17 Pressurised Ventilation system for all Switchgear rooms, MCC rooms complete with
all mechanical, electrical, accessories, civil and structural works.
2.02.18 Exhaust fans to be provided in all battery rooms, all toilets complete with electrical,
civil & structural works etc. Exhaust fans along with required ducting shall also be
provided for all underground Structures/Transfer Point.
2.02.19 Air conditioning of Main CHP control room, RIO rooms in MCC buildings, PLC room
in wagon tippler switchgear building and wagon tippler control rooms, operator’s
cabin & MCC room on Stacker/Reclaimer complete with all electrical, civil &
structural works etc. Air conditioning shall also be provided as elaborated in clause
no. 2.02.44.00 of this specification.
2.02.20 Minimum eight (8) Nos. sump pumps in track hopper complete with motors, local
control panel, level switches, individual discharge piping with fittings and valves to
nearest plant drain including pipes etc. upto disposal point.
2.02.21 Minimum two (2) Nos. sump Pump for each TP-6 and wagon tippler complex
complete with motors, local control panel, level switches, individual discharge piping
with fittings and valves to nearest plant drain including pipes etc. upto disposal point.
2.02.22 Eight (8) Nos. In-line Magnetic Separators at the discharge end of Conveyor 1A/1B,
4A/4B, 8A/8B, 11, 13 and four (4) nos. suspended magnets on conveyor 1A/1B and
conveyor 9A/9B complete with reject chutes, reject trolleys, supporting arrangement,
and all mechanical, electrical, civil, structural works and accessories. Independent
motorized arrangement for hoisting and travel of each suspended magnet shall also
be provided.
2.02.23 Seven (7) Nos. Electronic Belt weighers complete with all mechanical, supporting
arrangement, electrical, and accessories on conveyors 1A/1B, 5A/5B, 9A/9B and 13.
2.02.24 One (1) No. Electronic Belt weigher mounted on stacker reclaimer complete with all
mechanical, supporting arrangement, electrical, and accessories.
2.02.25 Seven (7) Nos. Metal Detectors complete with all mechanical, electrical, civil,
structural works and accessories on Conveyor 1A/1B, 5A/5B, 9A/9B and 13
2.02.26 One (1) No. belt vulcanizing machine of adequate size complete with all mechanical,
electrical, accessories and consumables for one year consumption. Further, belt
jointing facilities as specified shall be provided.
2.02.27 Two (2) nos. Rota side Wagon Tipplers alongwith hydraulically driven side arm
charger and electronic weighing bridges including all accessories, electricals and
associated civil structural & architectural works.

2.02.28 Two (2) nos. Apron Feeders & two (2) nos. dribble conveyor complete with drives
including all accessories, electricals, supporting structures, approach/ maintenance
platform and associated civil & structural works etc.
2.02.29 Complete dust suppression system for control of fugitive dust in track hopper, wagon
tippler hopper, paddle feeder, transfer points, crusher house, coal stock yard
complete with enclosed pump houses, water tanks, pumps, drives, hoisting
arrangements, piping, valves etc. electrical, accessories, civil, structural and
architectural works as briefly specified below :
a. Plain water dust suppression around the Track Hopper top and wagon tippler
top through fogging nozzles.
b. Plain water dust suppression around stockyard through sprinklers
c. Complete plain water dust suppression system with two (2) nos. pumps and
one (1) tank mounted on paddle feeder or on trolley including ring header
inside track hopper for supplying plain water.
d. Complete dry fog type dust suppression system at all Transfer Points,
Crusher House both at discharge and loading points including all electrical
and accessories.
e. Belt Sealing arrangement in Bunker bays for control of dust coming out of
coal Bunkers.
f. Water Pump houses & water tanks for dust suppression/ extraction, service
water, cooling water and potable water system.
2.02.30 Service water, potable water system and cooling water system for complete coal
handling plant.
2.02.31 Complete dust extraction system for control of fugitive dust in crusher house with
complete pumps, drives, hoisting arrangements, piping, valves etc. electrical
accessories, civil, structural and architectural works.
2.02.32 Cooling water system for scoop couplings, for complete coal handling plant as
specified elsewhere in the specification.
2.02.33 Monorails and electrically operated hoist blocks as well as hand operated chain
pulley blocks for servicing/installation/easy replacement of drive machinery, different
types of pulleys for all conveyors, GTU and other equipment from ground level to
their locations and vice-versa.
2.02.34 All buildings in bidder’s scope shall be complete with all electrical, civil, structural,
architectural works, cable trenches, fire safety walls, foundation, earth mat, fencing,

earthing for transformers. All cables, duct banks, trenches, cable trestles shall be
complete with associated civil/ structural work and necessary civil foundations.
2.02.35 Drainage of all CHP buildings, track hopper, wagon tippler hopper, tunnels, conveyor
galleries and coal stock yard including all civil & structural works as detailed out
elsewhere in the specification.
2.02.36 All equipment/fittings, supporting structure, along with insert plates, bolts,
accessories, MS sleeves, base plates, grouting as may be required and proper
alignment etc.
2.02.37 Complete unused set of all special tools and tackles, which are necessary or
convenient for erection, commissioning and overhauling of any equipment, covered
under the scope.
2.02.38 First fill of all consumables e.g.; oils and lubricants for one year toppings
requirements.
2.02.39 Preservative shop coating, final painting of all structures and equipment under the
scope.
2.02.40 All inserts, anchor bolts, foundation bolts for Bidder’s equipment, platforms etc. in
the entire CHP (including the transfer points, bunker buildings & conveyors galleries
in Employers scope).
2.02.41 All necessary grouting & finishing of the floor after welding at all such pockets & else
where is in Bidder’s scope.
2.02.42 Electrical System / Equipment
Unless specifically excluded in clause no. 2.04.00 bidder’s scope of work shall
include all electrical works as required for putting into successful operation of the
Coal Handling Plant covered under this specification. The sizing of the various
equipments shall be as defined in the specification.
2.02.42.01 One (1) no. 6.6 KV Load break switch and one (1) no. 6.6 KV junction box for each
Stacker cum Reclaimer machine.
2.02.42.02 LT SWITCHGEAR
415V Switchgear/motor control centers (as shown in electrical single line diagram),
busduct (as applicable), distribution boards, One (1) AC fuse board in each MCC
room, emergency stop Push buttons for all LT motors, local motor starters for
ventilation fans as required for plant and equipment.

In addition, 2 nos. of 125A switch fuse feeders (total load 50 KVA) & 2 nos. of 400A
MCCB (total load 100 KVA) shall be provided on each LT MCC-IIA, MCC-IIB, MCC-
IIC, MCC-IID & MCC-IIE for employer’s use.
In addition, twenty (20) % spare feeder (minimum one) for each type and rating
of the outgoing feeders shall be provided on that MCC.
Outgoing feeders shall be segregated stream wise and equally distributed on

each bus section of the MCC.
Contractor shall provide two (2) nos. of 415V, 63A feeders for 24V DC chargers
in each RIO room and control room, also contractor shall provide three (3) nos. of
415V, 63A feeders for UPSs in the control room.
2.02.42.03 TRANSFORMERS
One (1) Dry type transformer for each S/R machine.
2.02.42.04 MOTORS
Motors along with couplings and coupling guards for all rotating auxiliaries covered
under this package. All motors shall be with cable glands & lugs.
2.02.42.05 CABLES
(a) LT Power, control & Instrumentation cables, HT & LT trailing cables and any
special cables required for connection between equipment / devices in
Bidder’s scope.
(b) LT Power, control & Instrumentation cables:
i) Between Employer’s DDCMIS, RI/Os, 6.6KV CHP switchgear,

6.6/0.433KV transformers and Bidder’s equipments.
ii) Between Employer’s 6.6KV CHP switchgear & 6.6/0.433KV

Transformers and Employer’s DDCMIS / RI/Os.
For termination of cables at employer’s DDCMIS/RIO panel end, cage clamp (post
mounted) type terminals are envisaged. Bidder to provide suitable lugs for
termination of the cables. The exact arrangements and details of terminal blocks
shall be provided to successful bidder during detail engineering. The shield of
instrumentation cables shall be terminated on a shield of solid bar provided in
employer’s panel. The signal connection and cabling philosophy shall be as
enclosed at Annexure-I to Sub-Section-IIIB-05 “Instrumentation Cables”.
In addition to above bidder shall also supply power supply cables for employer’s 24V
DC chargers (2 nos for each RIO room and 2 nos for CHP control room) and
employer’s UPS (3 nos for CHP control room).

2.02.42.06 CABLING, EARTHING AND LIGHTNING PROTECTION
(a) i) Cable trays with supporting structure, trenches, duct banks etc. as
required for the cables to be supplied by the Bidder for the complete
coal handling system.
ii) Cabling viz., cable laying along with cable accessories for cables
supplied by the bidder.
iii) Cable trestle in Bidder’s scope is as marked in the General Plant

Layout drawing, however, exact coordinates shall be finalized during
detail engineering. Bidder shall provide necessary cable trays and
supports in their cable trestle and upto the equipment in CHP for all
Bidder’s cables and Employer’s HT & Control cables. Employer shall
lay their cables in the trays provided by the Bidder.
iv) Employer will provide necessary cable trays in their cable

trestle/structure as marked in the General Plant Layout drawing,
however, exact coordinates shall be finalized during detail
engineering. Bidder shall lay their cables in the trays provided by the
Employer. However, cable routing along with supporting structure and
trays from Employer’s trestle / structure upto Bidder’s CHP equipment
are included in Bidder’s scope.
(b) Grounding and lightning protection for the plant and equipment under
Bidder’s scope along with its interconnection to the nearest employer’s earth
grid at two points.
(c) Underground and over ground earthing of Employer’s 6.6/0.433KV CHP

transformers and 6.6 KV CHP Switchgear.
(d) Eight risers exclusively for employer C&I system in each RIO/control room
connected to earth mat shall be provided. Further earth flats for panel ground
in each RIO/control room shall be provided.
2.02.42.07 ILLUMINATION SYSTEM
Illumination system for complete internal and external lighting of associated plant,
equipment and buildings under Bidder’s scope.
2.02.42.08 220V DC System for the complete coal handling plant except for DC requirement at
MCC-IIE shall be provided by the bidder complete with Batteries, chargers and
DCDB. Two(2) nos. DCFB shall be provided at each location of DC requirement
which shall receive 220V DC from the main CHP DCDB except at MCC-IIE which
shall receive 220V DC from employer’s DCDB. Further the bidder shall provide and
terminate Two (2) nos. of 220V DC 32A feeders at Employer’s 6.6 KV Switchgear.

2.02.42.09 CONTROL SYSTEM
a) All drives related to Coal Handling System including Conveyers, Sump

Pumps, Dust Suppression System, except for the systems like Stacker
Reclaimer and wagon tippler shall be controlled through microprocessor
based Distributed Control System (DCS) being procured by Employer under
separate package (Station C&I Package). This DCS system shall perform all
functions such as auto / manual operation of gates/ valves/ dampers, pumps,
drives, local / remote selection of operation, status indication, annunciation,
interlock and protection of pumps/drives etc.
b) The above DCS system shall also interface with the systems like Paddle
feeders, S/R, Mobile trippers over bunkers, Belt weighers, Metal Detectors,
Inline Magnetic separators, Suspended Magnets, Coal sampling Units,
Hydraulic scoop Coupling etc. for which all the required controls , interlocks,
protection, annunciations etc are to be provided by the Bidder, for remote
operation and monitoring facility. All the alarms shall also be repeated in the
employer’s DCS and the bidder shall provide all the required contacts, field
inputs etc. for the same. For complete list of such systems, refer
corresponding mechanical chapters.
c) Brief description of capabilities of DDCMIS system being procured by

employer are given below.
(i) Controller loop reaction time (from change of input and the input
module to the corresponding control command output) for closed
loop/modulating control shall be 500 milli seconds.
(ii) Controller reaction time for ON/OFF control shall be one (1) second or
higher. For few specific applications controller reaction time 200 milli
seconds is envisaged. These response timings are from change in
input of digital input module to change of output in digital output
module, with both the modules in the same RIO. In case any
equipment/system being supplied by bidder requires such fast
controller reaction time, bidder shall clearly bring out the same in his
offer along with reasons for the same.
(iii) The maximum permissible cable distance for input/output in the field
from DDCMIS/RIO panel is 400 meters. In case cable length is more
than permissible cable length of DDCMIS then two runs of
instrumentation cables or higher size shall be provided by contractor,
as finalised by employer during detail engineering.
(iv) In case any equipment/ system being supplied by the bidder under
this package, has control requirements better than those specified
above, control of such equipments/system shall be through
standalone microprocessor/PLC based system to be supplied by

bidder. Suitable interface to employer’s control system preferably

OPC compliant (through Ethernet port) to be provided.
Bidder shall clearly bring out in his offer any such equipments /
systems, along with reasons and details of control system offered.
d) For successful implementation of the same, the Bidder shall furnish I/O list,
drive list along with KKS code and all other details/drawings/data/information
like write-ups and detailed logic diagrams for controls, interlock and
protection of Bidder’s equipment, recommended control loops, recommended
mimics/graphics. Any other data as might be required by Employer during
detailed engineering stage shall also be forwarded without any cost
repercussions. A representative of Bidder shall also be required to be
present during Factory acceptance Testing of Employer’s DDCMIS system at
the finally selected DDCMIS Vendor’s work for testing of the finally
implemented control system. The bidder shall furnish termination details for
all I/Os to be connected to Employer’s RIO/control system cabinets as per
philosophy approved by Employer during detail engineering stage. The
format and exact details by bidder shall be approved by employer during
detail engineering. While preparing I/O list and drive list during detail
engineering the bidder shall obtain details of exact DDCMIS/RIO
configuration from employer and include details of the same in these lists to
be furnished by bidder.
Bidder shall provide all necessary supervision/assistance for proper

commissioning of his equipment to Control System Supplier through
Employer.
e) Bidder shall provide independent PLC based control system consisting of

control Desk, PLC Panels, I/O racks, along with its power supply
arrangement etc. for the control of each stacker cum reclaimer machine.
f) Bidder shall provide independent PLC based control system consisting of

control desk, PLC panels, I/O racks along with its power supply arrangement
etc. for the control of wagon tipplers.
g) The control systems for stacker Reclaimer & wagon tippler system shall have
provision of dual connectivity to Employer’s DCS for status indication.
2.02.43.00 INSTRUMENTS
(a) All the Instruments as indicated in enclosed flow schemes/diagrams and

relevant tender drawings, corresponding Mechanical sections and meeting
redundancy and other requirements specified under technical specifications
are to be provided as a minimum.

(b) All Instruments which are Integral to equipment required for control,
monitoring and operation of the equipment/plant/ Systems are to be
provided. All the instruments shall be provided by the Bidder to meet actual
system requirements subject to Employer’s approval.
(c) Further, all the instruments / equipments including transmitters, transducers

temperature elements, switches which are required to implement the control
philosophy as specified in corresponding mechanical sections shall also be
provided by the bidder.
(d) Temperature transmitters are also to be supplied by the bidder for the
temperature elements supplied by the bidder. These temperature
transmitters shall be mounted in junction boxes, supplied by the bidder. The
instrumentation cables/thermocouples extension cables up to temperature
transmitters and from the output of temperature transmitters to employer’s
DCMIS/RIO panel are in scope of bidder only.
Temperature elements shall be suitably grouped depending on physical

locations and shall be connected to the JBs in which temperature
transmitters are mounted. Multi pair instrumentation cable shall be used to
connect output of temperature transmitters to employer’s DDCMIS. The
arrangement of temperature transmitters in junction boxes and location of
junction boxes will be discussed and finalised during detail engineering
2.02.44.0 ELECTRICAL BUILDINGS
i) One(1) No. switchgear building near wagon tippler to house Bidder’s CHP
MCC-IIA, MLDB & Welding DBs as required, etc. and Employer’s 24V DC
battery (2mx1m) in the ground floor. An air-conditioned 8m x 6m room for
accommodating Employer’s RI/O panels shall be provided in the ground
floor. An independent air-conditioned room for accommodating Bidder’s PLC
panels, RI/O panels, UPS and programming OWS as per the PLC
configuration diagram shall be provided. Two (2) nos. Employer’s
6.6/0.433KV, 1600KVA transformers are to be located by the side of the
building.
ii) One (1) No. switchgear cum CHP main control building near crusher house
to accommodate Bidder’s CHP MCC-IIB, MLDBs, Welding DB as required,
TR panels for ILMS/SM, 220V DC charger panels etc. and Employer’s 6.6KV
Switchgear. A separate room shall be provided to accommodate bidder’s
220V Battery. Employer’s 6.6KV switchgear consists of two incomer panels,
one bus coupler panel, two bus VT panels, four spare feeder panels & feeder
panels for Bidder’s CHP HT loads (as indicated in electrical single line
diagram). Two (2) Nos. of Employer’s 6.6/0.433KV, 2000KVA transformers
are to be located by the side of this building. Additionally one air conditioned
control room (15m x 10m) shall be provided to accommodate Employer’s

CHP Control desk and associated equipments. One ventilated room of size
5m x 5m adjacent to control room shall be provided to accommodate
Employer’s batteries for 24V DC charger and UPS.
iii) One(1) no. switchgear room near Track-hopper area to house Bidder’s MCC-
IIC , MLDBs & Welding DBs, TR panels for ILMS/SM & Employer’s 24V DC
battery (2m x 1m) as required etc. in the ground floor. A separate air
conditioned (8m x 6m) room shall also be provided in the ground floor for
accommodating Employer’s RI/O panels.
iv) One (1) No. Switchgear room in TP-4 to house Contractor’s CHP MCC-IID,
MLDBs and Welding DB as required and Employer’s 24V DC battery (2m x
1m). One (1) no. air conditioned room of size 8m x 6m for Employer’s RI/O
panels and its power supply panels shall also be provided in TP-4.
v) One (1) No. Switchgear room in TP-5 to house Contractor’s CHP MCC-IIE,
MLDBs and Welding DB as required and Employer’s 24V DC battery (2m x
1m). One (1) no. air conditioned room of size 8m x 6m for Employer’s RI/O
panels and its power supply panels shall also be provided in TP-5. Two (2)
Nos. of Employer’s 6.6/0.433KV, 1000KVA transformers are to be located in
the TP-5.
vi) Two (2) nos. of control room building, one for each wagon tippler shall be
provided. The air-conditioned control rooms shall be suitably located in the
first floor with view balcony to have better view for the control of wagon
tipplers and shall accommodate Bidder’s control desks and I/O panels / HMI
etc. Ground floor rooms of the respective control room building shall be
utilized for placement of any other equipment.
vii) Civil works shall include foundation, trenches, slits, support channels,
fencing, fire walls etc. for Employer’s Transformers, HT Switchgear &
Busduct, PLC panels, R I/O panels, 24V DC Battery & Chargers and any
other Employer’s equipment as indicated elsewhere. Proper covered shed
shall be provided on the transformers to give cover from the falling coal dust.
viii) 1600mm free space on either side the HT/LT Switchgear shall be provided
for adding any future panels. In addition to the above, at least 1500mm
clear space shall be made available from the walls to the Electrical panels.
In case two switchgear / Panel rows are provided in one room minimum
2500mm free space shall be provided in between them. Clear height of the
MCC/Switchgear building shall be 4000mm and incase of Bus duct entry the
same shall be 4500mm. Each MCC / Switchgear room shall be provided
with rolling shutter of size 3.0M(W)X3.5M(H). However, for Stacker reclaimer
MCC room and for MCC rooms in the TPs, the above details shall be
reviewed separately as per system requirement.

2.02.45.00 CIVIL
2.02.45.01 The work to be performed under this specification consists of providing all labour,
materials, construction equipment, tools and plant, scaffolding, supplies,
transportation, all incidental items not shown or specified, but reasonably implied or
necessary for successful completion of the work including Bidder‟s supervision and
in strict accordance with the drawings and specifications. The nature of work shall
generally involve earthwork in excavation including controlled blasting & very deep
underground excavation, extensive de-watering, shoring and strutting, sheet piling,
back filling around completed structures and plinth protection, area paving , disposal
of surplus excavated materials, piling, concreting including reinforcement and form
work, brick work, fabrication and erection of structural / miscellaneous steel works,
inserts, architectural items & finishes such as plastering, painting, flooring, doors,
windows & ventilators, glass and glazing, rolling shutters etc., permanently colour
coated profiled steel sheeting, anchor bolts, R. C. C. trenches with covers, laying
and testing of water pipes, sanitation, water supply, drainage, damp proofing, water
proofing and other ancillary items.
2.02.45.02 The work shall have to be carried out both below and above ground level and shall
be involving, basements, equipment foundations including vibration isolation
systems, grounding, slabs, beams, columns, footings, rafts, walls, steel frames, brick
walls, stairs, trenches, pits, access roads, culverts, conveyer galleries, trestles,
penthouses, track hopper, wagon tippler, underground tunnels, crusher house,
transfer towers, finishes, complete architectural aspects, drainage, sanitation, water
supply (from terminal points to various buildings, conveyor galleries) and all other
civil, structural and architectural works associated with the complete Coal Handling
Plant.
2.02.45.03 Scope of the Bidder shall also include supply and laying earthing mat all around the
periphery of buildings, structures, and outdoor equipments, as per the approved
drawings.
2.02.45.04 The analysis design and detailed drawing for the structures like track hopper,
tunnels etc. coming below the railway track shall be got approval by the Bidder from
the Concerned railway authority before taking up construction. All necessary
payment for above work shall be made by the bidder to the Railway authority.
2.02.45.05 The work shall also involve arranging construction water from underground sources,
storage in underground/ overground tanks and taking the water to construction site
through pipelines by pumping or by road tankers etc., including all necessary
accessories, tools & tackles etc.
2.02.45.06 Access roads to all buildings/facilities (in Bidder Scope) will be in the employer‟s
scope. However, these access roads would not be available during the construction
phase. Bidder shall construct and maintain temporary access roads as required, by

him for approach to the building/facilities in his scope for his construction/erection
activities.
2.02.45.07 For the buildings, which are in employers scope, Bidder shall review & give
clearances for all NTPC generated civil & structural drawings, prepared based on
Bidder’s scope drawing and load data.
2.03.00 TERMINAL POINTS
2.03.01 Broad terminal points for coal handling plant have been indicated in the tender
drawings. Within these terminal points, all equipment and services, civil, structural
and architectural works, electrical distribution, piping network etc. as required for
coal handling plant will be furnished and erected by the bidder unless specifically
excluded as follows:
2.03.01.01 Bidder’s scope/responsibilities with regard to Employer’s tripper floor of bunker

building shall include but not limited to the following :
2.03.01.02 Bidder shall generally support technological structures including Bidder’s platforms
on foundation/support provided by Employer, through anchor fasteners. The Bidder
shall supply and install all anchor fasteners of requisite capacity to support his
structures. Anchor fasteners shall be used for supporting all such equipment, where
the static and dynamic load due to equipment is within the safe load carrying
capacity of the anchor fasteners.
2.03.01.03 The Employer shall provide the pockets only for those equipment foundations where
the load to be transferred is beyond the safe load carrying of anchor fasteners. For
such equipment, subsequent supply and installation of foundation bolts including
grouting of pockets shall be done by Bidder.
2.03.01.04 In case, fixtures (for supporting of equipment and structure including Bidder
platforms) viz. Foundation/mounting bolts along with templates, inserts and
embedment (including pipe sleeves) along with lugs, etc. are required to be
embedded during the first stage of concreting, then the Bidder shall make such
fixtures available at site (before casting of foundation) for installation by Employer at
the time of the concreting stage itself. During concreting, Bidder shall depute his
engineers to verify that all such fixtures are installed correct to layout and levels as
per their design drawings. Any modification required on these fixtures subsequent to
their placement shall be done by Bidder. Incase stools (for supporting of equipment
and structure including Bidder platforms) are to be embedded in concrete, Bidder’s
scope shall include supply and fixing of such stools before concreting.
2.03.01.05 All small size Openings having size (within 150 mm x 150 mm area) which are
required on Floors, Walls, Cladding, Roof etc. shall be neatly created and finished by
the Bidder using appropriate tools. The Employer shall however provide larger size
Openings.

2.03.01.06 All grouting of pockets, Underpinning of Base Plates, filling and finishing of Openings
etc. shall be done by the Bidder. Anchor Fasteners shall be fixed in position by
Bidder as recommended by the manufacturer and approved by the Employer.
2.03.01.07 Wherever Bidder is permitted by Employer to take support from any of the
Employer’s Structures, the Bidder shall ensure that no damage is done, to the
Employer’s Structures including Painting thereof. In case of any damage to the
Employers Structure and/or Painting, then the Bidder shall rectify the same to the
complete satisfaction of the Employer.
2.03.01.08 Details / Data of all openings required by the Bidder in Floors / Walls / Cladding /
Roof to be provided by the Employer shall be given by the Bidder. Basic load data
(i.e. floor loading and major equipment loading) for starting of civil engineering
activity by Employer shall be furnished by Bidder within 45 days of LOA. Final load
data (along with mounting details) shall be submitted by Bidder to Employer
progressively within 4 months of LOA. These submissions by Bidder shall be listed
in Engineering Information Flow Schedule to be furnished by the Bidder. If any
additional tertiary beams are required subsequently after receipt of loading data due
to change of loading or its location by the Bidder, then the same shall be provided by
the Bidder.
If the details / data of all Openings required by the Bidder in Floors / Walls / Cladding
/ Roof are not furnished by the Bidder, as per the Engineering Information Flow
Schedule then all such required Openings shall be created by the Bidder himself, at
a later date in Floors / Walls / Cladding / Roof by using special tools, as required. In
this case secondary and tertiary steel members including edge protection to the
openings shall also be provided by the Bidder.
2.03.01.09 Bidder shall furnish the load data from the conveyor 7A/7B to be considered in
design of tripper floor of bunker building. Bidder shall provide fixed bearing at
location where his conveyor’s 7A/7B rest on employer’s bunker building.
2.03.02 All the equipment, conveyors, short supports, stringers, deck and seal plates, head
and tail end frames, operating and maintenance platforms, complete technological
structures, bolts, anchor fasteners, embedments, inserts, templates, chute work, flap
gates and actuators, ventilation, service water, potable water, monorails, electric
hoists, manual hoists, chain pulley blocks, internal & external illumination (except for
the area listed under exclusion in cl.2.04.00 under this sub-section), cabling, cable
trays & cable tray supporting system, equipment earthing and lightning protection
system and all associated electrical works covered under tripper floor of the bunker
building shall be in Bidder’s scope.
2.03.03 Water supply connections for dust suppression, service water system, potable water
shall be provided at two different locations by the employer, details of which are
given in the tender drawing. Further network of piping including all pumps, tanks,
necessary accessories, supports and fittings etc. for distribution of potable water,

water for dust suppression and service water system in all Transfer Points, crusher
house, control rooms, MCC rooms, Tripper floors, toilets, wagon tippler complex etc.
shall be under the scope of the bidder.
2.03.04 Regarding erection of TP-9, contractor shall ensure no load is transferred from his
structure to the existing conveyor gallery of conveyor 8A/B.
2.03.04 Electrical Terminal Points
(a) HV Terminal box of Bidder’s equipment.
(b) Incoming 220 V DC supply terminals of bidder’s two(2) nos. of DCFBs in

MCC-IIE room in bunker area.
(c) Employer’s DCS/ R I/O Panels for control/instrumentation cables.
(d) 415 V side of LT transformer and ash water switchgear as shown in single
line diagram.
2.03.05 Civil
(a) Construction power shall be provided by the Employer as per the provision of
Erection Conditions of Contract.
(b) The trunk sewer lines are proposed to be installed by the employer. The
sewerage from all the facilities planned under the contract shall be connected
by the Bidder to this trunk sewer network.
2.04.00 EXCLUSIONS
2.04.01 Supply, laying and fixing of rail over track hopper is excluded from the scope of this
Contract. However, necessary pockets for fixation of rails in rail supporting beams
shall be in the scope of Bidder.
2.04.02 Civil, structural and architectural works for bunker buildings including bunkers &
tripper floors are excluded from the Bidder’s scope.
2.04.03 Site leveling is excluded from the scope of this Contract. However site clearance i.e.
removal of vegetation including bushes and trees etc. shall be the responsibility of
the Bidder.
2.04.04 Supply and erection of the following items are excluded from Bidder’s scope:
(a) 6.6 kV cables (except trailing cables)
(b) 6.6 kV Switchgear (except JB & HT LBS for S/R)

(c) Control cables between Employer’s 6.6KV switchgear located in main plant
area and Bidder’s LT switchgear.
(d) Illumination for Traveling Tripper Floors.
(e) Grounding mat and lightning protection in bunker area.
(f) DCS based control system including its power supply system for main CHP
control.
3.00.00 SYSTEM DESIGN BASIS
3.01.00 The rated capacity of the CHP shall be 1200 TPH. The mechanical and structural /
civil system shall be designed for 1320 TPH capacity and round the clock operation
with both the streams operating simultaneously.
3.02.00 Following shall be considered while designing the CHP:
a) The Coal delivered to the power station shall be of size 250 mm & below.
However occasionally 1-2% coal of 400 mm lump size may also be
encountered.
b) HGI of the Coal shall be between 45 to 65. Normally moisture content in coal
will vary between 12% to 20%. However for design purposes, moisture
content of 20% shall be considered.
c) Due to open cast method of mining involved, the coal may contain shale and
sand stone as high as 20%. Also occasionally metal pieces like broken
shovel teeth, brake shoe, wires etc., may also come alongwith coal from
open cast mine.
d) The coal “as received” shall contain varying percentage of fines. Coal with
such fines may tend to form adhesive lumps, particularly during monsoon
when surface moisture is at its maximum value.
e) The sizing and selection of the vital equipment viz. crushers, vibrating
screening feeders, paddle feeders etc. covered under the system shall be
based on the above characteristic of coal and operating conditions. Bidder
shall ensure that equipment/ system efficiency shall not be affected
particularly during monsoon when surface moisture is at its maximum value.
3.03.00 For the purpose of volumetric computation, the bulk density of the coal shall be
taken as 800 kg/m3. Therefore for calculation of belt conveyor capacity, for their
drives & drive motors kW requirement, and sizing (volume calculations) of chute,
hoppers etc. the above bulk density shall be considered. For all other purposes viz.
for stresses/ load on structures, torque calculations of paddle wheel of paddle
feeder, bucket wheel of Stacker / Reclaimer, Loading on Apron feeder table loading

on VSF tables, sizing of actuators for flap gates, R&P gates, calculations of plugged
chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3.
3.04.00 All mechanical, and structural / civil system design shall consider simultaneous
running of both the streams at rated load starting of one stream with the other
stream in standstill condition as well as starting of one stream with the other stream
in operation.
3.05.00 Coal Flow paths
3.05.01 For the purpose of conducting guarantee test coal, flow is divided into following coal
flow paths.
(i) Flow Path I (Direct Stream):
Paddle feeder taking feed of incoming coal from track hopper and
discharging crushed coal into last bunker of Unit # 4 through traveling tripper
on Conveyor 7A/7B including all intermediate Conveyors and equipments.
(ii) Flow Path II (Stacking System)
Apron feeder taking feed of incoming coal from wagon tippler and staking
crushed coal in stockyard using yard conveyor 11 with stacker/ reclaimer at
position farthest from TP-7 and boom conveyor at highest angle including all
intermediate equipments.
(iii) Flow Path III (Reclaiming Stream):
Reclaiming coal from stockyard using yard conveyor 11 with stacker

reclaimer at farthest position from TP-8, with the boom conveyor at its lowest
position and feeding last bunker of Unit # 4 through travelling tripper on
conveyor 7A/7B including all intermediate equipments.
(iv) Further for the purpose of Guarantee tests Conveyor 13 and 14 alongwith all
associated equipment shall also be considered.
3.05.02 Performance and Guarantee Tests shall be conducted in such a way that all the
conveyors in both the streams are covered. For this purpose it may be necessary to
repeat the Performance & Guarantee tests until all the conveyors are covered.
Combination of conveyors to be tested shall be at the discretion of the Employer.
The maximum liquidated damages calculated as above, for any one of the paths
shall be levied on Bidder.
3.05.03 Bidder shall also demonstrate that all intermediate equipments can perform as per
specification and design requirement. Simultaneous operation of both the paths in
conveyor streams shall also be demonstrated during PG Test.
3.05.04 Performance and Guarantee tests have been elaborated elsewhere in the
specification.

PART - A
SUB-SECTION-IIB-01
GUARANTEE TEST PROCEDURE

CLAUSE NO. GUARANTEE TEST PROCEDURE
1.00.00 STANDARD GUARANTEE AND ACCEPTANCE TESTS AND TESTING

PROCEDURE FOR COAL HANDLING PLANT
1.01.01 SYSTEM FACILITIES
1.01.02 In accordance with Section GTR placed at Part-C after commissioning and before
handing over, the entire plant shall be subjected to System Trial Operations.
1.01.03 The duration of Trial Operations of the complete equipment shall be fourteen (14)
days with minimum twelve hours daily operation. For successful Trial Operation, the
trial shall necessarily include steady operation of the plant at its rated flow path
capacity for at least one hour duration per day on an average.
1.01.04 PERFORMANCE REQUIREMENTS
The Contractor shall guarantee that the equipment offered shall meet the ratings and
performance requirements stipulated for various equipments covered in the
specification.
1.01.05 GUARANTEES
The Contractor shall furnish a declaration in the manner prescribed and included in
the relevant Attachment of Section-VII for the following guaranteed parameters
which shall attract levy of liquidated damages for shortfall in Performance.
Capacity in T/Hr (equivalent to 100% of rated) of conveyor system including the

intermediate equipments for each of the two parallel conveyor streams separately or
any combination thereof to be tested in the following flow path operations.
For the purpose of conducting guarantee test coal, flow is divided into following coal
flow paths.
(i) Flow Path I (Direct Stream):
Paddle feeder taking feed of incoming coal from track hopper and
discharging crushed coal into last bunker of Unit # 4 through traveling tripper
on Conveyor 7A/7B including all intermediate Conveyors and equipments.
(ii) Flow Path II (Stacking System)
Apron feeder taking feed of incoming coal from wagon tippler and staking
crushed coal in stockyard using yard conveyor 11 with stacker/ reclaimer at
position farthest from TP-7 and boom conveyor at highest angle including all
intermediate equipments.

TECHNICAL SPECIFICATIONS SUB-SECTION-IIB-01
SECTION-VI GUARANTEE TEST
PART-A PROCEDURE
(iii) Flow Path III (Reclaiming Stream):
Reclaiming coal from stockyard using yard conveyor 11 with stacker

reclaimer at farthest position from TP-8, with the boom conveyor at its lowest
position and feeding last bunker of Unit # 4 through travelling tripper on
conveyor 7A/7B including all intermediate equipments.
(iv) Further for the purpose of Guarantee tests Conveyor 13 and 14 alongwith all
associated equipment shall also be considered.
1.01.06 Major Equipment Capacity
Guaranteed capacity in T/Hr of the following:
Paddle Feeders
Apron Feeders
Crushers
Stacker Reclaimer
Wagon tippler with side arm charger
Note : Guaranteed (rated) capacities of above equipments are indicated in section

III-A-01.
1.01.07 Power Consumption
Total power consumption for all the equipments including auxiliaries with single
stream operation at its guaranteed flow path capacity except.
- Lighting
- Hoists
- Coal sampling unit
- Sump Pumps
- Elevators
- DS, DE, Ventilation, SW System, Potable water system
1.01.08 Performance Requirements to be Demonstrated
Performance requirements of various individual equipments / systems as specified,

including but not limited to certain minimum requirements as spelt out in the
Guarantee Test procedure shall also be demonstrated during the Guarantee Tests
to the full satisfaction of the Employer.

PART-A PROCEDURE
2.00.00 GUARANTEE TEST PROCEDURE
In accordance with Section GTR placed at Part-C, on successful completion of

System Trial Operation and commissioning, the plant shall be subjected to
guarantee tests. Further, the guarantee tests shall be conducted as per the
procedure specified in the following paragraphs.
2.01.00 Pre-Requisites to the Guarantee Tests
2.01.01 The prerequisites to be ensured by NTPC and the Contractor prior to start of the
tests are placed at Appendix-I and Appendix-II respectively.
2.01.02 After successful completion of trial operation and commissioning the plant shall be
jointly inspected by NTPC and the Contractor & a joint protocol shall be signed that
the plant is fit for guarantee tests.
2.02.00 Testing for Guarantees
2.02.01 Flow Path Capacity Tests
(a.) For each of the Flow Paths, two conveyor streams shall be formed with
suitable CRISS-CROSS Combinations of ‘A’ or ‘B’ Conveyors/ intermediate
equipments. Composition of each stream shall be decided by the Engineer
and shall be recorded as per Appendix-III.
(b.) All above streams formed shall be independently tested for performance &
guarantee. Further, the equipments/ conveyors (except common
equipments) used for performance testing of one stream shall not be used for
performance testing of the other stream.
(c.) In case of direct flow path, guarantee test should include operation of all the
trippers. However, for measurement of guaranteed power consumption
farthest tripper shall be operated.
(d.) Stacking and Reclaiming will be done near the drive house so that the
conveyor is tested under fully loaded conditions.
(e.) While operating the guaranteed capacity of the flow paths, non-spillage of
coal and non-choking of chutes/ equipments shall be demonstrated as
indication of smooth continuous flow through the conveyor system.
2.02.02 Major Equipment Capacity Tests
(a.) Guaranteed capacity of all the major equipments as identified shall be

established separately by operating only one equipment out of the two of a
set at a time. Following equipments shall be considered:

PART-A PROCEDURE
Equipment Capacity Requirement
(1.) Paddle Feeders
(2.) Crusher (after blanking the screen of VSF)
(3.) Stacker Reclaimer
(4.) Height and Base Width of Stockyard
(5.) Apron feeders
(6.) Wagon Tippler with side arm charger
2.02.03 Power Consumption Measurement
(a.) The guaranteed power consumption as total sum of all the equipments as
specified shall be measured during capacity test of the identified Flow Paths
for both the streams separately.
The load of the following items shall not be considered during measurement
of Power Consumption for guarantee:
Lighting
Hoists
Sump Pump
Coal Sampling Unit
Elevator
DS, DE, Ventilation, SW system, Potable water system.
(b.) Measurement Terminal(s)
The guaranteed power consumption for the entire Flow Path(s) shall be
taken during capacity test as sum of the power measurements at the
following terminals.
(1.) 3.3/6.6/11 kV CHP incoming terminals
(2.) 415 V CHP MCC incoming terminals.
(3.) Switchgear terminal of any load connected to Employer’s Switchgear.

PART-A PROCEDURE
Further the power consumption for the equipments being fed from CHP
board/LT board but not to be considered for guaranteed power consumption
shall be measured separately at their respective MCC/LT & HT switchgear
input terminals and shall be subtracted from the total power consumption
measured. However, if conditions permit, such equipments may not be
operated during power measurement duration.
For Stacker/ Reclaimer machine, the average power consumption shall be

measured through energy-meter at HT switchgear feeder of Stacker/
Reclaimer. For Conveyors, the power consumption shall be measured at
their respective switchgear terminals.
Guaranteed power consumption of the yard conveyor(s) shall be measured

during flow path capacity test in stacking mode whereas for balance
equipments (balance conveyors and S/R machine) the power consumption
shall be measured during capacity test of reclaim flow path with boom of
stacker reclaimer at lowest angle. Lighting, A/C & Ventilation loads on the
Stacker/ Reclaimer shall not be considered for guarantee.
(c.) Time Duration
Power Consumption measurement shall be done only for 30 minutes after

the conveyor flow rate stabilizes at the guaranteed capacity. However, for
Stacker/ Reclaimer(s), the average power consumption shall be measured
for entire duration of reclaim flow path capacity test.
(d.) Meters
Ammeter/Voltmeter readings shall be noted from the meters mounted on the

control desk / LT switchgear / HT switchgear or if necessary by means of
clamp type meters.
For power measurement two wattmeter method / one wattmeter method (2 or

3 elements) shall be used. Accurate clamp type digital 3 phase wattmeters
can also be used. Power measurement shall be taken after stable condition
is achieved.
Wattmeters shall have a min. accuracy class of ± 1% Energy meter shall be

of min ± 2%. CTs & VTs shall have accuracy of ±1%. All meter readings shall
be recorded. No corrective allowance shall be allowed over the measured
values.
The details of wattmeters and energymeter alongwith their calibration

certificate shall be furnished to NTPC before start of tests. These measuring
instruments shall be calibrated from govt. approved test house.

PART-A PROCEDURE
Calibration certificates of all instruments must not be more than 1 year prior
to test date. Seals of the instruments shall be opened at site in the presence
of Engineer-in- charge. Zero error shall be checked before conducting the
PG Test.
2.02.04 GENERAL
(a.) Test Duration
(1.) Normal duration of the above capacity tests shall be four hours. However,
minimum one (1) hour continuous & steady operation shall be required to
establish the guaranteed capacities.
(2.) In case of any minor interruption due to operation of electrical protection

as well as stoppage due to safety reasons, the duration of test shall be
extended by the time lost in such interruptions. In case of exceptionally
longer interruptions calling for re-mobilization and re-preparation of plant
the implications shall have to be mutually discussed and agreed upon.
(b.) Weighing scales
(1.) For measurement of flow capacity of a stream and individual equipments,

weighing scales installed in the system shall be used.
(2.) Belt weigher mounted on the luffable boom of Stacker/ reclaimer shall not
be used for this purpose.
(3.) Readings for flow rate capacity test shall be taken at intervals of every 3
minutes.
(4.) Belt weighers accuracy as demonstrated/ observed jointly before the

guarantee testing may be considered for allowing correction factor over
the recorded flow capacity reading.
(c.) The observations of guarantee test for various streams/ equipments shall be
recorded in the formats at Appendix – III to XI.
2.03.00 Testing for Demonstration Requirements
The specified performance parameters of various equipments/ system including but

not limited to the following shall be demonstrated to the full satisfaction of the
Employer.

PART-A PROCEDURE
2.03.01 Conveyors
(a.) Conveyor Profile
(1.) Check against lifting of Conveyor belts over concave curves at the time of
start under empty belt condition.
(2.) Check against wrapping/folding of belt over convex curves/transition

zones.
(3.) There should not be any roll back of coal pieces on moving or stopped
conveyors
(4.) There shall not be build up of coal in chutes , spillage of coal from
skirt/conveyor/hoods while the belt is running.
(5.) Smooth non-jerky running of conveyors with no spillage of coal and

centric running of conveyors without vibrations of drives and galleries.
(b.) Coasting Time
Coasting down time of fully loaded conveyors shall be measured and

compared with design values. Check for spillage/blockage of coal from skirts/in
chutes to be made. There shall not be build up of coal in chutes after stoppage
of fully loaded conveyor so as to cause spillage of coal during next start.
(c.) Belt Alignment
To check against any sway during operation under different loadings and
different conveyor criss-cross combinations.
(d.) Idlers and self aligning idlers
To check for satisfactory performance of idlers and self-aligning idlers
(e.) Control/Sequential Operation
(a) Performance checks for specified controls including sequential starting/

stopping of conveyors and other equipments as per approved control
write-up.
(b) Satisfactory operation of PLC and control systems including absence of

spurious trips/communication failures of PLC to be demonstrated.
(c) Demonstration for detection of operated pull cord/belt sway switch along
with display in CRT of conveyor number and operated pull cord /belt
sway number.

PART-A PROCEDURE
(f.) Protection Switches
Satisfactory operation of pull chord, belt sway, zero speed, chute blockage and
other safety / protection switches.
(g.) Load Start
Demonstration of the ability of conveyor to start under full designed load.
(h.) Simultaneous Operation
Demonstration of simultaneous operation of both the streams under full load

for 30 minutes in order to check healthiness of the system, electrical systems
etc
(i.) Vibration Level in Conveyors
Both velocity and amplitudes for all the conveyor drives and in each conveyor
gallery under different conditions of conveyor operation as desired by site.
Vibration limits of drive equipments shall be as per VDI 2056 / equivalent.
Observations shall be recorded as per the format at Appendix-V.
Vibration of conveyor galleries at trestles and pt. between trestles shall be

measured and these values shall be within allowable limits.
Vibrations of Crusher houses floors and transfer point floors shall also be
measured and these shall be within allowable limits.
(j.) GEAR BOXES
Temperature rise not to exceed design values.
No leakages
No abnormal sound.
Satisfactory performance of hold back devices in preventing running back of

conveyor belts in case of conveyor being stopped in fully loaded (at design
load) condition to be demonstrated.
(k.) Fluid Coupling.
No excessive rise of temperature.
Satisfactory and quick operation of scoop in manual/remote modes with no oil

leakages.

PART-A PROCEDURE
(l.) Brakes
Satisfactory and non jerky operation to avoid hold up of Coal in chutes.
(m.) Skirt board and skirt sealing, inspection door, chute joints
Perfect sealing with no spillage/no dust from sealing areas.
2.03.02 Stacker / reclaimer
(a.) Stacking at maximum boom height.
(b.) Starting of Boom Conveyor at full load (at design load = rated capacity +25%)
at maximum / minimum inclinations.
(c.) Reclaiming at maximum and minimum stockpile heights
(d.) Uniform to and fro travel speed and proper reeling / unreeling of flexible cables.
(e.) Satisfactory operation of all limit switches, protections and other controls.
(f.) No sway of Boom Conveyor during stacking and reclaiming at different loads
and inclinations.
(g.) Proper hoisting / luffing operation without jerks and operator cabin level
adjustment.
(h.) Check against folding of belt in spaces between horizontal and inclined
troughing idlers at the start of Stacker Reclaimer.
(i.) No leakage from hydraulic couplings, seals, heat exchangers, instrument

tappings etc
(j.) Demonstration of proper functioning of hydraulic and manual rail clamps and
boom locking.
(k.) Proper functioning of communication system on stacker reclaimer.
2.03.03 Metal Detector
(a.) Tests for detection of specified smallest size pieces (25 mm sphere) of
different metals including aluminium.
(b.) Operation of sand bag marker.
(c.) Demonstration of coast count, total count for multiple tramp metal pieces.

PART-A PROCEDURE
2.03.04 In-Line Magnetic Separators
(a.) Demonstration of magnet capacity to separate out specified sizes and weights
of magnetic pieces buried under (rated load) coal:
MS cube of 20mm side
Brake shoe of railway wagon (15 kg)
MS plate of 250x250x10mm size
Shovel teeth and spikes (carbon steel)
MS round bar of 50 kg with L/D ratio not exceeding 5
(b.) Collection of picked up pieces into tramp Iron chutes/ trolley
(c.) Proper discharge of picked up metal pieces into tramp metal chute (with no
coal pieces going into it)
(d.) Position adjustment
2.03.05 Flap Gates
(a.) Demonstration of remote, local and manual actuation of gates. Demonstration

of successful changeover even while feeding coal.
(b.) Check for stroke and operation of limit switches/ torque switches
2.03.06 Travelling Trippers
(a.) Check for smooth to & fro travel
(b.) Operation of brakes and rail clamps at full load.
(c.) Check against dragging during start up or running (“over speed protection”).
(d.) Check against blockage of discharge chutes at full load.
(e.) Check against folding of belt in spaces between horizontal and inclined
troughing idlers at the start of Tripper.
(f.) Proper functioning of communication system on trippers.
2.03.07 Dust Suppression System
(a.) Measurement of head of pumps.

PART-A PROCEDURE
(b.) Pressure available at nozzle manifolds (on random basis) in running condition
not to be less than 2.5 kg / cm2
(c.) Satisfactory spray atomization and dust suppression effectiveness of all the DS
systems as per Appendix-IX
(d.) Measurement of SPM before and after DS system operation as per Appendix -
IX.
(e.) To measure pressure available at inlet to sprinkler in coal yard in running

conditions and this should not be less than 4.5 kg / cm2
(f.) Complete coverage of yard by spray units in stockyard.
(g.) Measurement of noise level and vibration ( velocity and amplitude) at the
bearing of motors and pumps
2.03.08 Ventilation system
(a.) Measurement of rated volumetric capacity of fans of atleast 2 nos. of each type
and rating.
(b.) Measurement of vibration (velocity and amplitude) at the bearing of motors and
fans (wherever possible)
2.03.09 Package Air Conditioning (PAC) Unit
(a.) Specified temperature and humidity of conditioned space under worst ambient
conditions.
(b.) Demonstration of rated capacity of PAC unit.
2.03.10 Belt Weighers
(a.) Demonstration of specified weighing accuracy of + 0.25% (+1% in case of

boom conveyor of stacker reclaimer) between 20% and 120% of rated capacity
(b.) Satisfactory operation of flow rate indicator and totaliser etc.
2.03.11 Vibrating Screening feeder
(1.) Demonstration of variable capacity adjustment
(2.) Observation of little tendency of choking/ build-up with coal having maximum
moisture of 20%
(3.) Little transmission of vibration to building structure, floor
2.03.12 Coal Sampling Unit
(1) Demonstration of bias testing on random basis

PART-A PROCEDURE
(2) Demonstration of satisfactory of operation of CSU which shall necessary

include ability to collect samples automatically and continuously for a minimum
period of 7 days of conveyor operation without requiring manual intervention.
2.03.13 Paddle Feeders
Long travel speed test, i.e., demontration of speed variation of paddle wheel from
20% to 100% capacity, to be carried out. The paddle feeders should be able to move
in both to and fro directions while feeding coal upto rated capacity without slippage
of wheels and spillage of coal
Demontration of variable capacity adjustment
No fouling with paddle table and structure
Proper reeling and un-reeling operation of flexible cable
Demonstration of minimum 50% margin between normal working pressure and

stall/trip pressures (Ex : In case normal working pressure is 150 kg/cm2 then stall/trip
pressure shall be 225 kg/cm2 and relief valve setting shall be above 225 kg/cm2).
Demonstration of dust suppression system of Paddle Feeders is to be as per clause

2.03.07 above.
2.03.14 Crushers
Output coal size to be sieve analyzed and (-) 20 mm coal to be more than 98% for
ring granulator type crusher.
Vibration measurement (velocity and amplitude) is to be recorded at bearings as per

appendix. Vibration is to be within allowable limits.
No excessive rise of temperature of bearings
One crusher is to be tested for output and size after blocking VSF.
Proper functioning of vibration monitoring system to be checked.
2.03.15 Belt Scrappers
Satisfactory operation of belt scrappers shall be demonstrated even with wet coal as
specified. Scrapping efficiency of belt scrapper shall be minimum 95%.
2.03.16 Noise Levels
2.03.16.01 Noise level measurement, for conformance to specified levels, to be done around
the following equipments/ areas:

PART-A PROCEDURE
(a.) Conveyor Discharge Terminal (including discharge chute, gearbox, coupling

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

PART-A PROCEDURE
e) Unmanned tests of safety devices like brakes etc.
f) Testing as per manufacturer’s PG Test Procedure given in Annexure-I
2.03.18 Movable belt feeder
a) Demonstration of remote, local and manual actuation.
b) Check for travel, brake and operation of limit switches.
2.03.19 Wagon tippler
a) Smooth operation of wagon tippler with out jerks
b) Demonstration of guaranteed capacity of unloading of wagons in terms of

load, no. of wagons and tippling rate and entries to be made as per format.
c) Free flow of coal from the wagon tippler hopper even with wet coal having
20% moisture.
d) Demonstration of tippling rate of 20 wagons/hr.
e) Demonstration of side arm charger for auto operation of 58 wagon rake.
(f) Demonstration of DS spray system as per clause 2.03.07”.

PART-A PROCEDURE
Annexure -I
Elevator
Sl. No. NAME OF THE PROCEDURE EXPECTED REMARKS

TEST RESULTS /RESULT
OBTAINED
1.0 Trial Run Test each landing (5

times)
a) Push the “UP”, Cage should Results of Test

“STOP” and “DOWN” respond
buttons at every correctly to 1 2 3 4 5
landing each button
b) Try to operate the Hoist must not

hoist with the “UP” start.
and “DOWN” button
leaving the landing
door open (cage door
closed)
c) Close the landing -do-

door and also the
cage door, keep the
stop button pressed
while trying to
operate the Elevator
with the "UP” &
“DOWN” buttons five
times.
d) At each landing floor,

the level deviation
should be within
specified limits.

PART-A PROCEDURE
Annexure -I
OBTAINED
2.0 Check for Operate the elevator with Cage should Results of Test
operation from the “UP” “STOP” & respond
inside cage “DOWN” button five times correctly to 1 2 3 4 5
each button
3.0 Check for a) Try to operate the The elevator

interlocking elevator “UP” & must not start
“DOWN” leaving the when testing
cage door open according to
(landing door closed). a,b,c and d.
(All the doors are to be
tried separately)
b) Try to operate the -do-
elevator “UP” &
“DOWN” leaving the
trap door open (cage
and landing door
closed).
c) Try to operate the -do-
elevator “UP” &
“DOWN” keeping the
emergency stop button
pressed after the test.
d) Check the other -do-
interlocking equipment
in the same way (each
landing)
e) Turn the switch
“Location / Operation”
in the electric box on
the cage roof to
“Erection” and test
according to a), b) and
c) from the cage roof.
Reset the switch to
“Operation”

PART-A PROCEDURE
Annexure -I

OBTAINED
4.0 Check for a) Start at the ground Cage must

Automatic landing and operate stop at the
System “Stop from the push button next landing in
Next Landing” box in the Cage, Push the direction of
the 0-button as soon travel.
as the elevator has
started.
b) Continue upwards and

test all landings in the
same way.
c) Make the test Cage must

according to a) & b) stop at the
but now in the opposite next landing in
direction the direction of
travel.
NOTE : At the top and

bottom landing, no signal
is required from the the 0-
button (STOP NEXT
LANDING) to stop the
elevator. The elevator
stops automatically due to
the top and bottom limit
cams.
5.0 Check for travel Before start of test, check

speed and record voltage and
frequency of incoming
power supply
a) Start from ground

landing and operate
the “UP” button
b) Start a “Stop Watch”

when cage is in line
with first landing

PART-A PROCEDURE
Annexure -I
Sl. No. NAME OF PROCEDURE EXPECTED REMARKS

THE TEST RESULTS /RESULT
OBTAINED
c) Stop the “Stop Watch” The rated travel

when cage is in line speed should
with second landing be checked at
and note the timing. 415 V, 50 Hz
Press “Emergency and should be
Stop” button as specified
d) Release “Emergency
Stop” button and
press “DOWN” button.
e) Start the “Stop watch”

with second landing
f) Stop the “Stop Watch”

with first landing and
note the timing.
Continue to ground
landing where cage
will automatically stop.
Calculate travel speed
by the formula :
Speed = Distance (m) / Time (minutes)
N.B. The test may be repeated for longer travel distances
6.0 Checking of a) Electro-magnetic The Electro-

Safety Devices brake and manual magnetic brake
brake release and Manual
operation during brake release
power failure. shall function as
per their design
and the brake
shall hold
without creep at
all levels.

PART-A PROCEDURE
Annexure -I
Sl. No. NAME OF PROCEDURE EXPECTED REMARKS

THE TEST RESULTS /RESULT
OBTAINED
b) Over travel switch Cage must stop

automatically at
Ground and
Top landings.
c) Reverse phase relay Lift will not start

operation in case of
reversal of
phase
d) Alarm at the basement Should operate

when button is
pressed in cage
e) Remote control for

testing the safety
devices as per
Technical
Specifications
7.0 Drop Test Make the test according Safety Device Ensure that no
to supplier’s procedure should stop person is present
cage in less inside the cage
than 7 m. of during the test.
travel
Note : Remember to reset

the safety device after the
test has been carried out.
8.0 Measurement Current and power Measured

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

PART-A PROCEDURE
Annexure -I
Note : 1. All tests to be conducted with full load
2.Erection platform and erection crane to be removed before conducting tests.
NTPC /Site Project Manager Contractor
-------------------------- -----------------
Signature : Signature :
Name : Name :
Designation : Designation :

PART-A PROCEDURE
APPENDIX-I
GENERAL
PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY NTPC
1. Availability of adequate and uninterrupted supply of coal.
Specifications of coal as per N.I.T and as observed during the test shall be
recorded as per attached format (Appendix-IA).
2. Sufficiently empty bunkers to facilitate continuous tripper dumping of coal

during the test. Sufficient space in stockyard towards drive end of yard
conveyor during stacking. Sufficient heap of Coal towards tail end of yard
conveyor during reclaiming of Coal.
3. Uninterrupted power supply within specified parameters for the duration of

the test.
4. Belt protection switches, local stop push buttons, hooters, brakes/rail clamps
in working order.
5. Adequate and uninterrupted water supply.
6. Plant communication system
7. Proper lubrication and oil level of all equipments.
8. Free rotation of idlers and pulleys.
9. Cleanliness of plant and removal of coal spillage at the start and during
Tests.
10. Power supply voltage and frequency shall be as per technical specifications.
11. Availability of dry coal during testing of DS system

PART-A PROCEDURE
APPENDIX-IA
COAL PARAMETERS
Project :
Package :
Date :
As specified, As observed
during the test
1. Size
2. HGI
3. Moisture
4. Shale and sand-stone content
NTPC Contractor

PART-A PROCEDURE
APPENDIX-II
PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY CONTRACTOR
1. Deputation of team to site to associate with the Guarantee tests,
2. Calibration of belt weigher scales and accuracy of same to be demonstrated

to NTPC.
3. Arrangement of wattmeters / energymeters calibrated and sealed from

approved Govt. test house or NTPC site laboratory. Arrangement of any
other instrument/ accessory for the test.
4. Proper adjustment of skirt boards and belt cleaners prior to the start of tests.
5. Arrangement of calibrated equipments for measurement of vibration & noise

levels.
6. Protection Relays of LT/HT switchgears and all motor feeders shall be

checked.
7. Belt protection switches, local push buttons, hooters, brakes/rail clamps to be

in working order.
8. Free rotation of idlers and pulleys.
9. Protection relays of LT/HT switchgears and all motors/transformer feeders to

be checked.
10. Sufficient illumination.

PART-A PROCEDURE
ANNEXURE – IIA
FORMAT FOR SUBMISSION OF GUARANTEE TEST PROCEDURE
Clause No. as per Provision of Name and NTPC

LOA/ Tech. Specs. LOA / Tech. Methodology of comments on
Specs. Test proposed the tests
by Vendor proposed by
vendor

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

PART-A PROCEDURE
Sl.No Time Flow Rate Totaliser
Total plant run time :
Average Flow Rate :
NTPC Contractor

PART-A PROCEDURE
APPENDIX-IV
POWER MEASUREMENT
Project :
Package :
Date :
1. Equipment/Stream Composition :
2. Motor Description :
3. Sr. No. of meters used :
4. Date of Calibration of instrument and name of test house :
5. Multiplying factor (M.F.) of the wattmeter :
6. Wattmeter Readings (to be taken at 1 minute intervals) :
Sl. Measureme Time Voltage Curre- kw Reading Total Remarks

No. nt Terminal (Volts) nt M.F. (W1+W2)
Location (amps) MF kw
W1 W2

PART-A PROCEDURE
APPENDIX-IV
7. Energymeter Readings
Sl. Equip- Time Energymeter Equipment Remarks*
ment Duration Readings kwHr kw (R2-
R1)/(t2-t1)
Initial Final Initial Final
*Reason and duration for system trip/stop may be recorded in remarks column.
NTPC Contractor

PART-A PROCEDURE
APPENDIX-V
VIBRATION LEVEL MEASUREMENTS
Project :
Package :
Date :
Time :
Details of vibration Level Meter
1. Make
2. Model & Sl.No.
3. Date of calibration with name of Test House

Sl.No Equip- Pick Vibration level Amplitude/Velocity
ment *Point
Horizontal Vertical Axial
Micron/ micron/ Micron /
mm/ sec. mm/sec. mm/sec.
* Reading shall be taken at all the bearings of motor, gear box and driven
equipment. In case of conveyor galleries, vibrations shall be measured at
min. three locations, at midpoint of stringer between two short supports.
NTPC Contractor

PART-A PROCEDURE
APPENDIX-VI
NOISE LEVEL MEASUREMENT
Project :
Package :
Date :
Details of Sound Level Meter
1. Make
2. Model
3. Date of calibration with name of Test House
Sl.No Equipment Equipment Measurement* Sound Remarks

with load/capacity point no. level dBA.
location
NTPC Contractor
* For each equipment location, a Projected Plan Diagram shall be made and the
location of measurement points shall be identified.

PART-A PROCEDURE
APPENDIX-VII
PROFORMA FOR POWER MEASUREMENT OF STACKER / RECLAIMER
1. Stream composition
2. Description of following Motors
a) Boom Conveyor
b) Bucket Wheel
c) Long Travel
d) Main Hydraulic Pump
3. Sr. No. of Energy meter used
4. Date of Calibration of instrument and name of test house.
5. Multiplying factor of Energy Meter.
6. Energy meter Readings (to be taken at H. SWGR. FDR of S/R OR In comer

of MCC on S/R)
Sl. Equipment Time Duration Energy meter Equipment Remarks

No. Readings KW
KWHR
Inti Final T2 Initial Final (R2-R1) / (T2-T1)

al R1 R2
T1
• Reason and duration for trip/ stop may be recorded in remarks
Sd/ Sd/
NTPC CONTRACTOR

PART-A PROCEDURE
APPENDIX - VIII
WAGON TIPPLER
1. Nos of Wagon Tippled :
2. Time of placement of first wagon :

on wagon tippler platform
3. Time of removal of last wagon :

from wagon tippler platform
4. Total no. of wagons tippled :
5. Total time take (3-2) :
6. No. of tips/hr. = Total wagon tipped

Total time taken
= Sr.No.4 =
Sr.No.5
7. Over all performance : Satisfactory / Not satisfactory
8. Date of testing :
For NTPC For Vendor

PART-A PROCEDURE
APPENDIX - IX
DUST SUPPRESSION SYSTEM
Fixing of acceptance criteria of ambient air quality
Acceptance criteria of ambient air quality shall be considered with respect to

respirable dust only. Respirable dust is defined as particles having particle size
less than 10 microns meter (Not even equal to 10 microns meter).
The particle size analysis of dust at any one of the area shall be carried out as a
sample by placing the High Volume Sampler in the designated test point (1.5 to 3
M radius of application point) for a period d 8 hours without the system in operation
under load.
The sample thus collected will be subjected to the particle size analysis by sieve
Analysis method as a standard test laboratory.
The quantity respirable dust shall thus be determined from particle size Analyser.
Percentage of quartz in respirable dust will be determined by X-ray diffraction.
Acceptable Norms :
i) If the respirable dust fraction contain less than 5% quartz. The permissible
concentration of respirable dust shall be less than 2 Mg/M3.
ii) In case, respirable dust has more than 5% quartz, the permissible concen-
tration of respirable dust shall be computed as per following formula.
Threshold limit value for respirable coal dust in work environment (Mg/M3)
10
=
(% Quartz in respect Dust +2)
iii) % Quartz shall be determined by X-ray diffraction.
TEST METHOD (Testing shall not be done during Monsoon)
For determining the ambient respirable dust level average 4 hourly sample reading
shall be taken with high volume sampler at each test point (1.5 to 3 Meters radius
of application point) with dry fog dust suppression system, plain water dust
suppression system and material handling system in operation on load. The
average of three such readings shall be taken for each test point to compute the
respirable dust level. Respirable dust level will be determined by analysis of the
sample using sieve analyzer.

PART-A PROCEDURE
APPENDIX - X
SIDE ARM CHARGER
1. Capacity : Haulage limit of -----MT.

(--- Nos loaded wagons)
2. It can/cannot pull ---Nos wagons : Satisfactory / Not satisfactory
3. If not, mention the reasons :
4. Time of test :
5. Date of test :
For NTPC For Vendor

PART-A PROCEDURE
APPENDIX - XI
WEIGH BRIDGE
A. Wagon Tippler No :
B. Date of Test :
Sr. Date Type of Wagon measured Weight mentioned

Remarks
No. wagons Weigh bridge on Wagon Tippler
Gross Tare Net Net Wt. Tare Wt.
Wt. Wt. Wt.
For NTPC For Vendor

PART-A PROCEDURE
PART - A
SUB-SECTION-IIC-01
SPARES

CLAUSE NO. SPARES
SPARES
1.00.00 GENERAL
The Contractor shall include in his scope of supply all the necessary Mandatory
spares, start up and commissioning spares and recommended spares and indicates
these in the relevant schedules of the Bid Form and Price Schedules. The general
requirements pertaining to the supply of these spares have been described in the
following paras.
2.00.00 MANDATORY SPARES
(a.) The list of mandatory spares considered essential by the Employer is indicated
in section –VI, part-F. The Bidder shall indicate the prices for each and every
item (except for items not applicable to the Bidders design) in the ‘Schedule of
mandatory Spares’ whether or not he considers it necessary for the Employer
to have such spares. If the Bidder fails to comply with the above or fails to
quote the price of any spare item, the cost of such spares shall be deemed to
be included in the bid price unless the bidder specifies "not applicable" for the
type of equipment/system offered by him. However during execution if such
spares are found to be applicable, the Contractor shall supply them without
extra cost to the Employer. The Bidder shall furnish the population per unit of
each item in the Bid Forms and Price Schedules. Whenever the quantity is
mentioned in “sets” the Bidder has to give the item details and prices of each
item.
(b.) Whenever the quantity is indicated as a percentage, it shall mean percentage

of total population of that item in the this Project, unless specified otherwise,
and the fraction will be rounded off to the next higher whole number. Wherever
the requirement has been specified as a ‘set’ it will include the total
requirement of the item for a unit, module or the station or as specified. Where
it is not specified a ‘set’ it will include the total requirement of the item for a unit,
module or the station or a as specified. Where it is not specified a ‘set’ would
mean the requirement for the single equipment/system as the case may be.
Also one set for the particular equipment. e.g. ‘set’ of bearings for a pump
would include the total number of bearings in a pump. Also the ‘set’ would
include all components required to replace the item; for example, a set of
bearings shall include all hardware normally required while replacing the
bearings.
(c.) The Employer reserves the right to increase/decrease the quantity or delete
any of the mandatory spares parts prior to award of contract.
(d.) The prices of mandatory spares indicated by the Bidder in the Price Schedules
shall be used for bid evaluation purposes.

TECHNICAL SPECIFICATIONS
STAGE-II (2X195 MW) SUB-SECTION-IIC-01 PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE SPARES 1 OF 4
PART-A
CLAUSE NO. SPARES
(e.) All mandatory spares shall be delivered at site at least two months before
scheduled date of initial operation of the first unit. However, spares shall not
be dispatched before dispatch of corresponding main equipments.
(f.) Wherever quantity is specified both as a percentage and a value, the

Contractor has to supply the higher quantity until and unless specified
otherwise.
3.00.00 RECOMMENDED SPARES
(a.) In addition to the spare parts mentioned above, the contractor shall also
provide a list of recommended spares for 3 years of normal operation of the
plant and indicate the list and total prices in relevant schedule of the Bid Form
and Price Schedules. This list shall take into consideration the mandatory
spares specified in this Section-VI, part-F and should be independent of the list
of the mandatory spares. The Employer reserves the right to buy any or all of
the recommended spares. The recommended spares shall be delivered at
project site at least two months before the scheduled date of initial operation of
first unit. However, the spares shall not be dispatched before the dispatch of
the main equipment.
(b.) Price of recommended spares will not be used for evaluation of the bids. The
price of these spares will remain valid upto 6 months after placement of
Notification of Award for the main equipment during which the Contractor shall
provide necessary justification for the quoted prices for these spares. However,
if the Contractor fails to provide the aforesaid justification of the quoted prices,
the prices of recommended spare shall remain valid for 3 months from the last
date of providing such justification to the satisfaction of the Employer.
4.00.00 START-UP & COMMISSIONING SPARES
Start-up and commissioning spares are those spares which may be required during
the start-up and commissioning of the equipment/system. All spares used till the
plant is handed over to the Employer shall come under this category. The
Contractor shall provide for an adequate stock of such start up and commissioning
spares to be brought by him to the site for the plant erection and commissioning.
They must be available at site before the equipments are energized. The unused
spares, if any, should be removed from there only after the issue of Taking Over
certificate. All start up spares which remain unused at the time shall remain the
property of the Contractor.
5.00.00 COMMON REQUIREMENTS:
5.01.00 The Contractor shall include in his scope of supply all the necessary Mandatory
spares, start up and commissioning spares and recommended spares and indicates
these in the relevant schedules of the Bid Form and Price Schedules. The general
requirements pertaining to the supply of these spares is given below.
SECTION-VI
PART-A
CLAUSE NO. SPARES
5.02.00 The Contractor shall indicate the service expectancy period for the spares parts
(both mandatory and recommended) under normal operating conditions before
replacement is necessary.
5.03.00 All spares supplied under this contract shall be strictly inter changeable with the
parts for which they are intended for replacements. The spares shall be treated and
packed for long storage under the climatic conditions prevailing at the site e.g. small
items shall be packed in sealed transparent plastic with desecrator packs as
necessary.
5.04.00 All the spares (both recommended and mandatory) shall be manufactured alongwith
the main equipment components as a continuous operation as per same
specification and quality plan.
5.05.00 The contractor will provide Employer with cross-sectional drawings, catalogues,
assembly drawings and other relevant documents so as to enable the Employer to
identify and finalise order for recommended spares.
5.06.00 Each spares part shall be clearly marked or labeled on the outside of the packing
with its description. When more than one spares part is packed in a single case, a
general description of the content shall be shown on the outside of such case and a
detailed list enclosed. All cases, containers and other packages must be suitably
marked and numbered for the purposes of identification.
5.07.00 All cases, containers or other packages are to be opened for such examination as
may be considered necessary by the Employer.
5.08.00 The contractor will provide the Employer with all the addresses and particulars of his
sub suppliers while placing the order on vendors for items/components/equipments
covered under the contract and will further ensure with his vendors that the
Employer, if so desires, will have the right to place order for spares directly on them
on mutually agreed terms based on offers of such Contractors.
5.09.00 The Contractor shall warrant that all spares supplied will be new and in accordance
with the contract Documents and will be free from defects in design, material and
workmanship.
5.10.00 In addition to the recommended spares listed by the contractor, if the Employer
further identifies certain particular items of spares, the contractor shall submit the
prices and delivery quotation for such spares within 30 days of receipt of such
request with a validity period of 6 months for consideration by the Employer and
placement of order for additional spares if the Employer so desires.
5.11.00 The Contractor shall guarantee the long term availability of spares to the Employer
for the full life of the equipment covered under the contract. The Contractor shall
guarantee that before going out of production of spares parts of the equipment
covered under the Contract, he shall give the Employer atleast 2 years advance

SECTION-VI
PART-A
CLAUSE NO. SPARES
notice so that the latter may order his bulk requirement of spares, if he so desires.
The same provision will also be applicable to sub-contractors. Further, in case of
discontinuance of manufacture of any spares by the Contractor and/or his sub
contractors, Contractor will provide the Employer, two years in advance, with full
manufacturing drawings, material specifications and technical information including
information on alternative equivalent makes required by the Employer for the
purpose of manufacture/procurement of such items.
5.12.00 In case of equipment supplied with grease/lubricants from imported origin, the
supplier shall clearly indicate the indigenous equivalent of the grease/lubricant and
source of supply so as to enable the Employer to procure these items from
indigenous sources.

SECTION-VI
PART-A
PART - B
MECHANICAL

COAL HANDLING PLANT PACKAGE PART-B
PART - B
SUB-SECTION-IIIA-01
SYSTEM PARAMETERS AND OPERATION

& CONTROL PHILOSOPHY

CLAUSE NO. TECHNICAL REQUIREMENTS
A-01 : SYSTEM PARAMETERS AND OPERATION &

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

i. Rated Capacity (Guaranteed) : 1200 TPH
ii. Design capacity
(a) For boom conveyor of stacker/ reclaimer : 1500 TPH
(b) For other conveyors of proposed CHP : 1320 TPH
iii. Belt width : Minimum 1200 mm
iv. Maximum Belt speed for conveyors : 3.2 M/sec.

v. Belt Speed for belt feeders : 2 M/sec approx.
2.01.01 Belting and Pulleys
(a.) Belt ratings shall be selected in such a way that there are only three (3) ratings
for Nylon/Nylon/polyester/polyamide belting. This however excludes sealing
belt (for sealing slots of tripper floor) and belting of belt feeders. (Belting shall
be completely interchangeable among same rating of belt.) Minimum number
of plies for belting shall be four (4). Other details of belting shall be as specified
else where in the specification.
(b) For Pulley, following minimum parameters shall be followed:

(1.) Shell thickness : 16 mm (Min.)
(2.) End disc plate thickness : 24 mm(Min.)
(3.) Maximum allowable deflection of shaft at hubs : 5 Minutes

(4.) Diameter :
(i) All drive pulleys : 800 dia (min.)
(ii) All balance pulleys : 630 dia (min)
MUZAFFARPUR THERMAL POWER PROJECT SUB-SECTION-IIIA-01

STAGE-II (2X195 MW) SYSTEM PARAMETERS PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE AND OPERTION & 1 OF 30
PART-B
BID DOCUMENT NO. : CS-0350-155(R)-2 CONTROL PHILOSOPHY
Further approval from belt manufacturers shall be obtained by the contractor

regarding the adequacy of the pulley diameters.
d) Maximum type of pulleys permitted based on pulley diameter and shaft diameter
shall be limited to five (5). These shall comprise of two (2) nos. drive pulleys and
three (3) nos. for all balance pulleys. Pulleys for Belt Feeder, fixed & travelling
tripper, SS pulleys & S/R pulleys are not included in the above categories.
(a) Nos. required : Four (4)
(b) Guaranteed (rated) capacity : 900 MTPH
(c.) Capacity adjustment capacity : 20% to 100% of

(in case of hydraulic drive) guaranteed capacity
(d) Maximum coal lump size to be handled

by paddle feeder : 400 mm
(e) Total travel by each feeder carriage : 260 m
2.01.03 Coal Crushers & Vibrating Screen Feeders

(a) Nos. required : Four (4) each
(b) Guaranteed (rated) capacity

(considering 100% feed coal
above (+)20 mm size) : 660 MTPH
(c.) Input size (for sizing of crusher) : (-) 250 mm (occasionally

1-2% 400 mm lump)
(d) Guaranteed size of output from : Min 98% down to (-)20 mm

Ring Granulator type crusher
2.01.04 Travelling Trippers (Mobile)

(a) Nos. required : Two (2)
(b) Type : Motor driven rail mounted,

two way chute discharge
2.01.05 Stacker cum Reclaimer
(a) No. required : One (1)
(b) Rated Capacity (Guaranteed)

SECTION-VI
PART-B
(i) Stacking : 1200 TPH
(ii) Reclaiming : 1200 TPH
(c) Design Capacity (With specified

Degree of bucket fill and ring volume
(i) Stacking : 1320 TPH
(ii) Reclaiming (Peak) : 1500 TPH

(Considering 80% degree of fill of
water fill capacity of bucket and
50% of annularing volume and
discharge per min. not exceed 55).
(d) Height of stockpile to be formed : 10 meters
(e) Width of each stockpile at base : 50 meters
(f) Boom length (Center of slew to center

Of bucket wheel) : 41 meters
(g) Lump size to be handled : (-) 20 mm
2.01.06 Apron Feeder
(b) Guaranteed (rated) capacity : 1200 MTPH
(c) Design capacity : 1320 MTPH
2.01.07 Wagon Tippler (Rota side)
(b) (i) Guaranteed (Rated) capacity : 20 tips/hr (min)
(ii) Design capacity : 25 tips/hr (min)

2.01.08 Side Arm Charger
(b) Guaranteed (rated) haulage capacity : 58 wagons (DFC25)

SECTION-VI
PART-B
2.01.09 Dust Control System
The capacity of the dust control system specified hereinafter is for Contractor’s
guidance only. Contractor shall provide adequately sized and fool proof dust control
system, the performance of which should be guaranteed by the Contractor as
required in the Technical specifications. The performance guarantee test procedure
is to be submitted by the Contractor. However, the capacity of the offered system
shall not be less than the specified values below.
a) Track Hopper Dust Suppression System (Plain water type)
(1) Capacity of each nozzle : 2.0 lpm at 2.5 kg/ cm2
(2) Nozzle spacing. : 500 mm
(3) No. of dust suppression : min. one sub header of

nozzles that can be 15 mtr length each on
operated simultaneously one side of Track Hopper or
on both side of Hopper max. four (4) such sub-headers
along the Track Hopper.
b) Wagon Tippler Dust Suppression System (Plain water type)
(1) Capacity of each nozzle : 2.0 lpm (min.) at 4.5 Kg/cm2 (min)
to make suitable fogging.
(2) Nozzles spacing : 500mm
(3) No of zones : One (1) no.
(4) No. of nozzles operating : All

Simultaneously
c) Dust Suppression System (Plain water type)
(1) Operation : Water sprayed with fogging nozzle
(2) Location of spray : 1) Paddle Feeder (trolley

Mounted)
(3) Capacity / Pressure at : 2.0 lpm / 2.5 kg/cm2

inlet of spray head

SECTION-VI
PART-B
d) Dust Suppression System (Dry fog type)
(1) Operation : Water & air sprayed by Fogging

nozzle.
(2) Location of spray : At all coal discharge & receipt

point on all transfer point &
crusher house
(3) Capacity & Pressure : 0.5 Kg/cm2 for water (min.)

at inlet of spray head 5.0 Kg/cm2 for air (min.)
e) Stockyard Dust Suppression System
(1) Maximum number of nozzles : Two (2) Nos.

operating simultaneously for
each stacker cum reclaimer
(2) Capacity & Pressure : 500 Lpm/4.5 kg./sqcm(g)

of each spray nozzle
f) Dust extraction system
Type : Venturi scrubber type
Location : Belt feeder after crusher

& Vibrating Screening
Feeder at crusher house.
2.01.10 Service Water System
Service water connections are to be provided in conveyor galleries & tunnels at 50

meter interval and one (1) no. on each floor of Transfer Points, toilets and minimum
two (2) nos. on each floor of crusher house.
(a.) Flow at each valve : 5 cub.m/hr
(b.) Minimum discharge

Pressure at tap point : 2 kg/sq.cm
(c) No. of valves operated : 6 nos.

simultaneously

SECTION-VI
PART-B
2.01.11 Potable Water System : As specified elsewhere in the spec.
2.01.12 Ventilation System
A Mechanical Ventilation System
i. Underground Areas : Minimum 15 supply air changes and mini-

mum 7 exhaust air changes per hour.
ii. Other Areas Minimum 10 supply air changes per hour.
B. Pressurized Ventilation System: Minimum 15 supply air changes per hour
C. Air Conditioning System : Adequate number of air changes to

Maintain in uniform temp. & humidity as
specified elsewhere.
2.01.13 Chutes
Minimum clear cross section of chute : 800 mm x 1000 mm (inside both ways).
Minimum clear cross section of : 750mm X 1000mm (inside both ways)

discharge chute for stone picking
2.01.14 Hoists
Suitable hoists as specified elsewhere shall be provided for erection & servicing of
all major equipment. The equipment to be covered shall include (but not limit to) all
conveyor drive units, all pulleys, crushers along with drive units, in line magnetic
separators, sampling units, sump pumps, various DS/service water/potable water
pumps, gravity take up units, apron feeders, suspended magnet, removal of
equipment from tunnels, & underground building lifting of belt drum at all transfer
houses/crusher house/bunker floors etc.
2.01.15 All other equipment under the scope shall be suitable to the system capacities
parameters as specified above.
3.00.00 OPERATION AND CONTROLS
3.01.00 This section is intended to cover control/instrumentation and operational philosophy

as specified hereinafter complete in all respects, required for complete coal handling
plant.
3.02.00 General Requirements
The instruments and controls to be furnished and erected under this specification
are as required for safe and satisfactory operation of the Coal Handling System, as

SECTION-VI
PART-B
outlined under mechanical section and as specified elsewhere in the specification.

For the equipment and materials procured by the Contractor from his sub-vendors,
the Contractor shall study the specification, safety requirements, interface drawings
for such equipment and material in detail and shall coordinate his work with his sub
vendors and Employer’s DDCMIS system and supply instrumentation and control to
suit the actual Coal Handling equipment.
3.02.01 Standards / Codes
All construction, installation, workmanship, design & equipment shall conform to

acts, rules & regulations of the jurisdiction within which the project is to be located,
and to the current edition of the following or equivalent standards or codes, in so far
as they apply :
American Iron & Steel Institute (AISI)
American Society for Mech. Engineers (ASME)
American Society for Testing & Materials (ASTM)
American Wire Gauge (AWG)
Institute of Electrical & Electronic Engrs. (IEEE)
Instrument society of America (ISA)
National Electrical Code (NEC)
National Electrical Manufacturers Association (NEMA)
United States of America standards (USAS)
Bureau of Indian Standards (BIS)
Conveyor Equipment Manufacturers Association (CEMA)
3.02.02 This Sub-section shall be read in conjunction with Electrical Sub-sections.
3.03.00 General Construction and Design
3.03.01 General Construction
Control desks/panels and annunciation system shall be as per the requirement of

electrical Section. Annunciations, indications, electrical meters and instrumentation
shall be provided as specified.

SECTION-VI
PART-B
3.03.02 Design
The complete coal handling plant except for stacker-reclaimer and wagon tippler
shall be controlled from Employer’s DDCMIS system as detailed elsewhere.
The Contractor shall provide a comprehensive control indication and annunciation

scheme. Contractor shall furnish block diagram and write-up on the scheme
proposed. The final scheme will be approved by the Employer. In general,
interlocking shall be achieved through feed-back signals from field equipment.
Comprehensive Annunciation and Indication scheme shall be provided such that, it
will be possible for the operator to locate and identify the fault from the face of
DDCMIS/LVS/Control-Panel/ TFT itself. The scheme shall include the basic remote
control instrumentation, indication and annunciation requirements as per various
technical specification requirements.
However, the Contractor may offer any alternative proposal which he considers to be
equal, superior to the scheme as described in subsequent clauses below for
achieving reliable and trouble free operation of the plant, for consideration of the
employer.
4.00.00 OPERATION AND CONTROL PHILOSOPHY
The coal handling system shall be controlled from the following control points.
4.01.00 Coal Handling Plant Main Control Room
Overall, operation of the following equipment of Coal Handling Plant shall be

controlled from the main CHP control room.
(a.) Conveyors, feeders, flap gates, R & P gates, crushers, hydraulic scoop
couplings.
(b.) Paddle feeders (running status with stop facilities).
(c.) Complete Dust Suppression system, service water system, cooling water
system & potable water system.
(d.) Ventilation system (group/individual control as required).
(e.) In line Magnetic separators and Suspended Magnet (ON/OFF control with
indication).
(f.) Metal Detectors (ON/OFF control with indication).
(g.) Coal Sampling Units.
(h.) Belt weigher (ON/OFF control with indication)

SECTION-VI
PART-B
(i.) Stacker Reclaimer (ON/OFF status with stop facilities).
(j.) Mobile trippers over bunkers (tripper position indications).
(k) Apron feeders & dribble conveyor (indication only).
4.02.00 Local Control Panels
Local control stations for following equipment’s shall be provided
(a) Paddle feeders along with its dust suppression system
(b) Mobile trippers over bunkers
(c) Belt Weighers
(d) Metal detectors
(e) Electric hoist - wall mounted control box with pendent push button controls.
(f) In line magnetic separators
(g) Suspended Magnet
(h) Sump Pump
(i) Coal Sampling Units
(j) Dust suppression system for wagon unloading at track hopper and wagon
tippler.
(k) Hydraulic scoop coupling.
All the above local control panels shall be accessible and located near their
respective equipment and shall be complete with all the required controls, interlocks,
annunciation’s etc. However, for items (i.), (j) and (k) above, controls shall be
through Employer’s DDCMIS/contractor’s PLC as applicable. Further, necessary
controls, indications and annunciations for all the above equipment shall also be
provided at main CHP Control Room as described under relevant clause.
4.02.01 Stacker / Reclaimer Control
The entire control & operation of Stacker Reclaimer machine shall be from the
operator’s cabin on the machine itself. Flat TFT monitor shall be provided at the
Control desk of the operator’s caption.

SECTION-VI
PART-B
4.02.02 Wagon Tippler control Room
The entire control & operation of wagon tipplers, apron feeders and side arm charger
shall be from the wagon tippler control room.
4.03.00 In addition to the remote control of various equipment, local stop push button
stations shall be provided for all equipment.
4.04.00 System Operation
4.04.01 Operation philosophy of the plant, in general, shall be as elaborated below:
(a.) Coal flow path selection shall be done from CRT/Keyboard to select any one
of the following conveying paths.
(1.) Track hopper to boiler bunker
(2.) Track hopper to stock yard
(3.) Stock yard to boiler bunkers
(4) Wagon Tippler to boiler bunker
(5) Wagon Tippler to stockyard
(6) Combination of above
The coal handling system operator will select any one of the above paths from OWS
located on the main control desk. The flow stream path is then selected by
positioning different flap gates/ movable discharge pulley at desired positions by
means of keyboard available at the central control desk. Once the system is in the
operation, the gates/ movable discharge pulley can not be moved from their
positions and path. Flap gates which do not come in the stream in which coal flow is
taking place, can be operated at any time. However, for the flap gates in bunker area
conveyors, it shall be possible to change flap gate position while the conveyor is in
operation and feeding coal using interlock bypass facility, provided that sequential
permissive are available.
The Control system will be designed for “Auto” & “Manual” operation of the
conveyors in the selected path. Auto/Manual Selection shall be done from keyboard.
Auto Mode : In the “Auto” mode, the conveyors and related equipment will start
sequentially when the “System Start” is activated. During stopping, when the
“System Stop” is activated, all conveyors will also stop sequentially (in the reverse
sequence) allowing time delays for clearing the belts.

SECTION-VI
PART-B
Manual Mode : In Manual Mode, the operator will start the conveyor system, in the
same sequence as in Auto mode from keyboard. The operator will also stop the
conveyor system, by pressing "System stop" or individual “Stop” push
buttons/command from keyboard in the reverse sequence.
During “Sequence Start” in both Auto and Manual modes, first the required number
of hooters (3 phase induction motor type) will be energized simultaneously for a
preset time of 1 minute or so (adjustable at site) as per the program. After the preset
time, the hooters will stop and a preset time of two minutes (adjustable at site) as
per program will be allowed for the movement of the personnel and for the
permissive of the conveyor system operation. This condition will be indicated on the
panel by glowing of lamp “Coal Handling Sequence Start”. The starting permissive
will be available for a period of 5 minutes (Pre-programmed and adjustable in the
field). In the event the last conveyor / equipment is not started within this preset time
of 5 minutes, the start command for equipment not started will be withdrawn. The
system cannot be started again unless the “Sequence Start” push button is again
pressed and the hooters sound again, as described before. Those conveyors and
equipment, which have already started, will continue to run.
The status indication in the graphic display against all conveyors and equipment in
the selected path/stream will start slow flickering. However, all status indications
against all flap gates / movable discharge pulley in the selected path will glow
steadily. Therefore, from the selected flow stream path of the flap gates / movable
discharge pulley, the operator will come to know the conveyors and equipment to be
started for the selected path/stream. After a conveyor/equipment is started, the
status indications against that conveyor / equipment will change to steady glow
indicating that it is running.
Graphic display status indicators associated with a particular motor/equipment shall

flicker fast in case of fault / trip.
In addition, emergency stop push button on the control desk for immediate shut
down of complete plant shall be provided.
For changeover of feed from one row of Bunkers to another row of Bunkers without
stopping of the CHP, provision shall be made for interlock bypass on the control
desk for flap gates of all conveyors in Boiler area for a preset period. If the
changeover, in above specified time, is not completed then the entire CHP shall
stop.
(i) Lamp test facility will be provided for the annunciation and mimic lamps.
4.05.00 Conveyor System
(a) Normally the movement of the paddle feeders feeding coal from the track
hopper to the reclaim conveyor shall be controlled from the paddle feeder

SECTION-VI
PART-B
itself based on instructions from main control room. The operation of the
apron feeders feeding coal from the wagon Tippler hopper to the reclaim
conveyor shall be controlled from wagon tippler control room.
(b) The paddle feeder carriages shall move continuously to and fro along their
tracks. Suitable limit switches and anti-collision devices (both mechanical
limit switch operated and infra red type) shall be provided to enable them to
change direction of movement as soon as they come within a specified
distance of each other and at the end of travel in one direction.
(c) The operation and stoppage of the paddle feeders shall be signaled in the
main control room of the coal handling plant. It shall be possible to stop the
paddle feeder from main control room. It shall be possible to stop the track
hopper conveyor from respective paddle feeder.
(d) Approach of a Railway wagon rake to the plant shall be signaled (visual and
audible) in the Track Hopper or Wagon tippler Control room as well as to the
main coal handling plant control room, as soon as the rake come within 100
meters distances from the track hopper or Wagon tippler. Provision shall be
made for the same by the Contractor in control desk.
(e) Each conveyor shall be protected against damage to the edge of the belt due
to excessive sideways movement by providing an adequate number of belt
sway switches. In addition, each conveyor shall be provided with one (1) No.
speed detection device (zero speed switch). The zero speed switches shall
be designed to sense belt speed. In case of speed of belt goes below 85% of
rated speed, it shall trip the conveyor.
(f) All the conveyors shall be protected from reverse running due to power
failure by providing mechanical or electrical locking system.
(g) The starting sequence of the conveyors shall follow a direction opposite to
that of flow of material i.e. :
(1.) In case of direct conveying of coal to boiler bunkers, start from bunker
conveyor and end up with reclaim conveyors below track
hopper/Wagon Tippler.
(2.) In case of stacking of coal in stock yard, start from yard conveyor and
end up with reclaim conveyors below track hopper/wagon tippler
hopper. However, for yard conveyor to start, the stacker-cum-
reclaimer shall be in operation.
(3.) In case of reclamation of coal from stock yard, start from bunker
conveyors and end up with yard conveyor alongwith Stacker/
Reclaimer.

SECTION-VI
PART-B
(4.) The starting of paddle feeder shall be interlocked with operation of the
reclaim conveyors below track hopper.
(5) The starting of apron feeders and wagon tipplers shall be interlocked
with operation of the reclaim conveyors below wagon tippler hopper.
(6) The starting of mobile trippers shall be interlocked with operation of the
bunker bay conveyors.
(h) Inter locking of yard conveyor with stacker-cum-reclaimer boom conveyor

shall be provided.
(i) Any individual equipment (belt conveyor etc.) should not be allowed to start
unless the equipment immediately following the same in the direction of flow
of material is already in operation.
(j) Stop/tripping of any equipment from running condition shall trip all preceding
equipment in the system, except crushers but shall not effect succeeding ones
which shall continue to operate.
(k) Adequate number of pull-cord switches shall be provided at suitable intervals

along the length of each belt conveyor, which shall enable the respective
conveyor to be stopped immediately. Each pull chord switch shall be
identified by a specific number on HMI in the main control room. Each belt
sway switch shall also be identified by a specific number on HMI in control
room.
(l) Means shall be provided to pre-warn personnel working nearby when starting
any conveyor, stacker-cum-reclaimer, Wagon tippler and mobile tripper.
(m) Interlocking of various conveyors shall be achieved with Flap Gate, discharge
pulleys, Rack & Pinion gate, limit switches and zero speed switches.
(n) Suitable indication for paddle wheel rpm shall be provided on the local panels.
Manual facility to control the cutting rate of paddle feeder shall also be
provided.
(o) Motors shall start only when the brake/rail clamp if-provided, is in “not
applied’‘condition. This signal shall be obtained from limit switch provided for
that purpose.
(p) Ring granulators shall be provided with speed and vibration monitoring
instruments. Ring granulators shall trip in case speed/ vibration is going
beyond tolerable limits of design. Temperature sensing devices shall be
installed on all bearings of each of the ring granulator to trip the ring
granulator in case of temperature goes beyond limit. Audio-visual
annunciation shall be provided in main control room and locally also.

SECTION-VI
PART-B
(q) Once a conveyor trips, flap gate directing coal from this conveyor shall change
over its position with a time delay and shall come back to the original position
again. This is to prevent jamming of gate.
(r) Tripping of the respective conveyor shall be provided in case any of paddle
feeders and mobile trippers starts running along with conveyor belt at speed
higher than their rated speed by providing an over speed sensing device on
the equipment.
(s) It shall be possible to trip track hopper conveyor, bunker conveyor and yard
conveyor from paddle feeder, mobile tripper and stacker / reclaimers
respectively.
(t) Where ever scoop type coupling provided for HT motors, the coasting time of
respective conveyor, thrustor brake, actuator selection and the chute size
shall be so selected such that there is no spillage of coal from any down
stream conveyors during next start.
(u) Wherever the conveyor/belt feeder is provided with the movable discharge
pulleys in place of flap gates, the starting of the conveyor/belt feeder will be
interlocked with the position of the movable discharge pulley.
4.06.00 Interlocking
(a.) The following conveyors / equipment will come under interlock scheme :-
(1) All conveyors
(2) All flap gates
(3) All movable belt feeders/pulleys
(4) Rack & Pinion Gates
(5) Metal detectors
(6) Magnetic Separators and suspended Magnet
(7) Crushers
(8) Paddle Feeders
(9) Belt scale
(10) Mobile Trippers
(11) Stacker/Reclaimer

SECTION-VI
PART-B
(12) Wagon tipplers
(13) Apron feeders & dribble Conveyors
(b.) The following equipment will not come under interlock of the conveyor
scheme.
(1.) All dust suppression systems & service water system.
(2.) Ventilation systems
(c.) All conveyors and equipment will have local push button stations each
consisting of :
(1.) Pos - I, Pos - II & stop button for flap gate and R & P gate
(2.) Emergency stop push button (Red) for other equipment
(d.) Belt scale shall be started when relevant conveyors are started.
(e.) The dust suppression systems will be energized as soon as the conveyors
are energized.
(f.) Coal handling plant shall be tripped in case of detection of fire.
(g.) Interlock for H.T. Motor :
H.T. motors used will continue to run on no load by disengaging the fluid
coupling in case of failure of any process interlock. The H.T. motors will
however be tripped in case of any motor fault like O/L, high motor winding
temperature etc. In addition, in case of normal stop command, after running
of the system, motors will stop.
(h.) The following are the various safety interlocks for the conveyors and other
equipment. This list is indicative only and the Contractor shall develop a
comprehensive interlocking scheme.
Conveyors
a) Pull - Chord switch - not operated
b) Belt sway switch - not operated
c) Under speed switch - closed at 90% speed of the conveyor within designed
accelerating time.
d) Motor protection - not tripped
e) Local stop PB – reset

SECTION-VI
PART-B
f) Chute Block switch - not operated.
g) Brakes for conveyor – not operated.
h) Trip circuits healthy.
i) Temp. of fluid coupling oil - not high
Paddle Feeders
a) Motor O/L - not tripped
b) Local E-Stop PB - reset
c) Stop PB in main CHP control room - reset
d) All Limit Switches – reset
e) Over speed limit switch – not tripped
Travelling Tripper:
a) Stop PB in Local control station - reset
b) Motor O/L not tripped.
c) Over Travel Limit switches - not tripped.
Magnetic Separators / Metal Detectors / Suspended Magnets
a) O/L / fault relay - not tripped.
b) Stop PB (Local & Remote) reset.
c) Metal detector reset
d) Oil temperature - not high
Flap Gates/ R & P Gates:
a) End of travel limit switches - reset.
b) Torque limit switches - reset.
c) Local stop - reset.
Ring Granulator
a) Zero speed - not operated

SECTION-VI
PART-B
b) Temp. of fluid coupling oil - not high.
c) Local stop push button reset.
d) Temperature of bearings – not high.
e) Cooling water flow switch – reset
Wagon tippler
a) Motor O/L – not tripped
b) Local E-Stop PB-reset
c) Stop PB in main CHP Control Room reset.
d) All limit switches - reset
e) All limit Switches – not tripped.
Apron feeder
a) Motor O/L – not tripped.
b) Local stop PB – rest
c) Dribble Conveyor – not tripped.
4.06.01 The lists of indications and audio-visual annunciation given in subsequent clauses
are indicative only and the same shall be finalised during detail engineering.
4.06.02 Status indications in Large Video Screen
Following individual status indications shall be provided in LVS with individual

ON/OFF/TRIP indications on CRT.
(a.) Conveyor 'ON'
(b.) Flap Gate/Rack and Pinion gate.
(c.) Belt scale flow rate indication and totalizer.
(d.) Belt sway switch operated for each conveyor (individual switch indication on
CRT).
(e.) Pull cord switch operated for each conveyor (Individual switches indication on
CRT).

SECTION-VI
PART-B
(f.) Zero speed switch operated for each conveyor
(g.) Paddle Feeder ‘ON'
(h.) Travelling tripper position.
(i.) Crusher ON
(j.) MD/ ILMS/ SM/ CSU ON
(k.) DS/ SW/PW/CW/DE/ Vent ON (System wise)
(l.) Stacker-cum-reclaimer ON (any travel position)/stacking/reclaiming
(m.) Unit wise MW indication, total coal flow & Bunker level.
(n.) Wagon Tippler – ON
(o.) Apron feeder - ON
Further Mimic lamps for HT and LT SLDs shall be provided on the control desk.
4.07.00 Annunciation System:
DDCMIS/Control desk shall be provided with adequate number of facia type

annunciation windows operating through DDCMIS for the following audio-visual fault
annunciation purposes. Wherever group annunciation is provided, alarm status of
individual equipment shall be provided on OWS.
(a) 3.3 kV Breaker Trip (Group wise for each board)
(b) 415 V MCC Breaker Trip (MCC wise)
(c) Bus under voltage for each LT MCC & HT switchgear buses.
(d) Following group wise annunciation shall be provided for transformers :
(1.) Buchholz alarm
(2.) Winding/oil temperature high alarm
(3.) Oil level low alarm
(4.) Buchholz trip
(5.) Winding/oil temperature high trip
(e) A.C Control Supply failure.

SECTION-VI
PART-B
(f) D.C. Control Supply failure.
(g) Annunciation supply failure.
(h) Both CPU fail
(i) Stand by CPU in service
(j) H.T. motor overload alarm (individual)
(k) HT motor bearing/ winding temp. high alarm (for each) and trip (for each)
(l) HT motor trip on electrical fault (for each)
(m) LT motor overload tripped (for each).
(n) Crusher vibration monitor alarm (for each).
(o) Belt sway switch operated (for each)
(p) Pull cord switch operated (for each)
(q) Zero speed switch operated. (for each)
(r) Chute plugged (for each)
(s) Wagon rake arrived.
(t) Paddle feeder over speed tripped (for each)
(u) Tripper over speed tripped (for each)
(v) Stacker-reclaimer tripped (for each)
(w) Magnetic separator fault and cleaning belt trip.
(x) (i) Metal Detector fault (for each)
(ii) Metal detected / MD not reset (for each)
(y) Belt Scale fault (for each)
(z) Sampling system faults and trips (for each)

(ab) Dust suppression/service water system faults and trips (system wise)
(ac) Water level low in tanks (for each)
(ad) Oil temperature of fluid coupling high

SECTION-VI
PART-B
(ae) Crusher low speed & crusher bearing temperature – high.
(af) Wagon tippler tripped (for each)
(ag) Apron feeder tripped
(ah) 20% spare window
For identification of the fault for a particular conveyor or equipment, status indication
against that conveyor / equipment in the mimic will start fast flickering and the
annunciation window will be blinking against that particular fault. In addition, a
buzzer (alarm) will start sounding. After acknowledgement of the fault, the buzzer
will stop, but the fast flickering on the mimic and the steady glow on the annunciation
window will continue until the fault is cleared and the Reset push button is pressed.
When the fault is cleared and the Reset push button is pressed, the status indication
of that conveyor / equipment on the mimic will start slow blinking if it is on selected
path otherwise it will go off and the steady glow in the annunciation window will go
off. However, pressing of the Reset push button before clearance of the fault, will
have no effect on the lamps.
At the time of a fault, the faulty conveyor / equipment, as well as the preceding
conveyors / equipment in the interlock sequence, will stop except H.T. motors for
which only scoop coupling will be disengaged and motor will continue to run for
process fault. In case of motor fault, H.T. motor will trip but the succeeding
conveyors / equipment will continue to run. The status indication against the
preceding conveyors / equipment will start slow blinking while the faulty conveyor /
equipment will be fast blinking.
Start command shall not be initiated unless reset button in pressed after clearance
of fault.
The sequence of operation of the annunciation system shall be as follows :-
Condition Status
Normal : Ann. Window : Off.
Status indication : Steady glow
Buzzer : Off.
Fault : Ann. Window : Blinking.

Status indication : Fast blinking
Buzzer : Sounding.
Press Ann. Window : Steady glow.

Accept. PB.
Status indication : Fast blinking
Buzzer : Off.
Press Reset Ann. Window : Off.

SECTION-VI
PART-B
PB (When
fault is Status indication : i) Steady blinking (if on
cleared): selected path)
ii) Off (if not on selected path)
Buzzer. : Off.
(a.) Conveyors / Equipment
(1.) It shall be possible to operate the dry fog system on to coal stream only
when corresponding conveyors/equipment are running with material at
spray application points.
(2.) If a running pump trips stand-by pump shall start automatically. It shall be
possible to select any of the pumps as auto standby from main CHP
control room.
(3.) Pump/pumps shall trip with a time delay, if discharge valves fail to open.
Suitable pressure/flow switch shall be provided to sense this condition.
(4.) Pumps shall trip in case of low level of water in tank.
(5.) All feeding pumps to tank shall trip in case of high pressure & no flow by
pressure switch.
(6.) Motorized inlet valve to Dust Suppression tanks shall close in case of
High-High level & open in case of low level.
(7.) Pumps shall be started manually or from DDCMIS. If any of the

pump/pumps trips, stand-by pump/pumps shall start automatically. It shall
be possible to select any of the pumps as auto stand - by.
(8.) Following annunciation’s shall be provided at local control panel.
(i) Motor electrical protection operated (Group)
(ii) Discharge water pressure low (Group)
(iii) Water level low in tank (Individual)
(9.) Following individual indications shall be provided at local control panel.
(i) Motor ON/OFF/TRIP
(ii) Discharge pressure healthy

SECTION-VI
PART-B
(iii) Water level high in tank.
(b.) Wagon unloading (At Track Hopper & Wagon Tippler Hopper)
(1.) System shall be operated from local control panel. However, the controls
shall be through DDCMIS.
(2.) Dust suppression system shall be provided to cover the Track Hopper in
minimum one & maximum twenty sections. Push button for each section
shall be located on each side of track hopper at convenient location. Dust
suppression shall be provided to cover W.T. hopper. Push button shall be
located at convenient location.
(3.) Pumps shall be started manually or from DDCMIS. If any of the

pump/pumps trips, stand-by pump/pumps shall start automatically. It shall
be possible to select any of the pumps as auto stand - by.
(5.) Following annunciation’s shall be provided at local control panel.
(j) Motor electrical protection operated (Group)
(ii) Discharge water pressure low (Group)
(iii) Water level low in tank (Individual)
(6.) Following individual indications shall be provided at local control panel.
(i) Motor ON/OFF/TRIP
(ii) Discharge pressure healthy
(iii) Water level high in tank.
(c) Stock yard Dust suppression system
(1.) Water supply pumps shall be started in Manual mode from Main CHP
control room. Controls shall be through DDCMIS.
(2.) If any of the running pump/ pumps trip, standby pump/ pumps shall start
automatically (pressure switch signal shall not be used for this purpose).
(4.) All feeding pumps to tank shall trip in case of high level in tank

SECTION-VI
PART-B
(d) Paddle Feeder Dust Suppression System
Trolley mounted dust suppression system arrangement shall be provided as

described else where in the specification and shall be controlled from the local
control panel. Rest of the system to supply ground storage tanks and ring
header etc. shall be controlled from main CHP control room.
(e) Following individual inputs shall be provided to DDCMIS system from all the
above dust suppression systems (except trolley mounted system for paddle
feeders) for alarms/indications.
(i.) Motor ON/OFF/TRIP
(ii.) Water level low in tank
(iii.) Water level high in tank
(iv.) Discharge pressure low
4.09.00 Metal detectors
(a) It shall be possible to start the conveyors only after energizing the metal
detector and ‘Metal detector reset’ condition. Once the metal is detected, the
corresponding conveyor shall trip.
It shall be possible to restart the conveyors, after local resetting of metal

detector and putting back the marker bag in position. Metal detector ON/OFF
push buttons shall be provided in main control room also.
(b) In case of tripping of conveyor system, metal-detector shall get de-energized

after a time lag.
(c) Following individual indications shall be provided on local control panel.
(1) Metal detector ‘ON’
(2) Metal detected
(3) Metal detector 'reset'.
(4) Metal detector faulty.
4.10.00 Sump Pumps
(a) Sump Pumps shall start and stop by the level switches in the sump
automatically. Further manual override start / stop push button shall be
provided locally on ground level.

SECTION-VI
PART-B
(b) Any of the pumps can be selected as auto-standby.
(c) If the sump level continues to be high even after the first pump is under
operation second pump shall start automatically.
(d) The following indications for sump pumps shall be provided on local Control
Panel.
(1.) Water level high
(2.) Motor ON/OFF/TRIP.
4.11.00 Coal Sampling system
(a) Coal Sampling Unit shall be controlled through main coal handling plant
DDCMIS. Controls and interlocks for proper material flow shall be provided
similar to conveyor system. Mimic shall be provided in the Operator Work
Station (OWS) at main CHP control room.
(b) Only one start/stop push button along with selector switches for various modes
of operation of coal sampling system shall be provided for automatic operation
of complete coal sampling system. This control facility shall be provided at
main CHP control desk as well as locally. In any case, local push button
stations shall be provided for all individual equipment of coal sampling system
near the equipment.
(c) All necessary automatic controls shall be provided for meeting the
requirements of ASTM-D-2234.
(d) Following indications shall be provided on local control panel
(1.) System ON/OFF/TRIP
(2.) Primary cutter stuck up between parking positions.
(e) In case of primary cutter getting stuck between parking positions, preceding
conveyor shall trip and annunciation shall appear at Main CHP Control room.
(f) There shall be protection in the primary coal sampler to trip the conveyor belt in
case primary sampler falls on running conveyor due to coupling failure etc.
Individual motor ON/OFF/TRIP indications shall be provided at main CHP

control room.
Paddle feeders shall be controlled from the local control panel suitably mounted on
the unit. Requirement of operation as described else where in the specification shall

SECTION-VI
PART-B
be complied with. Following indications shall also be provided on the local control
panel:
(a.) Motor ON/OFF
(b.) Motor O/L protection operated
(c.) Brakes applied (if provided)
(d.) “Digital pressure indications of Hydraulic Power pack including those of

hydraulic pump discharge, return (leakage) traverse pump discharge (forward
and reverse) oil line.”
(e.) Coal flow rate
Main Hydraulic pressure of paddle feeder wheel drive system to be reduced to

minimum through its control circuit during each tripping of main drive motor.
4.13.00 Travelling Trippers
(a) Mobile tripper unit shall be locally controlled from the operating platform
suitably located with the unit as per instructions given from main CHP control
room.
(b) End travel limit switches shall also be provided.
(c) Travel drive motor shall start only when brake and rail clamps are in
disengaged condition.
(d) It shall be possible to trip the bunker Conveyors from tripper.
(e) When the last bunker is full, it shall not be possible to change over the tripper
flap gate from bunker feeding position to last bunker feeding position.
(f) As soon as the bunker conveyor trips, tripper flap gate shall change over its
position after a time lag.
(g) Two nos. emergency stop button one on each side shall be provided on tripper
to stop the machine at any position. The control unit on tripper shall be
provided with start / stop push button and indication lamp for travel / gate. The
tripper brakes and rail clamps shall be energised (and released) when the
tripper motors are ON and the brakes will be applied when the travel motors
are OFF. Two travel limit switches shall be provided at either end of tripper
carriage for limiting the travel drive between two ends of the track. The first one
shall be normal limit and the second one for over travel limit. In addition to
above, position indication for bunker position of tripper will be provided in Main
control room. Necessary position encoders/limit switches shall be provided.

SECTION-VI
PART-B
(h) Following individual indications shall be provided on local control panel
(1.) Motor ON/OFF/TRIP
(2.) Brakes applied
(3.) Rail clamps applied
(4.) Flap gate position
(i) Indication of tripper flap gate positions shall be given in the main CHP control
room.
(j) It shall be possible for operator to manually trip the coal feeding eqpt. viz.
paddle feeders or stacker / reclaimers from the tripper.
(k) Chute blockage switch shall be provided at each leg of chute and shall trip the
tripper conveyor in case of blockage.
4.14.00 Flap Gates/ R&P Gates
All Flap Gates/ R&P Gates shall be motorised with remote controlled from the main
control desk. Their position shall be indicated on the mimic of main control room.
4.15.00 Belt Weighers
Each belt scale shall give output to DDCMIS for display of flow rate indicator and
totalizer on TFT and print out at main CHP control room. 4 Nos. rate flow rate
indicators, one for each paddle feeder shall also be furnished to display the
instantaneous TPH on respective paddle feeder using the output of belt scale on
Conveyors. Each belt scale shall also have rate flow indicator and totaliser mounted
near the unit. Belt weighers shall also be provided on Stacker-Reclaimer as
described elsewhere in the specification.
4.16.00 Magnetic separator / Suspended Magnet
It shall be possible to start the conveyor only after energising the magnet of ILMS or
SM. Further, if conveyor system trips magnetic separators shall get de-energised
after a time lag and suspended magnet will remain energised and can be de-
energised locally. Also if drive motor of cleated belt of ILMS trips, magnetic
separator shall not get de-energised, but conveyor system shall trip and audio-visual
annunciation shall appear at main CHP control room.
Following individual indications shall be provided on local control panel
(a.) Magnetic separator ON.

SECTION-VI
PART-B
(b.) Incoming supply ON
(c.) ‘Under current relay’ operated
(d.) Cleated belt motor ON/OFF/TRIP
(e.) Oil temperature high
4.17.00 Service water, Cooling Water and potable water pumps
(a) These pumps shall be started from main CHP control room
(b) Pump shall trip in case of low water level in tank.
(c) Following individual inputs shall also be provided to DDCMIS system for
alarms/indications :
(1.) Motor ON/OFF/TRIP
(2.) Discharge water pressure low
(3.) Water level low in tank
(4.) Water level high in tank
4.18.00 Stacker/ Reclaimer
(a) The Stacker cum reclaimer shall be controlled from the operator’s cabin in the
machine through PLC system of stacker cum reclaimer.
(b) Slew speed shall be controlled through Power transducers on Bucket wheel
drive motor for uniform feeding. Setting of Power transducer shall be done from
operators cabin.
(c) Slew reversal shall be automatic through
(1.) Power transducer on Bucket wheel and/or
(2.) Extreme end limit switches and/or
(3.) Manual command.
(d) At the end of Slew Pass Stacker - Cum - reclaimer drive shall advance
automatically to required depth of cut. Depth of cut shall be controlled through
the setting of power transducer on Bucket wheel. It shall also be possible to set
the depth of cut through a separate setting knob in operator cabin.
(e) All controls shall be based on feed back signals from field equipment.

SECTION-VI
PART-B
(f) All electronic circuitry shall have self-diagnostic features.
(g) Operator’s cabin shall maintain horizontal level automatically as per Boom
Conveyor position.
(h) For all drives, zero speed shall be ensured before affecting reversal, by
providing suitable speed sensing device.
(i) Motors shall start on when the Brake and/or rail clamp, is in “Not Applied
condition”. This signal shall be obtained from limit switch provided for that
purpose.
(j) If wind velocity is high, it shall cut off power supply to stacker - cum-reclaimer
with a time delay, after giving sufficient time to operator to bring the Boom in
minimum wind pressure direction/ position.
(k) All sequential interlocks for proper material flow shall be provided.
(l) It shall be possible to operate the lubrication system from operators cabin.
(m) Manual - Local.
With the selector switch in this position all drive functions on the stacker - cum
- reclaimer can be operated by push buttons local to the drives. All other
operation initiating devices shall be locked out.
(n) Manual – Remote
Manual controls facility shall also be provided in control desk and keyboard
(operator’s cabin) as below :
(1.) Individual controls shall be provided for each equipment.
(2.) Manual slew speed variation and depth of cut setting facilities shall be
provided.
(o) Following minimum audio-visual annunciation shall be provided through

integral type annunciation system in operators cabin in stacker - reclaimer.
Annunciation system shall meet the requirements specified in the relevant
electrical sections.
(1.) Wind velocity high
(2.) Lubrication system trouble for slew drive
(3.) Lubrication system trouble for bucket wheel drive.
(4.) Hoisting system trouble.

SECTION-VI
PART-B
(5.) Chute plugged
(6.) Coal flow rate high
(7.) Belt sway switch operated
(8.) Zero speed switch operated
(9.) Pull chord switch operated
(10.) Motor electrical protection operated (Individual)
(11.) For L.T. transformer Wind temp. high alarm and trip.
(12.) LT breaker tripped
(13.) HT switch tripped
(14.) 20% spare windows.
(15.) Rail clamps of stacker reclaimer not engaged.
(p) Following individual indications shall be provided in operator’s cabin and CRT
(1.) Motor ON / OFF / TRIP
(2.) Control supply healthy
(3.) All necessary position/motion/level indications
(q) Ammeters shall be provided in control desk for all the motors.
(r) Wind velocity indication shall be provided in operator's cabin.
(s) Contractor shall provide a comprehensive interlock and protection scheme and
include a block logic diagram and write up on the scheme proposed. The final
scheme shall be subject to approval of Employer. Sequential interlocking as
applicable shall be provided. This shall be a part of main interlock scheme
/writeup for the entire Coal Handling Plant.
(t) Boom conveyor shall be interlocked in such a way that it cannot start in
reclaiming mode unless yard conveyor is running. In addition, yard conveyor
would not start unless boom conveyor is running in stacking mode (with CHP in
stacking mode). Following indications shall also be provided in operator’s
cabin.
(1.) Boom conveyor stacking
(2.) Boom conveyor reclaiming

SECTION-VI
PART-B
For indications/interlocks indicated above, and for communication system

between stacker/ reclaimer and main control room, contractor shall provide all
necessary control cables.
(u) It shall be possible to trip stacker/ reclaimer from main CHP control room also.
(v) A push button shall be provided in operator’s cabin to trip the yard conveyor.
4.19.00 Wagon Tippler
Wagon tippler shall be controlled from the local control panel suitably placed.
Requirement of operation as described elsewhere in the specifications shall be
complied with. Following indications shall also be provided on the local control panel:
(a) Motor On/OFF
(b) Motor O/L protection operated
(c) Brakes applied (if provided)
(d) Hydraulic power Pack indications as applicable.
(e) Dribble Conveyor
Main Hydraulic pressure of champing drive system to be reduced to minimum
through its control circuit during each tripping of main drive motor.
4.20.00 Summary of control philosophy
Contractor shall furnish summary of control philosophy indicating permissive, trip

and interlock conditions for each drive/equipment. It shall clearly list all permissive
conditions (conditions required to start the drive), all the trip/protection conditions
and each auto start/open and auto stop/close condition for each drive/equipment.
The sequential start-up and shut-down steps for a group of drive/equipments shall
also be described clearly.
The above summary conditions shall be comprehensive to include all process

conditions and shall be elaborated in clear and unambiguous way, and shall include
tag numbers of devices and equipments.
4.21.00 Logic Diagram
The contractor shall furnish comprehensive logic diagram showing all interlock,
protection, sequence and alarm requirements of complete system to the employer
during detail engineering stage. In this logic diagram, tag number corresponding to
I/O list and drive list shall be clearly indicated. The format of this logic diagram shall
be informed by employer during detail engineering. The recommended logic and
write-up shall match fully.

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-02
PADDLE FEEDER

A-02: PADDLE FEEDER
1.00.00 GENERAL
Paddle Feeders shall be supplied and erected complete with rails including
necessary supporting structures, approach/maintenance platforms with hand railings
and ladders, cable reeling drums with trailing cable, cable trays, all electricals
including machine mounted local control panel.
1.01.00 Codes & Standards
The design, manufacture, inspection and testing of Paddle Feeders shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Paddle Feeders shall conform to the
latest edition of the Indian standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those specified,
shall also be accepted. Nothing in this specification shall be construed to relieve the
contractor of the required statutory responsibility. In case of any conflict in the
standard and this specification, the decision of the Employer shall be final and
binding.
1.02.00 DESIGN REQUIREMENT
1.02.01 Travelling paddle feeders of self-contained, self-propelled design shall be furnished

and erected to scoop out coal from the hopper and each feeder shall be capable of
travelling back and forth along the entire length of the hopper and transfer the coal
from the hopper uniformly onto the conveyors below. Each paddle feeder shall have
capacity to scoop out coal at the guaranteed capacity in both forward and reverse
motions with no indication of wheel slipping (water tank full). Each paddle feeder
shall be designed for guaranteed capacity while handling entire range of lump sizes.
1.02.02 It shall operate on the principle of positive discharge and shall not depend on friction
or moisture content.
1.02.03 The Paddle wheel shall be driven by a stepless hydraulic drive. Carriage travel shall
be achieved through electric motor gearbox (2 speeds) and flexible coupling or
through hydraulic drive.
1.02.04 All equipment shall be designed to withstand any rate of acceleration imparted by
drives or any strain resulting from a sudden change in load. Further, the design of
paddle feeder carriage should be such that it does not run off from its rails due to
sudden change in load or other reasons.
1.02.05 The Contractor shall include in his proposal necessary electricals for paddle feeder
and carriage such as motorized cable reeling drum with trailing cables, and end limit
switches for protection against over travel of the feeder carriage. Two separate cable
reeling drums one for Power cable and one for Control cable shall be provided for
each machine. The cable reeling drum and trailing cable of each feeder shall be
suitable for the entire length of the hopper upto maintenance bay. Mechanical track
stops alongwith buffers on each end of rails and on paddle feeders shall also be

STAGE-II (2X195 MW) SUB-SECTION-IIIA-02 PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE PADDLE FEEDER 1 OF 6
PART-B
provided. For specification of dust suppression equipment for paddle feeder, refer
relevant Sub-section of this Specification.
1.02.06 For designing the paddle wheel as well as travel drive, Contractor shall consider the
hopper fully loaded with coal on either side of the paddle wheel to the maximum
capacity. The hydraulic system normal average working pressure shall be selected
considering the above loading condition. Further hydraulic system shall be designed
to stall / trip beyond a certain pressure above the normal average working pressure.
The minimum margin between the normal working pressure and the stall / trip
pressure shall be 50%.
1.02.07 Feeder carriage drive shall be suitably designed so that the forward & reverse
movement of carriage can be achieved without stopping the scooping operation.
Tank filled with water in DS system shall also be considered for travel drive.
1.02.08 Rail structure shall be designed considering two-wheel support and accounting no
frictional force from the other two wheels and considering hydraulic motor stall
condition.
1.02.09 For selection and specification of drive motors (other than the hydraulic motor),
gearboxes, all types of couplings associated with paddle feeder and other
equipment, relevant sections of this specification shall be referred to.
1.02.10 Contractor’s design of paddle feeder should not incorporate a separate loading table
(impact cradle) below the paddle feeders. However, the height of fall of coal between
paddle wheel and conveyor belt shall be kept minimum. Hydraulic components shall
be provided with dust proof cover for protection against spillage of coal/ dust.
Pressure /Temp. gauges shall be located at convenient locations for continuous
observation by operator. Proper oil level gauge to be provided at hydraulic oil
reservoir tank.
1.02.11 Three (3) pairs of Control cables shall be provided in the control trailing cable of
each machine for connecting Employers telephone and P.A. equipment to be
provided on each machine.
1.02.12 For Hydraulic system, in case the oil temperature is high then proper external
cooling is to be provided , viz, heat exchanger, before the oil returns back to the oil
tank.
1.03.00 CONSTRUCTION REQUIREMENT
1.03.01 The paddle feeders shall run on rails mounted on the supporting structures of
associated conveyors. Both paddle feeder and carriage drives shall be mounted on
the feeder carriage.
1.03.02 The paddle feeder wheel shall comprise of suitable numbers of vanes with cutting
edges. The vanes shall be of high strength steel construction with removable tiscral
or equivalent liner plates. Vanes shall be easily removable individually. Tip of the
vane shall reach inner most point of hopper table.

SECTION-VI
PART-B
1.03.03 The feeder carriage shall be of steel construction and of robust design. Skirt plates
shall be provided integral with the equipment for collecting the material drawn by the
paddle feeder from the track hopper and discharging on to the conveyor belt. Feeder
skirts of paddle feeders shall be extended at least by 500 mm on either side of the
paddle wheel to avoid spillage of coal. Necessary baffle/retainer plates for suitably
guiding the flow of coal from track hopper to the reclaim conveyor being fed by
paddle feeders shall be provided. Hand railing shall be provided on the top deck of
feeder carriage together with an access ladder.
1.03.04 The feeder carriage shall be provided with suitable number of double flange wheels
of steel construction, complete with sealed bearing unit. The drive mechanism shall
be suitable for continuous reversible motion of the carriage. Start/stop switches shall
be provided at the local control panel for the operation of paddle wheel and feeder
carriage. The carriage shall automatically reverse its motion, when two paddle
feeders operating on the same track come within a predetermined distance. Suitable
anti-collision device (infrared and mechanically operated limit switch type) shall be
provided. Provision shall be made to trip the track hopper conveyor from respective
paddle feeder and provision shall be made for tripping of paddle feeder from CHP
main control room.
1.03.05 Rope actuated stop switches shall be provided along the travelling structure for
emergency use.
1.03.06 Suitable indication of paddle wheel ‘rpm’ shall be provided on the paddle feeder
control panel and flow rate indicator of belt weigh scale shall also be duplicated on
control panel of paddle feeder. Operating controls shall be mounted at a suitable
height such that it can be operated from walkway. Encoder shall be provided on the
paddle feeder to give 4-20 mA. Signal to the DCS to the exact location of the
machine.
1.03.07 Suitable rail cleaners shall be provided at the leading as well as trailing side of the
feeder carriage for both tracks.
1.03.08 Suitable cable trays/troughs shall be provided along the travel of paddle feeder for
supporting and guiding the trailing cables. In order to save flexible cables from
damage due to tension/over-tension protection switches shall be provided. Isolating
switch to isolate the power supply to the machines shall be provided in each power
JB to be located at the center of travel length.
1.03.09 Various equipment of Paddle Feeder assembly shall be easily accessible. It shall be
possible to replace electrical, mechanical and hydraulic components of paddle
feeder when positioned at hopper. Various drive equipment and hydraulic/other
components shall be so arranged that coal spillage from track hopper mouth does
not accumulate near/over them.
1.03.10 Provision shall be kept for automatic tripping of track hopper conveyor in the event of
paddle feeder getting dragged (i.e. travel speed in excess of rated speed). Paddle
feeder once tripped due to jamming or operation of emergency push button, shall not
start unless the hydraulic pressure is back to “normal”.

SECTION-VI
PART-B
1.03.11 Paddle feeders rails should be mounted on continuous running member. The
splicing of rails shall necessarily be at vertical support location only. Splicing in
between vertical support will not be accepted.
1.03.12 The longitudinal distance between two vertical supports shall be 3000 mm (min.)

SECTION-VI
PART-B
DATA SHEET – PADDLE FEEDER
1.00.00 GENERAL
1.01.00 Type of paddle feeder Mobile, Rotary plough
1.02.00 Input Coal parameters As described elsewhere in the

specification
1.03.00 Location Underground below track hopper
2.00.00 DESIGN & CONSTRUCTION
2.01.00 Paddle Wheel
2.01.01 No. of paddle wheel vanes Suitable
2.01.02 Material for Vane liners TISCRAL / equivalent

(Replaceable)
2.02.00 Drive Arrangement
2.02.01 Paddle Wheel Stepless Hydraulic drive
2.02.02 Feeder Carriage & flexible Electric Motor with gear box
coupling OR
Hydraulic Drive
2.02.03 Minimum No. of starts per hour for 15 Starts/hour (with minimum 10
drive chain equipment consecutive starts)
2.02.04 Paddle wheel speeds Stepless variable
2.03.00 Paddle Feeder Rails
2.03.01 Size 90 lb/yard
2.03.02 Support Arrangement To be mounted on supporting

structure of conveyors with
continuous support below rail.
2.04.00 Feeder Carriage wheels
(i) Nos. Suitable
(ii) Type Double Flange
(iii) Bearings Sealed type

SECTION-VI
PART-B
2.05.00 Anti Collision Device Mechanical and Infra red type
2.06.00 Cable Tray Height & width Min. 300 mm above floor & 300
mm wide all along the length of
track hopper on both sides.
2.07.00 Control Local
2.07.01 Location of Control Panel On the feeder carriage
2.08.00 Idlers for conveyor Belt As per relevant Sub-section for

Belt conveyor system
2.08.01 Spacing of carrying idlers in the 600 mm (maximum)

loading zone of paddle feeders
2.09.00 Chute work and hopper 20 mm thick TISCRAL or eqvt.

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-03
BRAKES & CLAMPS

A-03: BRAKES AND CLAMPS
1.00.00 GENERAL
Brakes shall be provided for decelerating of driven equipment/conveyors as per

requirement.
Rail clamps shall be provided for various mobile machines traveling on rails.
2.00.00 STANDARDS
The design, manufacture, inspection and testing of Brakes & Clamps shall comply
where the equipment is to be installed. The Brakes & Clamps shall conform to the
latest edition of the standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance, shall also be accepted.
Nothing in this specification shall be construed to relieve the contractor of the
required statutory responsibility. In case of any conflict in the standard and this
specification, the decision of the Employer shall be final and binding.
3.01.00 Electro Hydraulic Thruster Brakes/Disc Brakes
The necessary Electro Hydraulic Thruster (AC) brakes / disc brakes, totally enclosed
and fail safe, shall be provided as required for various equipment’s. Braking torque
shall be adjustable from 0 to 100% of rated braking torque. The thruster brake shall
be actuated by compression springs.
3.02.00 Clamps
3.02.01 Electro-hydraulic thruster and manual rail clamp shall be designed for holding the
machine stationary.
3.02.02 Electro-hydraulic thruster and manual rail clamp shall be actuated by compression
springs, the spring shall apply the clamping force directly on the Rail clamp
mechanism once power supply is cut-off. The force transmission mechanism from
spring to rail clamp faces shall be very simple with minimum linkages.
3.03.01 Thruster Brakes
3.03.01.01 The electro hydraulic thruster shall be fitted with the brake. Limit switches shall be
provided for brake applied/released positions. The windings shall be provided with
class-B insulation suitable for 415V ± 10% at 50 Hz ± 5% and combined variation of
± 10%. Brake lining shall be asbestos with inter woven brass wires capable of
withstanding 200°C temperature.

SECTION-VI
COAL HANDLING PLANT PACKAGE BRAKES AND CLAMPS 1 OF 3
PART-B
3.04.00 Clamps
3.04.01 Electro Hydraulic thruster shall be fitted directly above spring.
3.04.02 Rail clamp shall be provided between the two travel wheels. Further, limit switches
shall be provided for Rail clamp ‘ENGAGED’ and ‘DISENGAGED’ signals.
3.04.03 Minimum clearance between the Rail clamp face and rail surface shall be 50mm.
However, this clearance may not be uniform for both the faces of Rail clamp
throughout the length of rails. Rail clamp shall operate satisfactorily under this
condition without the need for any adjustments.
3.04.04 In addition to electro hydraulic thruster clamps, separate manual clamps for stacker
reclaimer and traveling tripper shall also be provided.

SECTION-VI
PART-B
DATA SHEET: BRAKES AND CLAMPS
1.0.0 GENERAL
1.1.0 Brakes (i) For decelerating of conveyors &

rotating equipment’s.
(ii) Brakes are mandatory for H.T.

drives involving scoop type
coupling except crusher motor.
1.2.0 Rail Clamps For various mobile equipment travelling

on rails.
2.0.0 DESIGN & CONSTRUCTION REQUIREMENT
2.1.0 Brakes
2.1.1 Type Electro Hydraulic Thruster brakes A.C.

operated or Disc brakes.
2.1.2 Braking Torque Adjustable from 0 to 100% of rated

braking torque.
2.1.3 Brake Shoes Operated directly by spring
2.1.4 Shoe lining Asbestos with interwoven brass wires.
2.1.5 Max. Temperature for shoe lining 200 degree C.
2.1.6 Thrustor Class-B insulation, IP-65 protection.
2.2.0 Clamps
2.2.1 Rail Clamp support Independent from the rails.
2.2.2 Limit Switches “ENGAGED” & "DISENGAGED” signals.
2.2.3 Clearance between Rail clamp face Minimum 50 mm

& Rail surface
2.2.4 Material for Rail clamp Mechanism Forged steel
2.2.5 Thruster Class-B insulation, IP-65 Protection
2.2.6 Type Electro hydraulic thruster, manual

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-04
MONORAILS AND HOISTS

A-05: CHUTES AND HOPPERS

1.00.00 GENERAL
Chutes & Hoppers, flap gates and rack & pinion gates shall be furnished integral
with coal handling system being supplied. All necessary accessories, electricals etc.
shall be provided to ensure proper flow/storage/bifurcation of coal as per system
requirements.
1.01.00 CODES AND STANDARDS
The design, manufacture, inspection and testing of Chutes & Hoppers shall comply
where the equipment is to be installed. The chutes, hoppers shall conform to the
latest edition of the following standards and codes. Other internationally acceptable
binding.
IS:4682 :Code of practice for lining of vessels and equipment for chemical
processes.
IS:2062 : Structural Steel (Standard Quality)
IS:11592 : Code of practice for selection and design of Belt Conveyors.
1.02.00 DESIGN AND CONSTRUCTION
1.02.01 Chutes, Hoppers
1.02.02 The minimum valley angle of chutes shall be 60 degrees from horizontal.
1.02.03 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal
without any accumulation anywhere.
1.02.04 Complete chute work above the drive floor for conveyors provided with ‘In-line belt
magnetic separators’ shall be of 10 mm thick SS - 304 in the zone of magnetic field.
1.02.05 Direct impact of material on conveyor belt shall be avoided by providing an inclined
surface at 60 degrees valley angle at the feeding point to guide the material in the
direction of belt travel. Further, chute construction below flap gate shaft shall be
such that there will not be any accumulation of coal dust between chute and flap
gate in that zone.
1.02.06 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL / SAILHARD
/ LSLAS07 or equivalent material. Long chutes guiding flow from considerable height
shall be provided with impact plates wherever change in direction of flow takes
SECTION-VI
COAL HANDLING PLANT PACKAGE CHUTES AND HOPPERS 1 OF 8
PART-B
place. Hinged inspection doors of leak proof construction shall be provided for
access/ maintenance purpose, at approachable heights for chutes and flap gates. All
chutes should have one inspection door at every floor and for the ones in between
the floors (more then 1.5 meter above the operating floor level) suitable access for
trouble free maintenance shall be provided. For sealing of inspection doors labyrinth
type arrangement to be provided. In addition to positive locking arrangement,
mounting bolts, to tighten the door further against rubber shall also be provided.
1.02.07 Bottom side of the chutes on which the coal slides shall be welded to the side plates
to form a trough. Bottom sides along with its adjacent sides shall be flanged and
made from TISCRAL or equivalent material of 20 mm thickness. The non-striking
surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to
the flange provided on the trough. Inside welding shall be provided in the corners for
permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be
joined through bolted flange connection to form the chute legs. Adequate care shall
be taken to locate the flange joint away from floor level for easy maintenance.
Bolted flange joints shall be of dust tight construction and necessary sealing material
shall be provided in all the flange connections for adequate sealing.
Complete chute work in the region of flap gates shall be fabricated from 20 thk
TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree)
complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While
finalising the chute work inside the building, arrangement for shifting and replacing
chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be
provided.
1.02.08 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum
4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors
with suitable access to them. Further, serrated rubber seal shall also be provided at
the very inlet of head chute to minimize dust nuisance.
1.02.09 Separate maintenance sealed door shall be provided for access to belt cleaners in
head pulley hood, flap gates for maintenance and inspection doors shall be of
hinged with positive locking facility.
1.02.10 (a) There should be sufficient clear space to install, remove and maintain
scrappers without cutting structures.
(b) Slope of plates below scrappers to direct coal scrapped by these to the main
stream shall be 60O min.
1.03.00 Skirt Boards
1.03.01 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage.
Suitable ‘Skirt Plates’ shall be provided for entire feeding chute and shall be
extended minimum 3m ahead of front edge of chute and 500 mm beyond rear edge
of chute. The width of the Skirt Boards shall be two-third the conveyor belt width. In

SECTION-VI
PART-B
the belts where coal of appreciable lump size (250 mm) is being conveyed, the gap
between the bottom of the skirt board and the belt shall be made to increase
uniformly in the direction of belt travel. The height of the skirt boards shall be
sufficient to contain the material volume as it is loaded on the belt and shall not be
less than 750 mm. The skirt plates shall be fitted with modular segmented and
replaceable rubber skirting pads having facility of adjusting the pressure on the belt
conveyor and shall have provision of on line removal for the purpose of easy
maintenance. Such segmented rubber pads with its holding down adjustment
arrangements shall be of proven design. The edges of segmented pads shall be
installed at an angle for providing a better seal. All care shall be taken while
designing, to combine good sealing with minimum belt wear.
1.04.00 Flap Gates
1.04.01 The motor operated 2 position flap gates shall be provided in transfer chutes as
specified and shall be complete with electrically operated actuators. The gates shall
be of robust construction and suitable for trouble free operation. The face of the flap
gate shall be made out of 20 mm thick TISCRAL or equivalent material.
1.04.02 The equipment shall be capable of being operated for at least 15 switchings per hour
at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at
rated load and thrust.
1.04.03 The motor rating for the actuator shall be so selected as to provide sufficient thrust
for operation of the flap gates against the moving weight of coal and/or flap gate.
The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be
completely dust tight.
1.04.04 Lever arm shall be provided between actuator and flap gate shaft for obtaining
required thrust.
1.04.05 The actuators shall be capable of preventing any over travel. Suitable travel
dependent limit switches controlling the travel of the flap gates on either direction
shall be furnished. These shall be placed internal to the drive unit and shall be
completely dust-proof. The limit switches shall be capable of adjustments to vary the
total length of travel of the gates.
1.04.06 Suitable thrust dependent limit switches shall be provided in the actuator, which shall
trip off the actuator motor in case of excessive thrust due to jamming of the gates
during its travel in either direction. The same shall also be integral to the drive unit
and shall be dust proof.
1.04.07 Provision for alternative manual operation shall also be made using declutchable
hand wheel. The diameter of hand wheel shall be selected considering convenient
force to be applied by a single operator. However, minimum diameter of hand wheel
shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be
provided. Manual effort required to operate the flap gate shall not exceed 25 kgs.

SECTION-VI
PART-B
1.04.08 All the two way chutes, one way of which is leading towards the future conveyor
shall be provided with blind flange.
1.04.09 All the actuators in the plant should be selected based on heaviest loading, but the
rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case.
1.04.10 Suitable stiffening arrangement shall be provided between the two faces of the gate
plate. At the end of the travel the total length of edge of the flap gate shall rest on a
suitable projected surface from chute to prevent leakage of coal dust through the
available clearance between chute and flap gate.
1.04.11 Maximum feasible counterweights shall be provided for better utilisation of system.
However, for calculation of thrust required, the benefit of counterweight shall not be
taken into considerations.
1.04.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the
gate shaft. Suitable provision for regreasing shall be provided.
1.04.13 For standardization purposes, only one standard type of actuator for flap gates shall
be provided. The standard type actuator shall be selected for maximum thrust as
calculated for various locations. Flap gate actuator as a whole and individual
component wise shall be completely interchangeable for all locations.
1.04.14 The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall be
suitable for motor stalled condition and associated twisting.
1.04.15 Approach/maintenance platforms complete with the chequered plate floor, hand
rails, ladders etc. shall be provided for all flap gates. The platforms shall be
extended for access to dust and debris chute inside buildings.
1.04.16 Shaft & flap gate shall be tightly fitted to each other.
1.04.17 Flap gate actuator shall be supported from Floor/Platform.
1.05.00 Rack & Pinion Gates
1.05.01 Rotary actuator operated rack and pinion gates shall be provided at various
locations as specified. The gate shall be mounted such that coal load does not act
vertically on gate.
1.05.02 Suitable manually operated rod gates shall be provided over rack and pinion gates
for their easy operation and maintenance.

SECTION-VI
PART-B
1.05.03 The rack and pinion gate shall be guided properly and suitable rollers with bearings
sealed for life and dust proof shall be provided.
1.05.04 The rack and pinion gates shall be of mild steel construction with liner plate of 10
mm thick TISCRAL or equivalent material. The gates shall be operated by means of
double rack and pinion. The material for rack & pinion wheel shall be cast steel and
shaft shall be EN.-8.
1.05.05 Provision for alternative manual operation of motorized rack and pinion gates shall
also be made. Limit switch for safety of person operating the hand wheel shall be
provided.
1.05.06 Manual effort required to operate the rack and pinion gate shall not exceed 25 kg.

SECTION-VI
PART-B
DATA SHEET : CHUTES AND HOPPERS
1.0.0 GENERAL
1.0.1 Coal Parameters As specified elsewhere
2.1.0 Chutes & Hoppers
2.1.1 Minimum Valley Angle 60 degrees
2.1.2 Material :
(a) Chute work
Sliding zones & adjacent sides 20 mm thk. TISCRAL / equivalent
No striking/ Non sliding zones 10 mm thk MS
Chute with valley angle 80 degree and All four sides of 20 mm thk.
above TISCRAL/equivalent material
In the zone of magnetic field of ILMS SS-304 10 mm thk.

(chute above floor over which ILMS is
suspended)
In the zone of flap gates 20 thk TISCRAL/ equivalent material
Discharge Hoods over head pulleys 4 mm thk M.S. with rubber curtain
2.1.4 Inspection Doors Hinged & leak proof construction

(min. size 350 x 450 mm)
2.1.5 Chute Construction
(a) Corners One face of removable bolted flange

connection
(b) Joints Bolted Flange joints of dust tight

construction
(c) Bolt size Min. M-16
(d) Bolts spacing Not more than 125 mm C/C
(e) Fixing Arrangement Bolts with plain spring washers
2.2.0 Skirt Boards
2.2.1 Length Entire feeding chute shall be

extended minimum 3mm ahead of
front edge of chute & 500 mm
beyond rear edge of chute.

SECTION-VI
PART-B
2.2.2 Height Not less than 750 mm
2.2.3 Width 2/3 of belt width
Side plate Min. 10 thk TISCRAL/equivalent
Top cover 6 mm thk M.S.
2.3.0 Flap Gate
2.3.1 Type Linear actuator operated, 2 position
2.3.2 Travel 60 to 70 deg. (with limit switches on

both sides).
2.3.3 Automatic operation
(i) Drive Dust tight motor driven with suitable

linkages
(ii) Minimum Actuator Rating 2500 kg with 1 m lever arm
(iii) No. of Operation / Hr 15 (with 10 consecutive switchings)

Travel and Thrust dependent limit
(iv) Protection
Switches.
2.4.4 Manual Operation
(a) Maximum effort Convenient for single operator by

declutchable hand wheel regardless
of electrical power.
(b) Minimum Handwheel 500 mm
Diameter
2.4.5 Flap gate shaft
(i) Diameter minimum 150 mm
(ii) Material EN-8
2.5.0 Rack & Pinion Gate Rotary actuator operated with

provision of manual operation
2.5.1 Material Mild Steel
2.5.2 Liner 10 mm thick TISCRAL/equivalent
2.5.3 Rack & Pinion Cast Steel

SECTION-VI
PART-B
2.5.4 Shaft EN-8
2.5.5 Max. time for closing/ opening 50 sec.(Approx)
2.5.6 Maximum manual effort 25 kgs.
2.5.7 Limit switches Both travel & thrust dependent
2.5.8 Main shaft dia. Minimum 150 mm
2.5.9 No. of Operations /hr. 15 (with 10 consecutive)
2.5.10 Diameter of rod for Rod Gate 40 mm(Min.)

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-05
CHUTES & HOPPERS

A-05: CHUTES AND HOPPERS

1.00.00 GENERAL
Chutes & Hoppers, flap gates and rack & pinion gates shall be furnished integral
with coal handling system being supplied. All necessary accessories, electricals etc.
shall be provided to ensure proper flow/storage/bifurcation of coal as per system
requirements.
The design, manufacture, inspection and testing of Chutes & Hoppers shall comply
where the equipment is to be installed. The chutes, hoppers shall conform to the
binding.
IS:4682 :Code of practice for lining of vessels and equipment for chemical
processes.
IS:11592 : Code of practice for selection and design of Belt Conveyors.
1.02.01 Chutes, Hoppers
1.02.02 The minimum valley angle of chutes shall be 60 degrees from horizontal.
1.02.03 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal
without any accumulation anywhere.
1.02.04 Complete chute work above the drive floor for conveyors provided with ‘In-line belt
magnetic separators’ shall be of 10 mm thick SS - 304 in the zone of magnetic field.
1.02.05 Direct impact of material on conveyor belt shall be avoided by providing an inclined
surface at 60 degrees valley angle at the feeding point to guide the material in the
direction of belt travel. Further, chute construction below flap gate shaft shall be
such that there will not be any accumulation of coal dust between chute and flap
gate in that zone.
1.02.06 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL / SAILHARD
/ LSLAS07 or equivalent material. Long chutes guiding flow from considerable height
shall be provided with impact plates wherever change in direction of flow takes
SECTION-VI
PART-B
place. Hinged inspection doors of leak proof construction shall be provided for
access/ maintenance purpose, at approachable heights for chutes and flap gates. All
chutes should have one inspection door at every floor and for the ones in between
the floors (more then 1.5 meter above the operating floor level) suitable access for
trouble free maintenance shall be provided. For sealing of inspection doors labyrinth
type arrangement to be provided. In addition to positive locking arrangement,
mounting bolts, to tighten the door further against rubber shall also be provided.
1.02.07 Bottom side of the chutes on which the coal slides shall be welded to the side plates
to form a trough. Bottom sides along with its adjacent sides shall be flanged and
made from TISCRAL or equivalent material of 20 mm thickness. The non-striking
surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to
the flange provided on the trough. Inside welding shall be provided in the corners for
permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be
joined through bolted flange connection to form the chute legs. Adequate care shall
be taken to locate the flange joint away from floor level for easy maintenance.
Bolted flange joints shall be of dust tight construction and necessary sealing material
shall be provided in all the flange connections for adequate sealing.
Complete chute work in the region of flap gates shall be fabricated from 20 thk
TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree)
complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While
finalising the chute work inside the building, arrangement for shifting and replacing
chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be
provided.
1.02.08 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum
4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors
with suitable access to them. Further, serrated rubber seal shall also be provided at
the very inlet of head chute to minimize dust nuisance.
1.02.09 Separate maintenance sealed door shall be provided for access to belt cleaners in
head pulley hood, flap gates for maintenance and inspection doors shall be of
hinged with positive locking facility.
1.02.10 (a) There should be sufficient clear space to install, remove and maintain
scrappers without cutting structures.
(b) Slope of plates below scrappers to direct coal scrapped by these to the main
stream shall be 60O min.
1.03.00 Skirt Boards
1.03.01 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage.
Suitable ‘Skirt Plates’ shall be provided for entire feeding chute and shall be
extended minimum 3m ahead of front edge of chute and 500 mm beyond rear edge
of chute. The width of the Skirt Boards shall be two-third the conveyor belt width. In

SECTION-VI
PART-B
the belts where coal of appreciable lump size (250 mm) is being conveyed, the gap
between the bottom of the skirt board and the belt shall be made to increase
uniformly in the direction of belt travel. The height of the skirt boards shall be
sufficient to contain the material volume as it is loaded on the belt and shall not be
less than 750 mm. The skirt plates shall be fitted with modular segmented and
replaceable rubber skirting pads having facility of adjusting the pressure on the belt
conveyor and shall have provision of on line removal for the purpose of easy
maintenance. Such segmented rubber pads with its holding down adjustment
arrangements shall be of proven design. The edges of segmented pads shall be
installed at an angle for providing a better seal. All care shall be taken while
designing, to combine good sealing with minimum belt wear.
1.04.00 Flap Gates
1.04.01 The motor operated 2 position flap gates shall be provided in transfer chutes as
specified and shall be complete with electrically operated actuators. The gates shall
be of robust construction and suitable for trouble free operation. The face of the flap
gate shall be made out of 20 mm thick TISCRAL or equivalent material.
1.04.02 The equipment shall be capable of being operated for at least 15 switchings per hour
at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at
rated load and thrust.
1.04.03 The motor rating for the actuator shall be so selected as to provide sufficient thrust
for operation of the flap gates against the moving weight of coal and/or flap gate.
The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be
completely dust tight.
1.04.04 Lever arm shall be provided between actuator and flap gate shaft for obtaining
required thrust.
1.04.05 The actuators shall be capable of preventing any over travel. Suitable travel
dependent limit switches controlling the travel of the flap gates on either direction
shall be furnished. These shall be placed internal to the drive unit and shall be
completely dust-proof. The limit switches shall be capable of adjustments to vary the
total length of travel of the gates.
1.04.06 Suitable thrust dependent limit switches shall be provided in the actuator, which shall
trip off the actuator motor in case of excessive thrust due to jamming of the gates
during its travel in either direction. The same shall also be integral to the drive unit
and shall be dust proof.
1.04.07 Provision for alternative manual operation shall also be made using declutchable
hand wheel. The diameter of hand wheel shall be selected considering convenient
force to be applied by a single operator. However, minimum diameter of hand wheel
shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be
provided. Manual effort required to operate the flap gate shall not exceed 25 kgs.

SECTION-VI
PART-B
1.04.08 All the two way chutes, one way of which is leading towards the future conveyor
shall be provided with blind flange.
1.04.09 All the actuators in the plant should be selected based on heaviest loading, but the
rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case.
1.04.10 Suitable stiffening arrangement shall be provided between the two faces of the gate
plate. At the end of the travel the total length of edge of the flap gate shall rest on a
suitable projected surface from chute to prevent leakage of coal dust through the
available clearance between chute and flap gate.
1.04.11 Maximum feasible counterweights shall be provided for better utilisation of system.
However, for calculation of thrust required, the benefit of counterweight shall not be
taken into considerations.
1.04.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the
gate shaft. Suitable provision for regreasing shall be provided.
1.04.13 For standardization purposes, only one standard type of actuator for flap gates shall
be provided. The standard type actuator shall be selected for maximum thrust as
calculated for various locations. Flap gate actuator as a whole and individual
component wise shall be completely interchangeable for all locations.
1.04.14 The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall be
suitable for motor stalled condition and associated twisting.
1.04.15 Approach/maintenance platforms complete with the chequered plate floor, hand
rails, ladders etc. shall be provided for all flap gates. The platforms shall be
extended for access to dust and debris chute inside buildings.
1.04.16 Shaft & flap gate shall be tightly fitted to each other.
1.04.17 Flap gate actuator shall be supported from Floor/Platform.
1.05.00 Rack & Pinion Gates
1.05.01 Rotary actuator operated rack and pinion gates shall be provided at various
locations as specified. The gate shall be mounted such that coal load does not act
vertically on gate.
1.05.02 Suitable manually operated rod gates shall be provided over rack and pinion gates
for their easy operation and maintenance.

SECTION-VI
PART-B
1.05.03 The rack and pinion gate shall be guided properly and suitable rollers with bearings
sealed for life and dust proof shall be provided.
1.05.04 The rack and pinion gates shall be of mild steel construction with liner plate of 10
mm thick TISCRAL or equivalent material. The gates shall be operated by means of
double rack and pinion. The material for rack & pinion wheel shall be cast steel and
shaft shall be EN.-8.
1.05.05 Provision for alternative manual operation of motorized rack and pinion gates shall
also be made. Limit switch for safety of person operating the hand wheel shall be
provided.
1.05.06 Manual effort required to operate the rack and pinion gate shall not exceed 25 kg.

SECTION-VI
PART-B
DATA SHEET : CHUTES AND HOPPERS
1.0.0 GENERAL
2.1.0 Chutes & Hoppers
2.1.1 Minimum Valley Angle 60 degrees
2.1.2 Material :
(a) Chute work
Sliding zones & adjacent sides 20 mm thk. TISCRAL / equivalent
No striking/ Non sliding zones 10 mm thk MS
Chute with valley angle 80 degree and All four sides of 20 mm thk.
above TISCRAL/equivalent material
In the zone of magnetic field of ILMS SS-304 10 mm thk.

(chute above floor over which ILMS is
suspended)
In the zone of flap gates 20 thk TISCRAL/ equivalent material
Discharge Hoods over head pulleys 4 mm thk M.S. with rubber curtain
2.1.4 Inspection Doors Hinged & leak proof construction

(min. size 350 x 450 mm)
2.1.5 Chute Construction
(a) Corners One face of removable bolted flange

connection
(b) Joints Bolted Flange joints of dust tight

construction
(c) Bolt size Min. M-16
(d) Bolts spacing Not more than 125 mm C/C
(e) Fixing Arrangement Bolts with plain spring washers
2.2.0 Skirt Boards
2.2.1 Length Entire feeding chute shall be

extended minimum 3mm ahead of
front edge of chute & 500 mm
beyond rear edge of chute.

SECTION-VI
PART-B
2.2.2 Height Not less than 750 mm
2.2.3 Width 2/3 of belt width
Side plate Min. 10 thk TISCRAL/equivalent
Top cover 6 mm thk M.S.
2.3.0 Flap Gate
2.3.1 Type Linear actuator operated, 2 position
2.3.2 Travel 60 to 70 deg. (with limit switches on

both sides).
2.3.3 Automatic operation
(i) Drive Dust tight motor driven with suitable

linkages
(ii) Minimum Actuator Rating 2500 kg with 1 m lever arm
(iii) No. of Operation / Hr 15 (with 10 consecutive switchings)

Travel and Thrust dependent limit
(iv) Protection
Switches.
2.4.4 Manual Operation
(a) Maximum effort Convenient for single operator by

declutchable hand wheel regardless
of electrical power.
(b) Minimum Handwheel 500 mm
Diameter
2.4.5 Flap gate shaft
(i) Diameter minimum 150 mm
(ii) Material EN-8
2.5.0 Rack & Pinion Gate Rotary actuator operated with

provision of manual operation
2.5.1 Material Mild Steel
2.5.2 Liner 10 mm thick TISCRAL/equivalent
2.5.3 Rack & Pinion Cast Steel

SECTION-VI
PART-B
2.5.4 Shaft EN-8
2.5.5 Max. time for closing/ opening 50 sec.(Approx)
2.5.6 Maximum manual effort 25 kgs.
2.5.7 Limit switches Both travel & thrust dependent
2.5.8 Main shaft dia. Minimum 150 mm
2.5.9 No. of Operations /hr. 15 (with 10 consecutive)
2.5.10 Diameter of rod for Rod Gate 40 mm(Min.)

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-06
BELT CONVEYOR SYSTEM

A-06: BELT CONVEYOR SYSTEM

1.00.00 GENERAL
All Belt Conveyors shall be furnished and erected along with necessary supporting
structures, platforms, on ground or overhead galleries, trestle structure with
foundation footings, carrying and return idlers, automatic take-ups, pulleys, drive
motors with suitable reduction units and couplings, belting, feeder hoppers, transfer
chutes, flap gates, hydraulic couplings and other necessary accessories as per
scope specified elsewhere.
The design, manufacture, inspection and testing of the Belt Conveyor System shall
comply with all the currently applicable statues, regulations and safety codes in the
locality where the equipment is to be installed. The belt conveyor system shall
confirm to the latest edition of the following standards & codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance than those
specified, shall also be accepted. Nothing in this specification shall be construed to
relieve the contractor of the required statutory responsibility. In case of any conflict
in the standard and this specification, the decision of the Employer shall be final and
binding.
“Belt Conveyors for Bulk Materials” published by Conveyor Equipment

Manufacturers’ Association.
IS:7155 : Codes of Practice for Conveyor Safety.
IS:1891 (Part-I) : General Purpose Belting
IS:8598 : Idlers and Idler Sets for Belt Conveyors
IS:4009 (Part-II) : Conical Head Grease Nipples
IS:8531: Pulleys for Belt Conveyors.
IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical
Processes.
IS:11592 :Code of practice for selection and design of Belt Conveyors.
CAN / CASA - M422 M87 : Canadian standard association.
1.02.01 Design of belt conveyor system shall be suitable for coal parameters specified
elsewhere.

TECHNICAL SPECIFICATIONS SUB-SECTION-IIIA-06
SECTION-VI BELT CONVEYOR
PART-B SYSTEM
1.02.02 Slopes of conveyors, wherever applicable, shall not exceed 16 deg. depending on
the lump size, and other governing factors.
1.02.03 The guaranteed capacity of all conveyors shall be the rated capacity.
1.02.04 All conveyors (except boom conveyor of S/R) shall be designed for 110% of rated
capacity. The boom conveyor of S/R shall be designed for 125% of rated capacity.
Design capacity of the conveyor system shall be considered for the selection of belt
width, belt speed and the continuous motor rating at 50 deg C Ambient.
1.02.05 The drive chain equipment’s for various belt conveyor systems shall consist of drive
motors, fluid couplings, gear reduction units, low speed flexible couplings and
pulleys. For the ratings of various equipment’s as mentioned above in the drive
chain of conveyor systems relevant sections of this specification shall be referred to.
1.02.06 Conveyors and belt feeders shall be provided with electro hydraulic thrustor brakes
or fly wheels to adjust the coasting time of conveyors such that there will not be any
build up of material in the chutes. Further conveyor shall come to halt as early as
possible. All conveyors with HT drives (except bunker conveyors) shall be provided
with brakes.
1.02.07 Belt conveyor system shall be designed as per the latest edition of ‘Belt Conveyors
for Bulk Materials’ published by Conveyor Equipment Manufacturer’s Association’ or
equivalent International Standard. Ai value for idler shall be considered 2.8lb (min.)
for the purpose of conveyor design calculation only.
1.04.00 Belting
1.04.01 The belting shall be of either synthetic fabric such as Nylon-Nylon, polyester,
polyamide, etc. with rubber covers of adequate flexibility to give a troughing angle of
35 deg. For all the conveyors the number of plies, cover thickness, factor of safety
etc. shall be as per the recommendation of belt manufacturer, but not inferior to the
figures as tabulated in data sheet.
1.05.00 Idlers
1.05.01 Carrying idlers shall be provided with three equal rolls with troughing angle of 35
deg. and 2 deg. forward tilt (except in case of reversible conveyors).
1.05.02 In no case, shall the diameter of the idler roll be less than 152 mm for both carrying
side and return side. However for impact idlers roll the steel diameter shall not be
less then 139 mm and rubber thickness shall be minimum 25 mm.
1.05.03 Roller used in idlers shall be made from ERW steel tube. Wall thickness shall be
minimum 4.0 mm without any negative tolerance. The rollers shall be mounted on
EN-8 or equivalent material spindles by means of ball bearings of either deep groove
PART-B SYSTEM
type or seize resistant type (SKF/Equivalent), of 30 mm size for carrying idlers and
20 mm size for return idlers. The bearings shall be adequately sealed and lubricated
for life. The rolls shall be supported from fabricated steel brackets. Fixing
arrangement of rollers with brackets shall be drop-in type. For adjusting the
alignment of the idlers, slotted holes shall be provided in idler supporting base
plates. Direction of belt travel shall be clearly marked on the brackets of carrying
idlers by embossing / punching.
1.05.04 Idler rollers shall be waterproof, dust proof and weather proof against a high velocity
water jet. All idlers shall be provided with minimum double labyrinth dust seal.
1.05.05 Impact idlers used at the loading and transfer point shall be so designed as to avoid
direct loading impact, belt damage and excessive punishment to the carrier. The
material used in construction of this type of idlers shall be of resilient type.
1.05.06 The return idlers for all conveyors shall be single roll type. For conveyors longer
than 400m, two roll return idlers with 10 deg. troughing angle shall be provided.
1.05.07 The self-aligning idlers shall be direct acting type, complete with actuating rollers
fitted with the ball bearings and mounted inclined towards the belt. The idler frame
shall be suitably cradled about a vertical pivot, supported in bearing over a fixed
plate. Adequate sealing arrangement shall be provided to prevent contamination of
the lubricant by dirt and moisture.
1.05.08 Transition type troughing idlers shall be used adjacent to all pulleys to permit proper
support of the loaded belt near the pulleys without excessive stretch of the belt
edges. The transition idlers shall be provided with preferably adjustable concentrator
(end) rolls and long center rolls to suit the troughed belt contour between the last
regular troughing idler and the adjacent pulleys. The transition length and the
number of the transition idlers shall be selected depending upon the tensions, type
and size of belt, number of plies and other necessary governing factors.
1.05.09 All the conveyors shall be provided with one self cleaning type rubber disc return
idler located near the head pulley for cleaning the return belt.
1.05.10 Proper arrangement shall be provided in the brackets of all types of idlers for
preventing the rollers from coming out of the brackets during normal / abnormal
conditions.
1.06.00 Belt Cleaners
1.06.01 External Belt Cleaner
Spring loaded scraper type cleaner with modular segmented and replaceable
polyurethane scrapers blades complete with main cleaner, pre-cleaner (mounted
separately) along with accessories and necessary fines (reject of scrapper) chutes
shall be provided for all belt conveyors, tripper head pulley and belt feeders at
discharge pulleys. The modular units shall be easily replaceable. The scraper

PART-B SYSTEM
assembly shall be easily maintainable from outside without any interference with the
chute arrangement and assembly.
1.06.02 Internal Belt Cleaner
V-plough type belt cleaner made of mild steel flats and hard rubber strips with
automatic wear adjustment and necessary accessories shall be furnished for
cleaning internal surface of the conveyor belt.
1.07.00 Belt Take-up Arrangement
1.07.01 Automatic take-up of gravity type shall be generally provided with necessary take-up
arrangements complete with bend pulleys, take-up pulley, with its supporting / sliding
assembly, wire ropes with turn buckle arrangement (to adjust the level) for
suspending the separate take - up weight sliding assembly close to the ground,
counter weights and other accessories. Suitable guards marked up scale attached to
the frame to monitor belt stretch and access/maintenance platforms with handrails
all around etc. shall be provided. Adequate access from conveyor gallery/transfer
house/ground etc., as the case may be shall be provided to inspect, repair and
maintain the gravity take-up arrangement. Guides of take up pulley/counter weights
shall be sufficiently strong, of pipe/box cross section, so that they do not bend during
belt snapping.
1.07.02 The prime consideration should be to locate the automatic take-ups at a place where
these will work best, in relation to the drive, to keep belt tension at a minimum.
Other considerations such as available space, maintenance considerations and the
economics of the location should also be taken into account while designing. Take
up shall not be located over buildings unless indicated in tender drawings. Height of
take-up guide structure shall be sufficient to allow the take-up weight movement up
and down for all operating conditions of conveyor and to allow minimum two (2)
vulcanizing lengths margin in the belt or percentage of conveyor length (2.5% for
synthetic belting) whichever is larger. Suitable guides shall be provided both for take
up pulley and take up weight.
1.07.03 Two (2) meter safety fencing along with suitable gate and locking arrangement shall
be provided around gravity take-up at the base level / ground level.
1.07.04 Irrespective of take-up location, the travel zone of take-up weight shall start from a
suitable height above ground level.
1.07.05 Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley in
order to avoid damage of the pulley assembly in case of belt snapping. Similar
buffer arrangement shall be provided for take-up weight also, in case of, take-up
weight travel zone terminating above a building floor. Sandpits of 600 mm deep
shall be provided at ground below the take-up weights.
1.07.06 In case of double stream conveyors, a partition of 3 mm steel plate shall be provided
between the two take-up pulleys along entire travel zone of take-up pulleys.

PART-B SYSTEM
Intermediate platforms shall be provided in the take-up zone for maintenance of take
- up pulleys / counter weight.
1.07.07 Take-up weight shall consist of multi-blocks of RCC/Cast Iron and not of single block
to facilitate adjustment in weight if required during operation. Single heaviest piece
shall be suitable for easy handling. Take-up weight block shall be provided with edge
protection angle to take care of any damage. Take up weights shall be kept inside a
take up weight box frame structure and shall be properly anchored / bolted with the
main frame, so that the none of the weight shall be loose/free inside the box. The
box shall be painted with counter weight and conveyor number and shall have good
aesthetic look.
1.08.00 Hold Back Devices
1.08.01 Suitable hold back devices for preventing running back of the conveyor belt in case
of conveyor being stopped in loaded conditions due to power failure or during normal
operational delays shall be provided to give positive protection. The hold back shall
instantaneously engage without shock and be capable of protecting equipment and
personnel. It shall be released instantly when ‘power’ resumes or the ‘delay’ is
removed. The holdback devices shall be integral with gearbox.
1.09.00 Pulleys
1.09.01 Pulleys shall be provided as required for various conveyors. In determination of

pulley diameter, no account shall be taken of the pulley lagging. The nominal
diameter and face width of the pulleys shall be as stated in IS: 8531.
1.09.02 The snub pulleys on each conveyor shall be located to provide a belt wrap on the
drive pulleys of not less than 210 deg. wrap is envisaged for single snub drive only.
1.09.03 All drive pulley surfaces shall be hot lagged with vulcanised natural rubber lagging
grooved in diamond pattern.
1.09.04 All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with plain
lagging.
1.09.05 The rubber to be used for lagging of pulleys shall confirm to specifications listed in
data sheet of this section.
1.09.06 The rubber lagging of pulleys and method of lagging and testing the same shall
conform to IS:4682.
1.09.07 The pulleys shall be made from mild steel conforming to IS:2062 (Tested Quality).
However, for conveyors with in line magnetic separators, the head end pulleys shall
have shell and end disc made of non-magnetic stainless steel material..
1.09.08 All the pulleys shall be mounted on the forged steel shafts of EN-8 or equivalent
material of adequate proportion by taper lock arrangement, running in heavy duty
roller bearings with proper greasing arrangement. The plummer blocks for pulleys
shall be of horizontally split type construction with minimum (4) nos. bolts holding the
PART-B SYSTEM
two split halves and with min (4) nos. foundation bolts. The plummer blocks shall be
dust tight with double labyrinth seals. Conical head shape nipples conforming to
IS:4009, suitable drain plug and eye bolt shall be provided. Side covers of plummer
blocks shall be heavy duty metallic sheets. No plastic components shall be used.
1.09.09 Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall be
provided for all tail pulleys and bend pulleys for safety of operating personnel.
1.09.10 Suitable stiffening arrangements shall be provided in all pulleys as required. For
selection of pulley shaft dia of all the pulleys, a margin of atleast 20% shall be
considered on the maximum tension at designed Conveyor capacity. Selection of
pulley diameter, shell thickness, stiffening and shaft diameter shall be subject to
approval of Employer during detailed engineering.
1.10.00 Belt Protection Equipment
1.10.01 Pull chord Switch
Pull chord type (manually reset type) emergency stop switches shall be located on
both sides of belt conveyors along the walkways for the entire length of conveyors
for emergency stopping of conveyor. The enclosure shall be of cast aluminum with
degree of protection IP-65. It shall have a separate terminal box with a separate
hinged cover which shall be totally sealed from main box containing actuating
mechanism / limit switch etc. Local pull chord actuation shall be provided by means
of mechanical flap. Each switch shall have two NO and two NC contacts, which shall
be wired out to the terminal block. The terminal block shall have facilities of cable
looping. The Contact rating of the switches shall be rated for atleast 5 Amps,
breaking at 240 VAC at 0.3 p.f. lagging. Adequate length of rope and all accessories
shall be furnished. Pull chord in stone picking area shall be routed inside G.I. pipe of
1” size.
1.10.02 Belt Sway Switches
Belt sway switches of self resetting type shall be furnished at periodic intervals to
limit belt sway to permissible extent. The enclosure shall be of cast aluminum having
degree of protection of IP-65. It shall have a separate terminal box with a separate
hinged cover totally sealed from the main box containing actuating mechanism/ limit
switch etc. Each switch shall have two NO and two NC contacts one for alarm and
one for trip, which shall be wired upto terminal block. The terminal block shall have
facilities for cable looping. The contacts of the switches shall be rated for atleast 5
Amps. breaking at 240 VAC at 0.3 p.f. lagging. The roller length of the switch shall
be at least 150 mm. Belt sway switches shall also be provided at HGTU & VGTU to
detect excessive belt away.
1.10.03 Zero Speed Switch
Zero speed switch shall be non-contact (proximity) type electronic switch. Mounting
arrangement/ location shall be such that operation, effective sensing distance,
sensitivity etc. shall not be effected by accumulation of dust on rotating part or
surface of probe. Adequate mechanical protection by means of non-metallic shields
shall be provided on top of the switch to prevent any damage due to falling coal /

PART-B SYSTEM
metallic pieces etc. In built initial start up delay and nuisance, tripping delay through
timers shall be provided. Each switch shall have two NO and two NC contacts wired
out to the terminal blocks. The contact of the switches shall be rated for atleast 5
Amps. breaking at 240 VAC at 0.3 p.f. lagging. The monitoring unit shall have cast
aluminum body having IP-65 degree of protection. A separate terminal box with a
separate cover, which shall be totally sealed from main box, shall be provided.
Terminal blocks shall be suitable for terminating 1.5 mm sq. standard copper cable.
1.10.04 Chute Blockage Switches
One no. chute blockage switch of proven type (subject to approval of the employer)
shall be provided at a suitable height on each leg of the conveyors discharge chute,
vibrating screening feeders by pass chutes, crusher feeding chutes, tripper
discharge and feeding chutes nearest to the skirt boards. Chute blockage switch
shall trip the feeding conveyor in case of Chute blockage and protect the feeding
conveyor equipment. Chute blockage switch shall also be provided at each leg of
mobile tripper and shall trip the tripper conveyor.
The switch and its operating arrangement shall be suitable for working in dusty
areas. The minimum degree of protection of switch shall be IP-65. Local indication
of chute blockage switch actuation shall also be provided. Location of chute block
switch shall be such that washing does not affect it.
1.10.05 Sensing arrangement shall be provided in the DDCMIS based control system for
detecting the presence of material on the belt which shall in turn be used for
operating solenoid valves of dust suppression/extraction system elaborated
elsewhere. The arrangement shall detect three events simultaneously as follows:
(a.) Belt loaded
(b.) Belt running at more than preset speed.
(c.) Preset initial start delay.
1.10.06 The terminal boxes of all the belt protection equipments / switches shall be such that
all the components / terminals inside are easily accessible for inspection and
maintenance without removing the cables / connections / components.
1.10.07 Each pull cord and Belt sway switch shall have necessary chip for using in circuit for
the identification of the operated switch in main control room. The scheme for switch
identification shall be fail safe and shall have all diagnostic features. The scheme
shall have facility to by pass one or more switches, if required.
1.11.00 Drive Motors
1.11.01 Rating of all drive motors of conveyors shall not be less than 120% of the power
required at drive motor output shaft at specified design capacity. The motor rating
shall be at 50 deg Cent. ambient.
1.11.02 Single LT drive motors shall be used for conveyor drive ratings up to 160 KW. For
conveyor drive rating beyond 160 KW, single HT drive shall be used for conveyors.
PART-B SYSTEM
However for boom conveyor drive and intermediate conveyor drive on stacker-
reclaimer, single LT motor may be used above 160 KW also.
1.12.00 Conveyor Bridges
1.12.01 All overground and overhead conveyors shall be located in suitably enclosed bridge
structure. Structural steel bridges of adequate width and depth (2700 mm clear
head room) shall be provided complete with conveyor bottom deck plates, seal
plates, walkways of chequered plates with anti-skid arrangement(s), hand rails (on
both sides of each conveyor belt except where equipment (like paddle feeders,
stacker/ reclaimer, trippers etc.) traverse over conveyor supports.
1.12.02 The conveyor bridge shall have permanently colour coated steel sheeting covers on
roof and both sides, properly screwed or locked to steel structure as required.
Adequate provision of windows shall be kept. A continuous slot opening of 500 mm
shall be provided on both sides just below the roof sheeting.
1.12.03 The floors of outdoor conveyor galleries shall be designed and constructed as
follows:
Side and central walkways for double streams conveyors shall be 800mm and
1100mm wide respectively. The side walkways for single conveyors shall be 800
mm on one side and 1100mm on the other side. However, if the centre to centre of
conveyors or the width of the gallery is decided by some other criteria, maximum
walkway widths consistent with gallery sizes shall be provided. In the complete
length of conveyor gallery minimum walkway clearance as indicated above is to be
maintained inclusive of all equipments and clearances.
All conveyors shall be provided with 12 G steel seal plates throughout the length of
the conveyor gallery in such a way that complete gallery bottom surface area forms
a single water proof floor and no water / coal falls down from conveyor gallery incase
of cleaning / washing. It is envisaged to clean the conveyor gallery with water
periodically. All the water / coal slurry shall be suitably guided to down comers
provided at every trestle. Each downcomer shall lead the coal slurry into a 2 cub
meter brick wall tank at ground level having 2 Nos. decanting taps at suitable
elevations. Decanted water shall be led to the nearest drain in the Contractor’s
scope. Necessary arrangement shall be provided to avoid choking of downcomers
by bigger coal lumps and for cleaning of choked downcomers.
1.12.04 The conveyors shall be provided with continuous decking plate of minimum 3 mm
thickness plain steel sheet.
1.12.05 Structures and floors shall be so designed as to provide suitable space for routing of
200 NB fire fighting pipe with water, cables and conduits.
1.12.06 Steel trestles to support the conveyor bridge shall rest upon concrete foundations to
be provided by the Contractor. Complete trestle structures shall also be supplied by
the Contractor. Suitable approach/access platforms with hand railings shall be

PART-B SYSTEM
provided to approach the conveyor gallery (like in case of fire) through monkey
ladders on the trestles. Suitable wire mesh doors on steel frame construction
lockable from outside only shall be provided in the conveyor galleries at these
locations. All monkey ladders shall have cage for safety of personnel using them.
1.12.07 Independent supports for walkways, conveyor structures shall be provided. The
width of conveyor galleries shall be decided by the Contractors depending on the
equipment’s size and the walkway width as specified. However, in no case the width
of gallery shall be less than the width specified in tender drawings.
1.12.08 Provision shall be kept with platforms and ladders for crossing over the conveyors at
approximately every 100m intervals of route length and minimum one per conveyor.
1.13.00 Stone Picking
Manual Stone Picking arrangement at a suitable location in the conveyor gallery

before the crusher house shall be provided complete with platforms, overhead
lighting, handrailings, suitable seating, safety hook & holding arrangement for
manual pickers, disposal chutes to ground level etc. Six (6) nos. manual pickers
shall be positioned for stone picking. Three (3) nos. manual pickers shall be
positioned on each belt. Each manual picker shall cover 3 m long belt stretch
adjacent to each other and shall have provision of individual stone collector
discharge hood. The picked up stone lumps (upto 600 mm size) shall be collected
over the conveyor gallery walkway level from where these stones can be pushed
into the hopper/chute upto the ground level. Disposal chute from discharge hoods of
length upto 2 meters from ground level shall be provided etc.
In the gallery span of stone picking area, the gallery width shall be extended by a
minimum of one (1) mtr. on either side to accommodate the stone picking
accessories. Accordingly the width of Conveyor Gallery shall be 2 meters wide all
along the span of stone picking zone as compare to other gallery span. All trestle
coming in the zone of stone picking area shall be suitably encased by RCC. The
stone picking area should be suitably barricaded upto 2 mtr. height above ground
level so that no damage take place due to stone pile formation and its handling by
pay loaders.
1.14.00 Special Cleaning, Protection and Painting
All equipment’s of Coal Handling Plant inclusive of belt conveyor system and
technological structures shall be kept clean. Surfaces to be painted shall be
thoroughly cleaned of loose mill scale, rust etc. by wire brushing. All ferrous surfaces
shall be applied with one shop coat of 35 micron and one 35 micron site coat of red
oxide zinc chromate and two coats, each of 25 micron, synthetic enamel finishing
paints unless specified otherwise. A minimum of 120 microns Dry Film Thickness
(DFT) after finished coat of paint shall be ensured. However for deck plate in track
hopper and tunnels, painting specifications mentioned at sub section IIID-01 shall be
applicable. However idler rolls shall be applied with two coats & each 35 micron of
red oxide zinc chromate only.

PART-B SYSTEM
The painting colour code shall be provided to the Contractor during detailed
engineering.
1.15.00 Belt Vulcanizing Machine
1.15.01 Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice and
shall be of easy-to-handle type.
1.15.02 Equipment should be suitable for vulcanizing of entire splice width in single setting.
1.15.03 Equipment should be capable of applying uniform pressure over the splice by
pneumatic or hydraulic means.
1.15.04 Heating element should be preferably of flexible type.
1.16.00 Belt Jointing Facilities
For the purpose of jointing the belting or replacement of belting, following belt
facilities shall be provided:
1.16.01 5M X 5M paved area near take up to make joints.
1.16.02 Hooks shall be provided on TPs, Conv. Gallery to pull the old belt while replacing the
same with new belt.

PART-B SYSTEM
DATA SHEET: BELT CONVEYOR
1.0.0 GENERAL
1.1.0 Design Capacity 110% of rated (guaranteed) capacity for

all conveyors excepting boom conveyor.
For boom conveyor, the design capacity
shall be 125% of rated (guaranteed)
capacity.
1.2.0 Maximum slope 16 deg
1.3.0 Max. belt Sag between idlers 2%
1.4.0 Minimum Radius
(i) Concave curve 250 m (In case of travelling trippers, the

requirement of minimum radius shall be
decided based on the space availability)
(ii) Convex Curve 50 m
2.1.0 Belting
2.1.1 Type Synthetic Fabric of Nylon / Nylon,/

Polyester/polyamide
2.1.2 Cover Grade a) Flame test : Conforming to ISO:340
b) Drum Friction and Electrical Surface

Resistance Test: Conforming to
Canadian standard association CAN
/ CSA M-422- M87 Grade - C.
2.1.3 Cover Thickness (without –ve
tolerances). Synthetic belting
(a) Face 5.0 mm (min.)
(b) Bottom 2.0 mm (min.)
2.1.4 No. of plies Minimum 4
2.1.5 Drive Arrangement Snub drive

PART-B SYSTEM
2.1.6 Factor of Safety - 10 (Minimum) for N-N belt.

- 7 (minimum) for Steel Cord Belt.
2.1.7 Normal Working tension at design Less than 80% of max. allowable working
capacity tension
2.2.0 Idlers
2.2.1 Type
(a) Carrying Three roll, 35 degree troughing,

2 degree forward tilt
(b) Return Single Roll, For conveyors upto

400 m c/c length. Two roll with 10
degree angle for conveyors more than
400 m c/c length
(c) Loading point Impact type
2.2.2 Spacing
(a) Carrying idlers 1.2 m (0.6 m for convex curves and in the
paddle feeder travel range).
(b) Return idlers 3.0 m (for convex curves not more than
1.5 m.)
(c) Loading point Minimum six (6) with 400 mm spacing.
(d) Self-aligning troughing At 10 m distance from head & Tail pulleys

idlers with intermediate spacing 15m
(e) Self - aligning return idlers At 10 m distance from Head & Tail pulleys
with intermediate spacing 20m. (Not
required for conveyors more than 400m
c/c long where 2 roll return idlers are
provided).
2.2.3 Bearings
(a) Carrying Ball Bearings of deep groove type or

seize resistance type of min. 30 mm size,
lubricated for life.
(b) Return Ball Bearings of deep groove type or

seize resistance type of min. 20 mm size,
lubricated for life.

PART-B SYSTEM
2.2.4 Material
(a) Roller ERW Steel tube min. wall thickness

4.0 mm
(b) Spindle E.N. 8 or equivalent.
2.3.0 Belt Cleaners
2.3.1 External Spring loaded scraper type cleaner with

modular, segmented and replaceable PU
blades with separate main-cleaner & pre-
cleaner etc.
2.3.2 Internal V-Plough type, mild steel flats with hard

rubber strips.
2.4.0 Belt Take up
2.4.1 Type Automatic Gravity Type.
2.4.2 Location In relation to the drive to keep belt tension

at minimum.
2.4.3 Take-up travel To suit all operating conditions or (2.5%

for synthetic belt) of conveyor center to
center length whichever is larger. Further
the initial location of take-up shall be
decided in such a way that it is possible to
carryout min. two (2) nos. Vulcanizing
Joints without adding any external belt.
2.5.0 Hold Back Device Integral with gear Box
2.6.0 Pulleys
2.6.1 General (for all types of Pulleys)
Pulley shaft diameter Margin of minimum 20% shall be

Considered on maximum tension at
design capacity for arriving at the shaft
dia.
2.6.2 Drive Pulleys
(1) Lagging Hot lagged with vulcanised natural rubber
(2) Lagging thickness 12 mm thick grooved in diamond pattern

with grooves 6 mm wide x 6 mm deep

PART-B SYSTEM
(3) Minimum angle of wrap 210° degrees
(4) Maximum Out of roundness 0.5% of nominal diameter
2.6.3 Other pulleys
(1) Lagging Hot lagged with vulcanised natural rubber
(2) Lagging thickness 12 mm thick plain
2.6.4 Rubber for lagging
(1) Type Natural rubber blended with styrene

Butadiene rubber.
(2) Hardness 55 to 65 durometer (Shore A)
(3) Elongation Over 300%
(4) Strength 160-245 kg/cm2
(5) Abrasion loss 250 mm3 (max.) as per DIN 53516
(6) Specific Gravity Max. 1.5
(7) Adhesion Strength 10 kg/cm (minimum)
2.6.5 Bearings for Pulleys
(1) Type Heavy duty roller type
(2) Casing Horizontal Split Type
(3) Sealing Dust tight with double labyrinth seals.
(4) Lubrication Greasing arrangement with conical head

shape nipples.
2.6.6 Pulley Material Mild steel conforming IS:226 / IS : 2062
2.6.7 Shaft Material Forged Steel shaft EN-8 or equivalent

material.
2.7.0 Belt Protection Equipment
2.7.1 Emergency Stop Switch System
(1) Type Pull chord type (manually reset)
(2) Location Both sides of conveyor for entire length
(3) Spacing Approx 30 m

PART-B SYSTEM
2.7.2 Belt Sway Switches
(1) Type Limit switches snap action.
(2) Spacing One pair at 50m interval (Minimum two

(2) pairs)
2.7.3 Zero Speed Switches
(1) Type, Location Proximity switch, mounted on Bend pulley

of GTU.
2.8.0 Drive Motors
2.8.1 Type Three Phase Squirrel Cage Induction

Motors
2.8.2 Mounting (for conveyors) Base mounted
2.8.3 Continuous motor rating (Name 120% of actual power requirement at

plate rating) at 50OC Ambient motor output shaft at design capacity.
2.9.0 Conveyor Bridges
2.9.1 Walkways
(a) Construction Chequered plate with antiskid

arrangement.
Chequered plate steps shall be provided
where conveyor slope exceeds 10
degrees. (Totally sealed so that no water
falls down while washing.)
(b) Central walkway width 1100 mm
(c) Side walkway width 800 mm (for single conveyors, the width
of side walkways shall be 800 mm on one
side and 1100 mm on the other)
2.9.2 Side Windows
(a) Spacing (Center to center) 25.0 m on each side (in staggered

fashion)
(b) Size 1.2 m x 1.5 m
(c) Window material Refer Civil Section

PART-B SYSTEM
2.10.0 Trestles
2.10.1 Spacing of monkey ladders on

trestles
(a) Where height of conveyor : On every trestle

gallery (walkway level)
is 10 m or more.
(b) Where height of conveyor : On alternate trestle

gallery (Walkway level) is
less than 10m.

PART-B SYSTEM
PART - B
SUB-SECTION-IIIA-07
DRIVE EQUIPMENT

A-07: DRIVE EQUIPMENT
1.00.00 GENERAL
Suitable Drive Chain Equipment’s like electric motors, gearboxes (where applicable),
fluid couplings (where applicable), flexible couplings and other accessories shall be
provided for all the belt conveyor systems, paddle feeders, crushers, mobile trippers,
various pumps of dust suppression/extraction system, fans for ventilation system,
monorail electrical hoists and other equipment’s specified in this specifications.
Various requirements as spelt out in the Technical Specifications for individual
equipment’s shall be taken into consideration while designing the associated drive
chain equipment’s.
The design, manufacture, inspection and testing of Drive Equipment shall comply
where the equipment in to be installed. The Drive Equipment’s shall conform to the
binding.
IS:3688 : Dimensions for shaft ends
IS:3681: General plan for spur & helical gears
IS:7403 : Code of practice for selection of standard worm and helical gear boxes
1.02.00 DESIGN AND CONSTRUCTION REQUIREMENTS
1.02.01 GEAR BOXES
1.02.02 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces.
1.02.03 The gearboxes shall be designed for 24 hours continuous duty. For thermal and
mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with
cooling coils are not acceptable.
1.02.04 The gears used shall be helical conforming to IS:3681 (latest revision) or worm
reduction units or spiral bevel speed reduction units conforming to suitable Indian
Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest
revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical
type only.

SECTION-VI
COAL HANDLING PLANT PACKAGE DRIVE EQUIPMENT 1 OF 4
PART-B
1.02.05 Recommended oil grade shall be compatible with gear internals like material of
bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick,
drain plug etc.
1.02.06 Couplings
1.02.07 Flexible / Rigid Couplings
Couplings shall be used for power transmission depending upon duty requirements.
The design of the coupling shall be such that it can take shock and misalignment
without sacrificing its efficiency. Flexible couplings shall be used for low speed
application only. Geared type flexible coupling shall be used on low speed side for
all conveyors and other drive chains where gear box is provided. Other couplings in
the drive chains shall be either rigid or flexible type, depending upon the requirement
of equipment design.
1.02.08 Fluid Couplings
Fluid couplings shall be provided in all the drive machinery for belt conveyor systems
and coal crushers if the actual power requirement at motor output shaft is more than
40 kW. The fluid coupling for LT motors shall be of traction type. Cooling water
coils for traction type fluid coupling shall not be accepted. Scoop tube type fluid
coupling shall be provided for conveyors with HT motors and ring granulator type
coal crushers. Suitable electrically operated actuators shall be provided for scoop
tube operation from local as well as remote. Suitable provision for alternate manual
operation shall also be kept. Separate pump with motor or integral shaft driven oil
pump shall be provided for circulating the fluid coupling oil through oil cooler.
Arrangement for forced cooling water supply to oil cooler shall be provided by
Contractor. Suitable interlock using flow switches shall be provided in both oil as
well as water lines to trip the drive motor in the event of flow in either lines falling
below acceptable levels. Suitable pressure indicators and flow indicators shall be
provided in the cooling water lines along with all-relevant valves, and accessories.
Necessary isolation valves shall be provided in the oil / water line for maintenance of
any equipment in the line. Necessary interlock shall also be provided so that the HT
motor cannot be started from remote / local unless position of scoop tube permits no
load start of the motor. Tripping of downstream equipment while the system is under
normal operation shall result in scoop tube re-positioning to permit no load run of the
concerned HT motor. Temperature switch shall be provided in the oil circuit and shall
trip the system in case of high oil temperature.
Selection of rating & speed of actuator for scoop type fluid coupling shall be made
taking into consideration the coasting time of down stream and up stream conveyors
and the engagement/disengagement time achievable. The scoop tube operation
must be such so to ensure draining of oil from the operating circuit by providing a
double speed motor. The speed (for draining) shall be selected to match the
coasting time of down stream equipment/conveyor.

SECTION-VI
PART-B
DATA SHEET : DRIVE EQUIPMENT
1.0.0 GENERAL
1.1.0 Continuous Motor Rating (Name Plate Rating) at

50 Degree Centigrade Ambient temp. for Electric
Motors
a) For conveyors of belt conveyor systems *120% of actual power at

drive motor output shaft at
specified design capacity
b) Crushers, Mobile trippers travel drive, paddle *110% of actual power

feeders carriage drive, mono-rail hoists (travel requirement at drive motor
and hoisting), elevators, rack and pinion output shaft at guaranteed
gates, all the drives in sampling units, (rated) capacity.
various pumps of DS/DE systems, service
water systems, cooling water system, potable
water system and sump pumps, Ventilation
Fans
*The actual power at drive motor output shaft shall be calculated after considering
all the losses of down the line equipment’s of the drive train.
2.1.0 Gear Box
2.1.1 Type
(a) Below 40 KW Helical, worm, bevel as per

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

cooling coil
2.1.2 Service Factor As per accepted engineering

practice / manufacturer's
recommendations.
2.1.3 Ambient temperature for Thermal rating 50oC Minimum
2.1.4 Mounting On Machined/Ground

Surfaces

SECTION-VI
PART-B
2.1.5 Output Rating
a) For belt conveyor systems

@ Service factor X {1.2 times
the actual power requirement
at drive pulley shaft at design
capacity}
b) For other equipment
@ Service factor X {1.2 times

the actual power requirement
of the driven equipment }
@ Service factor shall include all the components considered by the supplier and
should be clearly indicated in manufacturer’s gear box selection catalogues.
2.1.6 Duty 24 Hrs. Continuous
2.1.7 Rating Not less than motor name

plate rating
2.2.0 Flexible Couplings
2.2.1 Type Geared coupling.
2.2.2 Rating Not less than motor rating.
2.3.0 Fluid Couplings For all motors having rating

more than 40 KW.
2.3.1 Type
(a) L.T. Motors Traction type
(b) H.T. motors Scoop tube type.
2.3.2 Rating Not less than motor

nameplate rating

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-08
BELT SCALE

A-08: BELT SCALE

1.00.00 GENERAL
Belt weigh scale for measurement of coal flow rate and quantity shall be provided at
specified locations. System shall be complete with flow rate indicator, totaliser,
control panel etc.
The design, manufacture, inspection and testing of Belt Scales shall comply with all
the currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The Belt Scales shall conform to the latest edition of
the following standards and codes. Other internationally acceptable
binding.
NEMA
NEC For electronic circuit enclosures.
IS:11547 Electronic weighing in motion system.
1.02.00 Design & Construction Requirements
1.02.01 The weigh scale shall be automatic and electronic type. It should be designed for
continuous automatic weighing, metering and printing of coal flow.
1.02.02 Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4
nos. weighing idlers. It shall have unitised construction for ease of installation and
shall be fully floating type (without pivot points). Minimum 4 nos. hermetically sealed
load cells of precision strain gauge type shall be applied in tension to support the
weigh bridge. The load cells shall have 100% overload protection and shall be
structurally safe upto to 250% of rated belt scale capacity.
1.02.03 Belt scale shall be electronic microprocessor based with its program stored in non-
volatile memory.
1.02.04 It shall be provided with self diagnostic features for trouble shooting of the entire belt
scale system.
1.02.05 Fully automatic zero and span calibration facility shall be provided.
1.02.06 The electronic systems offered by the Contractor shall include all signal conditioning,
power amplifiers and printed circuits etc. The printed circuits shall be encapsulated
against dust and moisture.
SECTION-VI
COAL HANDLING PLANT PACKAGE BELT SCALE 1 OF 3
PART-B
1.02.07 The flow rate indicator shall have minimum 4 digits. The flow totalizer should have 8
digits display scale with reset facility.
1.02.08 Complete belt scale system shall be suitable for 50°C ambient temperature and
100% relative humidity. It shall be suitable for out door installation in a dusty area.
The electronic circuit enclosure, sensors housing shall be dust and watertight. The
electronic printed circuits shall be encapsulated with epoxy or other suitable material
for protection against dust and moisture.
1.02.09 Minimum three years battery back up power failure protection shall be provided.
1.02.10 Belt scale shall be designed for a range of 20% to 120% of rated capacity with an
accuracy of atleast (+) 0.25 percent throughout its range. Belt scale provided on
Stacker Reclaimer Boom Conveyor shall have accuracy (in the horizontal position of
Boom) of (+) 1 percent for the range of 20% to 120% of boom conveyor rated
capacity.
1.02.11 Per two (2) belt weighers, the contractor shall furnish one (1) necessary test load
chain sets required for calibration and periodic testing of the equipment. The test
load chain shall be ‘two idler spaces’ longer than the weighing length of the weighers
and shall be complete with chain reset equipment with weight adding reels of
adequate size. The calibrated weight parameter length of the test chain shall be
stamped at a suitable location on the body of the equipment. The test chain shall be
installed near belt weigher with suitable arrangement for easy mounting/dismounting
of chain onto/from conveyor belt. Alternatively, supply of test weights for calibration
of belt scales is also acceptable.
1.02.12 Local panel for belt scale shall be of sheet metal.

SECTION-VI
PART-B
DATA SHEET : BELT SCALE
1.0.0 GENERAL
1.1.0 Ambient Temperature 50°C
1.2.0 Relative Humidity 100%
2.1.0 Type Electronic load cell type
2.2.0 Operation Microprocessor based fully automatic
2.3.0 No. of floating idlers Minimum four (4)
2.4.0 Load Cells
2.4.1 Type Strain gauge type hermetically sealed
2.4.2 Minimum Nos. Four (4)
2.4.3 Overload protection 100 % of rated belt scale capacity
2.4.4 Structural capacity 250 % of rated belt scale capacity
2.5.0 Flow Rate Indicator Electronic Digital Display Minimum 4

digits
2.6.0 Flow totalizer 8 digit display with reset facility.
2.7.0 Accuracy For entire range of 20% to 120% of

rated capacity
For S/R belt scale : Minimum + 1%

For others : Minimum + 0.25%
2.8.0 Calibration
2.8.1 Automatic Zero & span calibration
2.8.2 Manual With test load chain
(a) Test load chain length Two idler spaces more than weighing
lengths
(b) Chain reel equipment Complete with weight adding facility.

SECTION-VI
PART-B
BID DOCUMENT NO. : CS-0350-155-2
PART - B
SUB-SECTION-IIIA-09
DUST CONTROL & MISCELLANEOUS

SYSTEM

A-09: DUST CONTROL AND MISCELLANEOUS SYSTEM
1.00.00 GENERAL
1.01.01 The specification is intended to cover design, engineering, manufacture, supply,

erection, testing and commissioning of the complete, Dust Control and
Miscellaneous Systems as specified hereinafter required for the Coal Handling
Plant.
The Contractor shall refer to the other sections and scheme indicated in the tender
drawings to appraise himself of the work and scope of supply of the other
Contractors/Employer's and shall coordinate his work with the work of other
Contractors.
1.01.02 General Information/Description
1.01.03 Dust Control System
The dust control system to be furnished under this specification is required for
control of fugitive dust emissions from dust generation points such as transfer points,
feeders, crushers etc. Dust control is achieved by dust suppression/extraction
system.
Contractor shall guarantee and offer dust control system which shall not allow a dust
concentration in the ambient air inside the buildings more than acceptable limits as
per Employer approved guidelines or any internationally recognized hygienic
Standards/Codes.
The Capacity of dust control system specified elsewhere is for Contractor’s guidance
only. Contractor shall provide adequately sized fool proof dust control systems the
performance of which should be guaranteed by the Contractor. However, the
capacity of the offered system shall not be less than the specified values. Further,
for computation of design capacity of the pumps, permanent recirculation lines as
shown in tender drawings shall also be considered.
1.01.04 Miscellaneous Systems
Service water system, potable water system, cooling water system & sump pumps
shall be provided as specified elsewhere in this specification and as indicated in
tender drawings.
1.02.01 (a) Plain Water Dust Suppression System
Complete with water supply system, piping, spray heads, pumps, drive
motors with canopy (wherever required), couplings with enclosure,
electricals, supporting structures, approach/maintenance platforms, handling
for equipment, civil and structural works and necessary accessories.
STAGE-II (2X195 MW) DUST CONTROL & PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE MISCELLANEOUS 1 OF 19
PART-B
BID DOCUMENT NO. : CS-0350-155(R)-2 SYSTEM
(b) Dry Fog Type Dust Suppression System
Complete with water supply system, compressed air system, pressure

regulating units, flow activation system, necessary instrumentation for auto &
manual operation, drives, pumps, maintenance platforms, alongwith
associates civil/structures & electrical works.
1.02.02 Sump Pump
2x100% sump pumps alongwith level switches and piping up to nearest Employer’s
drain (max. up to 50.0 meters from outside the building) shall be provided at all
locations wherever natural drainage is not possible. Sump pumps along with drain
pits shall be provided at other locations also, if required, during detailed engineering
stage.
Service water distribution system complete with water supply system, valves, quick
couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy,
couplings with enclosure, electricals, including supporting structures, handling for
equipment’s, civil and structural works and necessary accessories shall be provided
throughout the coal handling plant area in Contractor’s scope.
1.02.04 Pipings, Fittings, Valves and Specialities
The material to be supplied for completing the pipe work shall include but not be
limited to the following:
(1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing
unions, couplings, caps, blank flanges, saddles etc. necessary for making
reliable piping system.
(2) Gaskets, ring joints, jointing material etc. as required.
(3) Instrument tapping connections, stubs.
(4) Gate / plug, globe and check valves to start/stop, regulate and to prevent back
flow.
(5) Duplex Strainers.
(6) Anchors, hangers and supports as required including secondary steel

embedment etc.
(7) Bolts, nuts, fasteners as required for interconnection piping, valves and fittings
as well as for terminal points.
(8) The entire water piping of DS / SW / PW / CW / DE system shall be

routed/supported on concrete pedestal and conveyor galleries. Wherever the
layout does not permit the pipes to be routed over ground, the same shall be
buried in conformity to the relevant standards & shall be provided with

SECTION-VI
PART-B
necessary protective coating as per relevant standards and as specified

elsewhere in the specification.
(9) Painting, anti-corrosive coatings etc. outside pipes as necessary.
(10) Welding electrodes and welding rods.
(11) The area around storage tanks, strainers, valves etc. (located out side pump
house) shall be paved.
1.03.00 Terminal Points
Employer shall provide supply of water for dust suppression/extraction system,

service water, potable water at terminal point as elaborated elsewhere. Beyond the
terminal point, the complete pipe work for water & air along with associated valves,
specialties, instruments, fittings and supports, pumps, tanks, etc. as required for the
satisfactory operation of dust control, service water, potable water, cooling water &
dust extraction systems shall be furnished by the Contractor.
1.04.00 Codes and Standards
The design, manufacture, inspection and testing of Dust Control & Miscellaneous
Systems shall comply with all the currently applicable statutes, regulations and
safety codes in the locality where the equipment is to be installed. The Dust Control
& Miscellaneous Systems shall conform to the latest edition of the following
standards and codes. Other internationally acceptable standards/codes, which
ensure equal or higher performance than those specified, shall also be accepted.
IS:778 : Gun Metal gate, globe & check valves for general purpose.
BS:5150 :Cast Iron Gate Valve for water works purposes
BS:5152 :Cast Iron Globe Valve for water works purposes
BS:5312 :Cast Iron Check Valve for water works purposes
S:1239 : Mild Steel tubes & fittings.
IS:2379 :Colour for the identification of pipe line.
IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm)
IS:5312 : Swing check type reflux (non return) valves.
IS:1520 : Horizontal centrifugal pump for clean, cold fresh water.
IS:5120 :Centrifugal pump for clean, cold & fresh water.
IS 2825 : Air Receivers.

SECTION-VI
PART-B
ANSI B 31.1:Code for pressure piping.
Hydraulic institute Standards of U.S.A.
Dry Fog Dust Suppression
1.05.01 At specified locations dry fog dust suppression system shall be provided which
comprises spray nozzles discharging plain water & air in a fine spray to form dry fog
to capture air borne dust particles and direct them into the main coal flow. This dry
fog shall be discharged through spray heads at the dust suppression zones.
The dry fog dust suppression system shall consist of the following:
(a) Fogging system & controls consisting of:
(i) Spray bar assemblies.
(ii) Pressure regulating units
(iii) Flow activation system
(iv) Instrumentation for auto spray
(b) Compressed air system consisting of:
(i) Two (2) nos. (one no. working and one (1) no. standby) air
compressors (screw type) for each group of dry fog dust suppression
system, alongwith air receivers as specified elsewhere.
(ii) Air receivers

(iii) Various instrumentation & valves.
1.05.02 (a) Track Hopper Dust Suppression
The dust suppression system for the track hopper shall consist of seventeen
(17) zone headers, each of approx. 15 meters length, routed along the entire
length of track hopper on one side. Each nozzle header shall be provided
with adequate number of spray nozzles spaced at 500 mm interval. Further,
at the track hopper the water spray shall be of fogging type with a minimum
pressure of 2.5 kg/sq.cm(g) at spray nozzle inlet. It should be possible to
operate maximum four (4) numbers of zones simultaneously on track hopper.
(b) Wagon Tippler Dust Suppression
The dust suppression system for the wagon tippler shall consist of two (2)
zone headers, each of sufficient length routed on each side. Each nozzle
header shall be provided with adequate number of spray nozzles spaced at
500 mm interval. Further, at the wagon tippler, the water spray shall be of

SECTION-VI
PART-B
fogging type with a minimum pressure of 4.5 kg/sq.cm(g) at spray nozzle

inlet. It should be possible to operate all zones simultaneously.
1.05.03 Paddle Feeder Dust Suppression
Trolley mounted pumping arrangement shall be provided for supplying water to the
mobile paddle feeders. In this arrangement, tank, supply pump(s) and spray nozzle
header shall be mounted on paddle feeder water tank trolley. The tank on Paddle
Feeder or on P/F trolley shall be filled through flexible hose tapings from a ring
header, which will remain, flooded through a connection from ground storage tank.
This storage tank shall have make up connection from the common dust
suppression system.
1.05.04 Each spray head in CHP shall have a provision for installing a pressure gauge
whenever required. Further, pressure gauges shall be provided at least at two
locations.
1.05.05 Coal Yard Dust Suppression System
Water shall be drawn from the water storage tank by electric motor driven pumps
and discharged via a pipe work system through spray heads. Spray heads shall
comprise of swiveling type spray units spaced at an interval of approximately 40
meters around each coal pile as shown in tender drawings. Manually operated
globe valve shall be provided to control water supply to each spray unit. Pressure at
inlet to spray unit shall not be less than 4.5 kg/cm2(g).
1.05.06 Sump Pumps
Sump pumps alongwith level switches & piping upto nearest Employer's drain (max
upto 50.0 mtrs. from outside the building) shall be provided at all locations wherever
natural drainage is not possible.
The capacity of each pump shall not be less than 50 M3/hr. Minimum 10% margin
on capacity and 20% margin on computed head shall be considered for selection of
pumps.
Size of the drain pit shall not be less than 2.0 meters x 2.0 meters x 1.8 meters
deep. One no. of settling pit shall also be provided before sump pit so that water
without heavy coal particles goes into sump pump pit. High and low level switches
shall be provided in the sump pump pit.
1.05.07 Service Water (SW) System
Service water connections are to be provided in conveyor galleries and tunnels at 50

meter intervals. Adequate number of these connections shall be provided in all
transfer houses with minimum one no. at each floor and with minimum two (2) nos.
at each floor in crusher house. Each connection shall be provided with one (1) no.
32 NB globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be
provided in each building.

SECTION-VI
PART-B
Service water distribution system shall be designed considering the water scheme
and water requirement indicated in tender drawings.
1.05.08 Potable water (PW) system
Potable water connections are to be provided in all transfer points, wagon tippler top,
crusher house, all tripper floors, the machinery well at both ends of track hopper,
track hopper top at both ends and all control rooms/MCC rooms and toilets etc.
Water shall be drawn from the water storage tank by electric motor driven pumps
and discharged via a pipe work system to the overhead drinking water storage PVC
tanks of 250 litres capacities. The drinking water storage tanks shall have provision
for maintenance & drain.
1.05.09 Hoists with monorail of adequate capacity shall be provided in the service water/dust
suppression/potable water pump houses.
1.05.10 Wet Type Dust Extraction System
Bidder shall provide wet type dust extraction system for Vibrating Screening feeder
and Belt Feeders after crusher in crusher house. The dust extraction system shall
be of Venturi scrubber type. One independent dust extraction system for each
stream shall be provided (Total 2 nos. system to be provided). Bidder may provide
multiple Units in each of the independent dust extraction system as per his design.
1.05.10.1 Venturi Scrubber System
Venturi scrubber type wet dust collection system shall be provided at crusher house
for extracting the dust from vibrating screening feeders & belt feeders after crushers.
The system shall operate on the principle of mixing of dust laden air with water by
collision in the venturi throat forming a mass of larger particles for successful
collection in the cyclones. The scrubber unit shall have a design for built in collection
of the damp dust in a sedimentation tank which shall be discharged automatically at
periodic intervals (time setting variable) into an additional ground based settlement
pit from which only clear water shall be led by drain line (by bidder) upto coal slurry
pond.
The scrubber unit shall be of minimum maintenance type design. The system shall
be complete with venturi unit, water pockets, risers, circulating water pumps,
throttling valve, pressure gauges, all associated valves/accessories, baffles,
reducing discs, partition plates, cyclones, discharge pipe, inlet, deflectors, inspection
doors of dust light/air tight construction, sedimentation tank, float control valve,
overflow trap, quick filling/discharge connection, duplex structures, automatic sludge
disposal arrangement.
Further, the dust sedimentation tank with the scrubber shall have water level
maintained inside if by means of float valves. Also water overflow with trap shall be
provided. Requisite water shall be circulated in the unit by means of circulating pump
located outside this scrubber.

SECTION-VI
PART-B
All items of scrubber exposed to water shall be spray galvanized. Min. 6mm thick
M.S. plate shall be used for tanks.
Pressure drop through the scrubber unit shall not exceed the range of 180 mm w.c.
An external monometer drop during operation. The system shall be designed with
min. consumption of slurry water. The dust collection efficiency shall be 95% down
the 10 micron size.
1.05.10.2 Arrangement shall be provided in the slurry discharge system for separating dust
and water and discharging only clear water to the coal slurry pond. The dust shall be
removed manually for subsequent transportation to yard. All materials including
piping, valves, trenches etc. required for the satisfactory operation of aforesaid
removal system shall be included in bidder’s scope.
1.05.10.3 Exhaust Fans :
The construction features of fan shall be same as specified elsewhere in the

specification.
1.05.10.4 Dust Collection Hood:
(i) The hood connections shall be designed for collection of dusty air from
various coal transfer, vibrating grizzly feeders, transfer chutes and other coal
dust generating points.
(ii) Centre line of the hoods shall be located at the point of generation of
maximum dust.
(iii) The hoods shall be adequately sized to collect all dusty air generated at the
point. Velocity in the hood must not be so high as to draw larger size
particles unnecessarily.
(iv) At all suction hoods (except for bunker dust extraction units) damper shall be
provided.
(v) The hoods shall be made of MS plate of adequate thickness.
1.05.10.5 Ducting
(i) The ducts for conveying dusty air shall be of round shape and of streamline
appearance.
(ii) The velocity of air in the duct shall be high enough (in the range of 18 to 21
metres/sec.) to transport in the suspended dust in the air.
(iii) Tentative layout of ducting shall be furnished by the Bidder along with the
offer.
(iv) Flexible connections shall be provided at the duct connections to inlet and
discharge of the fans. All flexible connections shall be non-collapsible type
and their length shall be kept to a minimum.
(v) Duct supports shall be provided as per stipulations here under :

SECTION-VI
PART-B
Diameter of duct Spacing of support
Less than 200 mm Maximum 3.00 metre
More than 200 mm Maximum 2.50 metre
(vi) Minimum One (1) No. Electrically operated damper shall be provided for
each stream of dust extraction system.
(vii) The ducting shall be made of MS Sheet with thickness not less than 14
gauge.
1.05.10.6 Suitable platform and ladders shall be provided for carrying out maintenance of dust
separator / collection tower.
1.06.01 Water Supply Pumps
1.06.01.01 Water supply pumps shall be provided as required.
1.06.01.02 The pumps shall be complete with drive motors, baseplate and other accessories.
The constructional features of the pump shall be as follows:
a) Pump casing may be axially or radially split. The casing shall be of robust
construction. Casing drain and vent connections shall be provided.
b) Impeller shall be made in one piece and securely keyed to the shaft. Locking
device shall be provided to prevent its loosening during all conditions of
operation.
c) Wearing rings shall be of renewable type. Opposed wearing surface shall be

of hardened material and shall have a hardness difference of at least 50
BHN.
d) Replaceable shaft sleeves shall be provided to protect the shaft where it

passes through bearings and stuffing boxes. The end of the shaft sleeve
assembly shall extend through the packing gland. Shaft sleeve shall be
securely locked or keyed to the shaft to prevent loosening or rotation. Shaft
and shaft sleeves shall be machined and assembled for concentric rotation.
e) The design of the shaft shall take into consideration the critical speed, which
shall be at least 20% away from operating speed.
f) Pump bearings shall be of antifriction type. Bearings shall be readily

accessible without disturbing the alignment of pump.
g) Packed stuffing boxes shall be of sufficient length to prevent leakage along

the shaft and shall be complete with all packing and lantern rings required.
h) Pumps shall be furnished complete with an approved type of flexible -

coupling.
SECTION-VI
PART-B
i) Couplings guards made of expanded metal and bolted to the base plate shall
be furnished.
j) The common base plate for pumps and motor shall be in one piece and shall
be made of fabricated steel.
k) Pump speed shall be less than 1500 rpm for pumps of capacity more than 10
m3/hr.
1.06.01.03 The power, head and flow characteristics of each pump shall be suitable for parallel
operation. The Power characteristics of the pumps shall be of non overloading type.
1.06.01.04 All rotating parts of the pumps shall be statically and dynamically balanced.
1.06.01.05 The motor shall be rated for continuous operation and confirm to companion
electrical specification. However, motor rating shall not be less than the max. power
demand throughout the entire range of operation of pump.
1.06.01.06 Design duty point of pump shall match with the average value of maximum and
minimum flow rates of the pump in the stable operation zone.
1.06.01.07 Materials of construction of pump components shall be as stated in data-sheet to

this section.
1.06.02 Sump Pumps
1.06.02.01 The pumps shall be of wet pit types, vertical shaft and impeller shall be specially
designed to pass large solids or unscreened liquids. The construction and material
shall be suitable for pumping coal/dust contaminated water with a minimum of
maintenance. All bearings of the pump shall be located above the water level.
1.06.02.02 The piping system shall be designed to suit operations of pumps including standby
pump.
1.06.02.03 Materials of construction of sump pump components shall be as stated in Data sheet
of this section.
1.06.03 Piping, Fittings, Valves and Specialties
1.06.03.01 Piping & Fittings
(a) Material of construction of piping and fittings shall not be inferior to those
given in data sheet of this section.
(b) All piping shall be capable of withstanding the maximum pressure in the
corresponding line at the relevant temperature.
(c) In general pipe sizes 65 mm NB and larger are to be joined by butt welding
and pipe work of size 50 mm NB and below by socket welding/screwed
connections. Joints at valves or specialities shall be flanged for sizes 65 mm
NB or large and screwed for sizes 50 mm NB and below. All galvanised

SECTION-VI
PART-B
piping shall be joined by screwed connections. Minimum pipe diameter

selected for DS/SW/PW/Cooling Water System (along with branch pipes)
shall be 32 NB. However, for dry fog DS system, the minimum pipe size shall
be 15 NB.
(d) End preparation for butt welding shall be done by machine/flame cutting.
Socket weld and preparation shall be saw/machine cut.
(e) Hangers and supports shall be capable of carrying the sum of all
concurrently acting loads. They shall be designed to provide the required
supporting effects and allow pipe line movements as necessary. All guides,
anchors, braces, dampers, expansion joints and structural steel to be
attached to the building/structure, trenches etc. shall be provided.
(f) All piping shall be routed on ground on concrete pedestals and at road
crossings, these shall be buried through hume pipes.
1.06.03.02 Valves and Specialities
(a) Valves & Specialities shall be used to start, stop or regulate the flow. All
valves/specialities below 50 mm size in service water/dust suppression/
potable water lines should be plug type of proven make.
(b) All valves shall be suitable for most stringent service conditions i.e. flow,
temperature and pressure under which they may be required to operate.
(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above
50NB and Globe valves shall be used for regulating the flow.
(d) Valves shall be provided with back seating bush to facilitate gland renewal
during full open operation.
(e) All gate and globe valves of size 65 NB and large shall be bolted bonnet,
outside screw, rising type with flanged ends. Valves of size 50 NB and
smaller shall be with screwed ends.
(f) Valves shall be provided with the following as necessary :
(1) Hand wheel
(2) Position indicator
(3) Draining arrangement.
(g) Material of construction of valves shall not be inferior to those given in data
sheet of this section.
(h) Globe valves shall be provided with contoured plug to have well
controllability.

SECTION-VI
PART-B
(i) Non-return valves shall be swing check type. These valves will have a
permanent ‘arrow’ inscription on its body to indicate direction of motion of the
fluid.
(j) All valves shall be provided with hand wheel, chain operated, extension
spindle and floor stand wherever required so that they can be easily operated
either at a lower or higher elevation as the case may be.
(k) Strainer shall be of duplex type designed with 3 way valves so that one filter
can be cleaned while the other is in operation. Suitable vent and drain
valves shall also be provided. Screen opening area shall be at least four
times the pipe cross sectional area. Pressure drop in clean conditions shall
not exceed 1.5 MWC at full flow.
(l) Bib cocks provided for potable water system shall be made of Copper Alloy /
Cast Iron.
1.06.04 Special cleaning, protection and painting
1.06.04.01 Piping & Fittings
(a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust
etc. by wire brushing.
(b) For overground exposed steel pipes, one shop and one site coat of red oxide
zinc phosphate and two coats of synthetic enamel finishing paints unless
specified otherwise shall be applied. A minimum of 120 microns Dry Film
Thickness (DFT) after finished coat of paint shall be ensured.
(c) For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall
be applied on the cleaned surface. Finally, it should be wrapped with
minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt
shall be generally touched with heavy duty bitumastic paint.
1.07.00 Pumps for DS/SW/CW/PW/DE systems shall be selected with minimum 10%
margin on capacity and 20% margin on computed head.

SECTION-VI
PART-B
DATA SHEET: DUST CONTROL & MISCELLANEOUS SYSTEM
1.0.0 GENERAL
1.1.0 Dust Control Dust suppression/ extraction

system
1.2.0 Miscellaneous systems Service water system, Potable

water system, Cooling water
system & Sump pumps.
2.1.0 Dust Suppression
2.1.1 Operation Water sprayed through nozzles.
2.1.2 Pumps 2x100% for water
2.1.3 Spray Head
(i) Minimum No. of nozzles per spray 4 (Four)

head
(ii) Pressure at inlet (dry fog) Min. 0.5 kg/cm2 for water
Min 5 kg/cm2 for air
(iii) Pressure at inlet (Plain water) Minimum 2.5 kg/sq. cm
2.1.4 Trolley Mounted Arrangement for

paddle feeders
(i) Ring header 100 NB on both sides of Track

Hopper
(ii) Hose Tapings At 25 meter intervals suitable for

Tank filling in 5 minutes
(iii) Trolley tank capacity Suitable for 1/2 hrs operation of

Paddle Feeder
2.2.0 Plain Water Dust Suppression
2.2.1 Pumps 2x100% electric motor driven
2.2.2 Minimum Pressure at inlet of spray 2.5 kg/sq. cm for Track Hopper
nozzles
4.5 Kg/sq. cm for wagon tippler

SECTION-VI
PART-B
2.2.3 Nozzle spacing for track hopper / 500 mm

Wagon tippler
2.2.4 Nozzles Fogging type (without air assisted)
2.2.5 Flow from each nozzle 2.0 Lpm
2.3.0 Dry Fog Dust Suppression
(i) Compressor Screw Type

(ii) No. of Compressors to be provided One working & one Standby, per
group
(iii) Air receivers One no. of min. 2 cu.m capacity
located near compressors & 200
litres capacity at various location
(iv) Nozzles Dry fog type
2.4.0 Coal Yard Dust Suppression
2.4.1 Pump 2 X 100% electric motor driven
2.4.2 Spray heads
(i) Type Swiveling type spray unit

40 m.
(ii) Spacing
(iii) Minimum Pressure at inlet 4.5 Kg/sq.cm
(iv) Flow from each sprinkler 500 LPM
(v) Throw of sprinkler spray Suitable to cover entire stockpile

surface as per tender drawing
(vi) Material of construction:
a) Nozzle SS-316L
2.5.0 Sumps Pumps
(i) Type 2x100% electric motor driven
(ii) Capacity 50 cub.m/hr minimum with 10%

margin
(iii) Head 20% margin on computed head
2.5.1 Drain Pits Minimum 2 x 2 x 1.8 mts. and 1

No. settling pit for slurry & high/low
level switches in drain pit.
SECTION-VI
PART-B
2.5.2 Piping To nearest plant drain
2.6.1 Water connections
(a) Conveyor Galleries and tunnels every 50 m
(b) Transfer points Min. 1 no. at every floor
(c) Crusher House Min. 2 nos. at every floor
2.6.2 Connection details 32 NB plug valve
2.6.3 Hose pipes with hose reel One in each building of 25 mtr.
Length with nozzle
2.7.0 Potable Water System
2.7.1 Pumps 2 X 100% electric motor driven
2.7.2 Water connections
a) Transfer points Minimum one (1) no. at each floor
(b) Crusher house Minimum two (2) no. at each floor
(c) Tripper floor Minimum one (1) no. at every

tripper bay.
(d) Machinery wells Minimum one (1) connection at

each machinery well in track
hopper
(e) Control room Minimum one (1) no. at each floor
(f) MCC rooms and toilets Minimum one (1) no. each
(g) Track hopper Top Min. one (1) no. at each end.
(h) Wagon tippler top Min. one (1) no.
4.0.0 CONSTRUCTION REQUIREMENTS
3.1.0 Water Supply Pumps for

DS/SW/PW/CW
3.1.1 Casing Axial or radially split with drain &

vent connection.
For DFDS system vertical type
pump is also acceptable.
SECTION-VI
PART-B
3.1.2 Impeller One piece, keyed to shaft along

with locking device
3.1.3 Shaft Critical speed atleast 20% away

from operating speed
3.1.4 Shaft sleeves At bearings & stuffing boxes.
3.1.5 Bearings Antifriction type
3.1.6 Wearing rings Renewable type (preferable)
3.1.7 Pump speed Below 1500 rpm for capacity more

than 10 cub. m/hr.
3.1.8 Head flow characteristics Suitable for parallel operation.
3.1.9 Materials
(a) Casing Cast Iron to IS:210, FG 260
(b) Impeller Bronze conforming to Gr.I of

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

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

IS:318
(e) Shaft Medium carbon steel
(f) Shaft sleeve Stainless steel conforming to AISI-

416 hardened.
(g) Gland packing Impregnated teflon
3.2.0 Sump Pumps
3.2.1 Type Wet pit type vertical shaft
3.2.2 Duty Capacity to handle large solids or

unscreened liquid.
3.2.3 Materials
(a) Casing and rotor housing Ni-Cast Iron (350 BHN)
(b) Rotor Ni-Cast Iron (350 BHN)

SECTION-VI
PART-B
(c) Shaft Medium carbon steel
(d) Gland Bronze
(e) Wearing rings Stainless steel
(f) Shaft enclosing tube Carbon steel
3.3.0 Pipings & Fittings

3.3.1 Joints
(i) Pipe to pipe
Pipe size < 50 NB Socket welding/screwed

Pipe size > 65 NB Butt welding
(ii) Pipe to valves

Pipe size < 50 NB Screwed
Pipe size > 65 NB Flanged
3.3.2 Isolation of flow Plug / Gate / Sluice valves

3.3.3 Regulation of flow Globe Valve
3.3.4 Valves
(i) Size > 65 NB Bolted bonnet outside screw rising

type.
(iii) Size < 50 NB Union bonnet with screwed ends

for Globe valve & screwed ends for
plug valve
3.3.5 Materials for Pipework
(a) For sizes 200 NB and Larger ERW carbon steel pipes to API-5L-
Gr.B/IS:3589 with minimum
thickness 6.35 mm
(b) For sizes 150 NB to 65 NB ERW carbon steel black pipes to

IS:1239 (Part-Heavy class).
(c) For sizes below ERW carbon steel galvanized

65 NB pipes to IS:1239 (Part-I) Heavy
class.
3.3.6 Materials for Valves & Specialities
(a) Cast Iron Valves 65 NB and above
(i) Body and bonnet Cast Iron to IS:210, Gr.FG-200

SECTION-VI
PART-B
(ii) Disc for non- return Cast Iron to IS:210, Gr.FG-200

valves
(iii) Seating surfaces and rings 13% chromium steel
(iv) Hinge pin for non return valves Stainless steel type AISI-316
(v) Stem for gate and globe valves 13% chromium steel
(vi) Back seat bush 13% chromium steel
(a) Gun metal valves (50 NB &

below and upto a working
pressure of 10 kg/cm2)
(i) Body Gun metal to IS:318, Gr-2.
(ii) Trim Gun metal to IS:318, Gr-2.
(b) Duplex Strainer
(i) Body MS fabricated
(ii) Strainer Stainless steel type element AISI-

316
(c) Pressure Gauge/Switch (to be

provided with isolating valves,
gauge cock, snubber and
syphon)
(i) Dial size 150 mm
(ii) Accuracy (+/-) 1% of range span
(iii) Bourdon AISI 316 SS
(iv) Block AISI 316 SS
(v) Movement AISI 316 SS
(vi) Case and Bezel Die cast Alum. Weather proof case
stove enameled block with
screwed type inner bezel of ABS
plastic and glycerin filled.
(vii) No. of contacts 2 NO + 2 NC
(viii) Type of contact Adjustable throughout the range.

SECTION-VI
PART-B
(ix) Degree of protection IP. 65
(d) Solenoid valve (to be provided

with isolating valve)
(i) Type 2/2 way Diaphragm type pilot

operated
(ii) Diaphragm molded synthetic rubber
(iii) Body Forged brass / SS
(iv) Pressure 0.5 to 10 kg/cm2
(v) Protection Class IP 65
(e) Flow Switch (to be provided

with isolating valves)
(i) Body Forged steel
(ii) Extension Rod/wire SS-304
(iii) Sleeve and Sleeve pipe SS-304
(iv) Cover Die cast aluminum
(v) Max. working pressure 10 kg/sq.cm
(vi) Repeatability ± 0.5%
(vii) No. of contacts 2 NO + 2 NC
(viii) Type of contact Adjustable throughout the range.
(ix) Protection class IP – 65
(f) Level Switch
(i) Type Displacer operated magnetic type
(ii) Displacer SS – 316
(iii) Wire rope SS – 316
(iv) Spring Housing Spring and SS – 316

sleeve pipe
(iv) Cover Cast Aluminum
(v) No. of Contacts 2 NO + 2 NC

SECTION-VI
PART-B
(vi) Type of Contact Adjustable throughout the range.
(viii) Protection class IP – 65
(g) Level gauges
(i) Type Float type mechanical gauge with

arrow scale
(ii) Accuracy (+/-)1% of full scale range
(iii) Material of construction
(aa) Float & Guide wire 316 SS
(bb) Elbows Suitable grade of SS
(cc) Housing Mild Steel
(dd) Cable fastener SS 304
(h) Plain water Dust Suppression

Nozzles (except for Stockyard
DS)
(i) Type Fogging, non-clogging type
(ii) Material Stainless Steel
(iii) Nozzle housing To ensure protection of nozzle

against damage.
(i) Y Strainer
(a) Body SS 304
(b) Plug SS 304
(c) Filter Element SS 316, 60 mesh

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-10
VENTILATION SYSTEM

A-10: VENTILATION SYSTEMS

1.00.00 GENERAL
The specification is intended to cover design, engineering, manufacture, supply,

erection, testing and commissioning of the complete Ventilation & air conditioning
systems as specified hereinafter for the smooth and trouble free operation of CHP.
1.01.01 The Contractor shall refer to the other sections enclosed to appraise himself of the
work and scope of supply of the other Contractors and shall coordinate his work with
the work of other Contractors.
1.02.00 GENERAL DESCRIPTION
1.02.01 Mechanical Ventilation system
The air quantity for mechanical ventilation system shall be estimated based on
equipment and solar heat loads and the temperature rise inside the building.
Necessary air filters shall be provided to supply only clean air into building. Exhaust
air shall be discharged at a suitable height above building. Exhaust fans shall be
provided for tripper floor, Toilets, Battery rooms. All underground structure shall be
provided with supply air as well as exhaust air fans.
1.02.02 Pressurised Ventilation System
The pressurised ventilation system having adequate nos. of supply air fans with
washable metallic pre filters, HDPE fine filters, and self closing flap (gravity louver
shutter), ducting along with 3 phase AC motor drives, electricals, supporting
structures, access / maintenance platforms shall be provided in all MCC/switchgear
room areas of coal handling plant to be furnished under this specification. The
pressurized ventilation system shall be designed considering 15 air changes per
hour to maintain these areas pressurised slightly above atmospheric pressure to
prevent ingress of dust from outside.
1.02.03 Air Conditioning System
Air conditioning system shall be furnished for control room area of main CHP control
building, wagon tippler control room, MCC room on S/R, operator’s cabin in Stacker
Reclaimer, office room in main CHP control room, office room in wagon tippler
control room and in electrical buildings. It shall be designed considering the
equipment heat loads, solar heat loads, heat gain into the room, adequate no. of air
changes etc. to maintain a uniform temperature and relative humidity within the air
conditioned areas.

SECTION-VI
COAL HANDLING PLANT PACKAGE VENTILATION SYSTEM 1 OF 11
PART-B
1.03.00 VENTILATION AND AIRCONDITIONING SYSTEM
1.03.01 Mechanical Ventilation System
The ventilation system generally consisting of adequate number of supply and

exhaust air fans, air filters, ducting along with 3 phase AC motor drives, electricals,
supporting structures, approach/maintenance platforms, civil and structural works
and necessary accessories shall be furnished for ventilating the track hopper,
underground portion of transfer points, underground conveyor tunnels. Exhaust fans
shall be provided for tripper floor, Toilets, Battery rooms. The exhaust fans for toilets
and battery rooms will be propeller type and for tripper floors will be axial flow type
complete with rain protection coal and bird screen.
1.03.02 Pressurised Mechanical Ventilation System
The ventilation system generally consisting of adequate number of supply fans,

metallic pre filters, HDPE fine filters, ducting along with 3 phase AC motor drives,
electricals, supporting structures, approach / maintenance platforms, necessary
shed, civil & structural works and necessary accessories shall be furnished for all
MCC/switchgear rooms.
1.03.03 Air Conditioning System
1.03.03.01 2x100% capacity air conditioning packaged units (PAC) with air cooled condensers
shall be provided for Main Control Room, wagon tippler control room, office room of
Main Control Room & various MCC Rooms as specified elsewhere in spec.
complete with supply and return air ducting.
1.03.03.02 Window ACs shall be provided for MCC room of S/R, operator's cabin of S/R and
RIO room.
1.03.03.03 Supply and return air distribution ducting complete with insulation, of resin bonded
mineral wool equivalent of density at least 24 Kg/m³ and thermal conductivity of max.
0.49 mw/cm°C conforming to IS:8183 including supporting structures, approach/
maintenance platforms, civil and structural works and necessary accessories shall
be provided.
1.03.03.04 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear
surrounding.
The design, manufacture, inspection and testing of Ventilation & A/C System shall
comply with all the currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. The Ventilation & A/C System shall
conform to the latest edition of the following standards and codes. Other
internationally acceptable standards/codes, which ensure equal or higher
performance than those specified, shall also be accepted. Nothing in this
specification shall be construed to relieve the contractor of the required statutory

SECTION-VI
PART-B
responsibility. In case of any conflict in the standard and this specification, the
decision of the Employer shall be final and binding.
IS:3588 : Specification for electrical axial flow fans.
IS:2312 :Propeller type AC Ventilation fans
IS:3963 :Specification for roof-extractor units
IS:4894 :Centrifugal Fans
IS:655 :Specification for Metal Air Duct
ARI:210 :Standard for Unitary air conditioning equipment.
ARI:270 :Standard for application, installation and servicing of unitary equipment.
IS:8183 :Specification for bonded mineral wool.
IS:661 :Thermal insulation for cold surfaces.
IS:4671:Expanded polystyrene for thermal insulation purpose.
IS:8148 :Packaged Air conditioners.
1.05.01 Axial Fans
1.05.02 Design duty point of the fan shall match with the average value of maximum and
minimum flow rates of the fan in the stable operation zone. The speed of the fan
shall not preferably exceed 960 rpm for fan with impeller diameter above 450 mm
and 1440 rpm for fan with impeller diameter 450 mm and less. The first critical
speed of rotating assembly shall be at least 25% above operating speed.
1.05.03 Impellers shall be axial flow type single piece.
1.05.04 Centrifugal Fans
1.05.05 The fan units shall be centrifugal type with radial bladed impeller. For design,
purpose out door ambient temperature shall be taken as 50 deg.C.
1.05.06 Fans shall be manufactured vibration free in operation and shall be designed to limit
noise level within limits specified in Data Sheet.
1.05.07 The motor shall be rated for continuous operation and conform to companion
electrical specification. However, motor rating shall not be less than the max. power
demand throughout the entire range of operation of fan.

SECTION-VI
PART-B
1.05.08 All fan mountings shall have adequate arrangement for vibration isolation.
1.05.09 The reverse flow through non-working fan shall be prevented by dampers. The
dampers shall be made out of 18 SWG MS sheets.
1.05.10 Design duty point of the fans shall match with the average value of maximum and
minimum flow rate of the fan in the stable operation zone.
1.05.11 Filters
1.05.12 Metallic Filters
Metallic cleanable filters shall be provided as required. Max. air velocity considered
shall be 2 m/sec.
1.05.13 HDPE Filters
HDPE filters should have an efficiency of 90% down to 5 microns. Velocity across
the filter shall be limited to 2.5 m/sec.
1.05.14 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99%
down to 5 microns. Pr. drop across the filter under clean condition shall not be more
than 10 mm w.c.
1.05.15 Packaged Air-Conditioning Unit
PAC units shall be provided as required.
1.05.16 PAC units shall be factory tested and assembled self contained units complete with
refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units
wherever required shall be insulated with expanded polyethylene conforming to
IS:4671.
1.05.17 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air
cooled condenser (outdoor air) section. Heavy gauge steel cabinet finished with
paint of approved colour, shall be used to house components of PAC.
1.05.18 The evaporator and condenser coils shall be arranged for direct expansion cooling
and shall be formed of aluminum fins mechanically bonded to seamless copper
tubes and electrically tinned. The inter-connecting refrigerant circuits shall comprise
of hermetically sealed scroll compressor and motor with all necessary isolation
valves, with adjustable set point, sight glass, copper tubing and pipeline ancillaries.
The condenser coils shall be air cooled by propeller type fans complete with safety
guards. The condensing coils shall be suitably arranged to avoid radiant heat pick-
up from solar sources.
1.05.19 Condenser capacity control shall be provided by means of fans and ‘head pressure’
sensing.

SECTION-VI
PART-B
1.05.20 The evaporator air blower(s) shall be centrifugal forward curved type belt driven by
individual motor(s) and suitable for the external static pressure. The fan assembly
shall be isolated from the casing by anti-vibration mounts. The fan/motor drive shall
be capable of capacity adjustment by pulley changes within +15% of design duty.
1.05.21 High efficiency filters shall be provided in the main supply air duct and in the fresh air
connection to return air duct.
1.06.00 Construction Requirements
1.06.01 General construction details of various equipment under Contractor’s scope shall be
as elaborated in subsequent clauses below.
1.06.02 Axial Flow Fans
Axial flow fans shall be provided as required.
1.06.03 Impellers shall be axial flow type and single piece cast aluminum with aerofoil blades
construction. It shall be finished all over and balanced dynamically. Impeller shall
be mounted directly on the motor shaft.
1.06.04 Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall
be provided with suitable supports. Access door shall be provided in the casing for
easy access to motor and impeller. Suitable arrangement for mounting of motor
shall be provided.
1.06.05 Rain protection cowls will be designed to suit wall exhausters/supply fans for
protecting fans/motors from rain. It will be provided with bird screen.
1.06.06 Inlet cone or bell and outlet cone shall be provided as required. It should be made of
G.I. or M.S.
1.06.07 Motor shall be of totally enclosed type complying with the companion electrical
specification. Suitable rain/sun shade for motors shall also be provided.
1.06.08 Centrifugal Fan
Centrifugal fans shall be provided as required.
1.06.09 The casing shall be of welded construction fabricated with heavy gauge material. It
shall be rigidly reinforced and supported by structural angles. The seams shall be
permanently sealed airtight. Split casing shall be provided on larger sizes of fans.
Casing drain with valves shall be provided wherever required.
1.06.10 The impeller shall have die formed curved blades fabricated out of MS heavy gauge
welded to the rim and back plate to have a non overloading characteristics of the
fan. Rim shall be spun to have a smooth contour. If required intermediate stiffening

SECTION-VI
PART-B
rings shall be required. The impeller, pulley and shaft sleeves shall be secured to the
shaft by key and/or nuts. The impeller along with driven pulley shall be dynamically
balanced. Fan shaft shall be of EN-8 equivalent.
1.06.11 The bearings shall be self-aligning heavy-duty ball or roller bearings. They shall be
adequately supported. They shall be easily accessible and lubricated properly from
outside.
1.06.12 Filters
1.06.13 Metallic Filters
Metallic cleanable filters shall consist of V-fold galvanised wire mesh inter spaced
with a flat layer of galvanised wire mesh. The density of the filter medium shall
increase in the direction of airflow. Wire mesh edges shall be suitably hemmed to
eliminate the danger of abrasion during handling. Filter medium shall be supported
on either side by galvanised expanded metal casing. Filter frame shall be
constructed from galvanised sheet of thickness not less than 18 gauge.
1.06.14 HDPE Filters
HDPE filters shall be provided as required. To facilitage periodic cleaning of filters

by water washing, tap of service water connection near the filters shall be provided.
1.06.15 High efficiency filter (for A/C purpose)
The media of the filter shall be made from either special synthetic non-woven bond
fiber design or made from micro fiber glass media. It shall be supported with GI wire
mesh or aluminum mesh and shall be housed in an aluminum sheet frame. It shall
be of washable type several times.
1.06.16 Package A/C Unit
1.06.17 A separate cubicle shall be provided within the overall casing to house the
thermostatic controls, which shall be electric/electronic solid state, prewired and
tested. The refrigerant system shall be protected by pressure limiting devices,
electric and thermal overloads and unloading facilities to provide the required control
range tolerances. A low voltage room thermostat or RTD based temperature sensing
device shall be provided for wall mounting. The casing shall be fitted with all
necessary coil drains and service connections/ entries.
1.06.18 PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The
units shall be fully packaged and incorporate integral room air sensing control
thermostats and manufacturers work fitted safety interlocks. All controls shall be
prewired to unit mounted control/power terminal boxes.

SECTION-VI
PART-B
1.06.19 Ventilation and Air Conditioning system ducting
All GI sheet metal ductwork required for ventilation and air conditioning system shall
be furnished by the supplier. All ducts and plenums unless otherwise noted shall be
constructed out of standard quality galvanised steel sheet. All sheet metal ducts
shall be fabricated and installed in conformity to the requirements of IS:655. Steel
supports for the ductwork shall be furnished as required. The thickness of ducting
steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be
1.25 mm. The flexible connection between fan and ducting shall be on teflon
impregnated canvas. The zinc coating on GI sheet shall be 275 gm/m2.

SECTION-VI
PART-B
DATA SHEET: VENTILATION SYSTEM
1.0.0 GENERAL
1.1.0 Mech. Ventilation System To provide ventilation using

fans for specified areas.
1.1.1 No. of air changes per hour
(a) For overground building Not less than 10 supply air

changes
(b) For underground areas Not less than 15 supply air

changes & 7 Exhaust air
changes
1.1.2 Equipment
(1) Underground tunnel Centrifugal fans/Axial Fans
(2) All other places Axial fans, roof ventilators
1.2.0 Pressurised ventilation system To provide clean air to all

MCC / Switchgear buildings
1.2.1 No. of air changes per hour Not less than 15
1.2.2 Equipment Centrifugal fans/Axial Fans
1.3.0 Air-conditioning system
1.3.1 Temperature to be maintained 24 ± 1 deg. C
1.3.2 Humidity to be maintained 60 ± 5% relative humidity
1.3.3 Fresh Air intake Minimum 1.5 air changes per

hour.
1.3.4 Equipment 2 x 100 % roof mounted

package AC units along with
ducting etc. and 2X100%
window AC
1.4.0 Outside Ambient Conditions As per weather data given in

project synopsis

SECTION-VI
PART-B
2.1.0 Roof Ventilators
2.1.1 Capacity 10% more of actual

requirement
2.1.2 Head 20% more of actual

requirement
2.1.3 Speed
(a) Impeller dia above 450 mm Max. 960 rpm
(b) Impeller dia less than or equal to 450 mm Max. 1440 rpm
(c) Critical speed 25% above operating speed.
2.2.0 Axial Fans

requirement
2.2.2 Head 20% more of actual

requirement
2.2.3 Speed
(a) Impeller dia above 450 mm Max. 960 rpm
(b) Impeller dia less than or equal to 450 mm Max. 1440 rpm
(c) Critical speed 25% above operating speed.
2.3.0 Centrifugal Fans

requirement
2.3.2 Head 20% more than actual

requirement
2.3.3 Speed Max. 1500 rpm
2.3.4 Outdoor temperature 50 deg. C.
2.3.5 Rating Continuous

SECTION-VI
PART-B
2.4.0 Packaged Air-Conditioning Unit
2.4.1 Type Roof top mounting
2.4.2 Service/application Continuous, round the

clock.
2.4.3 Capacity
(i) TR Suitable
(ii) CFM Suitable
2.4.4 Type of compressor Hermetically sealed scroll

compressor
2.4.5 Condenser Air cooled type
2.4.6 Fan Forward curved centrifugal

fan
2.4.7 Filter High efficiency filter
2.4.8 Cooling Coil
(a) Type Direct Expansion
(b) Material Copper
(c) Fins Aluminum mechanically

bonded.
2.4.9 Refrigerant Piping Copper
2.4.10 Insulation for PAC parts Expanded polyethylene of

density at least 15 kg/cub.m.
2.5.0 Filters
2.5.1. Metallic Filters
(1) Max. air velocity 2m/sec.
2.5.2 HDPE filters
(1) Efficiency 90% down to 5 microns
(2) Max. velocity 2.5 m/sec.

SECTION-VI
PART-B
(3) Testing As per BS 2831 / Sqv.
2.5.3 High Efficiency Filter
(1) Efficiency 99% down to 5 microns.
(2) Pr. drop across 10 mm W.C.
(3) Testing As per BS 2831 / Sqv.
2.6.0 Insulation for A/C Ducting Resin Bonded

Mineral wool as per IS:8183
2.6.1 Density 24 kg/cub.m
2.6.2 Thermal conductivity 0.49 mw/cm deg.C

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-11
CHP BUILDING

A 11: CHP BUILDINGS

1.00.00 GENERAL
Various buildings in coal handling plant like transfer houses, crusher house, control
rooms, MCC rooms complete with all associated civil foundations and other civil,
structural and architectural works shall be provided by the Contractor as per the
specification.
Construction/fabrication/erection and designing aspects of various buildings shall be

as per the Civil/Structural specifications.
1.01.00 Codes and Standards
The design and construction of CHP Buildings shall comply with all the currently
applicable statutes, regulations and safety codes in the locality where the equipment
is to be installed. The CHP Buildings shall conform to the latest edition of the Indian
standards and codes. Other internationally acceptable standards/ codes, which
required statutory responsibility. In case of any conflict in the standards and this
specification, the decision in the Employer shall be final and binding.
1.02.00 Design Requirements
1.02.01 All CHP buildings shall have sufficient space to accommodate the entire equipment
like head end, drive unit and tail end of various conveyors, crushers, hoppers,
chutes, control equipments, MCCs, batteries, supports for conveyor bridges,
tensioning arrangements, approach/maintenance platforms with ladders, external /
internal stairs, handrails, RCC floors, foundations etc. Moreover, ample space shall
be provided for maintenance purposes. Outside stairs to transfer points and crusher
house shall be open type. However, a weather canopy shall be provided at the top.
1.02.02 Mechanical Handling arrangements with adequate monorails etc. shall be furnished
for servicing and installation of various housed equipment as described elsewhere.
1.02.03 Building floors shall be washed periodically with water for which necessary slope &
drains shall be provided from each floor leading to minimum 4 nos down comers of
minimum 273mm OD each building. However for MCC, control buildings and pump
houses, minimum 150 mm dia, 4 nos galvanized MS pipes conforming to IS :1239
shall be provided. The system shall be designed considering water mixed with coal.
A drain pit shall be provided near each building to collect water/coal mixture.
Overflow from this pit shall be connected to nearest drain. 1 mtr x 1 mtr size
dust/debris MS chutes from all the floors to ground floor shall be provided at all
buildings/transfer houses and crusher house. The plate thickness shall note be less
than 6mm.
1.02.04 Various dimensions and relative elevations shown in tender drgs. for various
buildings/structures are minimum acceptable to the Employer. However, final

SECTION-VI
COAL HANDLING PLANT PACKAGE CHP BUILDINGS 1 OF 5
PART-B
dimensions for various buildings/structures and relative elevations shall be decided

based on actual details/maintenance requirements of contractor’s equipment to meet
technical specification requirements without any implication to the Employer. The
sizes of these houses shall be approved by the Employer at the stage of detailed
employer.
Openings in the floors of CHP buildings (i.e. TPs/CH etc.) shall be provided with
curb of 100mm high to avoid water falling down to lower floors.
1.02.05 Vertical bracings in transfer points and crusher house shall be provided only along
four sides. No bracing system projecting outside the building shall be allowed.
1.02.06 Floor at ground shall be provided in all transfer points, crusher house, ground
conveyors etc. Level of floor at ground shall be 500 mm above ground/grade level
unless noted otherwise. For enclosed ground conveyor 750mm wide plinth
protection along with drainage arrangement shall be provided along the conveyor on
both sides. Suitable opening at every 50mtr interval shall be provided on either side
in a staggered manner for exit / entry of personals. Necessary drains must be
provided all along the floors of ground conveyor.
1.02.07 The accessories for dust control & miscellaneous system like water pumps etc. shall
be housed in separate pump houses.
1.02.08 For areas where ground floor is located less than 500 mm above ground level/grade
level, outside face of the brickwalls shall be plastered with rich cement-sand mortar
(1:4) with neat cement finishing over it for a height of 500 mm above ground
level/grade level.
1.02.09 Toilet with potable water facilities shall be provided in all MCC Control Rooms,
crusher houses and potable water shall also be provided at all transfer houses,
crusher house, all tripper floors in bunker bay, track hopper top, wagon tippler, the
machinery well areas at the both ends of Track hopper and at pent house.
1.02.10 All associated civil & structural work for the elevator, elevator stairs, platforms at
various landings shall be supplied for crusher house and Transfer Point, where
elevator is provided.
1.02.11 Necessary facilities for ventilation of track hopper, tunnels, underground buildings,
control/MCC rooms, WT control room and Bunker bay shall be provided as specified
elsewhere.
1.02.12 External fire escape stair case alongwith internal staircase(wherever applicable)
shall be provided for all MCC/ control rooms & Crusher house.
1.02.13 5 mtr wide paving beyond the surface drains shall be done around all transfer points,
Crusher house for movement of trucks. The approach for trucks should be provided
around transfer point, crusher house and upto hoist lifting area.
1.02.14 All building shall have the fire protection provisions to meet TAC and IS – 3034
regulations.

SECTION-VI
PART-B
1.03.00 Construction Requirements
1.03.01 Transfer Houses
1.03.02 All overground buildings shall be of steel frame construction.
1.03.03 All underground & partially underground structures shall be entirely in RCC.
1.03.04 External staircases shall be provided for all transfer points.
1.03.05 The transfer houses shall have permanently colour coated steel sheet enclosure
with steel framed doors and louvered windows.
1.04.00 Crusher House
The crusher house shall have permanently colour coated steel sheet enclosure with
steel framed doors and louvered windows.
1.05.00 Control / MCC / WT Rooms
1.05.01 Control rooms, MCC rooms & WT control room shall be of RCC construction with
Brick enclosure. Fire safety wall in/around transformer yards shall be as per detailed
engineering.
1.05.02 MCC/Switchgear rooms shall be kept pressurised with dust free air by way of
pressurized ventilation. Office room and Control Rooms shall be provided with PAC
(Packaged Air Conditioning) units.
1.05.03 Air-conditioned areas of CHP buildings shall have double glass windows.
Roofs/sidewalls shall be provided with insulation to minimise the heat load. All
frames of doors and windows shall be of extruded aluminum and shall be capable of
isolating the conditioned space. All AC Control rooms & MCC rooms shall have
double door entry.

SECTION-VI
PART-B
DATA SHEET : CHP BUILDING
1.0.0 GENERAL
1.1.0 Underground/partially RCC Construction

underground Transfer Houses
1.2.0 Overground Transfer Houses, Steel Construction

Crusher House
1.3.0 Control/MCC rooms RCC construction

REQUIREMENT
2.1.0 Transfer Houses & Crusher House
2.1.1 Space requirement To accommodate all equipments drive

units, head/ tail ends of conveyors
transfer chutes etc. and to provide
adequate space for maintenance.
2.1.2 Floors RCC construction with facility to wash

the floors. Min. slope of 1:80 for floors
in TPs and 1:100 for floors in crusher
house shall be provided towards drain
pipes.
2.1.3 Walls/Enclosure Permanently colour coated cladding
2.1.4 Stairs Steel construction with minimum 1000

mm width.
2.1.5 Doors & Windows Steel construction
2.1.6 Monorails Capacity as per equipment installed
2.1.7 Drainage From each floor to drain pit suitable to

handle coal slurry.
2.1.8 Elevators Necessary space, platforms /

interconnections with the respective
buildings, machine room etc. wherever
applicable.
2.1.9 Vertical bracing Only along four sides.
2.1.10 Maintenance platform with handrails. Chequered plate floors Min.1500 mm

wide

SECTION-VI
PART-B
2.1.11 Flooring 50 mm thick metallic hardener like

ironite floor finish.
2.1.12 Level of ground floor 500 mm above ground level.
2.2.0 Control/MCC/ WT control Rooms
2.2.1 Construction RCC construction with Brick Enclosure
2.2.2 MCC Rooms Pressurised with dust free air
2.2.3 Control Rooms Air conditioned Environment

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-12
VIBRATING SCREENING FEEDER

A-12: VIBRATING SCREENING FEEDER
1.00.00 GENERAL
Vibrating screening feeder shall be provided before each crusher to ensure uniform
feeding of coal to the crusher and separation of (-) 20 mm coal from feed to the
crusher.
1.01.00 CODE & STANDARD
The design, manufacture, inspection and testing of Vibrating screening Feeder shall
locality where the equipment is to be installed. The Vibrating screening Feeder shall
conform to the latest edition of standards and codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance than those
specified, shall also be accepted. Nothing in this specification shall be construed to
relieve the contractor of the required statutory responsibility. In case of any conflict
in the standard and this specification, the decision of the employer shall be final and
binding.
IS:8723 - Dimensions for vibrating conveyors and feeders
1.02.01 The vibrating screening feeder shall be of mechanical type.
1.02.02 The screening feeder shall be capable to segregate the (-) 20 mm size of coal
alongwith coal dust, any muck & muddy coal (which is likely to be encountered
during rainy season) etc. The segregated material shall be directly fed onto the
corresponding belt conveyors/feeders through separate hoppers/chutes provided
under each screening feeder. The width of vibrating screening feeder shall match to
feed the material uniformly over the entire length of crusher rotor without any
deflectors in the feeding chute.
1.02.03 The screening area excluding solid deck area shall be minimum 0.75 m2 per 100
tonnes/hr of incoming feed. Inclination of the screening pan shall be so selected so
as to ensuing proper flow ability of Coal on the deck without any hindrance.
1.02.04 The equipment shall be designed in such a manner that choking does not occur
during operation, particularly during rainy season when the coal gets sticky.
1.03.01 The deck of vibrating screening feeder shall have continuous solid deck section in
the impact zone under direct coal fall and remaining deck shall be fitted with
perforated deck assembly. The solid deck section shall be provided with replaceable

SECTION-VI VIBRATING SCREENING
PART-B FEEDER
tiscral or eqvt. liner plate of adequate thickness. The perforated deck shall be wear
resistant and shall be rigidly fixed with main frame along the length of grizzly deck.
1.03.02 The vibrating screening feeders shall be mounted on the floor with the help of helical
springs made of alloy steel. No rubber/synthetic material for the support shall be
acceptable.
1.03.03 Vibrator bearings shall be grease lubricated, double spherical roller type suitable for
vibrating equipment. The bearings shall be sized for minimum 8,000 hours of
operation.
1.03.04 Suitable sealing arrangement shall be provided between the vibrating structure and
chute work to avoid dust nuisance in the surrounding area.
1.03.05 Proper arrangement to avoid dust ingress into lubricant of eccentric shafts shall be
provided.
1.03.06 Necessary arrangements shall be provided for maintaining / replacing the complete
vibrator assembly.
1.03.07 Marker plate to indicate stroke length and stroke angle shall be mounted.
1.03.08 In case of V- belt drive, suitable arrangement like taper bush or dobicon coupling
shall be provided, to avoid loosening of sheave mounted on eccentric shaft.
1.03.09 Dust hood shall be provided over the deck of screening feeder to avoid dust
nuisance.

PART-B FEEDER
DATA SHEET : VIBRATING SCREENING FEEDER

1.0.0 GENERAL
1.1.0 Functional Requirement Uniform feeding of (+) 20 mm coal

to crushers.
2.1.0 Type Mechanical vibrator
2.2.0 Inclination Suitably selected to ensure proper

flow ability of Coal without any
hinderance.
2.3.0 Pan Size
(a) Screen area Min. 0.75 sq.m per 100 TPH feed
(b) Pan width To match with crusher rotor length

without deflector plates
2.4.0 Performance size on deck Suitable to pass (-) 20 mm coal.
2.5.0 Liners on solid deck
- Type, Material Replaceable, Tiscral or eqvt.
- Thickness 16 mm minimum.
2.6.0 Perforated Deck Assembly
- Material TISCRAL or equivalent
- Construction Perforated deck plate
2.7.0 Support Helical springs only
2.8.0 Bearings
(a) Type Double spherical roller suitable for

vibrating screens.
(b) Lubrication Grease
(c) Life 8,000 hours Min.

PART-B FEEDER
PART - B
SUB-SECTION-IIIA-13
RING GRANULATOR AND VMS

A13: RING GRANULATOR AND VMS

1.00.00 GENERAL
Ring granulator type crusher shall be provided for sizing the input coal to (-) 20 mm
size. Crusher shall be supplied complete with accessories and subsystems.
The design, manufacture, inspection and testing of Coal Crushers shall comply with
all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Coal Crushers shall conform to the
latest edition of standards and codes. Other internationally acceptable
binding.
1.02.01 The crusher shall be of ring granulator type and shall be designed based on
following clauses and the data sheet enclosed.
1.02.02 The crusher design should be such that the crushing action is accompanied by the
minimum of attrition.
1.02.03 Uniform crushing impact shall be assured.
1.02.04 Maximum crushing efficiency shall be obtained, i.e., thermo dynamically, the ratio of
surface energy produced to the kinetic energy expended should be maximum.
Accordingly, the number of central discs along the rotor shaft shall be maximum with
minimum spacing in between.
1.02.05 The crusher shall be capable of delivering the normal rated output even when
handling damp sticky coal having maximum moisture content. No clogging or
building up of material on the crushing element shall develop.
1.02.06 Temperature sensing devices shall be installed on both bearings of each of the
crusher to trip the crusher incase temperature goes beyond limit.
1.03.01 The gap between cage bars/cage screen and the hammers shall be adjustable to
compensate for the normal wear and tear and the mechanism shall be made simpler
for easy operation and maintenance, having separate cage actuating shaft, gear
train and suitable hinge connection.

SECTION-VI RING GRANULATOR
PART-B AND VMS
1.03.02 The drive chain equipment for crusher shall consist of drive motors scoop type fluid
couplings and other couplings. The crushers with its drive chain equipments shall
be mounted on a base plate with necessary accessories, e.g., anchor bolts, coupling
guards etc. The specification of the fluid coupling shall be as discussed elsewhere.
Gear box shall not be used in the drive chain of crushers.
1.03.03 The entire inside surface of crusher coming in contact with coal shall be provided
with abrasion resistant steel liners.
1.03.04 The plummer block shall be of ‘Split Type’ design and shall be fixed with minimum
four numbers of high tensile steel bolt studs of adequate size complete with
adequate locking device and locating arrangement. In addition, the jacking screw
shall be provided for easy lifting of top part of the plummer block. The same shall be
of solid base with flat machined bottom surface all around having maximum contact
on the foundation plate.
1.03.05 Additional support shall be provided to plummer block across the longitudinal axis of
crusher rotor to take care of misalignment against certain jerk, regular vibration etc.,
with simple readjustment facilities. Further, plummer blocks shall be provided with
provisions for installing vibration monitoring equipment.
1.03.06 Necessary locking arrangements shall be provided for suspension bars at both the
ends of rotor assembly to arrest any relative movement of the same. In addition, the
design shall be such that these locking arrangements do not undergo any damage
during normal operation as well as under hammer replacement operation. Two
suspension bars shall be provided in each row to facilitate replacement of broken
hammers without requiring withdrawal of other hammers.
1.03.07 The general arrangement of crusher and the drive equipment shall permit atleast
50% extraction of suspension bars towards the drive end also, besides full extraction
towards non-drive end.
1.03.08 For safety, necessary tramp iron pocket of sturdy design with adequate cover shall
be provided inside the crusher. The bottom of tramp iron pockets shall be of grizzly
or screen type.
1.03.09 Maximum accessibility shall be provided for routine inspection and replacement of
parts. For these purposes, the doors shall be of hinge connection with effective dust
sealing arrangement. Hydraulically operated top cover of crushers shall be provided
for quick inspection and replacement of hammers.
1.03.10 The material for major components of crusher shall not be inferior to the quality and
standards as mentioned in data sheet.
1.04.00 VIBRATION MONITORING SYSTEM FOR COAL CRUSHER
1.04.01 Vibration monitoring system should be offered for crushers as indicative below :

PART-B AND VMS
Sl. Equipment Type No. * No. of Equipment bearing

No location type
per equip.
1. Coal Crusher Radial ring 4 2 As per
one at DE manufacturer's
one at design
NDE
Vibration shall be measured at each location in Horizontal as well as vertical
direction.
1.04.02 Specification of the Vibration Monitoring System

a) Number & type of One (1), Microprocessor based, monitoring system
vibration able to distinguish between high frequency
vibration caused by bearing trouble and low
frequency vibration caused by imbalance.
b) Number of channels 16 (Rack mounted in cabinet)
c) Transducer a) Velocity pick-up or a peizo- electric

accelerometer. Type shall be decided during
detail engineering based on the details of
equipment to be monitored.
b) Light weight stud mounting.
c) Frequency response 1 Hz -10 kHz.
d) Connecting cable Low noise fire proof coaxial cable to be laid in

flexible conduit.
e) Monitors (to be Dual channel monitor for each location alongwith :

located in CHP control
room) a) Buffered signal output and software for
vibration analysis through CHP control desk
HMI.
b) Recorder signal output
f) Display Analogue and digital
g) Alarm 0-100% full scale adjustable.
h) Trip 0-100% full scale adjustable.
i) Test Functional checking from front inhibiting alarm &

trip

PART-B AND VMS
j) Relays 0.25 A at 220 Volts DC or 5 Amp at 240V AC.

Independent potential free contacts for alarm & trip
purpose.
k) Signal Conditioner Individual 4-20 mA DC analogue output.
l) Power Supply 240 V ±10% AC, 50 Hz + 3%, -5%

PART-B AND VMS
DATA SHEET : CRUSHER
1.0.0 GENERAL
1.1.0 Type Ring granulator
1.2.0 Input Coal Parameters As specified elsewhere.
1.2.1 Extent of oversized lumps (occasional) in feed

coal
(a) Maximum percentage 1 to 2%
(b) Maximum lump size 400 mm
1.3.0 Coal Feeding Arrangement Through vibrating screening

feeder (However, the crusher
shall be designed/sized
considering zero passage of
coal through screen).
2.1.0 Number of rows of hammers 4 rows placed at 90deg
2.2.0 Hammer profile Toothed and plain alternately

or only toothed
2.3.0 Weight of each ring hammer Not to exceed 40 Kg.
2.4.0 No. of suspension bars passing through Max. of Two (2) number
each row of ring hammers
2.5.0 No. of holes in each segment of central and end Max. of Three (3) number
discs for suspension bars (for each row of
hammers)
2.6.0 Drive arrangement
2.6.1 Motor rating at 50oC Refer technical specification

elsewhere
2.6.2 Fluid coupling
Type Scoop tube type
2.7.0 Rotor Balancing
2.7.1 Type of balancing reqd. Both static and dynamic

PART-B AND VMS
2.7.2 Grade of balancing Q-16 as per VDI-2060 1966

(However, for purpose of
calculating the unbalanced
force for the design of
machine supporting
structure, balance grade as
given in the relevant section
for foundation design shall be
followed).
2.8.0 Plummer Block
2.8.1 Type of plummer block Split type
2.8.2 Type of sealing Labyrinth, dust tight

arrangement
2.8.3 Type of bearings Spherical roller
2.8.4 Lubrication Manual through grease gun
OR
with recommended grade of
oil in which case the plummer
block shall be designed with
oil filling, oil draining and
visual oil checking facilities
2.9.0 Tramp iron rejection Required for unbreakable

material facility
2.10.0 Output size adjustment facility Desirable
2.11.0 Top cover of crushers Hydraulically operated
3.0.0 MATERIAL OF CONSTRUCTION
3.1.0 Ring Hammers Manganese steel to IS - 276

Gr. III or made of low alloy
(sillico manganese) steel in
forged condition as per
ASTM –A 322 grade 9260
3.2.0 Rotor Shaft ASTM-A668, Class E / C-

45(IS 2004) / E8D, BS
970/1955
3.3.0 Suspension bars ASTM-A322, Grade AISI

4140 / EN-24, Bright bar

PART-B AND VMS
3.4.0 Cage bars/cage screens and side screen plates Manganese Steel (IS:276) /
3.5.0 Rotor Discs ASTM-A108, AISI 1045
3.6.0 Breaker plate Manganese steel IS-276 Gr.

III min. 40mm thick
3.7.0 Liners
(a) Material Material composition shall be

as that of breaker plate
above
(b) Thickness 20 mm minimum.

PART-B AND VMS
PART - B
SUB-SECTION-IIIA-14
TRAVELLING TRIPPER & BUNKER

SEALING ARRANGEMENT

A14: TRAVELLING TRIPPER AND BUNKER SEALING ARRANGEMENT
1.00.00 GENERAL
Mobile Trippers on bunker conveyors along with belt sealing arrangement shall be
furnished and erected complete with rails, including necessary supporting structures,
approach/ maintenance platforms with ladders and hand railings, trailing cables, all
electricals including machine mounted local control panel & control panel on one end
of Bunker, location of which shall be decided during detail engineering.
Complete Bunker Sealing arrangement shall be provided over the bunkers to

prevent dust emission into tripper bay.
The design, manufacture, inspection and testing of Mobile Tripper & Bunker Sealing
Arrangement shall comply with all the currently applicable statutes, regulations and
safety codes in the locality where the equipment is to be installed. The Mobile
Tripper & Bunker Sealing Arrangement shall conform to the latest edition of
standards and codes. Other internationally acceptable standards/codes, which
1.02.01 Mobile Tripper
1.02.02 The Mobile tripper on bunker conveyors shall be motor driven type. It shall consist
of structures, supports, walkways, rails, belt scrapper with adjustable rubber strip,
rubber lagged head and bend pulleys complete with shaft bearings, chutes, stops,
limit switches, brakes etc. The tripper shall have provision for dropping coal from
conveyor onto one side of tripper to the bunker or back to the conveyor for the
purpose of skipping intermediate bunkers. The rating of tripper travel motor shall be
adequate to move the tripper smoothly either in same or opposite direction to belt
direction under fully loaded conditions. Adhesive weight requirement and tractive
effort calculations shall be subject to approval of Employer. Coefficient of adhesion
shall be considered as maximum 0.15. Minimum two drive axles shall be provided
for tripper travel. Arrangement shall be provided at the starting point of the tripper to
avoid folding of belt.
In case of tripper running at a speed more than its rated speed due to chute jamming
or other reason, conveyor shall trip and annunciation shall appear.
1.02.03 Supply of adequate length of rails to cover the runway length for the motor driven
tripper shall be included. The supporting structures for the rails with necessary end

STAGE-II (2X195 MW) TRAVELLING TRIPPER PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE AND BUNKER SEALING 1 OF 4
PART-B
BID DOCUMENT NO. : CS-0350-155(R)-2 ARRANGEMENT
stops shall also be supplied under this specification. Suitable belt hold down guide
pulley shall be provided over the concave curve of belt over tripper.
1.02.04 The Contractor shall include in his proposal necessary electricals for traveling
trippers. One cable reeling drum alongwith adequate length of trailing cables (power
& control) shall be supplied for each of the traveling tipplers. Alternatively, drag chain
arrangement may be provided for trailing cables (power & control) for each traveling
tippler. Three (3) pairs of control cables shall be provided the control trailing cable of
each machine for connecting Employer’s telephone & PA equipment to be provided
on each machine. Isolating switch to isolate the power supply to the machines shall
be provided in each power JBs to be located at the centre of travel length.
1.02.05 The travelling trippers shall be provided with fail safe A.C. thruster operated brake of
totally enclosed type which shall engage as soon as tripper travel motor stops. A.C.
thruster operated rail clamps alongwith manual Rail clamps on both side of the
tripper shall also be provided. The specifications of brakes and clamps are as
discussed elsewhere.
1.02.06 For selection and specification of drive motor, gearboxes, pulleys belt cleaners and
all other equipment associated with tripper & Bunker sealing arrangement relevant
sections of this specification shall be referred to. Independent motorized linear
actuator shall be provided to operate each flap gate of the tripper chute.
1.02.07 Monorail & electric hoist shall be provided for lifting conveyor drum to bunker floors.
Monorail all along the tripper travel length to facilitate maintenance of tripper shall be
provided.
1.02.08 Bunker sealing arrangement
1.02.09 The sealing belt shall be of suitable grade (minimum 2 plies) with 5 mm x 5 mm
covers (fire resistant) in line with other conveyor belting. The belt shall rest on
12mm thick MS gratings of mesh size 180mmx175mm placed 50 mm below floor
level, provided over the bunker slot on tripper floor for tripper conveyor. Necessary
guide rollers, bearings, brackets, safety guards etc. shall be provided by the
Contractor. The bunker sealing arrangement shall keep the bunkers sealed and
prevent dust emission into tripper floor. The width of the bunker seal belt shall be at
least 100 mm more than the bunker slot opening.
1.03.02 Suitable dust cover shall be provided over tripper head pulley. Serrated rubber seal
shall be provided at open side to prevent dust nuisance. Suitable dust tight access
doors shall be provided. Spring loaded scraper type belt cleaner shall be provided
below the tripper head pulley for cleaning the carrying side of the belt.
1.03.03 The tripper shall run on rails (90 lbs/yard) with double flanged wheels. Rails for
tripper travel shall be mounted on supporting structure of respective conveyors.
SECTION-VI
PART-B
1.03.04 Suitable system having encoders for monitoring position of tripper in DCS shall be
provided. In addition, travel end limit switches and end stops shall also be provided.
1.03.05 Suitable access platform of chequered plate with ladders, handrailing and walkways
on both sides shall be provided for access/maintenance of equipment on tripper. In
addition, crossover platform shall be provided with tripper so that operator can cross
the belt through the same.
1.03.06 Suitable rail cleaners shall be provided on leading and trailing edge of tripper for
either track.
1.03.07 3mm deck plate continuous shall be provided below carrying idlers on the trippers.
1.03.08 For specification of flap gates/actuator on trippers relevant clauses of this

specification shall be referred to.
1.03.09 Tripper shall be operated as elaborated elsewhere.
1.03.10 Provision shall be kept for automatic tripping of bunker bay conveyor in the event of
travelling tripper getting dragged (i.e. travel speed in excess of rated speed)
1.03.11 The operating controls of the tripper shall be mounted at an height, easily accessible
from bunker floor.

SECTION-VI
PART-B
DATA SHEET ; TRAVELLING TRIPPER

1.0.0 GENERAL
1.1.0 Mobile Tripper Motor driven type rail mounted.
1.2.0 Bunker Sealing Arrangement Sealing belt type.
2.1.1 Mounting Rail mounted on rails (90 lbs/yard) with

double flanged wheels.
2.1.2 Drive Motor driven with suitable gearbox.

Suitable for minimum 60 starts/hours.
2.1.3 Pulleys
(a) Head & Bend Pulleys As specified elsewhere
2.1.4 Brakes AC operated electro hydraulic thrustor

type on either side of tripper.
2.1.5 Clamps Manual Rail clamps on either side of

tripper.
2.1.6 Walkways Both sides of tripper, 800 mm wide

each
2.2.0 Bunker Sealing Arrangement
2.2.1 Sealing Belt
(a) No. of plies Minimum two
(b) Top/Bottom cover Thickness 5 mm/5 mm (Fire Resistant)
(c) Width Atleast 100 mm more than bunker slot.
2.2.2 Guide Rollers As per requirements.
2.2.3 Bunker Slot
(a) Width As per tender drawing
(b) Cross bars over the slot opening 16 mm x 50mm MS plates

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-15
INLINE MAGNETIC SEPARATOR AND

SUSPENDED MAGNET

A15: IN-LINE MAGNETIC SEPARATOR AND SUSPENDED MAGNET
1.00.00 GENERAL
Inline Magnetic Separators shall be provided for continuous and automatic extraction
and discharge of tramp magnetic pieces from coal being discharged from conveyors
as specified. The sets shall be complete in all respects with drives, magnets, inline
belts, hoppers, chutes, tramp-iron boxes and all electrical ancillaries like control
panels etc. Suspended Magnetic Separator shall be provided for picking up tramp
magnetic pieces buried under coal from moving coal over Conveyor as specified.
1.01.00 CODES & STANDARD
The design, manufacture, inspection and testing of In line Magnetic Separators shall
comply with all the currently applicable statutes, regulations and safety codes in The
Magnetic Separators shall conform to the latest edition of standards and codes.
Other internationally acceptable standards/codes, which ensure equal or higher
1.02.01 Inline Magnetic Separator / Suspended Magnet
1.02.02 Magnet core material shall be pure annealed iron or equivalent high permeability
magnetic material. The coil shall be of aluminum wire with class ‘H’ insulation, to
limit the absolute temperature of the winding to 140 deg. centigrade. The oil used for
cooling the ILMS and SM shall be silicon based.
1.02.03 The ‘Force Index’ i.e. the product of flux density in gauss and rate of change of flux
density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000
(gauss x gauss/inch) minimum in hot condition for mounting height of 450mm in the
conveyors carrying uncrushed coal & 400 mm in the conveyors carrying crushed
coal. However, the strength of the magnet shall not be less than 1000 gauss in hot
running condition at distance of 450mm in the conveyors carrying uncrushed coal &
400 mm in the conveyors carrying crushed coal. The minimum strength of the
magnet shall be 1000 gauss at the specified mounting height at the centre of Belt
width. Contractor shall select magnet width to suit above.
Mounting height of 450mm in the conveyors carrying uncrushed coal & 400 mm in
the conveyors carrying crushed coal shall be taken between top of conveyor belt or
bottom of falling material trajectory and the surface of magnetic separator belt.
Characteristic curve of magnet with the value of flux density varying between 50 mm
to face of conveyor belt shall be provided. The cross section of magnet shall be
suitably designed to provide sufficient area for magnetising the coil effectively

STAGE-II (2X195 MW) IN LINE MAGNETIC PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE SEPERATOR AND 1 OF 4
PART-B
BID DOCUMENT NO. : CS-0350-155(R)-2 SUSPENDED MAGNET
covering full cross section of the discharge material. The magnetic separator shall
be located such that it picks-up tramp iron from coal trajectory after it has been
discharged from head pulley.
1.02.04 The tramp magnetic pieces buried under coal picked up by the magnetic separator
shall be discharged suitably to ensure that it falls into the tramp iron chute, which
shall be provided upto ground level. All conveyors with magnetic separator at head
end shall have non-magnetic SS pulleys. Head pulleys of all conveyors with in line
magnetic separator at head end shall be provided with SS shell and end disc.
However, hub and shaft shall be of same materials as in other pulleys. (EN-8 or
equivalent).
1.02.05 The motor and the gear reduction unit for driving the in-line belt shall be adequately
sized with minimum 20% margin to avoid any over loading during operation.
Suitable zero speed switch shall be provided. No Chain/belt drives shall be
accepted.
1.02.06 The belt shall be designed to withstand high temperature at the bottom of the
magnet and any serious damage due to the impact of the sharp edges of the tramp
iron. The belt shall be provided with rubber cleats spaced suitably. The belt shall be
of fire resistant grade. For other details of belt, refer belt specification as specified
else where. Side rollers shall be provided to keep the belt aligned.
1.02.07 The idlers and the pulleys supporting the belt shall be manufactured to the best
engineering practices and shall conform to relevant Indian Standards. For details of
idlers & pulleys, refer specification as specified else where.
1.03.01 In-line Magnetic separator / Suspended Magnet
1.03.02 The magnetic separator units shall be supported by suitable structural member from
the top by taking support from the operating floor beams with turn buckle
arrangement to facilitate the necessary adjustments during operation. Further,
electric Hoists operated cross travel arrangement shall be provided to move, each of
the magnetic separator individually, away to facilitate maintenance of the conveyor
discharge pulley/Belt.
1.03.03 ON/OFF control push buttons with indicating lamps shall be provided at the local
station. The materials of chutes and hoppers associated with magnetic separators
above the drive floor shall be SS-304 in the magnetic zone. Other chutes shall be of
1 mtr. sq. dimension and shall be made of MS. chutes shall have poking doors at all
floors to clear jammed material.
1.03.04 Suitable arrangements shall be provided in the magnet for keeping the coil of the
magnet dry from atmospheric condensation when the magnetic separator is not in
use.
1.03.05 Protection against high oil temperature in magnet shall be provided.

SECTION-VI
PART-B
DATA SHEET : ILMS/SM
1.0.0 GENERAL
1.1.0 Type In line or suspended magnet

type as specified.
2.1.0 In-line Magnetic Separator / Suspended Magnet
2.1.1 (a) Location of ILMS Over discharge pulley.
(b) Location of SM Over Conveyor (as per

tender drawing)
2.1.2 Force index (As defined earlier) Minimum 100,000
2.1.3 Strength of magnet at the specified mounting 1000 gauss.

height
2.1.4 Mounting height Mounting height of In Line

Magnetic Separator and
Suspended Magnet shall be
450mm in the conveyors
carrying uncrushed coal &
400 mm in the conveyors
carrying crushed coal
(between top of conveyor
belt & surface of magnetic
separator)
2.1.5 Magnetic Separator Belt
(i) Drive Unit Adequately sized with 20%

margin.
(ii) Belting Suitable to withstand high

temp. & impact of tramp iron.
(FR Grade)
(iii) Discharge Into Tramp iron chute.
2.2.0 Tramp Iron Items
(i) MS cube of 20 mm size

SECTION-VI
PART-B
(ii) Brake shoe of Railway Wagon (Cast Iron

15 Kg.)
(iii) MS plate of 250 x 250 x 100 mm size.
(iv) Shovel Teeth and spikes.
Material Carbon Steel
Size Typical
(v) MS round bar of 50 Kg with L/D ratio not

exceeding 5.
2.3.0 Control
Inline Magnetic Separator / Suspended Magnet Local and remote
2.4.0 Electric Supply 415V, 3 phase, 50 Hz input Silicon Rectifier units
2.5.0 Location of silicon rectifier unit Nearby control/MCC room
2.6.0 Handling Arrangement for inline Magnetic

separator/Suspended magnet
(a) Height adjustment With turn buckle arrangement
(b) Cross-travel Electric Hoist operated cross

travel facility.

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-16
METAL DETECTOR

A16: METAL DETECTOR
1.00.00 GENERAL
Metal detectors shall be provided at specified location to detect metallic objects in

the coal stream.
The design, manufacture, inspection and testing of Metal Detectors shall comply
where the equipment is to be installed. The Metal Detectors shall conform to the
binding.
1.02.01 Metal detectors shall have high reliability with enough sensitivity to detect 25mm
aluminum sphere below the burden of coal in case of synthetic belting. However, for
steel cord belting the sensitivity shall be 35mm. It shall also detect other metals, like
brass, copper, stainless steel, manganese steel, bars, scraps etc.
1.02.02 The equipment shall have provision for automatic static calibration with adjustable
sensitivity.
1.02.03 Metal detectors shall be completely solid state using latest state of art technology. It
shall be suitable for 50°C ambient and RH of 100%. The search sensor shall be
protected from rain and direct sunlight by means of a non metallic covering other
than wood. Control unit shall have adjustable controls for sensitivity, ON/OFF push
buttons, resettable operation counter, audio-visual alarms local remote selector
switch and all other necessary controls for trouble free operation of metal detector. It
shall be suitable for mounting on wall, column, structure etc. with IP-65 Degree of
protection. It shall be constructed from FRP of thickness not less than 2mm.
1.02.04 The metal detectors shall also have the following features :
(a.) The coils shall be protected against being struck by an oversized material/coal.
The coils should have adjustment for magnetite/iron in incoming coal. It should
ignore magnetite/iron and shall distinguish between metal pieces and
magnetite/iron.

SECTION-VI
COAL HANDLING PLANT PACKAGE METAL DETECTOR 1 OF 3
PART-B
(b.) In order to counteract interference from external sources such as motors,

lightning and radio-transmitters, and to nullify the effect of climate
changes/aging, dual receiver coils are to be used.
(c.) In order to allow passing of steel cord belt and metal belt fasteners without
giving alarm and at the same time detecting tramps, suitable arrangements
shall be provided.
(d.) In case a few non-magnetic idlers or non magnetic deck plates are required,
the Contractor shall provide these. However, these shall be metallic. Wood is
not to be used.
(e.) LED display of COAST COUNT to indicate the number of pieces of tramp iron
detected since last reset shall be provided so that the operator is alerted for the
pieces of tramps, if any, between tramp marker and coil before restoring
conveyor.
(f.) TOTAL COUNT, which is not resettable, shall also be provided on the same
LED display on demand.
(g.) The location of tramp metal pieces shall be indicated by sand bag marker.
1.03.00 CONSTRUCTION REQURIEMENT
1.03.01 Fiber glass enclosure (with IP 65 degree of protection) shall be provided for all type
of coils.
1.03.02 Sand bag markers shall be provided.
1.03.03 Local control panel shall be provided with IP:65 degree of protection.

SECTION-VI
PART-B
DATA SHEET : METAL DETECTOR
1.0.0 GENERAL
1.1.0 Type Coil type
2.1.0 Sensitivity - 25 mm aluminum sphere

below coal for synthetic
belting.
- 35mm Aluminum sphere

below coal for steel cord
belting.
2.2.0 Enclosure Fiber glass
2.3.0 Control Through local control panel.
2.4.0 Calibration Provision for automatic static

calibration with adjustable
sensitivity.

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-17
COAL SAMPLING UNIT

A17: COAL SAMPLING UNIT
1.00.00 GENERAL
a) Coal Sampling Unit shall be complete with necessary samplers, crushers,

flap valves, chutes, hoppers, belt feeders and sample collectors etc. to give
samples from any of the two streams running at guaranteed capacity.
b) Bidder shall source coal sampling system from a manufacturer / supplier who
has engineered and supplied two (2) numbers of coal sampling systems for
sampling coal / other bulk mineral from conveyor of 1000 MTPH and above
and working successfully for two years as on date of techno-commercial bid
opening.
The design, manufacture, inspection and testing of Coal Sampling Unit shall comply
where the equipment is to be installed. The Coal Sampling Unit shall conform to the
binding.
ASTM-D-2234 :Standard Methods for collection of a Gross Sample of Coal.
ASTM-D-2013 :Standard Method of Preparing Coal Samples for Analysis.
1.02.01 Coal sampling unit shall be automatic & provided at place specified elsewhere.
1.02.02 The coal sampling units suitable to give “Samples” conforming to ASTM-D-2234
shall be selected by the Contractor for taking samples from any of the two streams
running at guaranteed capacity. The different Equipment selected for coal sampling
unit shall be such that there shall be no loss of fines and moisture from the samples.
The capacity, make and model of all equipments of coal sampling unit shall be
subject to approval of the Emplyer.
1.02.03 The normal input feed size shall be considered as (-) 250 mm for coal sampling unit
before coal crusher. However occasionally (-) 400 mm lumps may also arrive. Coal
lump size after crusher (as fired coal) shall be (-) 20mm. However occasionally (-) 50
mm lumps may also arrive in as fired coal.

SECTION-VI
COAL HANDLING PLANT PACKAGE COAL SAMPLING UNIT 1 OF 4
PART-B
1.02.04 Primary samplers (separate for each conveyor) shall be rugged, able to withstand
severe shock loads and operate trouble free.
1.02.05 Belt feeders shall be provided for entire sampling path upto sample collector. The
feeders shall meter the flow accurately, produce a non-plugging condition and resist
sticky and wet coal.
For rejects path also, belt feeders shall be preferred. Screw conveyors for the same
shall be accepted only where space constraints do not permit distribution of coal
rejects to receiving conveyors below.
1.02.06 Sample crushers (make subject to Employer’s approval) shall be provided for
reducing the main input feed coal to 95% minus 8 mesh size and 100% minus 4
mesh size. Single stage crushing shall be provided. There should be no re-
circulation of fines in the crushers.
1.02.07 ‘Lot size’ shall be equivalent coal quantity handled in 8 hours operation assuming
average conveyor loading at 75% of rated conveyor capacity. However sampling
system shall also be suitable for taking one gross sample for each lot of “3500 Te”
coal (approx. equal to one rake load).
1.03.01 The traversing mechanism and all electric parts shall have dust tight protection.
1.03.02 Belt feeders shall be positively self cleaning and have dust tight construction. It shall
be provided with flanged belt, rubber lagged head pulleys and inspection doors. No
chain/belt drives shall be accepted.
1.03.03 The crusher’s base should be built of reinforced concrete and be sufficiently large in
mass.
1.03.04 The primary / secondary samplers shall be of dust tight construction and self
contained type.
1.03.05 The sample chutes shall have minimum valley angle of 60 degrees to horizontal and
shall be of stainless steel plates. The chutes shall be suitable to handle wet sticky
coal as specified elsewhere. The welding of chutes shall be done externally only.
The inside surface of the material near welds shall be smooth. Radius at corners not
less than 1" shall be provided in chutework. All solid connected members shall be by
means of bolting flanges with atleast 6 mm thick standard grade neoprene gasket
material between the metal flanges. No control gates to regulate the flow of material
shall be incorporated in the chute work.
1.03.06 Bias connections shall be provided at suitable locations. The materials rejected from
samplers shall be returned to main conveyor stream.

SECTION-VI
PART-B
1.03.07 Minimum 4 nos. sample collecting bins shall be provided with auto indexing. The
bins shall be provided with air tight connection.
1.03.08 The system shall be suitable for operation through Employer’s DCS/DDCMIS.

SECTION-VI
PART-B
DATA SHEET : COAL SAMPLING UNIT
1.0.0 GENERAL
1.1.0 Type Automatic
2.1.0 Codes & Standard ASTM D-2234
2.2.0 Uncrushed feed coal size (-) 250 mm
2.3.0 Crushed feed coal size (-) 20 mm
3.0.0 CHUTES
3.3.1 Min. angle 60 deg
3.3.2 Cross section Square/rectangular with

rounded corners.
3.3.3 Joints Bolted flanges with 6 mm

thick standard grade
neoprene gasket.
4.0.0 CRUSHER
4.4.1 Uncrushed (as received) feed coal size (-) 250 mm
4.4.2 Crushed (as fired) feed coal size (-) 20 mm
4.4.3 Output size ASTM D-2234
4.4.3 Stages of size reduction Single stage crushing
5.0.0 BELT FEEDER
5.5.1 Belt Flanged type, FR grade
5.5.2 Pulleys Rubber lagged head pulley
5.5.3 Drive Electric Motor

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-18
ELEVATOR

A18: ELEVATOR
1.00.00 GENERAL
This specification is intended to cover design, engineering, supply, erection, testing

and commissioning of the complete Rack & Pinion type Elevators as specified
hereinafter complete in all respects and adequate for safe, efficient and trouble free
operation of the elevator.
1.01.00 CODES AND STANDARD
The design, manufacture, inspection and testing of Elevator shall comply with all the
currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The Elevator shall conform to the latest edition of
standards and codes. Other internationally acceptable standards/ codes, which
1.02.00 DESIGN AND CONSTRUCTION REQUIREMENTS
1.02.01 GENERAL
1.02.02 This section covers the design, engineering, fabrication, installation, commissioning
and testing of the rack and pinion type vertical lift elevator including required
enclosures, hoist, mast and guide rail, cab drive unit machinery buffers, power cable,
control cable, mechanical and electrical equipment. The design of the elevator shall
be in such a way that the elevator operation will be safe at all times.
1.02.03 Elevator shall be located as indicated in the relevant tender drawings and shall be
capable of operating from the ground floor to the top interior platform with
intermediate stops at all interior platforms.
1.02.04 All mechanical and electrical operating devices and Trailing cable shall be designed
for outdoor operation with dusty and high humidity conditions and shall operate
equally well in any ambient temperature as per project synopsis. Additionally, all
mechanical and electrical components of the elevator shall be designed to withstand
a temperature of 50°C ambient.
1.02.05 ENCLOSURES
A three-sided enclosure with one access door shall be provided for ground landing.
At each platform landing above ground level, a one sided enclosure with access
door shall be provided. Enclosures shall be fabricated from tubular steel and/or
other structural shapes expanded metal or wire mesh of suitable height and primer
coated with one coat of the manufacturer’s standard primer and finish paint. The
ground landing shall be provided at a suitable height above the foundation slab to
ensure a safety space underneath the cage. The space under the landing shall be
surrounded by foundation enclosure. The staircase shall be provided for access to

SECTION-VI
COAL HANDLING PLANT PACKAGE ELEVATOR 1 OF 7
PART-B
the cage. Enclosure access doors shall be electrically and mechanically interlocked
so that they remain closed and locked except when the cab is at a landing. Doors
shall be bi-parting and swinging type.
Base of the three-sided enclosure shall be securely anchored to the ground level
floor slab using expansion type anchors.
1.02.06 Mast
Mast shall be provided in sections of suitable length, consisting of tubular sections

and/or structural shapes welded together to form a framework to which the rack is
bolted. Mast shall be securely anchored to the building structure.
1.02.07 Cab
1.02.08 Cab frame shall be fabricated from tubular steel and/or other structural shapes
enclosed with expanded metal or wire mesh.
1.02.09 Cab floor shall be of 6 mm thick Aluminum chequered plate or approved equivalent.
Cab shall be attached to a framed structure and form an integral part with the drive
mechanism located atop the cab.
1.02.10 Framed structure shall include guide rollers and safety hooks to ensure positive
engagement of the rack and pinion to prevent cab disengagement in case of roller
failure.
1.02.11 Cab roof shall be provided with an escape hatch electrically interlocked with the
hoist control system. Tubular steel handrail shall enclose the cab roof for
maintenance operations.
1.02.12 Cab door and landing level enclosure doors shall be electrically and mechanically
interlocked to prevent the cab from being operated unless the cab door and landing
level enclosure doors are fully closed and to prevent the doors from being opened
while the cab is in motion.
1.02.13 One cabin fan and two recessed fluorescent lamps along with the fittings to be
provided with one no. emergency light with battery & battery charger.
1.03.00 Drive Unit & Safety Device
1.03.01 Drive unit located on the cab shall be complete with AC squirrel cage induction
motor, reduction gear, drive pinion and an over-speed governor. Drive unit shall
incorporate an electric disc brake and an external manual brake release. The brake
on the electric motor will be self adjusting type. In case of the power failure, the
brake will be automatically applied & will stop the cab. A hand lever, which can be
operated from the cage, is to be provided to enable the occupants to ease the brake
and lower the cage to the bottom level. Motor shall be connected to a reduction
gear, which drives the pinion.

SECTION-VI
PART-B
1.03.02 An over-speed governor must be incorporated to protect the cab against over speed
during the cab downward motion. At a predetermined speed higher than normal, the
brake, mechanism shall be actuated and stop the downward motion of the cab
gradually. The brake should remain locked on following this action and has to be
manually reset before normal elevator operation can be resumed.
1.03.03 A remote control shall be provided for testing the safety device. The Contractor shall
ensure that no individual is in cab during the test.
1.03.04 The drive system shall be designed so that it will be capable to operate smoothly
without any tendency to rock or judder with all vertical, horizontal forces as well as
the moments through the rack.
1.03.05 Suitable arrangement shall be provided to bring the cage safely to the ground by
gravity in the event of power failure.
1.04.00 Buffers
Sufficient no. of buffers of spring loaded/hydraulic type shall be fitted below the cab.
The buffer shall be capable of stopping the cab without permanent damage or
deformation to themselves or any other part of the equipment. The no. of buffers
shall be fixed as to ensure proper sharing of impact loads by all of them.
1.05.00 Power Supply

Two in comers (one from Bus-A and one from Bus-B of the MCC) for the power
supply to each elevator shall be provided with castle key interlock.
1.06.00 Power and Control Cabinets
All electrical components furnished with the elevator shall be completely wired,
energised and checked.
All electrical control devices shall be in enclosures. Equipment furnished shall also
include the following :
(a.) Momentary contact push button for raise/lower control.
(b.) Reversing combination motor starter with a three phase thermal overload relay
for motor protection. However, the control circuit in the elevator will have
miniature circuit breakers.
(c.) Electric and mechanical interlocks on cab access door and landing level
enclosure doors.
(d.) An ultimate three phase over travel limit switch which cuts off power and
control supply in case of over travel. The switch can also be manually turned
to off position.
(e.) Safety device as mentioned elsewhere in this specification.

SECTION-VI
PART-B
(f.) An alarm push button shall be provided in the cage. Alarm signal will be
transferred to the auxiliary panel at elevator base.
The auxiliary panel at the base will have battery and battery charger for the
alarm horn. Potential free contracts for remote alarm shall also be provided.
(g.) Reverse phase relay connected to prevent operation of the cab with improper
phase rotation or failure in any phase in the power supply.
(h.) The cable shall be supported by brackets on the cage and guide rails. A cable
trolley will keep it in tension and will be guided on the same rail as the cage.
The trailing cable shall run through cable guides.
(i.) One auxiliary panel shall be furnished and mounted on the ground level
enclosure. Panel shall be in enclosure equipped with a main “ON-OFF” switch,
main Contractor, relays, control transformer and MCB’s, terminal blocks, and
all other accessories required for normal operation of the elevator.
(j.) One main control panel shall be furnished and mounted on the top of cab.
Panel shall be in enclosure equipped with necessary equipment like rectifier,
battery, battery charger, contactors, breakers, control transformer and MCB’s,
thermal overload relays and all other equipment and accessories required for
normal operation of the elevator.
(k.) Cab shall be controlled by a semiautomatic control system with push buttons
for ‘UP’ ‘Down’ and ‘Stop next landing’. The cab shall be controlled from inside
and shall have painted placard located above the door. Cab shall be furnished
with emergency alarm push button, limit switches, and all other necessary
control devices required to ensure safe and continuous cab operation, One
trailing cable shall connect the cab main control panel to the auxiliary panel at
ground level to supply the cab with all power requirements. An extra core of
equal size shall be provided for earthing of cab. Cable guides shall be installed
every 6 meters to avoid entanglement of this cable.
(l.) Each landing assembly shall include a limit switch and push button control
station installed and wired to a landing junction box.
(m.) All enclosures containing electrical, devices shall be provided with 240 Volts,
single phase space heaters with adjustable thermostat control.
(n.) Cab shall be equipped with a 220 Volts, 20W fluorescent lights, fan, 5A, 220V,
3 pin receptacle, emergency light, battery & battery charger.
(o.) Control cabinets shall be sheet steel enclosed dust, weather and vermin proof.
Sheet steel used shall be cold rolled and at least 2.0 mm thick. Degree of
protection of control cabinet shall be as per relevant electrical section. Control
cabinet shall be provided with hinged doors (s) with pad locking arrangements.
All doors, removable covers and plates shall be gasketted all round with
neoprene gaskets.
(p.) Each motor to be controlled from the control cabinet shall be provided with 3-
pole isolating switch. HRC fuses, contactors shall be of AC4 duty class with
SECTION-VI
PART-B
thermal overload relays with single phase preventer. The isolating switch and
contactor shall be rated at least 20% more than the connected motor full load
current. The controller and resistor for motor shall confirm to relevant IS and
shall be continuously rated for 150% full load current of the motor.
(q.) All fuses shall be of the HRC cartridge type mounted on plug in type of fuse
base having a prospective current rating of not less than 80 kA.
(r.) All push buttons shall have 2NO and 2NC self reset contacts.
1.07.00 Electric Motor
Elevator drive motor shall be squirrel-cage induction type designed and

manufactured to conform to the requirements of this specification.
Motor shall be designed for operation at the required speed, 415Volts, 3 phase, 50
hertz, and shall be suitable for full voltage starting, frequent starting S3 duty class as
per IS:4722 with CDF of 25% and maximum number of starts 120/hour at 50°C
ambient temperature.
Motor nameplate kW ratings shall not exceed when the equipment is operating
within the limits of the maximum load requirements. Motor shall have class “F” non-
hygroscopic insulation with temp. rise limited to Class B (IS:325),
Motor shall be totally enclosed and furnished with cast iron or Al alloy frame,
brackets, gaskets conduit box & fan cover. Motor shall be furnished with grease pre
lubricated, double-shielded, anti-friction bearing having life rating of not less than
42,500 hours under coupled service requirements. All exposed metal surfaces shall
be protected with a polyester paint or coating which is moisture & corrosion
resistant.
Motor shall be provided with internal 220 Volt AC single-phase space heaters or an
alternate heating system to prevent condensation within the motor during extended
periods of idleness.
Motor and driven equipment shall be direct coupled and mounted on a common
baseplate.
1.08.00 CABLES
Insulated armoured power /control cable shall be FRLS - HR insulated, stranded

copper / aluminum conductors and shall be provided in accordance with IS:1753
(latest edition) and IS:1554 (Part-I) (latest edition).
Trailing cables in the elevator shaft should be specially designed for the specific
service and shall conform to IS. Trailing cables shall be EPR insulated for 1.1 kV
and shall be neoprene jacketed flexible cord.
Conductor accessories including terminal materials like glands, lugs etc. markers,
tying materials, and cable supports shall be furnished and installed.

SECTION-VI
PART-B
1.09.00 Earthing
(a.) GENERAL
Complete earthing system shall be furnished for all equipments and

accessories of the elevator as per relevant IS.
(b.) MATERIALS
The earthing of all electrical items being supplied by the Contractor shall be in
his scope. For earthing the various equipment, conductor sizes shall be as
listed below :
(1.) Motor above 5 kW upto 30 kW 25x6 mm2 GI flat
(2.) Motors upto 5 KW and misc. small item like conduits,
junction boxes etc. 8 SWG GI wire

(3.) Cab earthing Additional core of trailing cable
The earthing strip/wire shall be connected to the earthing mat by the Contractor.
Clamps and other hardware of iron or steel used with the grounding system shall be
hot-dip galvanised. Bolts, washers, and nuts shall be hot-dip galvanised steel.

SECTION-VI
PART-B
DATA SHEET : ELEVATOR
1.0.0 GENERAL
1.1.0 Type of Service Passenger-Cum-Goods
2.1.0 Carrying capacity 1000 Kg
2.2.0 Rated speed Approx 25 - 40 mtrs / min.
2.3.0 Total Travel Shall be as per actual

dimension of the Building
2.4.0 No. of floors to be served As per requirement
2.5.0 Entrance As per requirement
2.6.0 Min. cab Floor size (inside) WxLxH 1.3m x 2.0m x 2.1 m
2.7.0 Various heights of landing floors to be served Suitable for working floors as
indicated in the tender
drawing.
2.8.0 Drive Motors (AC) One (1) No.
2.9.0 Cab Flooring 6 mm thk. Al. Chequered

plate.

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-19
STACKER CUM RECLAIMER

A-19: STACKER CUM RECLAIMER
1.00.00 GENERAL
1.01.00 Travelling Stacker cum Reclaimer
1.01.01 Travelling stacker cum reclaimer operating in conjunction with yard conveyor shall
be provided as specified. Stacker-cum-Reclaimers shall be capable of both stacking
and reclaiming complete with adequate length of rail track, and its foundation,
cantilever boom conveyor, boom hoist, reclaimer bucket wheel, control panel,
operators cabin, electrical power distribution system, motorised cable reeling drum,
adequate length of trailing cables etc.
2.00.00 CODES & STANDARDS
The design, manufacture, inspection and testing of Stacker cum Reclaimer shall
locality where the equipment is to be installed. The Stacker cum Relaimer shall
conform to the latest edition of the following standards and codes. Other
decision of the Engineer-in-Charge shall be final and binding.
ISO 5049/1 : Mobile Continuous Bulk Handling Equipment.
FEM : Federation Europeanne De La Manutention Section-I-Rules for

Design of Hoisting Appliances.
3.00.00 DESIGN REQUIREMENTS
3.01.00 The design average capacities shall be not less than 110% of rated(guaranteed)
capacities as specified elsewhere for both stacking and reclaiming. The continuous
motor rating at 50oC of the drive motor to be provided on each side of the yard
conveyor shall be 120% of the actual power requirement at motor output shaft.
3.02.00 Stacker/Reclaimer shall be capable of operating at high wind velocities upto 65

km/hr. It shall also be able to withstand maximum wind velocity as indicated in
Project Synopsis, when it is not operating. A suitable anemometer shall be provided
which shall indicate the wind velocity in the control cabin.
Electro-hydraulic thruster operated rail clamp and manual rail clamp shall be
provided for holding the stacker-cum-reclaimer. Suitable arrangement shall be
provided for keeping the stacker-reclaimer in fixed stable position when the weather
is stormy.
3.03.00 Stacker-cum-reclaimer shall operate on rail track running for adequate length to
cover the entire coal stockyard. The wheel load of stacker-reclaimer shall not exceed
27.0 tonnes. The ratio of boom length (as specified) to the rail track gauge shall not
exceed 5. Top of rail level shall be maintained at 0.7 m above the ground level, i.e.,

SECTION-VI STACKER CUM
PART-B RECLAIMER
coal pile base level unless specified otherwise. Suitable number of rail scrappers
shall be provided.
3.04.00 The machine shall be mounted on traverse carriage provided with driven and non-
drive wheels of cast or forged steel and double flange design. The track wheels
shall be combined in pairs in the track wheel bogies. The wheels shall rotate on self-
aligning roller bearings. Between the motor and the gearing, electro-hydraulic
thrustor brake shall be provided.
3.05.00 The reclaimer shall be capable of travelling at any desired speed within its speed
range. During stacking/reclaiming operation, the equipment travel shall be limited to
its travel zone and shall automatically stop when the machine reaches the extreme
ends of such travel zone.
3.06.00 The lower works of the under-carriage of the machine shall be designed to transmit
load on the wheel sets of the travel carriage in such a manner that the equipment is
stable during normal operating condition as well as during hazardous weather
condition with maximum permissible variation in centre distance of rails and rail top
levels. The rail mounting for under-carriage shall be four legged system with
hydraulic/mechanical equalising arrangement to make it three point suspension
system for the best stability during operation. The traverse carriage and the under-
carriage shall be interconnected in a manner which will permit uniform distribution of
overloads even if the rails are not level.
3.07.00 The upper frame of the machine shall be designed in such a manner that minimum
number of angular movement points affect the luffing operation. Also the variation of
moment/torque on slew bearing shall be minimum. The ring bearings shall be
dimensioned in such a way that all forces can be safely transmitted to the structures
of the wheels.
3.08.00 The roller bearing slewing ring shall be sealed against penetration of water and dust.
3.09.00 Angular movement points (hinge points) namely between equalising beam and base
frame, luff pivots and hydraulic cylinder hinge points shall be provided with
maintenance free bearings requiring no periodic lubrication during entire life span of
bearings. Minimum life span of self lubricating type bearings shall be 25 years with
average 10 hrs. daily operation.
3.10.00 The luffing motion shall be through hydraulic pumps and cylinders. In case of more
than one cylinder being used for boom luffing operation, necessary provisions shall
be provided such that the differential oil pressure between two cylinders are always
maintained within permissible limits, during luffing operation and as well as when the
boom is fixed at any position. In case of any undue increase in differential pressure,
the hydraulic circuit shall trip and suitable alarm indication shall be provided before
tripping. The hydraulic system of luffing shall be such that in case of failure of
hydraulic system due to leakage or any other reason the boom could be held in
position.
3.11.00 The boom shall revolve by atleast 180 deg. about the centre of the receiving hopper
and discharge/reclaim material on/from both sides of track anywhere within specified
radius of the boom.

PART-B RECLAIMER
3.12.00 The boom conveyor shall be of adequate capacity to match with the rate of peak
reclaiming by the bucket wheel. For other details, the relevant clauses on belt
conveyor system of this specification shall be referred to.
Boom conveyor shall be provided with a Belt Weighing Scale with weighing accuracy
(in the horizontal position of the boom) of ± 1% for a range of 20% to 120% of boom
conveyor rated capacity. The belt scale shall provide only flow rate indication in the
Operator's Cabin on the Stacker/Reclaimer. Rest of the features shall be as
specified in the relevant section of Belt Scale specification.
3.13.00 The bucket wheel assembly shall consist of 8 numbers of buckets of cell-less design
and stationary annular chute. The bucket shall be of suitable shape and design
which will enable to empty out the material fully from the bucket, and to prevent
spilling of the scooped material during transfer to boom conveyor. The buckets shall
be readily removable.
Bucket size shall be selected for peak reclaim capacity based on maximum 80%
degree of fill with respect to water fill capacity of the bucket. Further, not more than
50% of annular ring volume shall be considered as effective volume. Rate of bucket
discharges shall not exceed 55 per minute.
The teeth of the bucket shall be hard faced.
3.14.00 The bucket wheel drive shall be complete either with Hydraulic drive (with or without
gear box) or with electric motor, reduction gear unit moving in oil bath and suitable
coupling between motor and the gear unit. Bucket wheel drive system, structural
members, mast, hydraulic system etc shall be designed considering completely wet
coal with max. surface moisture. Adequate safety devices shall be provided to
prevent overloading of the bucket wheel drive, particularly when wheel will get stuck-
up in the stockpile. In such an event the power supply of the drive shall get
automatically cut-off. Suitable electro hydraulic thruster brake (if applicable) shall be
provided to avoid backward movement of the bucket wheel after the power supply is
cut-off and during maintenance work.
3.15.00 The boom conveyor with bucket wheel assembly, the mast and counter weight
mounted on the upper structure shall rotate on the bearing ring. The drive
mechanism shall consist of the gear rim and drive unit shall comprise of motor,
safety coupling, gear box and pinion. Protective devices against overloads shall also
be provided. The slew speed shall be variable. The boom conveyor shall be
provided with self training arrangement of latest design to avoid belt sway in Boom
Conveyor. Manual locking of boom shall be provided.
3.16.00 One tripper shall be furnished for stacker-cum-reclaimer unit for working in
conjunction with the yard conveyor. The tripper shall be complete with supporting
structure, walkways, platforms, railing, belt scrapper, head pulleys, bend pulleys,
hold-down pulley, chute and support with adequate number of wheels in bogie
construction travelling on the same rails as those of the stacker-cum-reclaimer.
3.17.00 Group-wise lubrication system shall be provided combining different zones of

lubrication points under different groups depending upon location and number of
lubrication points. Each group lubrication unit shall be independently functional
through separate pump (motorized), grease container, valves, metering devices,

PART-B RECLAIMER
pipes and other accessories etc. Preferably, the grease entry into various lubrication
points shall be vertically downwards. The grease container shall have adequate
capacity for supply of lubricants to all points and grease quantity for the points to be
greased shall be adjustable. Further, all the lubrication points shall be easily
accessible.
3.18.00 The stacker-reclaimer shall receive power through trailing cables. Separate
motorized cable reeling drums for power and control cable shall be provided with
arrangements for winding and rewinding of the cables. The trailing cables shall run
in a cable tray. Further, the trailing cable arrangement shall be such that the cables
run in-between the track rails. Cushion shall be provided in the cable reeling drums
for about 15 m extra cabling length.
3.19.00 Three (3) pairs of Control cable cores shall be provided in control trailing cable of
each machine for connecting Employer’s telephone and Public address equipment
to be provided on each machine.
3.20.00 Stacker-cum-reclaimer shall be operated as elaborated elsewhere in the

specification. Further, limit switches shall be provided to prevent traverse movement,
slew and hoisting etc. beyond the respective safe extremities. Interlocking shall also
be provided for S/R rail clamps and travel motors.
Yard conveyor can be stopped from control panel of stacker / reclaimer. Provision
also be given to trip the stacker/ reclaimer from CHP control room.
3.21.00 Travel drive equipment and slew drive equipment shall be suitable for 150 starts/hr.
with continuous reversals.
3.22.00 Speed control of long travel and slew drive motor (in case of electric drive) shall be
through Variable Voltage Variable Frequency System (VVVF) with minimum 6 (six)
pulse design. Necessary input & output devices to be provided to reduce harmonics,
as per IEE 519. All necessary protections e.g. Input Phase Loss, Earth Fault, Over
Voltage, Output Short Circuit, Load Loss, Input Transient Protection, Overload etc to
be provided. VVVF system shall be capable of generating suitable starting torque
with/without encoder. Squirrel cage Induction motor with VPI insulation shall be
provided with VVVF system.
3.23.00 Hydraulic control shall be provided for
(a) Hoisting/luffing
(b) Operator cabin level adjustment
(c) Equalising arrangement for travel carriage (in case of hydraulic equalising)
Axial piston pumps shall be provided for pressurising hydraulic control fluid.
3.24.00 All drive equipments shall be selected based on 110% of actual power requirement
at specified design capacity. Further for selection and specification of various
individual equipments, relevant clauses of specification shall be referred to.

PART-B RECLAIMER
In addition to the requirements elaborated above, the structural design of the

stacker-reclaimer shall be supplemented by following standards :-
ISO 5049/1 : Mobile Continuous Bulk Handling Equipment.
FEM : Federation Europeanne De La Manutention Section-I - Rules for

Design of Hoisting Appliances.
The supplier shall furnish the detailed basis of design (BOD) used for design of the
structural components of the stacker reclaimer. The BOD shall be comprehensive
and shall account for the various technical requirements of the specification and
should include all parameters, assumptions, structural codes adopted, loading
conditions and design software used. The supplier shall also furnish the basis and
computer printout of input & output data of calculations of foundation loads.
Manufacture of the stacker reclaimer shall be taken up by the supplier, only after
approval of the BOD by NTPC.
Should the stacker reclaimer under go any structural distress/ failure during
operation or in the anchored condition during the plant life of 30 years, apart from
meeting the other contractual requirements specified elsewhere, the supplier shall
have to furnish, to NTPC, the complete structural design document / calculations,
pertaining to the equipment.
4.01.00 Continuous R.C. C. Stacker / Reclaimer rail foundation to be provided throughout

the length of travel zone and suitable RCC platform to be provided at one end of
travel of the stacker-cum-reclaimer to rest the head end of the boom while either
under maintenance or out of operation.
4.02.00 The under-carriage shall be fabricated of steel plates and section.
4.03.00 The wheel mounting arrangement shall be such that the wheels can be dismantled
easily from their supports.
4.04.00 Walkways with hand railings shall be provided on both sides of boom conveyor.
4.05.00 The upper structure shall consist of rigid box type steel plate construction on which
the super-structure supporting mast, boom with bucket wheel and counterweight
boom with ballast are erected. The upper works shall be mounted on under-carriage
by means of large diameter ring bearing of double roll roller type.
4.06.00 The boom shall be fabricated from rolled steel plates and sections and shall be of
luffing type.
4.07.00 The counterweight boom with ballast which balances the boom conveyor shall be
mounted on the upper structure and shall be suitably dimensioned. The
counterweight boom shall be fabricated with rolled steel plates and sections.
Suitable boxes shall be provided for placing the counter weights.
4.08.00 The stacker-reclaimer shall be provided with one enclosed dust proof & air
conditioned operator's cabin and so located as to enable the operator to get clear

PART-B RECLAIMER
vision of both sides of the track and the cutting of coal by buckets. The cabin shall
be suitable for operation in monsoon and tropical conditions and the inside ambient
temperature shall be maintained at 270C. The cabin shall be provided with
toughened glasses with wipers and the arrangement shall be such that glasses can
be cleaned from outside without any scaffolding, Cabin door shall be provided with
hydraulic door closers. The cabin shall be kept in horizontal position through
hydraulic cylinders irrespective of the angle of inclination of the boom conveyor. All
controls for operation of all parts of the stacker-reclaim unit shall be provided in the
cabin within easy reach of the operator. Lights and fan for operator's cabin and
adequate number of flood lights for all necessary illumination for working at night
shall also be provided. Coal cutting by bucket wheel shall be clearly visible from
operator’s cabin.
4.09.00 Electrical/MCC room shall be fabricated of sheet steel with suitable floor matting.
The room shall be dust tight and air conditioned. Fire proof insulation shall be
provided under the roof of MCC room. Further, the door shall be provided with
hydraulic door closer.
4.10.00 Adequate number of impact idlers shall be provided integral with stacker-cum-
reclaimer at the region where the boom conveyor feeds material through transfer
chutes onto the yard conveyor for the protection of the yard conveyor.
4.11.00 Suitable arrangement shall be provided at the starting point (belt take off point) of
the tripper to avoid folding of belt while the tripper is in tension.
4.12.00 Dry type transformers, PCRD, CCRD and all drives shall be suitably protected from
accumulation of coal dust falling from the tripper section of machine by providing
conopy.

PART-B RECLAIMER
DATA SHEET
STACKER CUM RECLAIMER
1.0.0 GENERAL
1.1.0 Type : Travelling boom stacker cum bucket

wheel boom reclaimer
1.2.0 Quantity : 1 No.
1.3.0 Input Coal Parameters : As specified elsewhere
1.4.0 Wind Velocity
1.4.1 Maximum under operating : 65 kmph

condition
1.4.2 Maximum under non-operating : As indicated in weather data in Project

condition Synopsis
1.5.0 Height of Stockpile : 10 m
1.6.0 Design Capacity : 110% of rated (guaranteed) capacity
1.7.0 Peak Reclaim Capacity : 125% of rated capacity, (For bucket

size calculations)
1.8.0 Width of stock pile at base : min 50 m.
2.1.0 Stacker Reclaimer Travel

Mechanism
2.1.1 Type of Rail : 52 kg/ mtr.
2.1.2 Rail Track Gauge : Not Less than 20% of boom length.
2.1.3 Wheel Load : Not to exceed 27.0 Te.
2.1.4 Wheel Bearings : Self aligning roller bearings.
2.1.5 Top of Rail Level : 0.7 m above ground level unless

specified otherwise.
2.1.6 Drive Equipment : Electric motor with suitable coupling &

electro hydraulic Thruster brakes.

PART-B RECLAIMER
2.2.0 Bucket Wheel Mechanism
2.2.1 No. of Buckets : Eight (8)
2.2.2 Type of Buckets : Cell-less
2.2.3 Max. degree of fill for Buckets to : 80%

be considered.
2.2.4 Effective Ring volume to be : Max. 50% of annular ring Volume.

considered
2.2.5 Bucket discharge rate : Not to exceed 55 per min.

Hydraulic drive (with or without
2.2.6 Drive :
gearbox)
or
Electric motor with gear box & suitable
coupling.
2.2.7 Brake : Electro hydraulic thruster operated (for
electrical drive only). For hydraulic
motor the brake shall be integral to the
system.
2.2.8 Overload Protection : Suitable safety device with power

supply tripping.
2.3.0 Boom Conveyor
2.3.1 Design average capacity : a) 125% of rated reclaiming capacity.
2.3.2 Belt speed : About 3m/sec.
2.3.3 Length & Width of Belt
a) for Boom conveyor : 41 mtr Suitable for above capacity
2.3.4 Carrying Idlers : 350 troughing three equal rolls
2.3.5 Return Idlers : Single piece rollers
2.3.6 Drive : Electric motor with suitable coupling.
2.3.7 Gear Unit : Helical / bevel helical
2.3.8 Brake : Electro Hydraulic Thruster (if

applicable)

PART-B RECLAIMER
2.3.9 Skirt Board
a) for Boom conveyor : Liftable at head/tail end.
2.3.10 Type of Take up arrangement : Screw
2.4.0 Slewing Mechanism

Pinion driven by hydraulic drive (with or
2.4.1 Drive :
without gear box)
Or
Pinion driven by Squirrel cage
induction motor with gear unit &
suitable coupling.
2.4.2 Drive Mechanism Gear rim mounted with under frame
2.4.3 Bearing : Ring type roller bearing
2.4.4 Brakes : Electro hydraulic thrustor operated (for

electric drive only). For hydraulic motor
the brake shall be integral to the
system.
2.5.0 Luffing Mechanism
2.5.1 Drive : Hydraulic pumps & cylinders.
2.5.2 Protection : Against undue differential pressure
2.5.3 Hinge point bearings : Life lubricated antifriction bearings.
2.5.4 Bearing life to be considered : 25 years with 10 hrs/day operation.
2.6.0 Operators Cabin
2.6.1 Construction : Dustproof & Air conditioned
2.6.2 Inside Temperature : 270C
2.6.3 Doors : Hydraulic door closers
2.6.4 Level Maintaining Mechanism. : Hydraulic type.
2.7.0 Material for chutes and hoppers : 10 mm thk S.S. liner for cylindrical
portion of central hopper/chute. For
other locations, as specified in the
relevant section for chutes & hoppers.
2.8.0 Walkways on the tripper : Both sides, 800 mm wide each

PART-B RECLAIMER
PART - B
SUB-SECTION-IIIA-20
WAGON TIPPLER

WAGON TIPPLER
1.00.00 GENERAL
1.00.01 (a) Rotaside wagon tippler shall be furnished complete with all structural
members, tippler platform, tipping mechanism, tippler drive motors, brakes,
couplings, shafting and all automatic controls for positioning, tipping and
discharging the entire contents of the wagons into the hopper.
(b) Bidder shall source rotaside wagon tippler from a manufacturer/supplier who
has supplied minimum two (2) nos. of rotaside wagon tippler suitable for
tippling Indian Railway wagons used for transportation of coal or other
minerals which are in successful operation at least for a minimum period of
two (2) years as on date of techno-commercial bid opening.
1.01.00 Wagon Unloading System
1.01.01 The rake comprising of specified maximum 58 number of wagons shall be pushed
into the reach of in-haul equipment by a locomotive. Further placing of wagons over
tippler platforms and carrying away the empty wagons shall be accomplished with
the help of a side arm charger under scope of bidder.
1.01.02 Wagon tipplers shall be suitable to handle any type of wagons being used by Indian
Railways as on date for transportation of coal as per IS-10095 (Latest edition) and
latest RDSO standard G-33 Rev 1. It shall conform to all stipulations with regard to
suitability for handling wagons having width, height and length over coupler faces as
indicated by RDSO/railway authorities at the time of approval of wagon tippler
drawings.
1.01.03 Maximum moving dimensions of locomotive & wagon as per Indian Railway norms
shall be adopted for providing clearances with respect to structures, equipment and
tippler arrangement.
1.01.04 Complete wagon tippler and accessories shall have the approval of concerned
Indian Railway Authorities and RDSO. Further, the contractor shall submit to the
Owner detailed drawings of wagon tippler and accessories after getting the same
approved from the concerned Railway authorities. Bidder shall take care of the
observations of RDSO G-33 with Latest Amendments in their design & drawings for
wagon tippler and its accessories.
1.01.05 The top opening of wagon tippler hopper shall be suitable for receiving coal from
wagons for which the wagon tippler drawing shall be approved by RDSO/railway
authorities.
1.01.06 The bidder shall obtain all statutory approvals from the relevant RDSO/Railway
authorities, before the wagon tippler complex is put into operation. Any statutory
payment charges, to be made to the concerned authorities shall be to Bidder’s
account. It is the responsibility of the Bidder to carry out any modifications as
required by the RDSO/Railway authorities, at no extra cost to the Owner.

SECTION-VI
COAL HANDLING PLANT PACKAGE WAGON TIPPLER 1 OF 8
PART-B
1.02.00 Wagon Tippler Hopper
1.02.01 The wagon tippler hopper shall be of RCC construction and adequately sized to
accommodate the coal load of Minimum 300 MT received by 4 axle bogie having a
gross load of 140 MT and axle load of 32.5MT wagons of RDSO design used by
Indian Railways. For effective volumetric capacity computation of the hopper, the
angle of repose of coal shall be considered as 37°. The minimum valley angle of the
hopper shall be considered as 60°. The hopper shall have opening below which
apron feeders shall be provided to evacuate coal from the hopper and feed onto
associated belt conveyors below. Complete inside surfaces of the hopper shall be
provided with 50 mm thick guniting. Further it shall be possible to empty out all the
coal, without any dead stock from the hopper.
1.02.02 Steel gratings of mesh size 300mm x 320mm over wagon tippler hopper shall be
provided. The hopper and gratings shall be designed for movement of font end
loader/bulldozer over them. Bull-dozer weight shall be considered as approx. 35 Te.
2.00.00 CODES AND STANDRDS
The design, manufacture, inspection and testing of Wagon Tippler shall comply with
where the equipment is to be installed. The Wagon Tippler shall conform to the
latest edition of the standards, codes and RDSO G-33 Rev.1 Nothing in this
3.01.00 The wagon tippler shall be ‘rotaside’ type suitable to unload a coal wagon by lifting
and rotating it sideways. The angle of tip shall be not more than 160° giving 60°
angle to the side of the wagon for emptying the coal contents into the hopper below.
Wagon tippler design should take care of locomotive (weighing up to 150 MT)
moving over tippler table at a speed of 8Kmph.
3.02.00 During each cycle of operation, the tippler shall be capable of holding, completely
unloading and replacing the wagon to its original position without damage to the
tippler, wagon or the track.
3.03.00 The tippler shall be suitable for continuous operation, 24 hours a day, round the
clock. The tippling rate shall be 25 Tips per hour, accordingly all drive components,
hydraulics, electricals, structures shall be designed for 25 tips per hour round the
clock operation.
3.04.00 The wagon tippler structure shall be designed to conform to the requirements of
Indian Railway’s “Research, Design and Standards Organization, (RDSO)” with
regard to the nature of loading, impact factor and allowable stresses. It shall be the
sole responsibility of the contractor to ensure that each and every component of the
wagon tippler is adequate in rigidity, strength and of heavy duty construction of first
class quality to guarantee against failure or major damage, assuming proper
maintenance and usage. The tippler shall be designed to allow passage of all

SECTION-VI
PART-B
standard broad gauge (1676 mm) Indian Railways diesel locomotives over tippler
table at restricted speed.
3.05.00 Wagon Tippler weighing System
3.05.01 This specification calls for an electronic static weighing system to measure / record
the quantum of coal, wagon wise on the wagon tippler table before & after tippling.
The weighbridge with adequate number of load cells shall be provided beneath the
wagon tippler platform with a minimum accuracy of 1% of the gross weight of the
wagon. The platform shall be freely supported on the weigh bridge before and after
tippling for accurate weighing.
The wagon tippler weighbridge shall be designed to statically weigh the wagons in
an uncoupled condition. The system shall comprise of a weighbridge, a tippler table,
load cells, weight digitizer and an intelligent terminal with printer for computerized
printed output of data gross weight, tare weight, wagon number, time, date etc. The
weighbridge shall be chosen to accommodate 8 wheeler wagons of RDSO design
used by Indian Railways to move coal. The weighbridge shall be supported on
minimum 4 nos. compression type load cells mounted on free motion structural unit
assembly. The load cells shall be suitable for dusty environmental conditions.
3.06.00 The dimensions and elevations for Wagon Tippler and its complex as indicated in
the tender drawings are minimum requirements of the employer. Any increase in the
sizes or the parameters, if required to meet the requirement of RDSO Design
Guidelines G-33, Rev.01 shall be supplied by the Contractor without any cost
implication to employer.
4.01.00 Cradle
4.01.01 The cradle shall consist of a pair of heavy welded steel plate sections reinforced with
stiffeners and connected by side bearer beams pivotally attached, each section
being fitted with a massive trunion shaft carried in bronze bushed cast steel
bearings/antifriction type spherical roller bearing on each side, bolted to steel
pedestal carried on concrete pedestals. Circumferential driving rack shall be rigidly
bolted to the peripheries of the sectors. The sectors shall be made of cast steel.
Necessary features of safety against coming down of wagon tippler in the event of
failure of one of the drive pinions and / or gear racks shall be provided.
4.02.00 Rail Table
4.02.01 The rail table shall be constructed of rolled steel joints with standard steel rails (60
kg/meter) mounted on it. The table shall be pivoted from arms extended from the
sectors. The table shall be covered with chequered plates between the rails.
4.03.00 Feeders and Clamps
4.03.01 The wagon shall be clamped automatically by hydraulic system and firmly on the
cradle during the tippling without any damage or undue pressure on any part of the
wagon and no hand adjustment of any sort shall be necessary. Sliding side stop

SECTION-VI
PART-B
pads shall be of resilient material to prevent damage to either the wagon or the
stops.
4.04.00 Spill Plate
4.04.01 Fixed to the cradle of the tippler shall be a plain steel spill plate for deflecting
material into the tippler hopper.
4.05.00 Driving Gear
4.05.01 Multiple pinions meshing with cast steel racks bolted to the end sectors shall impart
drive through hydraulic as per manufacturers proven design, as applicable. Suitable
oil coolers shall be provided for hydraulic power pack. Suitable dust protective cover
shall be provided.
4.06.00 Brake
4.06.01 An automatic electro hydraulic brake shall be furnished to hold the tippler in any
position with the load and against any movement except that provided by drive.
4.07.00 Limit Switches
4.07.01 Limit switches of suitable type which can be readily adjusted to give the desired
tippling angle shall be provided. An emergency over tip limit switch operated by a
striker on the tippler trunnion shaft shall be furnished.
4.08.00 Lubrication
4.08.01 All bearings shall be properly lubricated. Grease nipples and reservoirs shall be
furnished wherever necessary.
4.09.00 Guards
4.09.01 All gears inside machinery pits and other moving parts shall be securely guarded.
4.09.02 All necessary base plates, guide plates, chequered plate covering for drive pit and
any other pits, all required fixing materials, inserts and sleeves shall be furnished.
5.00.00 RDSO REQUIREMENT
The Wagon Tippler shall fully meet the requirements of RDSO along with Latest
Amendments. However, Major requirements are as follows:
5.01.00 The Tippler shall be designed for handling a gross load of 140 tons taking into
consideration a 4 axled bogie wagon with an axle load of 32.5 tons plus the
overloading caused due to variable density of the bulk material and heap loading of
the wagon.
5.02.00 The Tippler shall be capable of handling one 4 axled wagon at a time having a
maximum length of 15m over the buffers or centre buffer couplers (CBC’s).

SECTION-VI
PART-B
5.03.00 The top clamping pressure shall be such as to hold the wagons firmly in position on
rails keep the bearing brasses and running gear from getting dislodged without
causing any deformation to the wagon structure.
5.04.00 Devices shall be built-in for spotting of wagons on the tippler table, so as to the
discharge the material in hoppers.
5.05.00 Size and gauge of rails on the wagon tippler platform shall be as per railway
specifications taking into consideration the maximum duty condition that the wagon
tippler has to undergo in field operation.
5.06.00 Marking- All tipplers shall be marked permanently and legibly at a clearly visible
place with the name of the manufacturer, serial number, the year of manufacturer,
type and capacity of tippler and RDSO allotted serial no.
5.07.00 Devices shall be built-in to prevent any over run of the wagons in either direction.
The tipper shall be designed so that the wagon is securely held in all operating
positions. Automatic devices shall be provided to hold the tipplers securely in any
position in the event of failure of the drive units. All tipplers shall have means to limit
the angle of tippling. Arrangements shall be made on tipplers to prevent feet being
trapped between the platform and the base of the tippler. Device shall be provided to
prevent an empty wagon from being released unit the tippler is back in original
position. The emergency stop controls shall be provided adjacent to the wagon
tipplers in readily accessible position.
5.08.00 Train & wagon Holding Devices
5.08.01 Wheel grippers: These are mandatory and should be so designed that balanced
pressure is applied on both sides of the wheel rim. It should have a floating
arrangement so as to ensure that force on each gripper is same and should have
some lateral float so that it can take a new position in case of variation in wheel
gauge. Wheel grippers should be free from serrations or any such provision on its
holding face wheel grippers should be made of soft material.
Retractable wheel chocks: These are mandatory and should be so designed that
flange of the wheel is not contacted while blocking tread of the wheel. Shape of the
chock should take into account the wheel incline, so that a line contact is made with
the wheel.
Clicking stops: These are not acceptable.
5.09.00 The design of the top clamping arrangement shall fulfill following requirements.
5.09.01 The top clamping of the wagon shall be done through hydraulically locked top
clamps. No external or moveable counter weights should be used with the hydraulic
clamps.
5.09.02 Top clamps should engage when the wagon tilts by more than 15 degree. Top clamp
locks should include a wagon bogie spring relief mechanism for permitting release of
bogie springs. Top clamps should exert the bare minimum pressure on the top

SECTION-VI
PART-B
coping of the wagon, so as to just keep it in position. The pressure exerted by the
top clamps at the tilt angle of 160 degrees should be just enough to bear the weight
of the empty wagon. Wagon bogie springs should get fully relieved in this position,
through the bogie spring relief mechanism.
5.09.03 The design of Top Clamping arrangement shall be of longitudinal/ transverse type
and provided with self-aligning feature, whereby the load is borne on the top at each
of the wagons. The longitudinal/ transverse type clamping shall have six transverse
top clamping beams i.e. the bearing face of the beam shall contact the top of the
wagon at 12 locations (six on each side).
Each bearing face shall contact the top of the wagon over a width of not less than
250 mm and shall provided with rubber pads or suitable alternative not less than 50
mm thick.
5.10.00 The side supports for tipplers shall meet the following requirements.
5.10.01 Full face contact between the side support beam and the side stanchions shall be
ensured. The side supports shall extend from a height of 1000 mm upto 2950 mm,
from rail level, i.e. contact the side of the wagon over a width of not less than 1950
mm. There shall be metal to metal contact between the side support beam and the
side stanchions of the wagon i.e, no rubber pad or any other alternative, shall be
provided on the contact face of the side support beam.
5.10.02 The side support beam shall be movable type, the movement being done by
hydraulic arrangement (No external or moveable counterweights should be used
with the side support beam). Facility of forward/backward movement should exist,
such that it should be able to move & touch the wagon without applying any
pressure on the wagon side wall. Movement of the side support should be controlled
and the speed should be crawling just before making contact with the wagon side
wall.
5.10.03 Pressure gauges should be mounted, at easily accessible location, for reading the
hydraulic pressure of the side support hydraulic arrangement.

SECTION-VI
PART-B
DATA SHEET
1.0.0 GENERAL
1.1.0 Wagon Type : Standard broad gauge, 4 axled wagons

as per RDSO standard and design used
by Indian Railways to move coal
1.2.0 Moving Profile : As per IR norms.
1.3.0 Rail Gauge : 1676 mm.
1.4.0 Weigh bridge : Load cell type
1.5.0 Duty : Continuous 24 hrs.
2.1.0 Wagon Tippler Hopper
2.1.1 Construction : RCC Construction.
2.1.2 Size : 300 Te
2.1.3 No. of openings : One (1)
2.1.4 Angle of repose of coal for : 37°

wagon tippler hopper sizing
2.1.5 Lining : 50 mm thick guniting.
2.1.6 Steel Grating
(i) Mesh size : 350 mm x 320 mm
(ii) Grating Section : Refer Sub-Section IIID-01.
2.2.0 Wagon Tippler
2.2.1 Type : Rotaside type
2.2.2 Tipping angle : not more than160°
2.2.3 Duty Requirement : Continuous operation
2.2.4 Cradle : Heavy welded steel plate construction

trunion mounted.

SECTION-VI
PART-B
2.2.5 Driving Gear

(i) Racks : Cast steel rack sections bolted to end
sectors.
(ii) Pinion : Multiple pinions meshing with rack.
2.2.6 Rail Table : Rolled steel joints with steel rails

mounted on it.
2.2.7 Drive : Hydraulic drive
2.2.8 Brake : Electro hydraulic thruster operated.
2.2.9 Clamping Top & side stops : Hydraulically operated

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-21
APRON FEEDER

A:21 – APRON FEEDER
1.00.00 GENERAL
Apron feeders complete with all accessories shall be furnished for wagon tippler
hoppers as specified.
The design, manufacture, inspection and testing of apron feeders shall comply with
where the equipment is to be installed. The apron feeders shall conform to the
latest edition of the standards and codes. Other internationally acceptable
shall also be accepted. Nothing in this specification shall be constructed to relieve
the contractor of the required statutory responsibility. In case of any conflict in the
binding.
3.00.00 DESIGN REQUIRMENTS
Apron feeders shall be of robust construction & designed for handling ROM coal as
specified and without any choking particularly during rainy season when coal is
sticking.
A drible conveyor shall be provided for proper clean up.
The pan and chain shall be of proven design and shall be with adequate factor of
safety.
The frame shall be manufactured from rolled steel section welded and bolted
together to form a rigid structure.
The roller shall be life time lubricated and shall be manufactured from alloy steel.
The chain Link shall be forged steel. Pins and rollers shall be of hardened steel .The
chain link shall be bolted to the pans.
Apron/pan shall be of suitable thickness which shall be constructed out of fabricated

MS with wear resistant liner plate or special alloy steel without any liner plate for the
duty requirement. The pan would be fitted directly to the chain attachment.
The head and tail end shall be of sturdy steel construction suitably stiffened. The
sprocket shall be made of cast alloy steel with case hardened teeth or forged steel.

SECTION-VI
COAL HANDLING PLANT PACKAGE APRON FEEDER 1 OF 3
PART-B
The traction wheel shall be made of cast steel with case hardened surface.
Tensioning arrangement with sufficient travel shall be provided for the tensioning of
the chain.
Complete dribble belt system consisting of head pulley, tail pulley, drive, motor,
stringers, deck plates etc. shall be provided.

SECTION-VI
PART-B
DATA SHEET
Angle of Installation : Horizontal
Chain Link : Forged alloy Steel
Apron pan : MS fabricated with wear resistant

plate or special alloy steel .
Traction wheel : Cast Steel
Rollers : Forged Alloy Steel
Drive : VVVF

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIA-22
SIDE ARM CHARGER

A:22 – SIDE ARM CHARGER
1.00.00 GENERAL
1.01.00 Side Arm Charger shall be furnished complete with travel rails, drive equipments
and associated accessories.
1.02.00 The rake comprising of specified maximum number of wagons shall be pushed into
the reach of inhaul equipment by a locomotive. Further placing of wagons over
tippler platform and moving out the empty wagons shall be accomplished with the
help of side arm charger.
The design, manufacture, inspection and testing of Side Arm Charger shall comply
where the equipment is to be installed and all norms stipulated by RDSO. The Side
Arm Charger shall conform to the latest edition of the standards and codes. Other
decision of the Emplyer shall be final and binding.
3.01.00 A single module of side arm charger shall be used for inhaul and outhaul operations.
The side Arm charger shall be suitable to handle 58 (DFC25) numbers of loaded
wagons. Thus, side arm charger shall be used for indexing forward the rake of
58(DFC25) nos. loaded wagons, placing decoupled wagons on the tippler table and
out hauling the empty wagons.
3.02.00 The rake of 58 loaded DFC25 wagons will be brought by locomotive and placed on
the pre-tipping line such that the leading wagon will be within the reach of the side
arm charger. Now the side arm charger will be coupled to the leading wagon, pull
the rake of 58 nos. loaded DFC 25 wagons towards tippler table. The first wagon will
be de-coupled manually from the rake and signal will be given to the side arm
charger operator that the wagon is de-coupled. Now the leading wagon will be
placed centrally onto the tippler table by side arm charger, (simultaneously ejecting
the empty wagon from the tippler table). After the loaded wagon is placed on the
tippler table, the arm is de-coupled from the loaded wagon. Adequate clearance
between tippler table and empty wagon shall be ensured. The side arm charger will
stop at the end of its strokes, the arm will be swung vertically-up and the machine
will move towards in-haul direction and occupies the initial position. In the meantime,
the tippler will tip the loaded wagon placed on the tippler table and return to its
original position. Before tippling operation of wagon tippler is completed, the arm of
the side arm charger will be swung to horizontal position and will be coupled to the
rake of remaining loaded wagons at waiting position just before the tippler table and
is now ready for the next cycle to start. After the tippling operation of wagon tippler is
completed the cycle will be repeated.
SECTION-VI
COAL HANDLING PLANT PACKAGE SIDE ARM CHARGER 1 OF 4
PART-B
4.01.00 The Side Arm Charger shall be suitable to handle 58 number of loaded DFC25
wagons. The pusher arm shall be vertically rotatable arm mounted on a carriage
running back and forth parallel to the train track.
4.02.00 The arm shall be raised to clear the movement of wagons and locomotives during
reversing back of positioner carriage and shall be lowered for engaging the head of
the arm with the wagon coupler for index strokes.
4.03.00 The arm shall be raised and lowered by means of hydraulic cylinder mounted on
the carriage. Suitable means shall be provided to prevent damage to the arms
should the arm be accidentally lowered into the side of wagon.
4.04.00 The arm shall be of robust construction either of cast steel or of heavy duty
fabricated steel for the required duty.
4.05.00 The construction of the head assembly of the push arm shall be such that no
damage is suffered by the couplers of wagons and engagement of arm over the
coupling assembly as well as transmittance of indexing forces to accelerate, run
and decelerate the train during the positioning cycle shall be very smooth.
4.06.00 The carriage frame shall be a suitable fabrication assembly of large proportions
massive enough in strength and rigidity for the required duty.
4.07.00 Travel Carriage Drive System
4.07.01 The travel carriage with push arm shall be propelled to and fro, parallel to train track
through hydraulic motor driving through a gear box and EHT brake.
4.08.00 The rating of the drive equipment and its characteristics shall match with indexing
forces required to be exerted in varying amounts depending upon train dynamics
and to suit haulage of 58 DFC25 wagon loaded rake.
4.09.00 The travel carriage shall ride on vertical bearing wheels and will be guided by
horizontal bearing wheels by suitably transmitting the thrust load from the positioner
arm to the foundation. The wheels/rollers shall be of forged steel and shall run on
the rails supported over the RCC pedestal.
4.10.00 Cushioned emergency bumpers (buffers) shall be provided at the forward and
return end of carriage travel run for protection. These shall be designed to arrest
the machine without undue shock in case the machine exceeds its extremities
because of any mal-operation.
4.11.00 Wagon Tipplers shall be provided with side arm charger for positioning of wagons on
the tipplers, such that.
a. Drive unit for the side arm charger should be of positive type by Hydraulic
Motors, so that sudden jerks/ slippages are avoided. Suitable technology should
SECTION-VI
PART-B
be used, so that the wagon can be moved at slow speeds for placement on
tippler table.
b. Side Arm Charger should be able to slow down to creeping speed just before
the final positioning.

SECTION-VI
PART-B
DATA SHEETS

REQUIREMENTS
1.1.0 Arm : Robust construction either of cast steel or

heavy duty fabricated steel.
1.2.0 Arm Drive : Hydraulic cylinder
1.3.0 Carriage Frame : Single fabrication assembly.

1.4.0 Travel Carriage drive :
1.4.1 Motor : Hydraulic motor driving through a gear box.
1.4.2 Travel brake : Integral part of hydraulic motor
1.4.3 Bearings for sheaves : Anti friction bearings.

SECTION-VI
PART-B
PART - B
ELECTRICAL

PART - B
SUB-SECTION-IIIB-01
MOTORS

MOTORS
1.00.00 GENERAL REQUIREMENTS
1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50 deg.

Centigrade and relative humidity of 95% shall be considered. The equipment shall
operate in a highly polluted environment
1.02.00 All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3%
& -5%, and 10% combined variation of voltage and frequency unless specifically
brought out in the specification.
1.03.00 Contractor shall provide fully compatible electrical system, equipments, accessories
and services.
1.04.00 All the equipment, material and systems shall, in general, conform to the latest
edition of relevant National and international Codes & Standards, especially the
Indian Statutory Regulations.
1.05.00 The auxiliary AC voltage supply arrangement shall have 6.6 KV and 415V systems.
It shall be designed to limit voltage variations as given below under worst operating
condition :
(a.) 6.6 KV +/- 6%
(b.) 415/240V +/- 10%
1.06.00 The voltage level for motors shall be as follows (other than VFD motors) :-
(a.) Upto 0.2 KW 240V, Single phase AC / 415V AC Three phase
(b.) Above 0.2KW to 200 KW 415V, Three phase AC
(c.) Above 200 KW 6.6 KV, Three phase AC

For CHP conveyor’s motor above 160 KW rating 6.6 KV Three phase AC supply is to
be used.
However, all the motors on the S/R machine shall be on 415V AC only.
Voltage rating for special purpose motors viz. screw compressors and those with
VFD shall be as per manufacturer standard.
1.07.00 Fault level shall be 40KA RMS for 1 second for 6.6 KV system and 45 KA RMS 1
second for 415V system. 415V system shall be solidly grounded and 220 VDC
system shall be isolated type.

STAGE-II (2X195 MW) SECTION-VI SUB-SECTION-IIIB-01 PAGE
COAL HANDLING PLANT PACKAGE PART-B MOTORS 1 OF 10
1.08.00 Paint shade shall be RAL 5012 (Blue) for indoor and outdoor equipment.
1.09.00 The responsibility of coordination with other agencies and obtaining all necessary
clearances shall be of the contractor.
1.10.00 Degree of Protection
Degree of protection for various enclosures as per IS:13947 shall be

as follows :-
i) Indoor motors – IP 54
ii) Outdoor motors – IP 55
iii) Cable box – indoor area – IP 54
iv) Cable box – outdoor area – IP 55
1.) Three phase induction motors : IS:325, IEC:60034
2.) Single phase AC motors : IS:996, IEC: 60034
3.) Crane duty motors : IS:3177, IEC: 60034
4.) DC motors/generators : IS:4722
5.) Energy Efficient motors : IS 12615
3.00.00 TYPE
3.01.00 AC Motors:
(a.) Squirrel cage induction motor suitable for direct-on-line starting.
(b.) Continuous duty LT motors upto 160 KW Output rating(at 50 deg.C ambient
temperature) ,shall be Energy Efficient motors ,Efficiency class – Eff 1,
conforming to IS 12615.
(c.) Crane duty motors shall be slip ring / squirrel cage type induction motor as per
the requirement
3.02.00 DC Motors Shunt wound.

4.00.00 RATING
(a.) Continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor.
(b.) Whenever the basis for motor ratings are not specified in the corresponding
mechanical specification sub-sections, maximum continuous motor ratings
shall be at least 10% above the maximum load demand of the driven
equipment under entire operating range including voltage and frequency
variations.
5.00.00 TEMPERATURE RISE
Air cooled motors
70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation.
Water cooled
80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance

method for both class 130(B) & 155(F) insulation.
6.00.00 OPERATIONAL REQUIREMENTS
6.01.00 Starting Time
6.01.01 For motors with starting time upto 20 seconds at minimum permissible voltage during
starting, the locked rotor withstand time under hot condition at highest voltage limit
shall be at least 2.5 second more than starting time .
6.01.02 For motors with starting time more than 20 second and upto 45 seconds at minimum
permissible voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 5 second more than starting time.
6.01.03 For motors with starting time more than 45 seconds at minimum permissible voltage
during starting, the locked rotor withstand time under hot condition at highest voltage
limit shall be more than starting time by at least 10% of the starting time.
6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above
requirements are not met.
6.02.00 Torque Requirements
6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall be
at least 10% motor full load torque.

6.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall
be 275% for crane duty motors.
6.03.00 Starting voltage requirement
(a) 85% upto 1500KW
(b) 80% from 1501KW to 4000KW
(c) 75% > 4000KW
7.00.00 DESIGN AND CONSTRUCTIONAL FEATURES
7.01.00 Suitable single phase space heaters shall be provided on motors rated 30KW and
above to maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided.
7.02.00 All motors shall be either Totally enclosed fan cooled (TEFC) or Totally enclosed
tube ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors
rated 3000KW or above can be Closed air circuit water cooled (CACW). Motors
located in hazardous areas shall have flame proof enclosures conforming to IS:2148
as detailed below
(a) Fuel oil area : Group - IIB
(b) Hydrogen generation plant Group – IIC (or Group-I Div-II as per
area : NEC)
7.03.00 Winding and Insulation
(a) Type : Non-hygroscopic, oil resistant, flame resistant
(b) Starting duty : Two hot starts in succession, with motor initially at
normal running temperature. However, conveyor
motors shall be suitable for 3 consecutive hot starts.
(c) 6.6 KV AC : Thermal class 155(F) insulation with winding

motors temperature rise limited to thermal class 130(B). The
winding insulation process shall be total Vacuum
Pressure Impregnated i.e. resin poor method. The
lightning impulse & interturn insulation surge
withstand level shall be as per IEC-60034 Part-15.

(d) 415V AC & : Thermal Class 130(B) or better

220V DC
motors
( e) Short circuit rings of conveyor motors shall be either

joint less or welded type. Brazed joint is not
acceptable.
7.04.00 Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft
currents.
7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable alarm
contacts to indicate inlet and outlet primary air temperature.
7.06.00 Noise level for all motors shall be limited to 85dB(A). Bearing housing vibration shall
be limited within the limits prescribed in IEC 60034-14/IS:12075. Motors shall
withstand vibrations produced by driven equipment. HT motor bearing housings shall
have flats in both X and Y directions suitable for mounting 80mmX80mm vibration
pads.
7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum
resistance type temperature detectors shall be provided for each phase of stator
winding. Each bearing shall be provided with dia type thermometer with adjustable
alarm contract and minimum one(1) number duplex Platinum resistance type
temperature detector.
7.08.00 Motor body shall have two earthing points on opposite sides.
7.09.00 HT motors can be offered with either Elastimold termination or dust tight phase
separated double walled (metallic as well as insulated barrier) cable boxes. In case
Elastimold terminations are offered, then protective cover and trifurcating sleeves
shall also be provided. Removable gland plates of thickness 3 mm (hot/cold rolled
sheet steel) or 4 mm (non magnetic material for single core cables) shall be provided
in case of cable boxes.
7.10.00 The spacing between gland plate & centre of terminal stud shall be as per Table-I.
7.11.00 All motors shall be so designed that maximum inrush currents and locked rotor and
pullout torque developed by them at extreme voltage and frequency variations do not
endanger the motor and driven equipment.
7.12.00 The motors shall be suitable for bus transfer schemes provided on the 6.6 KV/415V
systems without any injurious effect on its life.

7.13.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall be
provided on each phase in a separate neutral terminal box.
7.14.00 6.6 KV Terminal Box shall be suitable for fault level of 500MVA for 0.12 second.
7.15.00 The size and number of cables ( for HT motors) will be intimated to the contractor
during detailed engineering and the contractor shall provide the terminal box, cable
gland & lugs suitable for the same.
7.16.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the
following (without any further tolerance) except for BFP motor.
(a) Upto 110KW 11.0
(b) Above 110KW & upto 1500KW 10.0
(c) Above 1500KW & upto 4000KW 9.0
(d) Above 4000KW 6 to 6.5
8.00.00 TYPE TEST
8.01.00 HT MOTORS
8.01.01 The contractor shall carry out the type tests as listed in the “LIST OF TESTS TO BE
CONDUCTED” on the equipment mentioned there in. The Bidder shall indicate the
charges for each of these type tests separately in the relevant schedule of BPS and
the same shall be considered for the evaluation of the Bids. The type test charges
shall be paid only for the test(s) actually conducted successfully under this contract
and upon certification by the Employer's Engineer.
8.01.02 The type tests shall be carried out in presence of the Employer’s representative, for
which minimum 15 days notice shall be given by the Contractor. The Contractor shall
obtain the Employer’s approval for the type test procedure before conducting the
type test. The type test procedure shall clearly specify the test set-up, instruments to
be used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.
8.01.03 In case the contractor has conducted such specified type test(s) within last ten years
as on the date of bid opening, he may submit during detailed engineering the type
test reports to the owner for waivel of conductance of such type test(s). These
reports should be for the test conducted on the equipment similar to those proposed
to be supplied under this contract and test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client. The owner
reserves the right to waive conducting of any or all the specified type test(s) under

this contract. In case type tests are waived, the type test charges shall not be
payable to the contractor.
8.01.04 Further the Contractor shall only submit the reports of the type tests as listed in
“LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED” and carried
out within last ten years from the date of bid opening. These reports should be for
the tests conducted on the equipment similar to those proposed to be supplied under
this contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client. However if the Contractor is
not able to submit report of the type test(s) conducted within last ten years from the
date of bid opening, or in case the type test report(s) are not found to be meeting the
specification requirements, the Contractor shall conduct all such tests under this
contract at no additional cost to the Owner either at the third party laboratory or in
presence of client/owner’s representative and submit the reports for approval.
8.01.05 All acceptance and routine tests as per the specification and relevant standards shall
be carried out. Charges for these shall be deemed to be included in the equipment
price.
8.01.06 The type test reports once approved for any projects shall be treated as reference.
For subsequent projects if NTPC, an endorsement sheet will be furnished by the
manufacturer confirming similarity and “No Design Change”. Minor changes if any
shall be highlighted on the endorsement sheet.
8.01.07 LIST OF TESTS TO BE CONDUCTED
The following type tests shall be conducted on each type and rating of HT motor
(a) No load saturation and loss curves upto approximately 115% of rated
voltage
(b) Measurement of noise at no load.
(c) Momentary overload test (subject to test bed constraint).
(d) Full load test
(e) Temperature rise test at rated conditions . During heat run test, bearing
temp., winding temp., core temp., coolant flow and its temp. shall also be
measured. In case the temperature rise test is carried at load other than
rated load, specific approval for the test method and procedure is required
to be obtained. Wherever ETD's are provided, the temperature shall be
measured by ETD's also for the record purpose.

8.01.08 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED
The following type test reports shall be submitted for each type and rating of
HT motor
(a) Degree of protection test for the enclosure followed by IR, HV and no load
run test.
(b) Terminal box-fault level withstand test for each type of terminal box of HT
motors only.
(c) Lightning Impulse withstand test on the sample coil shall be as per clause
5.1.3.2, IEC-60034, Part-15.
(d) Surge-withstand Voltage test on interturn insulation as per IEC 60034-158
8.02.00 LT MOTORS
8.02.01 All equipment to be supplied shall be of type tested design. During detailed
engineering, the contractor shall submit for Owner’s approval the reports of all the
type tests as per relevant standards and carried out within last ten years from the
date of bid opening. These reports should be for the tests conducted on the
equipment similar to those proposed to be supplied under this contract and the
test(s) should have been either conducted at an independent laboratory or should
have been witnessed by a client.
8.02.02 However if the Contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in case the type test report(s)
are not found to be meeting the specification requirements, the Contractor shall
conduct all such tests under this contract at no additional cost to the Owner either at
third part laboratory or in presence of client/owners representative and submit the
reports for approval.
price.
For subsequent projects if NTPC, an endorsement sheet will be furnished by the
manufacturer confirming similarity and “No Design Change”. Minor changes if any

9.00.00 DRAWING SUBMISSION PROCEDURE
Unique manufacturer specific reference drawing nos. shall be allotted by owner to

drawings of the equipment or components. Drawing once approved (for any project)
shall be treated as reference drawings for subsequent projects. An endorsement
sheet shall be submitted by manufacturer confirming similarity and minor changes if
any shall be highlighted on the endorsement sheet. However owner reserves right to
get the drawings submitted afresh.
The reference drawings so approved once along with endorsement sheet shall be
used for factory inspection of equipment whenever package/project specific drawings
are not submitted afresh/approved.

TABLE - I
DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS
Motor MCR in KW Minimum distance between

centre of stud and gland plate in
mm
UP to 3 KW As per manufacturer's practice.
Above 3 KW – upto 7 KW 85
Above 7 KW - upto 13 KW 115
Above 125 KW-upto 200 KW 203
For HT motors the distance between gland plate and the terminal studs shall not be
less than 500 mm.
NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with
lugs installed shall be as follows:
Motor MCR Clearance
Upto 110KW 10.0mm
Above 110KW and Upto 12.5mm

150KW
Above 150KW 19.0mm

PART - B
SUB-SECTION-IIIB-02
LT SWITCHGEAR & BUS DUCT

LT SWITCHGEAR & BUSDUCT
1.00.00 CODES AND STANDARDS IEC: 60947, IS : 13947, IEC: 60439,IS:8623,IEC:61850
2.00.00 TYPE
Circuit Breakers Shall be air break, three pole, spring charged,

horizontal drawout type, suitable for electrical
operation.
Switchgear Fully drawout type single front
MCC Fully drawout type single front/Double front.
ACDB/DCDB Fixed type single front
3.00.00 SYSTEM PARAMETERS
415VAC +/- 10 %(SOLIDLY GROUNDED)
50 Hz +3%/-5%
45KA RMS(105 KA PEAK) / 1SEC (FAULT LEVEL)
240V DC ISOLATED TYPE
The temperature rise of the horizontal and vertical busbars and main bus link
including all power draw out contacts when carrying 90% of the rated current along
the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C
with all other types of joints over an ambient of 50 deg C. The temperature rise of the
accessible parts/external enclosures expected to be touched in normal operation
shall not exceed 20 deg.C. The temperature rise of manual operating means shall
not exceed 10 deg. C for metallic & 15 deg. C for insulating material. The above
temperature rise limits are applicable for busducts also without any current derating.
5.01.00 Breakers
5.01.01 Breakers shall have anti-pumping feature.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
COAL HANDLING PLANT PACKAGE PART-B 1 OF 13
BUSDUCTS
5.01.02 The incomer and bus coupler breakers for switchgear shall be electrically operated
with Numerical communicable relays.
5.01.03 Breakers shall have inherent fault making and breaking capacities. They shall have
shunt trip coils. All breakers shall have built in interlocks for equipment and
personnel safety.
5.01.04 Paralleling of two supplies shall be avoided by interlocking except for switchgear
where auto-changeover is provided. Breaker contact multiplication, if required, shall
be through latch relay.
5.01.05 Mechanical tripping shall be through red ‘Trip’ push button outside the panels for
breakers, and through control switches for other circuits.
5.01.06 Provision of mechanical closing of breaker only in ‘Test’ and ‘Withdrawn’ position
shall be made. Alternatively, mechanical closing facility should be normally
inaccessible, accessibility rendered only after deliberate removal of shrouds. It shall
be possible to close the door with breaker in test position.
5.01.07 Clear status indication for each circuit shall be provided through lamps, switch
positions or other mechanical means.
5.02.00 Switches, Contactors and Fuses
5.02.01 Incomers for MCCs and DBs rated below 250A could be load break isolators.
5.02.02 Motor starter contactors shall be of air break, electromagnetic type suitable for DOL
starting of motor, and shall be of utilisation category AC-3 for ordinary and AC-4 for
reversing starters. For conveyor motors, minimum rating of power contactors shall be
200% of the full load current of the motors. For other motors minimum rating of
power contactors shall be 160% of full load current of motor. DC contactor shall be of
DC-3 utilisation category.
5.02.03 Fuses shall be HRC type with operation indicator. Isolating switches shall be of AC
23A category when used in motor circuit, and AC 22A category for other
applications. Fuse switch combination shall be provided wherever possible.
5.02.04 The 250A & above feeders up to 630A shall have MCCB.MCCB shall be provided
with Microprocessor based inbuilt front adjustable releases(overload & short circuit)
and shall have adjustable earth fault protection unit also . MCCB shall have current
limiting feature. ON and OFF position of the operating handle of MCCB shall be
displayed and the rotary operating handle shall be mounted on the door of the
compartment housing MCCB. The compartment door shall be interlocked
mechanically with the MCCB, such that the door can not be opened unless the

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
MCCB is in OFF position. Means shall be provided for defeating this interlock at any
time by making use of special tools/tackles. MCCB shall be provided with padlocking
facility to enable the operating mechanism to be padlocked.
5.03.00 Panels
5.03.01 All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall
have prominent engraved indentification plates.
5.03.02 Local push button stations shall have metal enclosure of die cast aluminium or rolled
sheet steel of 1.6mm thickness & shall be of DOP IP55. The DOP shall be IP-65 in
case the same are located in dusty areas. Push buttons shall be of latch type with
mushroom knobs.
5.03.03 Where breaker/starter module front serves as compartment cover, suitable blanking
covers, one for each size of modules per switchboard shall be supplied for use when
carriage is withdrawn.
5.03.04 All non-current carrying metal work of boards/panels shall be effectively bonded to
earth bus of galavanised steel, extending throughout the switchboard/MCC/DB.
Positive earthing shall be maintained for all positions of chassis and breaker frame.
5.03.05 Suitable trolley arrangement shall be provided for breaker/starter modules. Two
trolleys per switchgear room shall be provided so that top most breaker module of all
types, sizes and rating can be withdrawn on trolley and lowered for maintenance
purpose.
5.03.06 The incoming connection to transformer of more than 1000KVA and inter-connecting
sections between switchboards shall preferably be of busducts. The busduct
enclosure shall be made of minimum 3mm thick aluminium alloy. The section of the
busduct should have adequate strength to withstand internal and external forces
resulting from the various operating conditions. Aluminium sheet hood shall be
provided for outdoor busduct enclosure joints to provide additional protection against
water ingress. The busduct top shall be sloped to prevent retention of water.The
busduct enclosure shall have DOP of IP55 and paint shade RAL 5012.
5.03.07 It should be possible to carryout maintenance on a feeder with adjacent feeders

alive.
5.03.08 DC fuse board shall consist of:
-1 no.63A switch as incomer with meters, lamps and auxiliary contactors.
-8 nos. outgoing feeders with 16A HRC fuses.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
5.03.09 AC fuse board shall consist of:
-1 no 63A TPN SFU as incomer with lamps and meters.
-9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing.
5.03.10 Main lighting distribution board(MLDB) to be located in MCC room shall consist of:-
a) Two(2) nos. x 100% rated, lighting transformers (415V/433V, delta/star, epoxy

insulated, air cooled, dry type). Transformer shall be 50KVA/100KVA rating for
10/15 nos. outgoing feeder.
b) TPN SFU on primary and secondary side of the transformer
c) 63A TPN SFU as outgoing feeders including 20% spare.
d) Voltmeter, ammeter with selector switches, indicating lamps.
e) The two incomers (One from Bus-A and One from Bus-B of the MCC) and one
bus-coupler for the power supply to each MLDB shall be provided with castle key
networks.
5.03.11 Welding distribution board (WDB) to be located in MCC room shall consist of:-
a) One (1) no welding transformer (415V/433V, delta/star, epoxy insulated, air

cooled, dry type). Transformer shall be 50KVA/100KVA.
b) TPN SFU on primary and secondary side of the transformer
c) 63A TPN SFU as outgoing feeders including 20% spare.
d) Voltmeter, ammeter with selector switches, indicating lamps.
5.03.12 MCCs located on the Stacker reclaimer, paddle feeders, travelling trippers shall be
fixed type, compartmentalized, single front and suitable for the system fault level.No
spare feeders are to be provided on these MCCs. Degree of protection for the MCCs
mounted on paddle feeders and travelling trippers shall be IP-65.
5.04.00 Control, Protection & Metering Requirements
5.04.01 Control circuits shall operate at suitable voltage of 110V AC or 240V DC. Necessary
control supply transformers having primary and secondary fuses shall be provided
for each MCC, 2 x 100% per bus section. However the breakers shall operate on
240V DC The auxiliary bus bars for control supply shall be segregated from main bus
bars. The control supplies shall be monitored.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
DC operated spring charging motor shall be suitable for voltage variation between
198V-242V DC. The closing coil of circuit breaker shall operate correctly at all values
of voltage between 187V-242V DC. The trip coil of circuit breaker shall operate
satisfactorily at all values of voltage between 154V-242V DC.
DC operated contactor coil shall have an economy resistor and shall be suitable for
satisfactory continuous operation at 187V-242V DC
5.04.02 Contractor shall fully co-ordinate overload and short circuit tripping of breaker with
upstream and down stream breakers/fuses/MCCBs motor starters. Various
equipments shall meet requirement of Type-II class of coordination as per IEC.
5.04.03 The protective relays shall be communicable numerical relays These numerical
relays shall be of types as proven for the application and shall be subject to
Employer’s approval Numerical relays shall have appropriate setting ranges,
accuracy, resetting ratio and other characteristics to provide required sensitivity. All
equipments shall have necessary protections as detailed in the standard scheme
drawings.
5.04.04 All equipments shall have necessary protections. However, following minimum
protections shall be provided:
1) Contactor controlled motor feeders (Motors up to 200 kW)
a) Instantaneous short circuit protection on all phases through HRC

cartridge type fuses rated for 80 kA rms (prospective breaking
capacity at 415V).
b) Thermal overload protection
c) Single phasing protection for motors protected by fuses
2) Incomers / buscoupler / outgoing breaker feeders other than motor feeders.
a) Three phase overcurrent protection (50)
b) Three phase earthfault protection (50N3)
c) Restricted earth fault protection for transformer incomers(64R)
d) Sync Check

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
5.05.00 General requirements of Numerical Relays
5.05.01 All relays and timers shall be rated for control supply voltage as mentioned
elsewhere under parameters and shall be capable of satisfactory continuous
operation between 80-120% of the rated voltage. Making, carrying and breaking
current ratings of their contacts shall be adequate for the circuits in which they are
used. Interrogation voltage for the binary inputs shall be suitably selected to ensure
avoidance of mal operation due to stray voltages.
5.05.02 Numerical relays shall have communications on two ports, local front port for
communication to laptop and a second port on IEC 61850 to communicate with
owner’s data concentrator through LAN.
5.05.03 All Numerical Relays shall have features for electrical measurement including
voltage, current, power (active / reactive) and energy parameters.
5.05.04 All Numerical Relay shall have key pad / keys to allow relay settings from relay front.
All hand reset relays shall have reset button on the relay front. Relay to be self or
hand reset shall be software selectable. Manual resetting shall be possible from
remote.
5.05.05 The protective relays shall have at least 10 Nos. programmable potential free
contacts. Programmable Auxiliary relays shall have contacts as required.
5.05.06 For control from DDCMIS, 24V DC signal shall be provided from DDCMIS to the
numerical relays. Preferably, no separate coupling relays shall be provided.
5.05.07 Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker
trip circuit both in pre trip and post trip conditions.
5.05.08 Schematics requiring auxiliary relays / timers for protection function shall be a part of
Numerical Relay. The number of auxiliary relay and timer function for protection
function shall be as required by the scheme. Auxiliary relays for interlocking purpose
shall be of self reset type.
5.05.09 The numerical processor shall be capable of measuring and storing values of a wide
range of quantities, all events, faults and disturbance recordings with a time
stamping using the internal real time clock. Battery back up for real time clock in the
event of power supply failure shall be provided.
5.05.10 Sequence of events shall have 1ms resolution at device level.
5.05.11 Ethernet switches shall be “substation hardened” and shall comply to IEC61850-3 for
communications and environment requirements. The Ethernet switches shall be of

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
managed type with four (4) nos. fiber optic cable and sixteen/eight nos. copper ports
to achieve the owners’ LAN configuration. One(1) no. Ethernet switch per switch
board shall be provided & these switches shall be mounted inside the switchgear
Panels. Ethernet switches shall be suitable for single mode FO cable connections
5.05.12 In case of remote controlled breaker panels, following shall be ensured.
The circuit breaker will normally be controlled from remote control panels (employer’s
DDCMIS) through closing and shunt trip coils. The Local control console of the relay
flush mounted on the switchgear would normally be used only for testing of circuit
breaker in isolated position, and for tripping it in an emergency. Provision for closing
& tripping of the circuit breaker locally from laptop through serial port shall be
possible to facilitate commissioning activities. The basic control scheme of breaker
feeders shall be developed as per the schematic logics in the relay. The schematics
shall be developed in soft inside the relay. Numerical relays shall be interfaced with
employer’s DDCMIS through 24V DC signal for closing / opening operations.
5.05.13 Hardwired contacts from the relay shall be wired to PLC / DCS system as per
requirements. The numerical relay shall be capable of measuring and storing values
of a wide range of quantities, events, faults and disturbance recordings.
5.05.14 The alarm / status of each of protection function and trip operation shall be
communicated to PLC/DCS. The numerical relays shall have built in feature /
hardware interface to provide such inputs to PLC / DCS for analog / digital values..
5.05.15 It shall be possible to carryout open / close operation of breakers from a laptop by
interfacing from the relay front port (RS232) during initial commissioning.
5.06.00 Meters / instruments
All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size
with 90 degree linear scales and accuracy class of 2.0.
5.06.01 All motors of 30kW and above rating upto 100 kw shall have an Ammeter & current
transducer. Each bus-section shall have bus VT, voltmeter with selector switch, and
other relay and timers required for protection. Adequate control and selector
switches, push buttons and indicating lamps shall be provided. Thermostatically
controlled space heaters with switches shall be provided to prevent condensation.
5.06.02 For all motor feeders related to dust suppression system and for all other motor
feeders having 100KW & above rating, contractor shall provide multifunction Digital
Energy Meter with communication facility to display the current, voltage, power
factor, power, energy related data locally and shall communicate these for remote
metering /audit/analysis purposes. The technical specification for Digital indicating
energy meter shall be as follow:

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
a) Input Voltage: 110 V AC/220 V DC
b) Input Current:1A
c) Size: 96X96 SQ.MM
d) Accuracy:1.0% for power & energy
e) Mounting: Flush mounting
f) Type:True RMS 3-PHASE V, I,KW,PF & KWHr indication
g) 4 Digit, seven segment LED display/LCD display, with floating decimal
h) Communication: In built RS 485 serial bus port
i) Operating Frequency: 45 HZ-65HZ
j) Dielectric Test: 2KV RMS for 1 minute
k) Over current: 10 times for 3 sec.
l) Aux. supply: 90V-300V AC/DC
m) Compliance: EMC/EMI
n) Field programmable CT ratio
o) Analogue Current and Energy Output (4-20 mA)
5.07.00 Control from Remote
Necessary hardware shall be provided in the switchgear panel like coupling relays (if
required ) of 24V DC, with max. burden of 2.5VA, auxiliary relays, current/voltage
transducers (4-20 mA, dual output) etc. to effect interlocks, exchange information /
status and exercise control from remote.
6.01.00 All 415V switch gear motor control centers (MCCs), AC & DC distribution boards (DB
s), etc shall have following features :
1) Shall be of metal enclosed, indoor, floor mounted and free standing type.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
2) All frames and load bearing members shall be fabricated using mild steel
structural sections or pressed and shaped cold rolled sheet steel of thickness
not less than 2mm.
3) Frame shall be enclosed in cold rolled sheet steel of thickness not less than
1.6mm.Doors and covers shall also be of cold rolled sheet steel of thickness
not less than 1.6 mm. Stiffeners shall be provided wherever necessary.
Removable gland plates of thickness 3mm (hot/cold rolled sheet steel) or 4
mm (non-magnetic material) shall be provided for all panels.
4) All switchboards/panels shall be of dust and vermin proof. All cutouts shall
have EPDM/Neoprene gaskets.
5) All switchboards, MCCs and DB s shall have following distinct vertical

sections.
a) Completely enclosed bus bar compartment for horizontal and vertical

bus bars.
b) Completely enclosed switchgear compartments (one for each circuit

housing circuit breakers, motor starter or switch-fuse feeder).
c) A full height vertical cable alley of minimum 250 mm width shall be

provided for power and control cables. Cable alley shall have no
exposed live parts and shall have no communication with busbar
compartment. Cable terminations located in cable alley shall be
designed to meet the form IVb type 7 (as per IEC 60439) for safety
purpose. The termination for each module shall have its own integral
glanding facility. Wherever cable alleys are not provided for
distribution board, segregated cable boxes for individual feeders shall
be provided at the rear for direct termination of cables.
d) For cable connection to circuit breaker, a separately enclosed cable

compartment shall also be acceptable.
e) Compartment for relays and other control devices associated with a

circuit breaker, wherever necessary.
f) The switchboards/MCC/DBs of 1600A & above rating shall be of DOP

IP42 & of IP52 for less than 1600A rating.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
g) All 415V switchgears, MCC’s, AC & DC distribution boards etc. shall be

painted by powder coating process. Paint shade for complete panels
excluding end covers shall be RAL9002 & RAL5012 for extreme end
covers of all boards.
h) All draw out modules shall have distinct service, test and isolated
positions with provision of external pad locking facility in each
position. Power contacts shall get disconnected in both test and
isolated positions whereas the control contacts shall get
disconnected in isolated position only.
6) Busbars shall be of high conductivity aluminium alloy or copper and entire

busbar system shall be insulated with PVC sleeves.
7) The cross section of the horizontal bus bars shall be uniform through out the
length of the switchboard and both horizontal as well as vertical bus bars
shall be adequately supported and braced to withstand the stresses due to
the specified short circuit currents. Neutral bus bar short circuit strength shall
be same as the main bus bars.
8) Minimum air clearance in air between phases and phase-earth shall be 25

mm for busbars and cable terminations. For all other components, the
Clearances shall be at least 10mm. Wherever above is not possible except
for horizontal and vertical busbars, insulation shall be provided by anti
tracking sleeving or barriers. However for horizontal and vertical busbars,
clearances specified above shall be maintained even when busbars are
insulated/sleeved. In case of DC DBs/ fuse boards, the busbar system shall
be insulated or physically segregated with barriers to prevent interpole short
circuit.
9) Busbar insulators shall be of track-resistant high strength non-hygroscopic,

non-combustible type and suitable to withstand stresses due to over-voltages
and short circuit current. Insulators and barrier of inflammable material such
as Hylam shall not be accepted.
10) All types of relays and timer shall be subject to Employer’s approval. They
shall be flush mounted with connections from inside, and shall have
transparent & dust tight cover, removable from front, drawout construction for
easy replacemernt and testing facility. The auxiliary relays and timer may be
provided in fixed cases.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
11) Terminal Blocks
Terminal blocks shall be 650V grade, 10Amps rated, made up of

unbreakable polyamide 6.6 grade. The terminals shall be either screw type
or screw-less (spring loaded) / cage clamp type with lugs. Marking on
terminal strips shall correspond to the terminal numbering in wiring
diagrams. All metal parts shall be of non-ferrous material. In case of screw
type terminals the screw shall be captive, preferably with screw locking
design. Maxi terminal / cage clamp type terminal blocks shall be provided
for signals to be interfaced with DDCMIS / PLC.
12) The switchgears/MCC shall be designed to offer adequate level of safety to

operating/ maintenance personnel. Means shall be provided to prevent
access to the live part to avoid accidents during service as well as
maintenance period. Bidder shall bring out the safety means provided to
achieve above. A detailed instruction plate suitable for wall mounting shall be
provided for each switchgear/MCC room describing various safe operating
procedure/safety precautions for safe operation and maintenance of
switchgear/MCC.
13) All current and voltage transformers as required for metering & protection
specified shall be completely encapsulated cast resin insulated type. Incomers
from transformers shall have CTs for transformer REF protection. The
accuracy shall be as follows:
CTs PTs
Protection 5P20,5VA 3P
Metering 1.0 0.5

REF PS
6.02.00 Indicating lamps shall be cluster LED type.All overload relays shall have overload
reset push button.
6.03.00 Switchgear/MCC shall have bottom cable entry.
7.00.00 TYPE TESTS
7.01.00 GENERAL
(a.) All equipments to be supplied shall be of type tested design. During detailed
engineering, the contractor shall submit for Owner’s approval the reports of
all the type tests as listed in this specification and carried out within last ten

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
years from the date of bid opening. These reports should be for the test
conducted on the equipment similar to those proposed to be supplied under
this contract and the test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client.
(b.) However if the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the
type test report(s) are not found to be meeting the specification requirements,
the Contractor shall conduct all such tests under this contract, at no additional
cost to the Owner either at third party lab or in presence of client/owners
representative and submit the reports for approval.
(c.) All acceptance and routine tests as specified below and in relevant standards
shall be carried out. Charges for these shall be deemed to be included in the
equipment price.
(d.) The type test reports once approved for any projects shall be treated as
reference. For subsequent projects if NTPC, an endorsement sheet will be
furnished by the manufacturer confirming similarity and “No Design Change”.
Minor changes if any shall be highlighted on the endorsement sheet.
7.02.00 BUSDUCTS (as applicable)
The following type test certificates on each rating of bus duct shall be submitted.
(a.) Heat run test on an assembly of representative sections and fittings
(b.) Short circuit test for a duration and current as covered in the specification on
an assembly of representative section.
(c.) One minute high potential power frequency voltage withstand test.
(d.) Degree of protection test.
7.03.00 L. T. SWITCHGEAR
The following type test certificates on each type & rating of L.T. Switchgear and MCC
panel shall be submitted.
(a.) Short time withstand test.
(b.) Temperature rise test.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
(c.) Type II - Short circuit co-ordination test for any three ratings of MCC module
as selected by the Employer.
(d.) Test sequence –1 & combined test sequence shall be carried out on each
rating of circuit breaker mounted inside the panel.
(e.) Degree of protection tests
(f.) Type test certificates for numerical relays.
8.00.00 DRAWING SUBMISSION PROCEDURE
Unique manufacturer specific reference drawing nos. shall be allotted by owner to

drawings of the equipment or components. Drawing once approved (for any project)
shall be treated as reference drawings for subsequent projects. An endorsement
sheet shall be submitted by manufacturer confirming similarity and minor changes if
any shall be highlighted on the endorsement sheet. However owner reserves right to
get the drawings submitted afresh.
The reference drawings so approved once along with endorsement sheet shall be
used for factory inspection of equipment whenever package/project specific drawings
are not submitted afresh/approved.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUSDUCTS
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PART - B
SUB-SECTION-IIIB-03
LT POWER CABLES

POWER CABLES
1.01.00 All standards, specifications and codes of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions as on date
of opening of bid. In case of conflict between this specification and those (IS : codes,
standards, etc.) referred to herein, the former shall prevail. All the cables shall
conform to the requirements of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working

voltages upto and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wires and tapes
for armouring of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for
working voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning
or decomposition of plastics.
ASTM-D-2863 Standard method for measuring the minimum oxygen
concentration to support candle like combustion of plastics.
IEC-754 (Part-I) Test on gases evolved during combustion of electric cables.
IEEE-383 Standard for type test of Class IE Electric Cables.
IEC -332 Tests on Electric cables under fire conditions.

Part-3 : Tests on bunched wires or cables (category -B)

STAGE-II (2X195 MW) SUB-SECTION-IIIB-03 PAGE
SECTION-VI, PART-B
COAL HANDLING PLANT PACKAGE POWER CABLE 1 OF 8
2.00.00 TECHNICAL REQUIREMENTS
2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground burried installation with chances of flooding by water.
2.02.00 Cables shall be armoured, flame retardant, low smoke (FRLS), type designed to
withstand all mechanical, electrical and thermal stresses develop under steady state
and transient operating conditions as specified elsewhere in this specification.
2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than
100 N/ sq.mm. Conductors shall be multi stranded.
2.04.00 XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg.
C and short circuit conductor temperature of 250 deg.C. PVC insulation shall be
suitable for continuous conductor temperature of 70 deg C and short circuit
conductor temperature of 160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It
shall not stick to insulation and inner sheath. All the cables, other than single core
unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as
per IS : 5831.
2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For
multicore armoured cables armouring shall be of galvanised steel as follows : -
Calculated nominal dia Size and Type of armour
of cable under armour
i) Upto 13 mm 1.4mm dia GS wire
ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6
mm dia GS wire
iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire /
2.0mm dia GS wire
iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire
/2.5mm dia GS wire
v) Above 55 & upto 70 mm 1.4mm thick GS formed wire /
3.15mm dia GS wire
vi) Above 70mm 1.4 mm thick GS formed wire / 4.0
mm dia GS wire
2.06.01 The aluminium used for armouring shall be of H4 grade as per IS:8130 with
maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of
aluminium wires/formed wires for armouring shall be same as indicated above in
clause 2.06.00 for galvanised steel.

SECTION-VI, PART-B
2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /
formed wire. Zinc rich paint shall be applied on armour joint surface of G.S.
wire/formed wire.
2.07.00 Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to meeting
all the requirements of Indian standards referred to, outer sheath of all the cables
(including trailing cables) shall have the following FRLS properties.
(a.) Oxygen index of min. 29 (As per ASTMD 2863)
(b.) Acid gas emission of max. 20% (As per IEC-754-I).
(c.) Smoke density rating shall not be more than 60% during Smoke Density Test
as per ASTMD-2843.
2.08.00 Cores of the cables shall be identified by colouring of insulation. Following colour
scheme shall be adopted:
1 core Red, Black, Yellow, Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
2.09.00 For reduced neutral conductors the core shall be black.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking

shall also be provided over outer sheath.
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Sequential marking of length of the cable in metres at every one metre-To be
embossed / printed
The embossing shall be progressive, automatic, in line and marking shall be legible
and indelible. For EPR cables identification shall be printed on outer sheath.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332
Part -3.

SECTION-VI, PART-B
2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum over the declared value in the technical data sheets.
2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes
etc.are not acceptable.
2.14.00 Cable selection & sizing
2.14.01 Cables shall be sized based on the following considerations:
(a) Rated current of the equipment
(b) The voltage drop in the cable, during motor starting condition, shall be
limited to 10% and during full load running condition, shall be limited
to 3% of the rated voltage
(c) Short circuit withstand capability
This will depend on the feeder type. For a fuse protected circuit, cable
should be sized to withstand the let out energy of the fuse. For
breaker controlled feeder, cable shall be capable of withstanding the
system fault current level for total breaker tripping time inclusive of
relay pickup time.
2.14.02 Derating Factors
Derating factors for various conditions of installations including the following

shall be considered while selecting the cable sizes:
a) Variation in ambient temperature for cables laid in air
b) Grouping of cables
c) Variation in ground temperature and soil resistivity for buried cables.
2.14.03 Cable lengths shall be considered in such a way that straight through cable joints are
avoided.

SECTION-VI, PART-B
2.14.04 All power cables of sizes more than 120 sq.mm. shall be XLPE insulated and
preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm.
3.00.00 CONSTRUCTIONAL FEATURES
(a.) 1.1 KV grade XLPE power cables shall have compacted aluminium
conductor, XLPE insulated, PVC inner-sheathed (as applicable), PVC outer-
sheathed conforming to IS:7098. (Part-I).
(b.) 1.1KV grade PVC power cables shall have aluminium conductor (compacted
type for sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as
applicable), PVC outer-sheathed conforming to IS:1554 (Part-I).
(c.) Trailing cables shall have tinned copper (class 5) conductor, insulated with
heat resistant elastomeric compound based on Ethylene Propyline Rubber
(EPR) suitable for withstanding 90 deg.C continuous conductor temperature
and 250deg C during short circuit, inner-sheathed with heat resistant
elastomeric compound, nylon cord reinforced, outer-sheathed with heat
resistant, oil resistant and flame retardant heavy duty elastomeric compound
conforming to IS 9968.
4.00.00 CABLE DRUMS
(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with water proof layer. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection. Wood
preservative anti-termite treatment shall be applied to the entire drum.
Wooden drums shall comply with IS : 10418.
(b.) Each drum shall carry manufacturer's name, purchaser’s name, address and
contract number, item number and type, size and length of cable and net
gross weight stenciled on both sides of the drum. A tag containing same
information shall be attached to the leading end of the cable. An arrow and
suitable accompanying wording shall be marked on one end of the reel
indicating the direction in which it should be rolled.
5.00.0 TESTS
years from the date of bid opening. These reports should be for the tests

SECTION-VI, PART-B
equipment price.
reference. For subsequent projects of NTPC, an endorsement sheet will be
Minor changes if any shall be highlighted on the endorsement sheet
5.01.00 TYPE TESTS
5.01.01 The reports for the following type tests shall be submitted for one size each of
XLPE/PVC Power cables:
S.No. Type Test Remarks
For Conductor
1. Tensile test For aluminium conductor only.
2. Wrapping test For aluminium conductor only.
3. Resistance test
For Armour Wires/ Formed Wires
5. Measurement of Dimensions
6. Tensile Test
7. Elongation test
8. Torsion test For round wires only
9. Wrapping test For aluminium wires/formed wires only
10. Resistance test
11.(a) Mass of Zinc Coating test For G.S. Formed wires /wires only.

SECTION-VI, PART-B
11.(b) Uniformity of zinc coating For G.S. Formed wires /wires only.
12. Adhesion test For G.S. Formed wires /wires only.
For PVC/XLPE insulation & PVC Sheath
13. Test for thickness
14. Tensile strength & elongation tests before ageing and after ageing
15. Ageing in air oven
16. Loss of mass test For PVC insulation and sheath only
17. Hot deformation test For PVC insulation and sheath only
18. Heat shock test For PVC insulation and sheath only
19. Shrinkage test
20. Thermal stability test For PVC insulation and sheath only
21. Hot set test For XLPE insulation only
22. Water absorption test For XLPE insulation only
23. Oxygen index test For outer sheath only
24. Smoke density test For outer sheath only
25. Acid gas generation test For outer sheath only

SECTION-VI, PART-B
For completed cables
26. Insulation resistance test

(Volume resistivity method)
27. High voltage test
28. Flammability test as per IEC - 332 Part-3 (Category -B)
5.01.02 The reports for all the type tests as per IS 9968 (Along with test reports for FRLS
Properties and flammability test) shall be submitted for one size of each voltage
grade of trailing cables.
5.02.00 Acceptance Tests and Routine tests

Refer QA table enclosed with specification.

SECTION-VI, PART-B
PART - B
SUB-SECTION-IIIB-04
CONTROL CABLES

TECHNICAL REQUIREMENTS
CLAUSE NO.
CONTROL CABLES
of opening of bid. In case of conflict between this specification and those (IS: codes,
standards, etc.) referred to herein, the former shall prevail. All the cables shall
conform to the requirements of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working

voltages upto and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wire and tapes for
armouring of cables.
IS : 4905 Methods for random sampling.
IS : 5831 PVC insulation and sheath of electrical cables.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D –2843 Standard test method for density of smoke from the burning
or decomposition of plastics.
ASTM-D-2863 Standard method for measuring the minimum oxygen

concentration to support candle like combustion of plastics.
IEC-754 (Part-I) Test on gases evolved during combustion of electric cables.
IEEE-383 Standard for type test of Class IE Electric Cables.
IEC –332 Tests on Electric cables under fire conditions.

Part-3 : Tests on bunched wires or cables (category -B)
SECTION-VI, PART-B
COAL HANDLING PLANT PACKAGE CONTROL CABLES 1 OF 7
CLAUSE NO.
2.00.00 TECHNICAL REQUIREMENTS
2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground burried installation with chances of flooding by water.
2.02.00 Cables shall be armoured. flame retardant, low smoke (FRLS), type designed to
withstand all mechanical, electrical and thermal stresses develop under steady state
and transient operating conditions as specified elsewhere in this specification.
2.03.00 Conductor of control cables shall be made of multi stranded, plain annealed copper.
2.04.00 PVC insulation shall be suitable for continuous conductor temperature of 70 deg C
and short circuit conductor temperature of 160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It
shall not stick to insulation and inner sheath. All the cables, other than single core
unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as
per IS : 5831.
2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as follows:
-
Calculated nominal dia. Size and Type of armour
of cable under armour
1) Upto 13 mm 1.4mm dia GS wire
2) Above 13 upto 25 mm 0.8 mm thick GS formed wire / 1.6 mm dia

GS wire
3) Above 25 upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia
GS wire
4) Above 40 upto 55mm 1.4 mm thick GS formed wire/2.5mm dia
GS wire
5) Above 55 upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia
GS wire
6) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia
GS wire
The gap between armour wire / formed wire shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /
formed wire. Zinc rich paint shall be applied on armour joint surface.
2.07.00 Outer sheath shall be of PVC (grade as applicable) and grey in colour . In addition to
meeting all the requirements of Indian standards referred to, outer sheath of all the
cables (including trailing cables) shall have the following FRLS properties.

SECTION-VI, PART-B
CLAUSE NO.
(a.) Oxygen index of min. 29 (As per ASTMD 2863)
(b.) Acid gas emission of max. 20% (As per IEC-754-I).
(c.) Smoke density rating shall not be more than 60% during Smoke Density Test
as per ASTMD-2843.
2.08.00 Cores of the cables of upto 5 cores shall be identified by colouring of insulation.
Following colour scheme shall be adopted.
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
5 core - Red, Yellow, Blue, Black and Grey
2.09.00 For cables having more than 5 cores, core identification shall be done by numbering
the insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say
for 10 core cable, core numbering shall be from 1 to 10). The number shall be printed
in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers shall be
of the same colour, which shall contrast with the colour of insulation. The colour of
insulation for all the cores shall be grey only. The numerals shall be legible and
indelible. The numbers shall be repeated at regular intervals along the core,
consecutive numbers being inverted in relation to each other. When the number is a
single numeral, a dash shall be placed underneath it. If the number consists of two
numerals, these shall be disposed one below the other and a dash placed below the
lower numeral. The spacing between consecutive numbers shall not exceed 50 mm.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking

shall also be provided over outer sheath:
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Sequential marking of length of the cable in metres at every one metre. -
To be embossed / printed.
The embossing / printing shall be progressive, automatic, in line and marking

shall be legible and indelible. For EPR cables identification shall be printed on
outer sheath.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC
332 Part -3.

SECTION-VI, PART-B
CLAUSE NO.
2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum over the declared value in the technical data sheets.
2.13.00 Inplant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc.
are not acceptable.
2.14.00 Cable selection & sizing

Control cables shall be sized based on the following considerations:
(a) The minimum conductor cross-section shall be 1.5 sq.mm.
(b) The minimum number of spare cores in control cables shall be

as follows:
No. of cores in cable Min. No. of spare cores
2C, 3C NIL
5C 1
7C-12C 2
14C & above 3
2.14.01 Cable lengths shall be considered in such a way that straight through cable joints
are avoided.
3.00.00 CONSTRUCTIONAL FEATURES
3.01.00 1.1 KV Grade Control Cables shall have stranded copper conductor multicore PVC
insulated, PVC inner-sheathed, PVC outer-sheathed conforming to IS:1554. (Part-I).
3.02.00 1.1KV grade trailing cables shall have tinned copper (class-5) conductor, insulated
with heat resistant elastomeric compound based on Ethylene Propyline Rubber
(EPR) suitable for withstanding 90 deg C continuous conductor temperature and 250
deg C during short Ckt., inner sheathed with heat resistant, oil resistant and flame
retardant heavy duty elastomeric compound conforming to IS 9968. Minimum
conductor size shall be 2.5sqmm.
4.00.00 CABLE DRUMS
(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with water proof layer. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection. Wood
SECTION-VI, PART-B
CLAUSE NO.
preservative anti-termite treatment shall be applied to the entire drum. Wooden

drums shall comply with IS : 10418.
(b.) Each drum shall carry manufacturer's name, purchaser’s name, address and
contract number, item number and type, size and length of cable and net gross
weight stenciled on both the sides of the drum. A tag containing same
information shall be attached to the leading end of the cable. An arrow and
suitable accompanying wording shall be marked on one end of the reel
indicating the direction in which it should be rolled.
5.00.00 TESTS
equipment price.
5.01.00 TYPE TESTS
5.01.01 The reports for the following type tests shall be submitted for one size of control
cables :
S. No. Type Test Remarks

For Conductor
1. Resistance test
For Armour Wires / Formed Wires

SECTION-VI, PART-B
CLAUSE NO.
2. Measurement of Dimensions
3. Tensile Test
4. Elongation test
5. Torsion test For round wire only
6. Wrapping test
7. Resistance test
8(a). Mass of zinc Coating test For GS wires/formed wires only
8(b). Uniformity of zinc coating For GS wires/formed wires only
9. Adhesion test For GS wires/formed wires only
For PVC insulation & PVC Sheath
10. Test for thickness
11. Tensile strength and elongation before ageing and after ageing
test
13. Ageing in air oven
14. Loss of mass test For PVC insulation and sheath only
15. Hot deformation test For PVC insulation and sheath only
16. Heat shock test For PVC insulation and sheath only
17. Shrinkage test
18. Thermal stability test For PVC insulation and sheath only
19. Oxygen index test For outer sheath only
20. Smoke density test For outer sheath only
21. Acid gas generation test For outer sheath only
For completed cables
22. Insulation resistance test(Volume resistivity method)
23. High voltage test
24. Flammability test as per IEC - 332 Part-3 (Category-B)

SECTION-VI, PART-B
CLAUSE NO.
5.01.02 The reports for all the type tests as per IS 9968 (Along with test reports for FRLS
Properties and flammability test) shall be submitted for one size of trailing cables.
5.02.00 Acceptance Tests and Routine tests

Refer QA table enclosed with specification.
.

SECTION-VI, PART-B
PART - B
SUB-SECTION-IIIB-05
INSTRUMENTATION CABLES

1.00.00 INSTRUMENTATION CABLES
1.01.00 GENERAL
1.01.01 The Contractor shall supply, erect, terminate and test all instrumentation cables for
control and instrumentation equipment/devices/systems included under Contractor's
scope.
1.01.02 Any other application where it is felt that instrumentation cables are required due to
system/operating condition requirements, are also to be provided by Contractor.
1.01.03 Other type of cables like fiber optic/co-axial cables for system bus, cables for
connection of peripherals etc. (under Contractor's scope) are also to be furnished by
the Contractor.
1.01.04 Contractor shall supply all cable erection and laying hardware trays, supports,
flexible conduits, cable glands, lugs, pull boxes etc. on as required basis for all the
systems covered under this specification.
1.02.00 Instrumentation Cable Specifications
1.02.01 All the instrumentation cables shall be Armoured, twisted, shielded multipair, pre
fabricated, flame retardant low smoke (FRLS) type. The Cables shall be provided in
non-returnable drums. The drum length shall be 1000m (+/-5%) up to & including 12
pairs and 500 m (+/- 5%) above 12 pairs.
1.02.02 Voltage grade of the instrumentation cables shall be 225V (peak value).
1.02.03 All instrumentation cables covered in this specification shall comply with VDE 0815,
VDE 0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN 4241475, ANSI MC
96.1, IS-8784, IS-10810 (latest editions) and its amendments read along with this
specification.
1.02.04 The conductor shall be of minimum 0.5-sq.mm size, high conductivity, multi-stranded
copper for all types of instrumentation cables where as the same shall be min.
1.5sqmm when used in the trailing cables.
1.02.05 The insulation of individual conductor shall be extruded PVC meeting the
requirements of VDE 0207 Part 4 compound Y I3. The outer sheath of
instrumentation cables shall be extruded PVC (compound YM1) as per VDE 0207
Part 5 and shall be of flame-retardant low smoke (FRLS) type. The cable shall be
provided with marking including manufacturer's name, insulation material, and
conductor sizes, no of pairs, voltage ratings, type of cable etc. at intervals not

STAGE-II (2X195 MW) SUB-SECTION-IIIB-05
SECTION-VI PAGE
COAL HANDLING PLANT PACKAGE INSTRUMENTATION
PART-B 1 OF 13
BID DOCUMENT NO. : CS-0350-155(R)-2 CABLES
exceeding 625mm. Progressive sequential marking of the length of the cable at

every one meter & progressive markings to read 'FRLS' at every 5 meters shall be
provided on the outer sheath of all instrumentation cables. The colour of outer sheath
shall be sky blue.
Fillers in multiple conductor cables shall be flame retardant and moisture

resistant. Cable accessories such as harnessing components, markers,
bedding, cable jointer, binding tape etc. shall also have flame retardant quality.
1.02.06 All instrumentation cables shall be provided with overall shielding. However, multipair
cables carrying analog signals shall be provided with individual pair shielding in
addition to overall shielding. Shielding shall be of Aluminium-Mylar tape with 100%
coverage and with atleast 20% overlapping. The thickness of individual pair shield
shall be 28 micron (minimum) and that of overall shield shall be 55 microns
(minimum). Separate drain wires for individual pair shield (wherever applicable) as
well as overall shield shall be provided. Drain wire shall be of seven (7) strand 20
AWG (0.51 Sq.mm) tin coated copper conductor. Maximum lay of individual twisted
pair shall be 50 mm. Bidder to ensure that individual core diameter shall be suitable
for maxi-termi connection. Insulation thickness of individual core shall be between
0.28 and 0.35 mm for 0.5 mm2 cables.
1.02.07 The outer sheath of the instrumentation cables shall meet the following minimum
requirements:
(i) An Oxygen index of not less than 29% and a Temperature index of not less
than 250 deg.C as per ASTMD-2863.
(ii) Maximum acid gas generation by weight as per IEC-754-I shall not be more
than 20%.
(iii) Smoke Density Rating shall not be more than 60% during Smoke Density
Test as per ASTMD-2843. The results of smoke density test shall be plotted
on a curve indicating light absorption vs. time as per ASTMD2843. The
average area under the curve (smoke density rating) shall not be more than
60%.
(iv) Complete cable assembly shall pass Swedish Chimney test as per SEN-
4241475 and flammability test as per IEEE-383.
The thickness of outer sheath shall be as per the guidelines given in VDE 0816.
Thickness of outer sheath shall not be less than 1.8 mm in any case. Allowable
tolerance of overall diameter of the cables shall be +/-2 mm max. over the
declared value in technical data sheets. The variation in diameter and the
ovality at any cross section shall not be more than 1.0 mm.

SECTION-VI PAGE
PART-B 2 OF 13
1.02.08 All instrumentation cables shall be suitable for continuous operation at 70 deg.C,
except for high temperature resistant teflon insulated cables which shall be suitable
for continuous operation at 205 deg.C. The cables shall be suitable for laying in wet
or dry locations in trays, conduits, ducts, trenches and under ground buried
installations.
1.02.09 The thermocouple extension cables shall be of single/multi pair, twisted & shielded,
PVC insulated, FRLS PVC sheathed and compatible for the type of thermocouples
employed. The material of conductor shall be as per ANSI MC-96.1. The material
and requirements of conductor insulation, shielding and outer sheath shall be as per
the above clauses.
1.02.10 Cable parameters such as mutual capacitance between conductors, conductor

resistance, insulation resistance, characteristic impedance, cross talk and
attenuation figures at 20 deg.C (± 3 deg.C) for various types of cables as applicable
shall be as specified under Table A.
1.02.11 Identification of the cores & pairs shall be done with suitable colour coding & band
marking as well as by numbering of cores/pairs as per VDE: 0815. The details of
colour coding etc. shall be as approved by Employer during detailed stage. Also refer
Table B for description of various type of cables.
1.02.12 The Contractor shall furnish all documentary evidence including cross-sectional drgs,
test certificates to substantiate the suitability of cables offered for different
applications. The contractor shall also clearly bring out the application wise details
for each type of cable offered.
1.02.13 All prefabricated cables shall have 10% spare cores which will not be connected to
pin connectors.
1.02.14 CABLE PARAMETER
Table – A : CABLE PARAMETER
Conductor Size 0.5 Sq.mm.
Parameter/ Individual and Overall Compensating cables

Type of Cable overall shielded Shielded(Type-G) (with/without Teflon
(Type F) coating) (Type
A,B,C)
Mutual 120 nF/Km. 100 nF/Km. 200 nF/Km

capacitance at
0.8 kHz (max.)

SECTION-VI PAGE
PART-B 3 OF 13
Conductor 73.4 ohm/km 73.4 ohm/km

Resistance (loop)For Type F (loop)
(max.)
Insulation 100 M ohm/ Km 100 M ohm/ Km 100 M ohm/ Km

resistance
Cross-Talk 60 dB 60 dB 60 dB
figure at 0.8
kHz (min.)
Characteristic 320 ohm 340 ohm

impedance
(max.)
Attenuation at 1 1.2 dB/Km 1.2 dB/Km

kHz (max.)
1.02.15 DESCRIPTION OF VARIOUS TYPE OF CABLES
TABLE – B
Type Conductor Description

Size
A 0.5 mm2 Two pair shielded and twisted pair T/C extension cable,
ANSI type KX, stranded conductor.
B 0.5 mm2 Two pair shielded & twisted T/C extension cable ANSI
type SX, stranded conductor.
C 0.5 mm2 Two pair shielded & twisted heat resistant teflon
insulation & Outer sheath T/C extension cable ANSI
type KX, stranded conductor.
F 0.5 mm2 Multi pair individual pair & overall shielded twisted pair
instrumentation cable (4/8/12/24 pair) for analog signals
with stranded copper conductor.
G 0.5 mm2 Multi pair overall shielded & twisted pair instrumentation
cable (2/4/8/12/24/48 pair) for binary signals with
stranded copper conductor.
I 0.5 mm2 Type F cable/type G cable with heat resistant teflon

insulation & outer-sheath for high temperature
application.

SECTION-VI PAGE
PART-B 4 OF 13
S As per Multi core/ Multi pair shielded cable for system specific
specific cables. Like conductivity type level switches, Vibration
Standard/ monitoring system cable, System Bus cable, Bus
Requirement communications cable etc. as applicable.
for each
application
1.03.00 INSTRUMENTATION CABLE INTERCONNECTION AND TERMINATION

PHILOSOPHY
1.03.01 The cable interconnection philosophy to be adopted shall be such that extensive
grouping of signals by large scale use of field mounted Group JBs at strategic
locations (where large concentration of signals are available, e.g. switchgear) is done
and consequently cable with higher number of pairs are extensively used. The
details of termination to be followed are mentioned in the given table C.
TABLE C:- CABLE TERMINATION TO BE FOLLOWED
Application Type Of Termination Type Of

Cable
FROM (A) TO (B) END A END B
Valves/dampers Marshalling Plug in Post moun G

drives (Integral ubicle/local group connector ted Maxi
Junction box) JB/Ter- termi/cage
mination/Control clamp type.
Cabinets/System
Cabinets
RTD heads Local junction box Plug in Maxitermi/ F

connector cage clamp
(Rail moun
ted) type.
Thermocouples CJC box Plug in Screwed/ A,B,C*

connector Cage clamp
Type
RTD Temperature Plug in Screwed/

thermocouple transmitter connector Cage clamp
Type

SECTION-VI PAGE
PART-B 5 OF 13
Local Junction Marshalling Maxitermi/ Post moun F,G

box, CJC box, Cubicle/local cage clamp ted Maxi
Group JB/ group (Rail moun termi/cage
MCC/SWGR JB/Termination/ ted) type. clamp type.
Control
Cabinets/System
Cabinets
Local Junction Group JB Maxitermi/ Maxitermi/ F,G

box, cage clamp cage clamp
MCC/SWGR (Rail moun (Rail moun
ted) type. ted) type.
Field mounted Group JB Maxitermi/ Maxitermi/c F,G

Instrument cage clamp age clamp
(Rail moun (Rail moun
ted) type. ted) type.
Marshalling Electronic system Post Post F,G

cubicle/ cabinet mounted mounted
Termination Maxi Maxi
Cabinet termi/cage termi/cage
clamp type. clamp type.
Marshalling / UCP mounted Post moun Plug in F,G (with

Termination equipments ted Maxi connector/ plug-in
system cabinets termi/cage Cage clamp connector at
clamp type. type (rail one end)
mounted).
DDCMIS/PLC PC, Printers etc. Plug in Plug in Mfr.’s

cabinets connector connector Standard
Notes 1 Normally 10% spare core shall be provided when the number
of pairs of cables are more than four pairs.
2 For analog signals individual pair shielding & overall

shielding & for Binary signals only overall shielding of
instrumentation cables shall be provided.
3 * For high temperature application only.

SECTION-VI PAGE
PART-B 6 OF 13
2.00.00 TERMINAL BLOCKS
2.01.00 All terminal blocks shall be rail mounted/post mounted, cage clamp type/maxi-termi
type (MTP) with high quality non-flammable insulating material of melamine suitable
for working temperature of 105 deg. C. The terminal blocks in field mounted junction
boxes, CJC boxes, etc., shall be suitable for cage clamp/ MTP connections. The
terminal blocks in Control Equipment Room logic/termination/marshalling cubicles
shall be suitable for post mounted maxi-termi/cage clamp connection at the field
input end. The terminal blocks for DDCMIS input/output connections from/to
SWGR/MCC, Actuators with Integral Starter (for coupling relays and check back
signals of 11 kV and 3.3 kV auxiliaries, LT drives/valves & dampers/solenoids, CT &
VT, etc.) shall be provided with built in test and disconnect facilities complete with
plug, slide clamp, test socket, etc. The exact type of terminal blocks to be provided
by the Contractor and the technical details of the same including width etc. shall be
subject to Employer's approval.
2.02.00 All the terminal blocks shall be provided complete with all required accessories
including assembly rail, locking pin and section, end brackets, partitions, small
partitions, test plug bolts and test plug (as specified above for SWGR connections)
transparent covers, support brackets, distance sleeves, warning label, marking, etc.
2.03.00 The marking on terminal strips shall correspond to the terminal numbering on wiring
diagrams. At least 20% spare unused terminals shall be provided everywhere
including local junction boxes, instrument racks/enclosures, termination/marshalling
cabinets, etc. All terminal blocks shall be numbered for identification and grouped
according to the function. Engraved labels shall be provided on the terminal blocks.
2.04.00 The terminal blocks shall be arranged with atleast 100 mm clearance between two
sets of terminal blocks and between terminal blocks and junction box walls.
2.05.00 For ensuring proper connections, Contractor shall provide suitable accessories,
along with insulation sleeves. The exact connecting accessory shall be finalised as
per application during detail engineering stage subject to Employer's approval
without any cost repercussions.
2.06.00 Internal wiring in factory prewired electronic equipment cabinets may be installed
according to the Contractor's standard as to wire size and method of termination or
internal equipment. Terminal blocks for connection of external circuits into factory
prewired electronic equipment cabinets shall meet all the requirements as specified
above.
3.00.00 INTERNAL PANELS/CABINETS/SYSTEM CABINETS WIRING
3.01.00 Internal panel/cabinet wiring shall be of multistranded copper conductor with FRLS
PVC insulation without shield and outer sheath meeting the requirements of VDE
0815.

SECTION-VI PAGE
PART-B 7 OF 13
3.02.00 Wiring to door mounted devices shall be done by 19 strand copper wire provided
with adequate loop lengths of hinge wire so that multiple door opening shall not
cause fatigue breaking of the conductor.
3.03.00 All internal wires shall be provided with tag and identification nos. etched on tightly
fitted ferules at both ends in Employer's approved format. All wires directly
connected to trip devices shall be distinguished by one additional red colour ferrule.
3.04.00 All external connection shall be made with one wire per termination point. Wires shall
not be tapped or spliced between terminal points.
3.05.00 All floor slots of desk/panels/cabinets used for cable entrance shall be provided with
removable gasketed gland plates and sealing material. Split type grommets shall be
used for prefabricated cables.
3.06.00 All the special tools as may be required for solderless connections shall be provided
by Bidder.
3.07.00 Wire sizes to be utilised for internal wiring.
(i) Current (4-20 mA), low voltage signals (48V) 0.5 Sq.mm.
(ii) Power supply and internal illumination. 2.5Sq.mm. minimum (shall be

as per load requirement.)
4.00.00 CABLE INSTALLATION AND ROUTING
4.01.00 All cables assigned to a particular duct/conduit shall be grouped and pulled in
simultaneously using cable grips and suitable lubricants. Cables removed from one
duct/conduit shall not be reused without approval of Employer.
Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the
higher voltage cable shall be in higher position and instrumentation cable shall
be in bottom tier of the tray stack.
4.02.00 Cables shall terminate in the enclosure through cable glands. All cable glands shall
be properly gasketed.
4.03.00 All cables shall be identified by tag. Nos. provided in Employer's approved format
at both the ends as well as at an interval of 5 meters.
4.04.00 Line voltage drop due to high resistance splices, terminal contacts, insulation
resistance at terminal block, very long transmission line etc. shall be reduced as far
as practicable.

SECTION-VI PAGE
PART-B 8 OF 13
4.05.00 The cables emanating from redundant equipment/devices shall be routed through
different routes.
5.00.00 CABLE LAYING AND ACCESSORIES
5.01.00 CABLE LAYING
1 Cables shall be laid strictly in line with cable schedule.
2 Identification tags for cables.
Indelible tags to be provided at all terminations, on both sides of wall or

floor crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in
cable trench/tray.
3 Cable tray numbering and marking.
To be provided at every 10m and at each end of cable way & branch
connection.
4 Joints for less than 250 Meters run of cable shall not be permitted.
5 Buried cable protection
With concrete slabs; Route markers at every 20 Meters along the route &
at every bend.
6 Road Crossings
Cables to pass through burried high density PE pipes encased in PCC. At

least 300 mm clearance shall be provided between
- HT power & LT power cables,
- LT power & LT control/instrumentation cables,
Spacing between cables of same voltage grade shall be in accordance with

the derating criteria adopted for cable sizing.
7 Segregation (physical isolation to prevent fire jumping)
a All cable associated with the unit shall be segregated from cables of
other Units.
b Interplant cables of station auxiliaries and unit critical drives shall be

segregated in such a way that not more than half of the drives are lost
in case of single incident of fire.

SECTION-VI PAGE
PART-B 9 OF 13
8 Cable clamping
All cables laid on trays shall be neatly dressed up & suitably clamped/tied to
the tray. For cables in trefoil formation, trefoil clamps shall be provided.
6.00.00 FIELD MOUNTED LOCAL JUNCTION BOXES
(i) No. of ways 12/24/36/48/64/72/96/128 with 20% spare terminals.
(ii) Material and 4mm thick fiberglass reinforced polyester.

Thickness
(iii) Type Screwed at all four corners for door. Door handle shall
be self locking with common key. Door gasket shall be
of synthetic rubber.
(iv) Mounting clamps Suitable for mounting on walls, columns, structures etc.
and accessories The brackets, bolts, nuts, screws, glands and lugs
required for erection shall be of corrosion resistant
material, included in Bidders scope of supply.
(v) Type of terminal Rail mounted maxitermi or cage-clamp type suitable

blocks for conductor size upto 2.5 mm2. A M6 earthing stud
shall be provided.
(vi) Protection Class IP:55 minimum for Indoor & IP-65 Outdoor applications
(vii) Colour To be decided during detailed engineering & subject to

Employer’s approval.
7.00.00 CONDUITS
7.01.00 All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild
steel in accordance with IS:9357 Part-I (1980) and Part-II (1981). The conduit interior
and exterior surfaces shall have continuous zinc coating with an overcoat of
transparent enamel lacker or zinc chromate. Flexible conduit shall be heat resistant
lead coated steel, water leak, fire and rust proof. The temperature rating of flexible
conduit shall be suitable for actual application.

SECTION-VI PAGE
PART-B 10 OF 13
8.00.00 TESTS
8.01.00 GENERAL
equipment price.
8.02.00 TYPE TEST
8.02.01 Following type tests reports shall be submitted for one size of each type of
instrumentation cables:
8.02.02 For Conductor (including Drain Wire)
Sl. Test Reference Standard Remarks

No.
1. Resistance Test VDE:0815
2. Diameter IS:10810
3. Tin coating test* As per relevant *Applicable for drain

(Persulphate Test) standard wire only

SECTION-VI PAGE
PART-B 11 OF 13
8.02.03 For PVC Insulation And PVC Sheath
Sl.No. Test Reference Remarks

Standard
1. Test for thickness** IS:10810
2. Tensile strength and elongation test VDE:0472

before and after ageing**
3. Ageing in air ovens** - do-
4. Loss of Mass Test -do-
5. Hot deformation test -do-
6. Heat shock test - do-
7. Shrinkage test** -do-
8. Cold bend/ cold impact test - do-
9. Colour fastness to water -do-
10. Thermal stability test -do-
11. Bleeding and blooming -do-
12. Oxygen index test (for sheath & fillers) ASTMD-2863
13. Smoke density test (for sheath & ASTMD-2843

fillers)
14. Acid gas generation test (for sheath & IEC-754-1

fillers)

SECTION-VI PAGE
PART-B 12 OF 13
8.02.04 For Al-Mylar Shield
Sl.No. Test Reference Standard Remarks
1. Continuity test As per relevant standard
2. Shield thickness test -do-
3. Overlap test -do
4. Noise interference IEEE-Transaction

test March'67
8.03.00 Acceptance tests and routine test
Refer QA table enclosed with the specification.

SECTION-VI PAGE
PART-B 13 OF 13
Annexure-I
Signal connection & cabling philosphy
(A) Drives: Various equipments of CHP to be controlled from Employer's DDCMIS shall be grouped in
following types of drives. Each type of drive shall have standard no. of inputs/outputs and predefined
type of operation. The type of cable to be used for connecting each type of drive to DDCMIS shall be
as indicated below.
(i) MCC / SWGR /LCP Type
Type of signal
from /to Description Cable type
S.NO. DRIVE TYPE DDCMIS
1 LTCHP (DOL) On Feedback
e.g. LT Conveyor,brake DI Feeder Not Healthy
4 Pair G-Type
pumps,fans etc Overload Trip
DO On Command
2 BW (Belt Weigher) On feedback
BW Fault
DI
Totalizer pulse 4 Pair G-Type
Remote selected
DO On Command
3 SM On Feedback
(Suspended Magnet) Under Current Relay Trip
Control supply not healthy
DI
Remote selected
8 Pair G-Type
SM Trip
Oil temp High
On Command
DO
Local mode selected
4 MD On Feedback
(Metal Detector) MD fault
Metal Detected
Metal Detector Bypass
DI
Remote selected
8 Pair G-Type
Local stop operated
Faullt in MD search coil
MD not reset
On Command
DO
Local mode selected
5 ILMS On Feedback
(Inline Magnetic Control supply not healthy
Separator) Cleated Belt Trip
Under Current Relay Trip
DI Remote selected
Oil temperature High
8 Pair G-Type
ILMS Faulty
Mag. Separator DC supply
on
On Command
DO Conveyor System Trip
Local mode selected
6 REV (RDOL) Overload trip
e.g. Flap gate, RPG Control supply not healthy
DI
scoop actuator Feedback Forward
4 Pair G-Type
Feedback Reverse
Forward Command
DO
Reverse Command
7 LTBRK-Synch Open Status
( LT breakers-
Close status
synchronisation type)
DI
Electrical protection
4 Pair G-Type
operated
In synch
Open command
DO
Close command
8 VVVF On/Off Feedback
e.g. Variable voltage
variable frequency, if DI Fwd/ Rev Feedack
applicable 4 Pair G-Type
VVVF Drive fault
On/Off command
DO
Fwd/Rev command
9 HTCHP On Feedback
(e.g. HT conveyor, DI Electrical protection
4 Pair G-Type
Crusher) operated
DO On Command
10 HTBRK-Synch Open Status
( HT breakers-
Close status
synchronisation type)
DI
Electrical protection
4 Pair G-Type
operated
In synch
Open command
DO
Close command
11 HTBRK- Non Synch Open Status
( HT breakers- Non
Close status
synchronisation type) DI
Electrical protection 4 Pair G-Type
operated
Open command
DO
Close command
NOTE: 1. For all the above mentioned DIs potential free type contacts shall be provided. The DOs of
DDCMIS will be of 24 V DC type (current rating max 100 mA). Suitable coupling relay shall be
provided by the contractor for the DOs of above mentioned type of drives mounted in
MCC/SWGR/LCP for MCC/SWGR/LCP in contractor's scope.
2. The interface drawings for various types of drives including cabling / TB nos to be followed shall be
as indicated in the drawings 0000-155-POI-A-065.
(ii) Solenoids
DO (Potential Control cable, no. of cores

1 Solenoids Open command
free contact) shall depend on grouping.
NOTE: Local control panels for power supply distribution for solenoids at respective locations shall
be provided by the contractor. From DDCMIS only potential free contacts will be wired to these local
cabinets and generation of power supply / distribution will be taken care by the contractor in local
panels.
(B) Process I/Os

(i) For Analog signals F type shall be used.
(ii) For Digital signals G type shall be used.
(iii) For each signal separate pair shall be used (from local JB /panel to DDCMIS).
PART - B
SUB-SECTION-IIIB-06
ILLUMINATION SYSTEM

ILLUMINATION
1.00.00 GENERAL
1.01.00 This specification covers the general description of design, manufacture and
construction features, testing, supply, installation and commissioning of the
illumination system equipment required to be provided by the bidder.
1.03.00 All standards and codes of practice referred to herein shall be the latest edition
including all applicable official amendments & revisions as on date of bid opening. In
case of conflict between this specification and those (IS codes, standards etc.)
referred to herein, the former shall prevail. All work shall be carried out as per the
following standards & codes.
1.04.00 Lighting Fixtures and Accessories
IS:1913 General and safety requirements for luminaries.
IS:2148 Flame proof enclosures of electrical apparatus.
IS:418 Tungsten filament general service electric lamps.
IS:1258 Bayonet lamp holders.
IS:1534 Ballast for fluorescent lamps.
IS:1569 Capacitors for use in tubular fluorescent, high pressure mercury

vapour and low pressure sodium vapour discharge lamp circuit.
IS:1777 Industrial luminaire with metal reflectors.
IS:2149 Luminaire for Street lighting.
IS:2215 Starters for fluorescent lamps.
IS:2418 Tubular fluorescent lamps for general lighting services.
IS:3323 Bi-pin lamp holders for tubular fluorescent lamps.
IS:3324 Holders for starters for tubular fluorescent lamps.
IS:4013 Dust-tight electric lighting fittings.

STAGE-II (2X195 MW)
SECTION-VI SUB-SECTION-IIIB-06 PAGE
PART-B ILLUMINATION 1 OF 13
IS:6616 Ballasts for high pressure mercury vapour lamps.
IS:8224 Electric Lighting fittings for Division 2 areas.
IS:9900 High-pressure mercury vapour lamps.
IS:9974 High pressure Sodium vapour lamps.
IS:10276 Edison screw lamp holders.
IS:10322 Luminaires.
IS:13021 AC Supplied Electronic Ballasts for tubular fluorescent lamps.
1.05.00 Lighting Panels, Switch-boxes, Receptacles and Junction Boxes
IS:2147 Degree of protection provided by enclosures for low-voltage

switchgear and control gear.
IS:1293 Plugs & socket outlets of rated voltage upto and Including
250volts & rated current upto and including 16 Amps.
IS:2551 Danger notice plates.
IS:13947 Low voltage switchgear and controlgear
IS:3854 Switches for domestic and similar purposes.
IS:6875 Control switches (switching devices for control and auxiliary

circuits including contactor relays) for voltages upto and
including 1000 V AC and 1200 V DC.
IS:13703 Low voltage fuses for voltages not exceeding 1000V AC or

1500 V DC.
1.06.00 Conduits, Pipes and Accessories
IS:2667 Fittings for rigid steel conduit for electrical wiring.
IS:3837 Accessories for rigid steel conduits for electrical wiring.
IS:9537 Conduits for electrical installations.

STAGE-II (2X195 MW)
1.07.00 Lighting Wires/Cables
IS:694 PVC insulated cables for working voltages upto and including
1100 V
IS:3961 Recommended current ratings for cables.(PVC Insulated and

PVC sheathed heavy duty cables and light duty cables).
IS:8130 Conductors for insulated electric cables and flexible cords.
IS:10810 Methods of tests for cables.
1.08.00 Electrical Installation Practices & Miscellaneous
IS:1944 Code of practice for lighting of public thorough fare
IS:3646 Code of practice for interior illumination.
IS:5572 Classification of Hazardous areas (other than Mines)having

flammable gases and Vapours for electrical installation
IS:6665 Code of practice for industrial lighting.
. National Electrical Code
. Indian Electricity Rules.
Indian Electricity Act
IS:5 Colour for ready mixed paints & enamels.
IS:280 Mild steel wires for general engineering purposes.
IS:374 Electric ceiling type fans & regulators.
IS:732 Code of practice for electrical wiring installations.
IS:1255 Code of practice for installation and maintenance of power

cables Upto and including 33KV rating.
IS:2062 Steel for general structural purposes
IS:2629 Recommended practice for hot-dip galvanizing of iron and steel.

STAGE-II (2X195 MW)
IS:2633 Methods for testing uniformity of coating of zinc coated articles.
IS:2713 Tubular steel poles for overhead power lines.
IS:3043 Code of practice for earthing
IS:5216 Guide for safety procedures and practices in electrical work.
IS:5571 Guide for selection of electrical equipments for hazardous areas.
BS:6121 Mechanical cable glands
2.00.00 LIGHTING SYSTEM DESCRIPTION
2.01.00 Normal AC Lighting System
Normal AC lighting system 415V, 3Phase, 4wire, will be fed from lighting panels
(LPs) which will be fed from the lighting distribution boards (LDBs) which in turn will
be fed from LT MCCs.
2.02.00 Emergency Lighting System
2.02.01 100W , 220V DC Lighting fixture shall be provided as follows:
- One (1) no. in each local control area
- Three (3) nos. in each MCC/ Switchgear room and control room
- One (1) no in each office room and each pump house
- Six (6) nos. in Track hopper shed
- Twelve (12) nos in track hopper tunnels
- Two (2) nos in each underground portion of TPs
- 0ne (1) no at every 5.0m height interval in the staircases of various TPs and
buildings under contractor’s scope
- One (1) no in each drive floor in each TP under contractor’s scope
- Four (4) nos in wagon tippler tunnel

STAGE-II (2X195 MW)
The above fixtures shall be mounted suitably on wall/columns at strategic locations

for safe movement of operating personnel and access to important control points
during an emergency, when the normal AC lighting system fails. These lighting
fixtures shall be fed from bidder's 220 V LDBs through DC lighting panels.
The supply to the DC lighting panels shall be automatically switched on in case of

loss of AC supply .The DC supply will be automatically switched off after about 3
minutes following the restoration of AC lighting system.
Four (4) nos. 240V AC lighting fixtures fed from UPS shall be provided on each
stacker reclaimer machine.
2.03.00 DESIGN PHILOSOPHY
1. A comprehensive illumination system shall be provided.
2. All lighting system shall be automatically controlled by synchronous timer.

Provision to bypass the timer shall be provided in the panel for manual
control.
3. The system shall include distribution boards, lighting panels, lighting fixtures,
junction boxes, receptacles, switch boards, lighting pole/masts, conduits,
cables and wires, etc. The system shall cover all interior and exterior lighting
such as area lighting, including Transformer yard etc. The constructional
features of lighting distribution boards shall be similar to AC/DC distribution
boards described in chapter of LT Switchgear. Outgoing circuits in LPs shall
be provided with MCBs of adequate ratings.
4. The illumination system shall be designed on the basis of best engineering

practice and shall ensure uniform, reliable, aesthetically pleasing and glare
free illumination. The lighting fixtures shall be designed for minimum glare.
The design shall prevent glare/luminous patch seen on VDU/ Large video
screens, when viewed from an angle. The finish of the fixtures shall be such
that no bright spots are produced either by direct light source or by reflection.
The diffusers/ louvers used in fluorescent fixtures shall be made of impact
resistant polystyrene sheet and shall have no yellowing property over a
prolonged period. The Lux levels to be adopted for various area are indicated
at Annexure – A.
5. Apart from maintenance factor as given below, Temperature correction

factor shall be considered in the lighting design for fluorescent fixtures
located in non air conditioned area.
(a) Air conditioned area : 0.8

STAGE-II (2X195 MW)
(b.) Non Air conditioned and other indoor area : 0.7
(c.) Dust prone indoor areas and outdoor areas : 0.6
6. All outdoor fixtures shall be weather proof.
7. All lighting fixtures & control gears shall be powder coated.
8. Wires of different phase shall normally run in separate conduit. For areas
illuminated by more than one circuit, the adjacent circuits shall be from
different phases.
9. Power supply shall be fed from suitable number of conveniently located

lighting distribution boards (LDB) and lighting panels (LP). AC lighting supply
shall be isolated from main supply by isolation transformers (415/433V, delta
/ star, epoxy insulated, air cooled, dry type) of max. rating of 100KVA and
fault level restricted to 3 KA at Lighting Panels. Minimum 2 ways shall be
kept as spare feeders in the lighting panels.
10. Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel.
The door shall be hinged and the panel shall be gasketted to achieve
specified degree of protection. The panel shall be provided with terminal
bocks for incoming and outgoing circuits, earthing terminals, removable
gland plates at bottom and canopy shall be provided with slope towards the
rear side of the panel. Wiring inside the panel shall be carried out with 1100
V grade PVC insulated stranded copper wires of adequate size. Terminal
blocks shall be 750 V grade, clip-on stud type, moulded in melamine and
shrouded.
All MCBs/ Isolators/ Switches/ Contactors etc. shall be mounted inside the
panel and a fibre glass sheet shall be provided inside the main door such
that the operating knobs of MCBs etc., shall project out of it for safe
operation against accidental contact. MCB’s shall be current limiting type
with magnetic and thermal release suitable for manual closing and automatic
tripping under fault condition with short circuit interrupting capacity of 9 KA
rms. Isolators of AC lighting panels shall be of TPN, continuous duty, load
make-break type and fuses shall be of HRC plug in type.
Synchronous timers shall be quartz controlled electronic type, complete with

rechargeable nickel cadmium cell, 24 hours range day dial, NO/NC contacts
etc. and suitable for operation on 240V AC supply. The exterior side of
panel, shall be powder coated with smoke grey, shade RAL9002 and the
interior side of panel, shall be white.

STAGE-II (2X195 MW)
Lighting panels shall have IP55 degree of protection in general. However LP

located in dusty areas shall have IP65 degree of protection.
Ladder approaches shall be provided for maintaining the fixtures wherever

applicable.
12. 20A, 240V AC industrial type receptacles shall be provided in the

following areas :
- Two in each switchgear / MCC room, Pump house and on stacker-

reclaimer.
- One on each floor of TPs and crusher house building
- At 30m interval on both sides of the conveyor gallery and track

hopper shed. At 50m interval on one side of yard conveyor
- These receptacles shall be energized from lighting panel. Maximum

three receptacles shall be connected in one circuit.
10A, 24V AC receptacles with IP55 DOP shall be provided in the following
areas.
- One in each switchgear / MCC room, Pump house and on stacker-

reclaimer.
- One on each floor of TPs and crusher house building
- It shall not be possible to insert 24V plug into 240V receptacle
- These receptacles shall be energized from lighting panel. Maximum

three receptacles shall be connected in one circuit.
13. All fluorescent fixtures shall have energy efficient ‘T5’ type fluorescent
lamps except those in div 2 hazardous area. The louvers of these fixtures
shall be designed for ‘T5’ type fluorescent lamps. All fluorescent lamps
shall have ‘cool day light colour designation. The mirror optics type
fluorescent fixtures shall have no iridescence effect.
2.03.00 Ballasts
2.03.01 All HPSV and HPMV lamp fixtures shall be provided with wire-wound ballasts. All
fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (Div-
II/Hazardous Area) shall be provided with electronic ballasts.

STAGE-II (2X195 MW)
2.04.00 All luminaires and their accessories and components shall be of type readily
replaceable by available Indian makes.
2.05.00 Fans & Regulator
2.05.01 Ceiling Fans, to be provided in non air-conditioned office / control room area shall be
suitable for operation on 240 V, 50 Hz, AC supply comprising of class ‘F’ insulated
copper wound single phase motor, 1200mm sweep, aerodynamically designed well
balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor,
suspension hook, canopies etc. finished in stove enameled white. Power factor of
fans shall not be less than 0.9. Each fan shall cover approximately 10sq.m. area.
2.06.00 Switch Box
2.06.01 Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick decorative,
perspex cover. Switchbox shall be hot dip galvanised
2.07.00 Junction boxes
Junction box for lighting fixtures shall be deep drawn or fabricated type made of min.
1.6 mm thick CRCA Sheet. The box shall be hot dip galvanised .
2.08.00 Conduits, Fittings & Accessories
Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for normal
area and galvanised heavy duty steel conduits with an additional epoxy coating for
corrosive area shall be offered. Alternatively glass reinforced epoxy conduits with
comparable compressive and impact strength with that of heavy duty steel conduits
may be offered.
2.08.01 Rigid Steel Conduits
(a.) Rigid steel conduits shall be heavy duty type,hot dip galvanised conforming to
IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded
on both sides and threaded length shall be protected by zinc rich paint.
Conduits shall be smooth from inside and outside.
2.08.02 Flexible Steel Conduits
2.08.03 Flexible conduit shall be water proof and rust proof made of heat resistant lead
coated steel.

STAGE-II (2X195 MW)
2.08.04 Pull-out Boxes
2.09.00 Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit
run .Boxes shall be suitable for mounting on Walls, Columns, Structures, etc.. Pull-
out boxes shall have cover with screw and shall be provided with good quality gasket
lining. Pull out boxes shall be weather proof type suitable for IP :55 degree of
protection. Pull out box & its cover shall be hot dip galvanised.
2.10.00 Lighting Wires
2.10.01 Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded
copper/aluminium wire for fixed wiring installation. colour of the PVC insulation of
wires shall be Red, Yellow, Blue and Black for R,Y,B phases & neutral, respectively
and white & grey for DC positive & DC negative circuits, respectively. Minimum size
of wire shall not be less than 1.5.sq.mm. for copper and 4 sq.mm. for aluminium. The
size of the lighting wires/ cables shall be selected such that the total voltage drop
from the LDB to the lighting fixture / receptacle does not exceed 3%.
2.11.00 Lighting Poles
2.11.01 The poles wherever required shall be of ERW tubes of specified lengths, stepped
tubular or swaged tubular and joined together. Lighting poles shall be painted with
two coats of red Oxide and Zinc chromate in Synthetic compound primer on the
exposed outside surface and with Bituminous paint all along the inside of the pole
and outside portion which shall be embedded in foundation at manufacturing stage.
2.12.00 Lighting Masts
2.12.01 Minimum six (6) nos. of lighting masts shall be provided for coal stockyard
illumination and two (2) nos. lighting mast for wagon tippler area illumination. Each
lighting mast shall be provided with minimum 12 nos. of 2x400W HPSV fixtures.
Lighting Masts shall be of continuously tapered polygonal cross section hot dip
galvanised presenting a pleasing appearance. The Mast shall be of 30M height with
lantern carriage to enable raising / lowering for ease of maintenance, including the
Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built
power tool, luminaries, suitable aviation warning light, lightning along with necessary
power cables within the mast. The mast shall be delivered only in three sections &
shall be joined together by slip stressed fit method at site. No site welding or bolted
joints shall be done on the mast.
2.13.00 Lighting fixtures shall generally be group controlled directly from lighting panel.
However, in office areas, control shall be provided through switch boxes. Each
switch shall control a maximum of three fluorescent fixtures.

STAGE-II (2X195 MW)
2.14.00 Wiring shall run throughout in separate conduits. Wires of different phases shall run
in different conduits. Wiring for lighting circuits and receptacle circuits shall be
carried out in separate conduits and from separate feeders.
2.15.00 Lighting panels etc. shall be earthed by two separate and distinct connections with
earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single phase
receptacles etc. shall be earthed by means of separate earth continuity conductor.
The earth continuity conductor 14 SWG GI wire shall be run alongwith each conduit
run. Cable armours shall be connected to earthing system at both the ends.
3.00.00 TESTS
3.01.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and
routine test, as per relevant specified standards.
3.01.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to
physical and dimensional checks.
3.02.00 Galvanizing Tests
3.02.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and shall
be inspected visually.
3.03.00 In addition following tests shall be conducted as acceptance tests.
(a.) Uniformity of coating - The coating of any article shall withstand four 1minute
dips in standard copper sulphate solution without the formation of an adherent
red spot of metallic copper upon the basic metal.
(b.) The quality of cadmium/zinc plating on items with screw threads shall be free
from visible defects such as unplated areas, blisters and modules and shall be
inspected visually.
(c.) In addition, the plating thickness shall be determined microscopically/

chemically or electronically.
4.00.00 COMMISSIONING CHECKS
1. On completion of installation work, the Contractor shall request the Project

manager for inspection and test with minimum of fourteen (14) days
advance notice.

STAGE-II (2X195 MW)
2. The Project manager shall arrange for joint inspection of the installation for
completeness and correctness of the work. Any defect pointed out during
such inspection shall be promptly rectified by the Contractor.
3. The installation shall be then tested and commissioned in presence of the

Project manager.
4. The contractor shall provide all, men material and equipment required to
carry out the tests.
5. All rectifications, repair or adjustment work found necessary during

inspection, testing and commissioning shall be carried out by the
Contractor without any extra cost. The handing over the lighting installation
shall be effected only after the receipt of written instruction from the
Employer/his authorized representative.
6. The testing shall be done in accordance with the applicable Indian

Standards and codes of practices. The following tests shall be specifically
carried out for all lighting installation.
(a) Insulation Resistance.
(b) Testing of earth continuity path.
(c) Polarity test of single phase switches.
(d) Functional checks.
7. The lighting circuits shall be tested in the following manner :
(a) All switches ON and consuming devices in circuit, both poles

connected together to obtain resistance to earth.
(b) Insulation resistance between poles with lamps and other consuming
devices removed and switches ON.

STAGE-II (2X195 MW)
ANNEXURE-A
Sl No. Location Average Type of Fixture

Illumination
Level(Lux)
(a) Switchgear rooms 200 Industrial trough type

fluorescent
(b) Control room, 300 Mirror optics with anti-glare

computer room, features
control equipment
room
(c) Offices, conference 300 Decorative mirror optics type

rooms,etc.
(d) Battery rooms 100 Totally enclosed corrosion

proof
(e) Transformer yard 10(general) HPSV flood light

50(on
equipment)
(f) Diesel generating 150 HPSV medium bay/Industrial

room, Compressor trough type fluorescent
room, pump house
etc.
(g) Fuel oil pump house 150 Flame proof fluorescent

fixtures suitable for division-2
hazardous area
(h) Cable galleries 50 Industrial trough type

fluorescent
(i) Street lighting-
primary roads - 20 HPSV street lights
secondary roads 10 Degree of Protection IP54

STAGE-II (2X195 MW)
(j) Outdoor storage 20 HPSV flood light

handlingand
unloading area
(k) DM plant,water 150 Industrial trough type/corrosion

treatment plant proof fluorescent
(l) Chemical stores 150 Corrosion proof fluorescent
(m) Permanent stores 150 Industrial trough type/HPSV
(n) Workshop.general 150 Industrial trough type

work bench fluorescent
(o) Laboratory
General 150 Mirror optics fluorescent
Analysis area 300 Corrosion resistant, fluorescent
(p) Garage/Car Parking 50 Industrial trough type

fluorescent
(q) Switchyard and all 20 (general HPSV flood light

outdoor areas
50(on strategic
equipment)
(r) Stone picking area 300 HPSV dust tight well glass
fixture (flood light type)
(s) Transfer points, 100 HPSV dust tight medium bay or

crusher house, track well glass fixture.
hopper, track hopper
shed, tunnels, bunker
house.
(t) Conveyor galleries 70 HPSV dust tight well glass

fixture.
(u) Stair cases 100 Min. one fixture at every

landing.
NOTE:- Any additional fixtures required to take care of the dark patches /
shadows shall also be provided.

STAGE-II (2X195 MW)
..
--
IfgCOMER !SOLATOR ,OUTGOING
2 0 A HCB'S
63A TPN + 6 3 A CONT + SYNC. TIMER 12 NOS. s p +

+ INDICATING LAMPS
6 NOS. SP
6% T P N + 6 3 A CONT + SYNC. T I M E R 6 NOS. S P +
+ INDICATING LAMPS
PART - B
SUB-SECTION-IIIB-07
CABLING, EARTHING & LIGHTNING

PROTECTION

CABLING, EARTHING & LIGHTNING PROTECTION
latest editions including all applicable official amendments and revisions as on date of
opening of bid. In case of conflict between this specification and those (IS codes,
standards, etc.) referred to herein, the former shall prevail. All work shall be carried
out as per the following standards/ codes as applicable.
IS:513 Cold rolled low carbon steel sheets and strips.
IS:802 Code of practice for the use of Structural Steel in Overhead

Transmission Line Towers.
IS:1079 Hot Rolled carbon steel sheet & strips
IS:1239 Mild steel tubes, tubular and other wrought steel fittings
IS:1255 Code of practice for installation and maintenance of power cables

upto and including 33 KV rating
IS:1367 Part- Technical supply conditions for threaded Steel fasteners. (Hot dip
13 galvanized coatings on threaded fasteners).
IS:13947 Degree of protection provided by enclosures for low voltage

switchgear and control gear
IS:2309 Code of Practice for the protection of building and allied structures
against lightning.
IS:2629 Recommended practice for hot dip galvanising of iron & steel
IS:2633 Method for testing uniformity of coating on zinc coated articles.
IS:3043 Code of practice for Earthing
IS:3063 Fasteners single coil rectangular section spring washers.
IS:6745 Methods for determination of mass of zinc coating on zinc coated

iron & steel articles.
IS:8308 Compression type tubular inline connectors for aluminium

conductors of insulated cables
IS:8309 Compression type tubular terminal ends for aluminium conductors

of insulated cables.
MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATION SUB-SECTION-IIIB-07

STAGE-II (2X195 MW) SECTION-VI CABLING EARTHING PAGE
COAL HANDLING PLANT PACKAGE PART-B & LIGHTNING 1 OF 24
BID DOCUMENT NO. : CS-0350-155(R)-2 PROTECTON
IS:9537 Conduits for electrical installation.
IS:9595 Metal – arc welding of carbon and carbon manganese steels -

recommendations.
IS:13573 Joints and terminations for polymeric cables for working voltages
from 6.6kv upto and including 33kv performance requirements and
type tests.
BS:476 Fire tests on building materials and structures
IEEE:80 IEEE guide for safety in AC substation grounding
IEEE:142 Grounding of Industrial & commercial power systems
DIN 46267 Non tension proof compression joints for Aluminium conductors.
(Part-II)
DIN 46329 Cable lugs for compression connections, ring type ,for Aluminium
conductors
VDE 0278 Tests on cable terminations and straight through joints
BS:6121 Specification for mechanical Cable glands for elastomers and

plastic insulated cables.
Indian Electricity Act.
Indian Electricity Rules.
1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS,
DIN, USA, VDE etc. will also be considered if they ensure performance and
constructional features equivalent or superior to standards listed above. In such a
case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in
English of the latest revision of the standards alongwith copies of all official
amendments and revisions in force as on date of opening of bid and shall clearly
bring out the salient features for comparison.
2.00.00 DESIGN AND CONSTRUCTIONAL FEATURE
2.01.00 Transformer yard and Switchyard
In transformer yard and switchyard area, cables shall be laid in RCC concrete
trenches with RCC covers. Inter-pole cabling in switchyard shall be in GI
conduits/shallow trenches. Minimum clear height of trestle shall be 3mtr and for
Rail/road crossing it shall be as per rail/road crossing norms.

2.01.01 False floors are not to be provided for cabling purpose.
2.01.02 Cable entry
Cable entry from outdoor underground/cable routes to the buildings, if any, shall be
above the finished floor level of the building to avoid water entry in to the room
through the trenches.
2.01.03 Trenches
PCC flooring of built up trenches shall be sloped for effective drainage with sump
pits and sump pumps.
2.01.04 Interplant cabling for main routes shall be laid along overhead trestles/duct banks.
However, from tap-offs, same can be through shallow trenches with approval of
Employer. In case of Duct banks, pull-pits shall be filled with sand and provided with
a PCC covering. Directly buried cables, if essential, shall not have concentration of
more than 4 cables in one route. For overhead trestles, the bottom of the steel
supporting structure shall be generally at 3.0M above the grade level except for
rail/road crossings where it shall be at 8.0M above grade level.
All overhead cable routes shall be along the route of the conveyor gallery on
separate supporting structures and cables shall be laid in vertical trays. The bottom
of the steel shall be such that the existing facilities, movement of trucks / human
beings etc. does not get affected. The cable trestle shall have a minimum 600mm
clear walk way and shall have maintenance platforms as required.
Cables shall not be routed through the conveyor galleries except for the equipment
located in the conveyor galleries for a particular conveyor i.e. protection switches,
etc.
Cables for PCS and BSS shall be routed along the conveyors through GI conduits.
2.01.05 Cable trenches shall be provided only in Switchgear/MCC rooms.
3.00.00 EQUIPMENT DESCRIPTION
3.01.00 Cable trays, Fittings & Accessories
3.01.01 Cable trays shall be ladder type for power cables & perforated type for control
cables complete with matching fittings (like brackets, elbows, bends, reducers, tees,
crosses, etc.) accessories (like side coupler plates, etc. and hardware (like bolts,
nuts, washers, G.I. strap, hook etc.) as required.
3.01.02 Cable trays, fittings and accessories shall be fabricated out of rolled mild steel
sheets free from flaws such as laminations, rolling marks, pitting etc. These

(including hardware) shall be hot dip galvanized as per relevant IS. Cable trays shall
be ladder type for power/control cables and shall be perforated type for
instrumentation cables.
3.01.03 Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard
lengths of 2.5 metre. Minimum thickness of mild steel sheets used for fabrication of
cable trays and fittings shall be 2 mm. The thickness of side coupler plates shall be
minimum 3 mm. Typical details of cable trays, fittings and accessories are shown in
the enclosed drawings
3.01.04 Cable troughs shall be required for branching out few cables from main cable route.
These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2
mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard
width of 50 mm & 75 mm with depth of 25 mm
3.02.00 SUPPORT SYSTEM FOR CABLE TRAYS
3.02.01 Cable tray support system shall be pre-fabricated similar or equivalent to "Unistrut
make”.
3.02.02 Support system for cable trays shall essentially comprise of the two components i.e.
main support channel and cantilever arms. The main support channel shall be of
two types: (i) C1:- having provision of supporting cable trays on one side and (ii)
C2:-having provision of supporting cable trays on both sides. The support system
shall be the type described hereunder
a. Cable supporting steel work for cable racks/cables shall comprise of various
channel sections, cantilever arms, various brackets, clamps, floor plates, all
hardware such as lock washers, hexagon nuts, hexagon head bolt, support
hooks, stud nuts, hexagon head screw, channel nut, channel nut with
springs, fixing studs, etc.
b. The system shall be designed such that it allows easy assembly at site by
using bolting. All cable supporting steel work, hardware fittings and
accessories shall be prefabricated factory galvanised.
c. The main support and cantilever arms shall be fixed at site using necessary
brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various
arrangements required to support the cable trays. Welding of the
components shall not be allowed. However, welding of the bracket (to which
the main support channel is bolted) to the overhead beams, structural steel,
insert plates or reinforcement bars will be permitted. Any cutting or welding
of the galvanised surface shall be brushed and red lead primer, oil primer &
aluminium paint shall be applied.

d. All steel components, accessories, fittings and hardware shall be hot dip
galvanised after completing welding, cutting, drilling and other machining
operation.
e. The typical arrangement of flexible support system is shown in the enclosed

drawings and described briefly below:
The main support channel and cantilever arms shall be fabricated out of
minimum 2.5 thick rolled steel sheet conforming to IS.
f. Cantilever arms of 300 mm, 600 mm and 750 mm in length are required,
and shall be as shown in the enclosed drawing. The arm portion shall be
suitable for assembling the complete arm assembly on to component
constructed of standard channel section. The back plate shall allow sufficient
clearance for fixing bolt to be tightened with tray in position.
3.02.03 The size of structural steel members or thickness of sheet steel of main support
channel and cantilever arms and other accessories as indicated above or in the
enclosed drawings are indicative only. Main support channels may be supplied in
any suitable lengths to minimise the wastage. Nevertheless, the support system shall
be designed by the bidder to fully meet the requirements of type tests as specified. In
case the system fails in the tests, the components design modification shall be done
by the Bidder without any additional cost to the Employer.
3.03.00 Pipes, Fittings & Accessories
3.03.01 Pipes offered shall be complete with fittings and accessories (like tees, elbows,
bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.) The
size of the pipe shall be selected on the basis of maximum 40% fill criteria
3.03.02 GI Pipes shall be of medium duty as per IS:1239
3.04.00 Junction Boxes
3.04.01 Junction Boxes shall be made of Fire retardant material. Material of JB shall be
thermoplastic or thermosetting or FRP type. The box shall be provided with the
terminal blocks, mounting bracket and screws etc. the cable entry shall be through
galvanized steel conduits of 20 mm diameter. The JB shall have suitable for installing
glands of suitable size on the bottom of the box. The JB shall be suitable for surface
mounting on ceiling/structures. The JB shall be of grey in color RAL 7035. All the
metal parts shall be corrosion protected. Junction boxes surface should be such that
it is free from crazing, blistering, wrinkling, color blots/striations. There should not be
any mending or repair of surface. JB’s will be provided with captive screws so that
screws don’t fall off when cover is opened. JB’s mounting bracket should be of
powder coated MS. Type test reports for the following tests shall be furnished.

3.04.02 Impact resistance for compact energy of 2 joules (IK07) as per BS EN 50102.
3.04.03 Thermal ageing at 70 deg C for 96 hours as per IEC60068-2-2Bp.
3.04.03 Class of protection shall be IP 55.
3.05.00 HV test.
3.05.01 Terminal blocks shall be 650 volts grade, 10 Amps rated, made up of unbreakable
polyamide 6.6 grade, complete with insulating barriers. Clip on type terminals,
washer, nuts and identification strips. Marking on terminal strips shall correspond to
the terminal numbering in wiring diagrams. All metal parts shall be non ferrous.
WAGO terminal of cage clamp with lugs shall also be acceptable. All terminal blocks
shall be suitable for terminating on each side two (2) nos. stranded copper
conductors of size up to 2.56 sq mm each.
3.06.00 Terminations & Straight Through Joints
3.06.01 Termination and jointing kits for 6.6 kV grade XLPE insulated cables shall be of
proven design and make which have already been extensively used and type tested.
Termination kits and jointing kits shall be pre-moulded type, taped type or heat
shrinkable type. 6.6 kV grade joints and terminations shall be type tested as per IS-
13573. Critical components used in cable accessories shall be of tested and proven
quality as per relevant product specification/ESI specification. Kit contents shall be
supplied from the same source as were used for type testing. The kit shall be
complete with the aluminium solder less crimping type cable lugs & ferrule as per
DIN standard.
3.06.02 Straight through joint and termination shall be capable of withstanding the fault level
of 40 kA for 0.12 sec with a dynamic peak of 100 kA for 6.6 kV system. Straight
through joints shall have provisions for shield connection and earthing wherever
required and complete with all accessories and consumables suitable for storage
without deterioration at a temperature of 50 deg. C with shelf life of more than five
years. 1.1 kV grade straight through joints shall also be of proven design.
3.07.00 1.1 KV grade STJ shall be of proven design.
3.07.01 Motor terminal boxes should of sufficient size to accommodate the selected cables.
In case the cable sizes can not be accommodated, power Junction boxes shall be
provided with cable interconnection between Junction boxes and motor terminal box.
3.08.00 Cable glands
3.08.01 Cable shall be terminated using double compression type cable glands. Cable
glands shall conform to BS:6121 and be of robust construction capable of clamping
cable and cable armour firmly without injury to insulation. Cable glands shall be

made of heavy duty brass machine finished and nickel chrome plated. Thickness of
plating shall not be less than 10 micron. All washers and hardware shall also be
made of brass with nickel chrome plating Rubber components shall be of neoprene
and of tested quality.
3.09.00 Cable lugs/ferrules
3.09.01 Cable lugs for power cables shall be tinned copper solder less crimping type
conforming to IS: 8309 suitable for aluminium compacted conductor cables. Cable
lugs and ferrules for control cables shall be tinned copper conforming to IS:8309 . The
cable lugs for control cables shall be provided with insulating sleeve and shall suit the
type of terminals provided on the equipments.
3.10.00 Trefoil clamps
3.10.01 Trefoil clamps for single core cables shall be pressure die cast aluminum or fiber
glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts,
washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand
the forces generated by the system short circuit current of 105 KA peak.
3.11.00 Cable Clamps & Straps
3.11.01 The cable clamps required to clamp multicore cables on vertical run shall be made
up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, self-
locking, de-interlocking type nylon clamps/straps shall be used. The clamps/straps
shall have sufficient strength and shall not get affected by direct exposure to sun
rays and outdoor environment
3.12.00 Receptacles
3.12.01 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot
dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm.
The boxes shall be provided with two nos. earthing terminals, gasket to achieve
IP55 degree of protection, terminal blocks for loop-in loop-out for cable of specified
sizes, mounting brackets suitable for surface mounting on wall/column/structure,
gland plate etc. The ON-OFF switch shall be rotary type heavy duty double break,
AC23 category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast
Aluminium. Socket shall be provided with lid safety cover. Robust mechanical
interlock shall be provided such that the switch can be put ON only when the plug is
fully engaged and plug can be withdrawn only when the switch is in OFF position.
Also cover can be opened only when the switch is in OFF position. Wiring shall be
carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of
adequate size. The Terminal blocks shall be of 1100 V grade made up of
unbreakable polymide 6.6 grade with adequate current rating and size. The welding
receptacles shall be provided with inbuilt ELCB rated for suitable 100mA sensitivity.

3.12.02 For Coal Handling Plant 415V TPN 63A welding sockets with switch having degree
of protection of IP-55 shall be provided in the following areas.
1) 1 Number on each floor of TPs and 2 nos. on each floor of the crusher house
building.
2) At 50m interval (starting from one end) on both sides of the conveyor
galleries. At 50m interval on one side of the yard conveyor.
3) 1 no. in each Switchgear / MCC rooms and Pump house and in stacker /
reclaimer machines.
4) Maximum three (3) nos. of receptacles can be connected to one circuit.

These receptacles shall be energised through welding distribution board.
3.13.00 Galvanising
3.13.01 Galvanising of steel components and accessories shall conform to IS:2629, IS:2633
& IS 4759. Additionally galvanising shall be uniform, clean smooth, continuous and
free from acid spots
3.13.02 The amount of zinc deposit over threaded portion of bolts, nuts, screws and
washers shall be as per IS:1367. The removal of extra zinc on threaded portion of
components shall be carefully done to ensure that the threads shall have the
required zinc coating on them as specified. However nuts and bolts of size lesser
than M12 can be electro galvanised / electro plated.
3.14.00 Welding
3.14.01 The welding shall be carried out in accordance with IS: 9595. All welding
procedures and welders qualification shall also be followed strictly in line with
IS:9595
3.15.00 EXPANSION FASTNER
3.15.01 Expansion Fastener shall be 'HILTI' make HSA-KA type or equivalent. Expansion
fastener shall only be used wherever insert plates are not available for supporting
the cable structure.
4.00.00 INSTALLATION
4.01.00 Cable tray and Support System Installation
4.01.01 Cables shall run in cable trays mounted horizontally or vertically on cable tray
support system which in turn shall be supported from floor, ceiling, overhead

structures, trestles, pipe racks, trenches or other building structures. All cable trays
shall be in vertical configuration in boiler, CHP & ESP areas.
4.01.02 Horizontally running cable trays shall be clamped by bolting to cantilever arms at an
interval of 2000 mm. Vertically running cable trays shall be bolted to main support
channel by suitable bracket/clamps on both top and bottom side rails at an interval
of 2000 mm. For vertical cable risers/shafts cable trays shall be supported at an
interval of 1000mm. Fixing of cable trays to cantilever arms or main support
channel by welding shall not be accepted. Cable tray installation shall generally be
carried out as per the enclosed drawings.
4.01.03 The cantilever arms shall be positioned on the main support channel with a
minimum vertical spacing of 300 mm unless otherwise indicated in the relevant tray
layout drawings
4.01.04 All cable way sections shall have identification, designations as per cable way
layout drawings and painted/stenciled at each end of cable way and where there is
a branch connection to another cable way. Minimum height of letter shall be not less
than 75 mm. For long lengths of trays, the identification shall be painted at every 10
meter. Risers shall additionally be painted/ stenciled with identification numbers at
every floor.
4.01.05 In certain cases it may be necessary to site fabricate portions of trays, supports and
other non standard bends where the normal prefabricated trays, supports and
accessories may not be suitable. In such cases the Contractor shall fabricate at site
suitable sections of trays, supports and accessories to make the installation
complete for the specific purpose after obtaining Project Manager's prior approval,
which shall be neat in appearance and shall match with the prefabricated sections
in the dimensions. They shall be applied with one coat of red lead primer, one coat
of oil primer followed by two finishing coats of aluminium paint.
4.02.00 Conduits/Pipes/Ducts Installation
4.02.01 The Contractor shall be fully responsible for properly embedding conduit pipe
sleeves wherever necessary for cabling work. All openings in the floor/roof/wall /
cable tunnel/cable trenches made for conduit installation shall be sealed and made
water proof by the Contractor.
4.02.02 GI pull wire of adequate size shall be laid in all conduits before installation. Metallic
conduit runs at termination shall have two lock nuts wherever required for junction
boxes etc.
4.02.03 Conduit runs/sleeves shall be provided with PVC bushings having round edge at
each end. All conduits/pipes shall have their ends closed by caps until cables are
pulled. After cables are pulled, the ends of conduits/pipes shall be sealed with

Glass wool/Cement Mortar/Putty to prevent entrance of moisture and foreign

material
4.02.04 Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by

other approved means. Conduits /pipe support shall be installed square and true to
line and grade with an average spacing between the supports as given below,
Conduit /pipe size (dia). Spacing
Upto 40 mm 1M
50 mm 2.0 M
65-85 mm 2.5 M
100 mm 3.0 M
4.02.05 For bending of conduits, bending machine shall be arranged at site by the
contractor to facilitate cold bending. The bends formed shall be smooth.
4.03.00 Junction Boxes Installation
4.03.01 Junction boxes shall be mounted at a height of 1200mm above floor level or as
specified in the drawings or as decided by Project Manager and shall be adequately
supported/mounted on masonry wall by means of anchor fasteners/ expandable
bolts or shall be mounted on an angle, plate or other structural supports fixed to floor,
wall, ceiling or equipment
4.04.00 Cable Installation (for cables upto & including 6.6kV grade)
4.04.01 Cable installation shall be carried out as per IS:1255 and other applicable standards.
Cable drums shall be unloaded, handled and stored in an approved manner on hard
and well drained surface so that they may not sink. In no case shall be drum be
stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as
possible. For short distances, the drums may be rolled provided they are rolled
slowly and in proper direction as marked on the drum. In absence of any indication,
the drums may be rolled in the same direction as it was rolled during taking up the
cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on
cable wheels and shall be rolled slowly so that cable comes out over the drum and
not from below. All possible care shall be taken during unreeling and laying to avoid
damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed
plastic caps to prevent damage and ingress of moisture.
4.04.02 While laying cable, ground rollers shall be used at every 2 mtr interval to avoid cable
touching ground. The cables shall be pushed over the rollers by a gang of people
positioned in between the rollers. Cables shall not be pulled from the end without

having intermediate pushing arrangements. Pulling tension shall not exceed the
values recommended by cable manufacturer. Selection of cable drums for each run
shall be so planned so as to avoid using straight through joints. Care should be taken
while laying the cables so as to avoid damage to cables. If any particular cable is
damaged, the same shall be repaired or changed to the satisfaction of Project
Manager.
4.04.03 Cables shall be laid on cable trays strictly in line with cable schedule furnished.
Where specific cable layouts are not shown on drawings, Contractor shall route
these as directed by the Project Manager
4.04.04 Power and control cables shall be laid on separate tiers. The laying of different
voltage grade cables shall be on different tiers according to the voltage grade of the
cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and cables
of subsequent lower voltage grades on lower tiers of trays. Single core cable in trefoil
formation shall be laid with a distance of four times the diameter of cable between
trefoil center lines and clamped at every 2mtr. All multicore cables shall be laid in
touching formation. Power and control cables shall be secured fixed to trays/support
with self locking type nylon cable straps with de-interlocking facilities. For horizontal
trays arrangements, multicore power cables and control cables shall be secured at
every five meter interval. For vertical tray arrangement, individual multicore power
cables and control cables shall be secured at every one meter by nylon cable strap.
After completion of cable laying work in the particular vertical tray, all the control
cables shall be binded to trays/supports by aluminium strips at every five meter
interval and at every bend.
4.04.05 Bending radii for cables shall be as per manufacturer’s recommendations and
IS:1255.
4.04.06 Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC pipe.
4.04.07 In each cable run some extra length shall be kept at suitable point to enable one
LT/two HT straight through joints to made, should the cable develop fault at a later
stage. Control cable termination inside equipment enclosure shall have sufficient
lengths so that shifting of termination in terminal blocks can be done without
requiring any splicing.
4.04.08 Wherever few cables are branching out from main trunk route troughs shall be used.
4.04.09 The installation work shall be carried out in a neat workman like manner & areas of
work shall be cleaned of all scraps, water, etc. after the completion of work in each
area every day. Contractor shall replace RCC/Steel trench covers after the
Installation work in that particular area is completed or when further work is not likely
to be taken up for some time.

4.05.00 Separation
4.05.01 In vertically stacked trays, at least 300mm clearance shall be provided between :
- HT power & LT power cables,
- LT power & LT control cables
4.05.02 Segregation
1) Segregation means physical isolation to prevent fire jumping.
2) All the cables of one stream shall be segregated from the cables of the other
stream and shall run on either side of the trestle.
4.05.02 All field switches for equipments corresponding to a stream located within a radius of
4-5 mtr. shall be wired out to a field junction box and from field junction box to control
panel/Input – Output cabinet by screened instrumentation cables.
4.06.00 Directly Buried Cables
a) Cable trenches shall be constructed for directly buried cables.

Construction of cable trench for cables shall include excavation,
preparation of sieved sand bedding, riddled soil cover, supply and
installation of brick or concrete protective covers, back filling and
compacting, supply and installation of route markers and joint markers.
Laying of cables and providing protective covering shall be as per IS:1255
and the enclosed drawings showing cabling details.
b) RCC cable route and RCC joint markers shall be provided wherever
required. The voltage grade of the higher voltage cables in route shall be
engraved on the marker. Location of underground cable joints shall be
indicated with cable marker with an additional inscription “Cable Joint”.
The marker shall project 150 mm above ground and shall be spaced at an
interval of 30 meters and at every change in direction. They shall be
located on both sides of road crossings and drain crossings. Top of cable
marker/joint marker shall be sloped to avoid accumulation of water/dust
on marker.
4.06.01 Cable tags shall be provided on all cables at each end (just before entering the
equipment enclosure), on both sides of a wall or floor crossing, on each
duct/conduit entry, and at every 20 meters in cable tray/trench runs. Cable tags
shall also be provided inside the switchgear, motor control centers, control and relay
panels etc. where a number of cables enter together through a gland plate. Cable
tag shall be of rectangular shape for power cables and control cables. Cable tag
shall be of 2 mm thick aluminum with number punched on it and securely attached

to the cable by not less than two turns of 20 SWG GI wire conforming to IS:280.
Alternatively, the Contractor may also provide cable tags made of nylon, cable
marking ties of ‘TY-CAB’ or equivalent type with cable number heat stamped on the
cable tags
4.06.02 While crossing the floors, unarmoured cables shall be protected in conduits upto a
height of 500 mm from floor level if not laid in tray.
4.07.00 Cable Terminations & Connections
4.07.01 The termination and connection of cables shall be done strictly in accordance with
cable termination kit manufacturer’’ instructions, drawings and/or as directed by
Project Manager. Cable jointer shall be qualified to carryout satisfactory cable
jointing/termination. Contractor shall furnish for review documentary
evidence/experience reports of the jointers to be deployed at site.
4.07.02 Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing,
soldering, drilling, cutting, taping, preparation of cable end, crimping of lug,
insulated sleeving over control cable lugs, heat shrinking (where applicable),
connecting to cable terminal, shorting and grounding as required to complete the
job to the satisfaction of the Project Manager.
4.07.03 The equipment will be generally provided with undrilled gland plates for
cables/conduit entry. The Contractor shall be responsible for punching of gland
plates, painting and touching up. Holes shall not be made by gas cutting. The holes
shall be true in shape. All cable entry points shall be sealed and made vermin and
dust proof. Unused openings shall be effectively sealed by 2mm thick aluminium
sheets.
4.07.04 Control cable cores entering control panel/switchgear/MCC/miscellaneous panels

shall be neatly bunched, clamped and tied with self locking type nylon cable ties
with de interlocking facility to keep them in position.
4.07.05 The panels where a larger number of cables are to be terminated and cable
identification may be difficult, each core ferrule shall include the complete cable
number as per the drawings. The ferrules shall be indelible interlocking type and
shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix letter
‘S’ alongwith cable numbers and coiled up after end sealing.
4.07.06 All cable terminations shall be appropriately tightened to ensure secure and reliable
connections.
4.07.07 It is the responsibility of the Contractor to terminate the cables at motor terminals in
correct phase sequence to ensure the proper direction of rotation.

5.00.00 EARTHING SYSTEM
5.01.00 Earthing system shall be in strict accordance with IS: 3043 and Indian Electricity
Rules/Acts.
All buildings / structures shall be interconnected together by min. two parallel

conductors. Contractor shall furnish the detailed design calculations for the earthing
system. Contractor shall obtain all necessary approvals for the system.
5.02.00 The earth conductors shall be free from pitting, laminations, rust, scale and other
electrical, mechanical defects
5.03.00 The material of the earthing conductors shall be as follows :
1) Conductors above ground level and in built up - Galvanized steel

trenches.
2) Conductors buried in earth - Mild steel
3) Earth electrodes - Mild steel rod
5.04.00 The sizes of earthing conductors for various electrical equipments shall be as below:
Equipment Earth Earth conductor above

conductor ground level & in built-up
buried in earth trenches
a) Main earth grid 40 mm dia.MS 65x8mm GS flat

rod
b) 33KV/11KV --- 65x8mm GS flat

switchgear/equipment 415V
switchgear
c) 6.6 kV switchgear / 415 V --- 50x6mm GS flat

MCC/ Distribution boards /
Transformers
d) LT Motors above 125 KW --- 50 x 6mm GS flat
25 KW to 125 KW --- 25 x 6mm GS flat
1KW to 25 KW --- 25 x 3mm GS flat
Fractional House power motor --- 8 SWG GS wire

e) Control panel & control desk --- 25 x 3 mm GS flat
f) Push button station / Junction --- 8 SWG GI wire

Box
g) Columns, structures, cable --- 50x6mm GS flat

trays and busduct enclosures
h) Crane, rails, rail tracks & other 25x6mm GS flat

non-current carrying metal
parts
5.05.00 Metallic frame of all electrical equipment shall be earthed by two separate and
distinct connections to earthing system, each of 100% capacity, Crane rails, tracks,
metal pipes and conduits shall also be effectively earthed at two points. Steel RCC
columns, metallic stairs, and rails etc. of the building housing electrical equipment
shall be connected to the nearby earthing grid conductor by one earthing ensured by
bonding the different sections of hand rails and metallic stairs. Metallic
sheaths/screens, and armour of multi-core cables shall be earthed at both ends.
Metallic Sheaths and armour of single core cables shall be earthed at switchgear end
only unless otherwise instructed by the Employer. Every alternate post of the
switchyard fence shall be connected to earthing grid by one GS flat and gates by
flexible lead to the earthed post. Railway tracks within the plant area shall be bonded
across fish plates and connected to earthing grid at several locations. Portable tools,
appliances and welding equipment shall be earthed by flexible insulated cable. One
separate core in the trailing/flexible cables shall be used for earthing purposes of the
moving machines. PLC equipment shall be earthed separately as per the
recommendations of the PLC manufacturer.
5.06.00 Each continuous laid lengths of cable tray shall be earthed at minimum two places by
G.S. flats to earthing system, the distance between earthing points shall not exceed
30mtr. Wherever earth mat is not available Contractor shall do the necessary
connections by driving an earth electrode in the ground.
5.07.00 Neutral points of HT transformer shall be earthed through NG resistors. The

Contractor shall connect the NGR earthing point to earth electrodes by suitable earth
conductors.
5.08.00 Neutral connections and metallic conduits/pipes shall not be used for the equipment
earthing. Lightning protection system down conductors shall not be connected to
other earthing conductors above the ground level.
5.09.00 Connections between earth leads and equipment shall normally be of bolted type.
Contact surfaces shall be thoroughly cleaned before connections. Equipment bolted

connections after being tested and checked shall be painted with anti corrosive
paint/compound.
5.10.00 Suitable earth risers as approved by Project Manager shall be provided above
finished floor/ground level, if the equipment is not available at the time of laying of
main earth conductor.
5.11.00 Connections between equipment earthing leads and between main earthing
conductors shall be of welded type. For rust protection the welds should be treated
with red lead compound and afterwards thickly coated with bitumen compound. All
welded connections shall be made by electric arc welding.
5.12.00 Resistance of the joint shall not be more than the resistance of the equivalent length
of conductors.
5.13.00 Earthing conductors buried in ground shall be laid minimum 600 mm below grade
level unless otherwise indicated in the drawing. Back filling material to be placed
over buried conductors shall be free from stones and harmful mixtures. Back filling
shall be placed in layers of 150 mm.
5.14.00 Earthing conductors embedded in the concrete floor of the building shall have
approximately 50 mm concrete cover.
5.15.00 A minimum earth coverage of 300 mm shall be provided between earth conductor
and the bottom of trench/foundation/underground pipes at crossings. Earthing
conductor’s crossings the road can be installed in pipes. Wherever earthing
conductor crosses or runs at less than 300 mm distance along metallic structures
such as gas, water, steam pipe lines, steel reinforcement in concrete, it shall be
bonded to the same.
5.16.00 Earthing conductors along their run on columns, walls, etc. shall be supported by
suitable welding / cleating at interval of 1000mm and 750mm respectively.
5.17.00 Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded below
permanent moisture level. Minimum spacing between electrodes shall be 600mm.
Earth pits shall be treated with salt and charcoal if average resistance of soil is more
than 20 ohm metre.
5.18.00 On completion of installation continuity of earth conductors and efficiency of all

bonds and joints shall be checked. Earth resistance at earth terminations shall be
measured in presence of Employer’s representatives. All equipment required for
testing shall be furnished by contractor.
5.19.00 Earthing conductor shall be buried at least 2000mm outside the fence of electrical
installations. Every alternate post of the fences and all gates shall be connected to
earthing grid by one lead.

6.00.00 LIGHTNING PROTECTION SYSTEM
6.01.00 Lightning protection system shall be in strict accordance with IS:2309
6.01.01 Lightning conductor shall be of 25x6mm GS strip when used above ground level
and shall be connected through test link with earth electrode/earthing system
6.01.02 Lightning system shall comprise of air terminations, down conductors, test links,
earth electrode etc. as per approved drawings
6.02.00 Down Conductors
1. Down conductors shall be as short and straight as practicable and shall

follow a direct path to earth electrode.
2. Each down conductor shall be provided with a test link at 1000 mm above
ground level for testing but it shall be in accessible to interference. No
connections other than the one direct to an earth electrode shall be made
below a test point.
3. All joints in the down conductors shall be welded type.
4. Down conductors shall be cleated on outer side of building wall, at 750

mm interval or welded to outside building columns at 1000 mm interval.
5. Lightning conductor on roof shall not be directly cleated on surface of

roof. Supporting blocks of PCC/insulating compound shall be used for
conductor fixing at an interval of 1500 mm.
6. All metallic structures within a vicinity of two meters of the conductors

shall be bonded to conductors of lightning protection system.
7. Lightning conductors shall not pass through or run inside GI Conduits.
8. Testing link shall be made of galvanized steel of size 25x 6mm.
7.00.00 QUALITY ASSURANCE PROGRAMME
7.01.00 Bidder shall furnish detailed Quality Assurance Program and Quality Plans for all
materials and accessories to be supplied and installed under the scope of the
specification as per General Technical Conditions of technical specification. The
Quality Plans shall include all tests/ checks as per relevant National/International
Standards and the requirements of this specification including tests listed in this
section.

8.00.00 TESTS
GENERAL
engineering, the contractor shall submit for Owner’s approval the reports of all
the type tests as listed in this specification and carried out within last ten years
from the date of bid opening. These reports should be for the test conducted
on the equipment similar to those proposed to be supplied under this contract
and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client.
equipment price.
8.01.00 Type Test reports shall be furnished for the following
8.01.01 Type tests on Cable Trays support system
Test 1: On main support channel type-C2 for cantilever arms fixed on one
side only.
a) Test 1A: A 3.5 metre length of main support channel shall be fixed vertically at
each end to a rigid structure as per the fixing arrangement as shown
in the enclosed drawing. Eight (8) nos. 750 mm cantilever arms shall
be fixed to the main channel and each arm shall be loaded over the
outboard 600 mm with a uniform working load of 100 kg.
Subsequently a point load of 100 kg shall be applied on arm 2. A
uniform proof load on all the arms equal to twice the working load
shall be then be applied. Deflections shall be measured at the points
shown in the enclosed drawings and at the following load intervals:
i) Working load

ii) Working load + point load
iii) Off load
iv) Proof load + point load
v) Off load
The deflection measured at working loads shall not exceed 16mm. The
permanent deflection after removing the combination of working load and
point load shall not exceed 10 mm at the arm tips and 6 mm on the
channel. No collapse of the structure shall occur with a combination of
proof load and point load applied.
b) Test 1B: Test 1A shall be repeated with Eight Cantilever arms uniformly loaded
and with the same point load on arm 2.
Test 2: On Main support channel type -C2 for cantilever arms fixed on both
sides
a)Test 2A: A 3.5 m length of main support channel C2 for cantilever arms fixing
on both sides shall be fixed at each end to rigid structure as per the
fixing arrangement as shown in the enclosed drawing. Six (6), 750
mm cantilever arms shall be attached to each sides and each arm
uniformly loaded to a working load of 100 kg over the out board 600
mm. A point load of 100 kg shall than be applied to arm 2, followed
by a uniform proof load of twice the working load on all the arms;
deflection shall be measured at points shown in the enclosed
drawings at the following load intervals.
i) Working load
ii) Working load + Point load
iii) Off load
iv) Proof load + Point load
v) Off load

The deflection measured at working loads shall not exceed 16mm.

The permanent deflection after removing the combination of working
load and point load shall not exceed 10 mm at the arm tips and 6 mm
on the channel. No collapse of the structure shall occur with a
combination of proof load and point load applied
b) Test 2 B: The test 2 A shall be repeated with the assembly but with an
asymmetrical load on the C2 column and point load applied to arm 8.
The 100 kg and 200 kg uniformly distributed loads shall be applied to
the upper three arms on one side and the lower three arms on the
opposite side.
Test 3: Tests on Channel Fixed on Beam/Floor
A length of main support channel section shall be fixed to steel

structure/floor and have loads applied as shown in the drawing
enclosed and as detailed below
a) Test 3A : A length of steel structure shall be rigidly supported. It should be

fitted on a metre length of channel section using beam clamps
welded/bolted. A point load of 1200 kg shall be applied to the
centre point via two brackets. No distortion or pulling of the
components shall take place.
b) Test 3B : With the components assembled as in Test 3A, two perpendicular

point loads of 600 kg shall be simultaneously applied at positions
150 mm either side of the centre line, no distortion or pulling of the
components shall take place.
c) Test 3C : With the components assembled as in Test 3A, a perpendicular

point load shall be applied at a point 150 mm on one side of the
centre line.
The load shall be gradually increased to the maximum value that

can be applied without causing distortion or pulling of the
components. This value shall be recorded.

Test 4 : Channel Insert Test
A 2.5 m length of C1 channel fixed to the concrete wall/ steel

structure as per actual site installation conditions. 6 nos. of 750 mm
cantilever arms shall be attached to C1 channel as shown in
enclosed drawing. Each arm uniformly loaded to a working load of
100 kg over the out board 600 mm. A point load of 100 kg shall
than be applied to arm 2, followed by a uniform proof load of twice
the working load on all the arms; deflection shall be measured at
points shown in the enclosed drawings at the following load
intervals.
i) Working load
ii) Working load + Point load
iii) Off load
iv) Proof load + Point load
v) Off load
The deflection measured at working loads shall not exceed 16mm. The
permanent deflection after removing the combination of working load and point
load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No
collapse of the structure shall occur with a combination of proof load and point
load applied
Test 5: Channel nut slip characteristics (what ever applicable)
Tests 5A1,5A2,5A3 : A length of channel C1 section 200mm long shall have

fitted bracket with the two bolts fixing as shown in
drawing enclosed.
With loads applied at the position shown in drawing

enclosed nut slip shall be determined with bolt torque of
30NM, 50 NM and 65 NM No fewer than three
measurements shall be made for each torque setting.
A minimum loading of 720 kg shall be obtained

before nut slip with bolt torque of 65 NM.

Tests 5B1,5B2,5B3: The length of channel C1 section 200 mm long shall

have fitted bracket with the one bolt fixing as shown in
drawing enclosed. With loads applied at the position
shown in drawing, nut slip shall be determined with bolt
torques of 30 NM, 50 NM and 65 NM. No fewer than
three measurements shall be made for each torque
setting.
A minimum loading of 350 kg shall be obtained before

nut slip with a bolt torque of 65 NM.
Test 6 Weld Integrity Test
After deflection test as per test 1A, 1B, 2, 3, 4 & 5, weld integrity shall be
checked by magnetic particle inspection to detect sub-surface cracks
developed, if any.
8.01.02 Cable termination kit and straight through joints should have been tested as per IS:
13573 for above 3.3 kV class and as per VDE 0278 for 3.3 kV class.
8.02.00 Routine/ Acceptance Tests
8.02.01 Routine Tests
a) Routine tests as per specification and applicable standards shall be carried

out on all equipments/items covered in the specification.
b) Physical & dimensional check on all equipments as per approved

drawings/standards.
c) HV/IR as applicable.
d) Check/measurement of thickness of paint/zinc coating/nickel-chrome plating

as per specification & applicable standard.
8.02.02 Acceptance Test
a) Galvanising Tests as per applicable standards
b) Welding checks
c) Deflection tests on cable trays:
One piece each of 2.5m length of cable tray of 300mm & above shall be
taken as sample from each offered lot. It shall be supported at both end &

loaded with uniform load of 76 kg/meter along the length of cable tray. The
maximum deflection at the mid-span of each size shall not exceed 7mm.
d) Proof load tests on cable tray support system
i) Tests on Main Support Channel shall be done if only C1 Channel are

in scope of supply and cantilever arms shall be fitted on one side. This
test shall be same as test 4 of type test.
ii) Test on Main Support Channel shall be done with C2 channel and
cantilever arms fitted on both sides, if C2 channels are in scope of
supply. This test shall be same as test 2A of type test. Then test (i)
above shall not be done.
iii) Nut slip characteristic test (it shall support minimum load of 350kg
before nut slips with a bolt torque of 65 NM). This test shall be same
as test 5B3 of type test.
The procedure for carrying out tests at “d” above shall be as per
details given in Type Tests in specification thereafter Die-Penetration
test shall be carried out to check weld integrity.
e) The above acceptance tests shall be done only on one sample from each
offered lot.
9.00.00 COMMISSIONING
9.01.00 The Contractor shall carry out the following commissioning tests and checks after
installation at site. In addition the Contractor shall carry out all other checks and tests
as recommended by the Manufacturers.
9.01.01 Cables
a) Check for physical damage
b) Check for insulation resistance before and after termination/jointing.
c) HT cables shall be pressure tested (test voltage as per IS:7098) before

commissioning.
d) Check of continuity of all cores of the cables.
e) Check for correctness of all connections as per relevant wiring diagrams.

Any minor modification to the panel wiring like removing/inserting,
shorting, change in terminal connections etc., shall be carried out by the
Contractor at no extra cost.

f) Check for correct polarity and phasing of cable connections.
g) Check for proper earth connections for cable glands, cable boxes, cable
armour, screens, etc.
h) Check for provision of correct cable tags, core ferrules, and tightness of
connections.
9.02.00 Cable trays / supports and accessories
1) Check for proper galvanizing/painting and identification number of the

cable trays/supports and accessories.
2) Check for continuity of cable trays over the entire route.
3) Check that all sharp corners, burrs, and waste materials have been
removed from the trays supports.
4) Check for earth continuity and earth connection of cable trays.
9.03.00 Earthing and Lightning protection system
1) Earth continuity checks.
2) Earth resistance of the complete system as well as sub-system.
9.04.00 GENERAL COMMISSIONING CHECKS (Application to all electrical equipments)
(a.) Check for name plate details according to specification.
(b.) Check for physical damage, if any.
(c.) Check for tightness of all bolts, clamps & connecting terminals.
(d.) Check for earth connection.
(e.) Check for cleanliness of insulators & bushings.
(f.) Check for lubrication of all moving parts.
(g.) Check for provision of heater.

SECTION A-A
X - FOR 6Klrnrn. TRAY

3M)rnrn. TRAY
- 20-25
- 10-15
COUPLER PLATE
1. LUTERUL :- M.S. SHEE7 MIN. 2mm. mK.
R TENDER PURPOSE
TRAY3A-211-001.DWG
10DLA HOLE
f (MP)
t3
----,--------.------ -
f- / -* X
NOTE.
1. AU DIMENSK)NS ARE IN mm.
3. UlXRUL :- 2mm. M.S. S H m Uln.

LADDER TRAY HORIZONTAL TEE
A=(2R+W+4)
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.E -6 NTPC L i m i t e d
I (I, ( A GOVERNMENT OF INDL4 ENTERPRISE )
+ -5 ENGINEERING DMSION
0
PROJECT
STANDARD
I
TITLE
CABLE TRAY DETAILS CROSS I
SIZE SCALE DRG. NO. REV. NO.
A4 NTS 0000-211-PIE-A-008 RB
TRAY2A-211-008
6
TWO LENGTHS OF C1 WELDED BACK TO BACK
I
CHANNEL NUT
90'
-
2=={=,
{,\;\3
--
--
-- -- -- --.- -- -
--k-
>--yl
--
90'
--- - \-_'_-I - C1 CHANNEL
----- I -
--
--
i
-- - C1 CHANNEL
-
ART-3
ART-I
NOTES
1. MATERIAL MILD STEEL
2. MATERIAL HOT DIPGALVANISED
-/T
CHANNEL
(X*) NTPC Limited

( A GOVERNMENT OF INDIA ENTERPRISE )
ENGINEERING DMSION
PROJECT
STANDARD
TITLE
CANTIIEVER ARMS
'IZE SCALE DRG. REV. NO.
0000-21 1 -POE-A-()16
~4 NTS RB
CAD FILE NAME : STAND-211-016 DWG
\0
C2 CHANNEL C1 CHANNEL
ASSEMBLY- 1 ASSEMBLY-2
ASSEMBLY- 1
UPPER FIXING C2 CHANNEL
ASSEMBLY-2
UPPER FIXING C1 CHANNEL
UPPER FIXING FOR CHANNEL VERTICAL SUPPORTS

-
C2 CHANNEL
&
C1 CHANNEL
I
I ASSEMBLY 1
I I I I HEAVY DUTY FLOOR
FOR C2 CHANNEL
ASSEMBLY 2
ING FOR C l CHANNEL
FLOOR FIXING FOR CHANNEL VERTICAL SUPPORTS
( A GOMRNMENT OF INDL4 ENIERPRISE )
TYPICAL DETAILS OF CABLE
CAD FILE NAME I STAND-211-018.DWG
1%
/.-gHANNEL
ffi W
'RAWLBOLT
{
w::'-*
_*% @.@ NUT
v
Mr 7@
ruLEDI
FOR FIXINGRAWLBOLT
WALL
RB FORTEIIDERPURPOSE
ONLY
*Wlt F1 L
RA rOR TENDER PURPOSE ONLY
IILV M E c c&l ARCH
NO. DESCRIPTION APPO D/IIE
CLFAREDBY
NTTPC T^irn-ited-
( A GryERNMET{T
OF INDA EITIIERPRISE
)
ENGINEERINGDMSKIiI
PROJECT
STANDARD
TITLE
FIXING OF CEANNEL IN TRENCE TAI,L
slzb. suALt NU. {tsv. Nu.
I luKtt. 0000-211-PoE-A-019
44 INTS I RB
CAD FILE NAME' STAND-211-019,I!VG
-
NOTES
1) MATERIAL : MILD STEEL.
2) FINISH : HOT DIP GALVANISED.

BRACKET-C2 CHANNEL CLAMP.
BRACKET-C1 CHANNEL CLAMP.
NOTES:
1) MATERIALS -MILD STEEL
2) FINISH-HOT DIP GALV.
1) 600mm TRAY-1 TO 6 TIER-C2
2 ) 3 0 0 m m TRAY-1 TO 3 TIER-C1
ANTILEVER ARM
ARRANGEMENT TYPE-B1
NOTES:
1) IN CASE OF HANGING SUPPORT
C2 TO BE USED AS MAIN SUPPORT.
2) ALL DIMENSIONS ARE IN MM.
ANTILEVER ARM ON
BOTH SIDES
ARRANGEMENT TYPE -B2

7INSERT PCATE
k . 1 CHANNEL
ARRANGEMENT TYPE-C1
NOTES:
1) U P TO 3 TIER C1 CHANNEL
2) ABOVE 3TIER & BOTH SIDE TRAY
C2 CHANNEL
3) ALL DIMENSIONS ARE IN MM.
ARRANGEMENT TYPE-Dl
BEAM OR RCC FLOOR
ANTILNER ARM
CC FLOOR L N E L
R TENDER PURPOSE
( A GOVERNMENT OF INDIA EWERPRISE )

ENGINEERING DIVISION
1 ) 600mm TRAY-1 TO 6 TIER-C2 CHANNEL
2) 300mm TRAY-1 TO 3 TIER-C1 CHANNEL
3) 300mm TRAY-4 TO 6 TIER-C2 CHANNEL
4) 1 5 0 m m TRAY-1 TO 6 TIER-C1 CHANNEL
MAIN SUPPORT
CHANNEL-C1 /CZ
ARRANGEMENT TYPE-S2
CHANNELS SUPPORTED BY -. -
-
tLUUH BtAM -
INSERT PLATE PROVIDED
FOR FIXING O F MAIN - -
SUPPORT CHANNEL
MAlN SUPPORT
CHANNEL IS
-.
VI a SUPPORTED BY
I.- 2 $ BRACKET-WELDED
q C C
I:
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4
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k -
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= s
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- -
r= ' >i
1) UP TO 3TIER-Cl CHANNEL
E ;I ABOVE 3 TIER-C2 CHANNEL.
E : 2 ) ALL DIMENSIONS ARE IN MM.
: ARRANGEMENT TYPE-S3
X
I:
I
BRACKET
WELDED
-flLI7
MAlN SUPPORT
X 0
-r
L -5
.-
CHANNEL C1/C2
a,
a
+
0 aJ
r4
a , "
I
ANTILEVER ARM
ARRANGEMENT TYPE-S4
DESCRIPTION
NOTE :
1. ALL DIMENSIONS ARE IN MM (SCALE NTs)
CONDUCTOR GRID
OUTSIDE THE BLDG.
INSERT IN RETAINING WALL
EARTH RISER WELDED TO MAIN

EARTH CONDUCTOR EMBEDDED
WELDED
7 \I IN CONCRETE.
RCC FLOOR SLAB
.Q 1 1 SO MIN
E A R T H RISER
~irxiited
PROJECT
NTPC
( A C O M R N M M OF INDIA ENTERPRISE )
ENGINEERING DMSION
-
I
STANDARD
TITLE I
SIZE SCALE
EARTHING D E T W
DRC. NO. REV. NO.
I
0000-211-POE-A-041
A4 NTS RB
CAD FILE N N E : STAND-Zil-C4I.W;
&
1 CAO FILE NAUE : STAND-211-MZ.D'*G
GROUND CONDUCTOR ALONG BUILDING WALL
h
10
I;, r
q-
5
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I!
l1
$
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GROUND CONDUCTOR
35x6 G I FLAT
T STEEL COLUMN
l1
l1
11
--
'
OC-
SEC. 5 - 5
I'
)-
If
1,
v" -
GROUND CONDUCTOR ALONG STEEL COLUMN STRUCTURE
NOTES
ALL DIMENSIONS A R E IN MM (SCALE-NTS)
1
2
C , 9
K~ TEPBEt fbKPt&
t'&/- p - - 4 EL
REV.
FA FDR TENDER PURPOSE ONLY
C& - 47 -
P F - - &,4y
E C Ul,-
NO DESCRIPTION m ~ c k 0 s . nM , r P P D m
--
CLEARED BY
.
iwX) NTPC Limited
(AcowwMENTOFlNDNDRD(TOOPR1M)
ENCWWlNC DNISK)F(
-
PROJECT
STANDARD
TITLE
EARTFIWG DETAlLS
SIZE SCALE ORG. NO. REV. '10.
0000-211-POE-A-043
A4 N TS R8
4
r 2MM Al SHEET
.
BUSHINGS THRO CABLE
i
I
i
EARTHING DETAILS TRANSFORMER I
j
i
i
il 1. THE TRANSFORMER NEUTRAL FOR H.T. TRANSFORMER SHALL BE EARTHED THROUGH j
FLATS AS SHOWN ABOVE. (SUPPLIED BY TRANSFORMER SUPPLIER) !
j
1
1
b
1
I
i
TYP. MFLON. TUBINIC LIGHTNING PROTECTION DOWN-COMER
(TO BE SEALED AFT€ ALVANISED BOX 2MM THK SHEET STEEL
INSTALLATION OF
CONDUCTOR)
2 7 x 8 OPENING
FOR WALL/COL./
60 HOLES FOR
FIXING C O M R
F R O N T 0
EARTH TERMINAL
LIGHTING PROTECTION DOWNCOMER TEST LINK WLDED TO BOX (TO BE
CONNECTED TO EARTHING
NOTES: - GRID)
1. THE DOWN COMER ENTRY AND EXIT POINTS IN TO BOX BE MADE
WATER- TIGHT AFTER LAYING OF CONDUCTOR.
SADDLE WTH
2. THE TEST LINK SHALL BE OF SAME WIDTH AND THICKNESS AS SPACER
THE DOWNCOMER.THE NUTS BOLTS AND WASHERS TO BE OF G.S SIDE VIEW
3. ALL DIMENSIONS ARE IN MM (SCALE-NTS)
DESCRIPTION
-
[m*] NTPC ~imited
( A C O M R N Y E N ~ O F M D ~ A ~ E )
ENWNEERIW DWSKHJ
PROJECT
. . STANDARD
TITLE
' LIGHTNING PROTCTION DETALIS.
SIZE SCALE DRG. NO. R&. NO-
0000-21 1 -FOE-A-047
A4 N TS RB
I CAD FILE NAME : STANC-211-O47.DK
33
BLOCK SPACING IOOOMM CENTRE TO CENTRE
TYPICAL DETAILS OF CLEATING HORIZONTAL

CONDUCTOR OVER WATER PROOFING
NOTE : ALL DIMENSIONS ARE IN MM
NTPC Lixxxited
( A GOVERNMN OF INDIA ENTERPRISE )
ENGINEERING DMSlON
PROJECT
STANDARD
TITLE
SIZE SCALE DRC. NO. REV. NO.

0000-21 1-POE-A-048 Re
A4 N TS
CM) FILE NAME : STAND-211-O&.DHC
I
SEE DETAIL
EARTH BACK FlLLED 'A'
AND RAMMED
PRECAST CONCRETE
C a M K i 50X250X4Mhi
\
T
+ C
(NTPC]
6- , , DIA. HOLES FOR
4 NOS. FIXING
1''0 CAST IRON

- NOTES:
LIGHTING 1. ALL DIMENSIONS ARE I N MM.
/ PU\TE
CABLE 2 . ROUTE MARKERS SHALL BE CONSTRUCTED
OF CONCRETE WITH CAST IRON PLATE.
WITH THE ROUTE INFORMATION ENGRAVED
ON IT. BOLTED ON TOP OF THE CONCRETE
j C C BLOCK AS SHOWN.
3. CAST l2ON PLATE SHALL BE OF 6 . 0 MM
THICKNESS
DETAIL- 'A'
GESCRl?T!O?4
CLEARED BY
[NTPC]
wffm NTPC
- ENClNWlNC
.- -.
Limited
( A o o M W M E N l O f INDU -RISE
D W
)
I I STANDARD I
I TITLE
SIZE
BURIED CABLE TRENCH DETAILS FOR LIGHTING
SCALE DRG. NO. R N . NO.
I
A4 NTS 0000-2 1 1 -POE-A-049 RB
21 1 -049.DWG
I
\
DIRECTLY BURIED CABLES DIRECTLY BURIED CABLES

IN SINGLE LAYER I N 'TWO LAYER
@-CABLE ROUTE MARKER DIMENSION l l D O V GRADE FOR 3.3 K V 22KV & 33KV
@-EARTH BACK FILLED & RAMMED MIN. CABLES TO l l K V
PROTECTIVE COVERS D1 750 900 1050
o) BRICKS FOR LOW d BETWEEN CABLES OF SAME CLASS

VOLTAGE CABLES
X300MM BETWEEN CABLES OF DEFT CLASS
b) RCC FOR HIGH VOLTAGE CABLES
WlTH HOLE AT EACH END TO TIE X400MM BETWEEN 1/C POWER CABLE AND
S
THE TO EACH OTHER WlTH G.S WlRE COMMUNICATION CABLE.
&----
ARMOURED POWR CABLE X300MM BETWEEN MULTlCORE POWER
CABLE & COMMUNlCATlON CABLE.
@- ARMOURED CONTROL CABLE
d - OVERALL DIAMETER OF THE BIGGER OF THE TWO CABLES
@- FINE SAND/RIDDLED SOIL COMPACTED x - SPACI~G SHALL BE TAKEN BOTH HORIZONTALLY AND
VERTICALLY.
1. SINGLE CORE CABLES SHALL BE RUN IN TREFOIL FORMATION AND SHALL BE BOUND B Y
SELFLOCKING CABLE n E s A T EMRY 750 MM.
2. CABLE IDENTIFICATION TAG SHALL BE TlED AT BOTH ENDS OF THE CABLE AN0 ALSO AT AN
INTERVAL OF 1 0 METRES.
3. I F THE MINIMUM CLEARENCE AS INDICATED THE A B O M TABLE FOR CABLES OF DIFFERENT
CLASSES ARE NOT FEASIBLE,BRICK BARRIERS SHALL BE USED BETWEEN ADJACENT CABLES
4. G.I.PIPE SHALL BE PROVlDED FOR ROAD CROSSING AT A MINIMUM DEPTH
OF 600 FROM THE GRADE LEVEL UNLESS OTHER WSE SPECIFIED.
5. ALL DIMENSIONS ARE IN MM (SCALE NTS)
ENGINEERING DMSlON
1 CAD RLE NAME : STAND-XK)-W3.CW-

NTPC Limited
, . ( A CoMRNMENT OF INDlA ENrmPRlSE )
ENGINEERING DMSION
PROJECT
Srmm
TITLE
TYPICAL DETAES OF F U C T U R E FOR TESTING
SIZE SCALE ORG' 0000-21 1-POE-A-03'7 REV. NO
A4 N TS
1 CAD FILE NAUE : STAND-211-OJ7.DW;
WORKING UDL = 100 KG
y,": :",',
AS INDICATED
PROOF UDL
POINT LOAD
= 200 KG
= 100 KG
CANTILEVER ARMS
ADDITIONAL POINT
LOAD OF 100 KG
INSTALLATION
SECTION
(ASWMETRIC LOADING)
OSITlON FOR APPLICATION
F 600 K G POINT LOAD FOR TEST 3C
POINT LOAD OF 600 KG

AT EACH POSITION FOR TEST 3 B
BEAM CLAMPS
AS ACTUAL
TWO BRACKETS
LENEHALLY FIXEL
POINT LOAD OF 1200 KG
FOR TEST 3 A
TEST 3 A , 3B & 3C
1 FIXING SHALL BE AS PER ACTUAL

SITE INSTALLATION CONDITION.
2. ALL DIMENSIONS ARE IN MM
CAO FILE NAME : STAND-211-OJ8.D%
& 3
PART - B
SUB-SECTION-IIIB-08
TRANSFORMERS

TRANSFORMERS
1.01.00 Transformers IS:2026, IS:11171, IEC 354, IEC 726
Bushing CTs IEC :185
2.00.00 TYPE
2.01.00 LT Dry-type Transformers Epoxy cast resin/resin encapsulated air

cooled type, Three-phase unit
3.00.00 FEATURES
3.01.00 Paint shade RAL 5012
3.02.00 Degree of protection
Dry- type transformers IP 22
Cable box IP 55
Kiosks & marshalling box IP 55
4.01.00 LT Dry-type Transformers Winding (by resistance method): 90 deg. C or lower as

permissible for class of insulation offered above
ambient of 50 deg. C .
5.01.00 Tap Changer
Off-circuit, +/-5% in steps of 2.5% shall be provided. It shall be hand operated by an

external handle with position markings, pad locking facility in each position and
mechanical stops to prevent over cranking beyond extreme positions in case of
outdoor type transformers. In case of indoor transformers / dry type transformers, it
shall be with shrouded bolted links.
5.02.00 Loading Capability
Continuous operation at rated KVA on any tap with voltage variation of +/-10%
corresponding to the voltage of the tap as well as in accordance with IEC 354.

STAGE-II (2X195 MW)
PART-B TRANSFORMERS 1 OF 4
5.03.00 Flux Density
Not to exceed 1.9 Wb/sq.m. at any tap position with +/-10% voltage variation from
voltage corresponding to the tap. Transformer shall also withstand following
overfluxing conditions due to combined voltage and frequency fluctuations:
5.03.01 110% for continuous rating.
5.03.02 125% for at least one minute.
5.03.03 140% for at least five seconds.
5.04.00 Noise Level Not to exceed values specified in NEMA TR-1.
Transformers shall be suitable for cable termination. If cable connection is

envisaged, a dust tight cable box shall be provided. Also, a sheet steel, vermin and
dust proof marshalling box shall be furnished with each transformer to accommodate
temperature indicators, terminal blocks for control cables etc. The transformer shall
be provided with all fittings and accessories to be complete in all respects for
satisfactory operation.
6.01.00 LT DRY-TYPE TRANSFORMERS
6.01.01 Enclosure
The transformer shall be placed in a cabinet. The cabinet shall be of a tested quality
sheet steel of minimum thickness 2mm and shall also accommodate cable
terminations. The housing door shall be interlocked such that it should be possible to
open the door only when transformer is off. The enclosure shall be provided with
lifting lugs and other hardware for floor mounting.
6.01.02 Core
Shall be High grade non-ageing cold rolled super grain oriented silicon steel
laminations.
6.01.03 Winding conductor shall be electrolytic grade copper or aluminium. Windings shall be
of class F insulation.
6.01.04 Bushings shall be Solid porcelain / RIP.
6.01.05 Bushing CTs Shall be provided in the LV neutral side with adequate rating for REF
protection, WTI, etc.

STAGE-II (2X195 MW)
6.01.06 Fittings
Winding temperature indicator (WTI) shall be Platinum resistance type temperature

detector in each limb.
7.00.00 TRANSFORMER SIZING
7.01.01 Size of the transformer shall be decided based on following:
Size shall be greater than or equal to total KVA of continuous load
+ (coincident factor x total kVA of intermittent load other than valves)
+ 0.2 x total valves kVA
+ kVA of largest rated valve or damper motor
+ Employer's requirement, if any.
Coincident factor of intermittent load, such as lifts, cranes, hoists etc shall be taken
as 0.5.
7.01.02 Based on the above consideration having arrived at the transformer capacity, the
final size of the transformer shall be selected from the preferred sizes as per IS.
8.00.00 TYPE TESTS
8.01.00 For each type and rating of transformers rated upto and including 2 MVA
The Contractor shall submit for Employer’s approval the reports of all the type tests
as listed in this specification and carried out within last ten years from the date of bid
opening. These reports should be for the tests conducted on the equipment similar to
those proposed to be supplied under this contract and the test(s) should have been
either conducted at an independent laboratory or should have been witnessed by a
client. In case the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the type test
report(s) are not found to be meeting the specification requirements, the Contractor
shall conduct all such tests under this contract at no additional cost to the Owner
either at third party lab or in presence of client/owners representative and submit the
reports for approval.
price.

STAGE-II (2X195 MW)
For subsequent projects of NTPC, an endorsement sheet will be furnished by the
manufacturer conforming similarity and “No design change”. Minor changes if any
8.04.00 Following is the list of type tests to be conducted (as per IEC) for transformers of
rating higher than 2 MVA (For transformer of rating upto 2MVA, only the valid test
reports are to be submitted in line with Cl 8.01.00).
8.05.00 Following is the list of type tests:
(a.) Short circuit test
(b.) Temp. rise test
(c.) Lightning impulse voltage test on all three limbs.
(d.) Partial discharge test on dry type transformers
(e.) Noise level test as per NEMA TR-1.
(f.) Degree of protection test for marshalling box.
(g.) Zero sequence Impedance
(h) Measurement of harmonics at no load.
8.06.00 The following special tests on all transformers shall be conducted under this contract
as routine tests as per IEC 60076:
(a) Repeat no load loss test after electrical tests.
(b) Measurement of capacitance & tan delta to determine capacitance between

winding and earth.

STAGE-II (2X195 MW)
PART - B
SUB-SECTION-IIIB-09
INSTRUMENTS

INSTRUMENTS
1.00.00 MEASURING INSTRUMENTS
1.01.00 Measuring instruments/equipment and subsystems offered by the Bidder shall be

from reputed experienced manufacturers of specified type and range of equipment,
whose guaranteed and trouble free operation has been proven. Further, all
instruments shall be of proven reliability, accuracy, and repeatability requiring a
minimum of maintenance. They shall comply with the acceptable international
standards and shall be subject to Employer's approval. All instrumentation
equipment and accessories under this specification shall be furnished as per
technical specifications, ranges, makes/numbers as approved by the Employer
during detailed engineering.
1.02.00 Every panel-mounted instrument requiring power supply shall be provided with a pair
of easily replaceable glass cartridge fuses of suitable rating. Every instrument shall
be provided with a grounding terminal and shall be suitably connected to the panel
grounding bus.
1.03.00 All local gauges as well as transmitters, sensors, and switches for parameters like
pressure, temperature, level, flow etc. as required for the safe and efficient operation
and maintenance as well as for operator and management information (including all
computation) of equipment under the scope of specification shall be provided on as
required basis within the quoted lump sum price.
1.04.00 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve
manifolds and all the other accessories required for mounting/erection of these local
instruments shall be furnished, even if not specifically asked for, on as required
basis. The contacts of equipment mounted instruments, sensors, switches etc. for
external connection including spare contacts shall be wired out in flexible/rigid
conduits, independently to suitably located common junction boxes. The proposal
shall include the necessary cables, flexible conduits, junction boxes and accessories
for the above purpose. Double root valves shall be provided for all pressure tapping
where the pressure exceeds 40 Kg./sq.cm.
2.00.00 SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE AND D.P.
2.01.00 ELECTRONIC TRANSMITTERS
Sr. Features Essential/Minimum Requirements

No.
1. Type of Transmitter Microprocessor based 2 wire type, HART protocol

compatible.

SECTION-VI
COAL HANDLING PLANT PACKAGE INSTRUMENTS 1 OF 11
PART-B
2. Accuracy ± 0.1% of calibrated span ( minimum)
3. Output signal range 4-20 Ma DC (Analog) along with superimposed

digital signal (based on HART protocol)
4. Turn down ratio 10:1 for vacuum/very low pressure applications.
30:1 for other applications.
5. Stability ± 0.1% of calibrated span for six months for

Ranges up to and including70 Kg/cm².
± 0.25% of calibrated span for six months for

Ranges more than 70 Kg/cm² (g).
6. Zero and span drift +/- 0.015% per deg.C at max span.
+/-0.11% per deg.C at min. span.
7. Load impedance 500 ohm (min.)
8. Housing Weather proof as per IP-55 with durable

corrosion resistant coating.
9. Over Pressure 150% of max. Operating pr.
10. Connection (Electrical) Plug and socket type
11. Process connection 1/2 inch NPT (F)
12. Span and Zero Continuous, tamper proof, Remote as well as

adjustability manual from instrument with zero
suppression and elevation facility.
13. Accessories -Diaphragm seal, pulsation dampeners, siphon

etc. as required by service and operating
condition.
-2 valve manifold for absolute pressure

transmitters (3-valve manifold for gauge/ vacuum
pressure transmitters) and 5 valve manifold for
DP/level/flow transmitters.
-For hazardous area, explosions proof enclosure

as described in NEC article 500.

SECTION-VI
PART-B
14. Diagnostics Self Indicating feature
15. Power supply 24V DC ± 10%.
16. Adjustment/calibration Total two (2) no. of hand- held type universal
/maintenance calibrators compatible with HART protocol , shall
be provided (for all three units).
Note.
In case it becomes necessary to use a DP transmitter for pressure

measurement, then a 3-valve manifold should be used in place of 2-valve
manifold.
LVDT type is not acceptable.
Where the process fluids are corrosive, viscous, solid bearing or slurry
type, diaphragm seals shall be provided. Parts below the diaphragm shall
be removable for cleaning. The entire volume above the diaphragm shall
be completely filled with an inert liquid suitable for the application.
2.02.00 ULTRASONIC LEVEL TRANSMITTERS
Sl. no Features Essential/Minimum requirements
1. Type of Transmitter Non contact Microprocessor based 2 wire

type, HART protocol compatible Ultrasonic
transmitter.
2. Output signal Galvanic ally isolated 4-20mA DC (Analog)

along with superimposed digital signal (based
on HART protocol).
3. Sensor Accuracy +/- 0.5% of calibrated span.
4. Sensor Repeatability 3 mm or better.
5. Power supply 24 V DC +/- 10%
6. Temperature To be provided within transducer.

compensation
7. Configuration Sensor unit and Electronic units are to be

separate. It shall be possible to mount the

SECTION-VI
PART-B
Electronic unit at a remote accessible location

from the transducer. All cables and weather
proof fittings to interconnect transducer to
electronic unit shall be provided by Bidder.
8. Housing Weather proof as per IP-55 with durable

corrosion resistant coating.
9. Calibration Through HART Communicator.
10. Zero and Span Continuous, tamper proof, remote as well as

adjustment manual adjustability from instrument. It shall
be possible to calibrate the instrument without
any level in the tank/sump etc
11. Sensor Material Corrosion resistant material to suit individual

application requirement.
12. False signal tolerance Transmitter shall be capable of ignoring false

echoes from internal tank/sumps obstructions
such as pipes, heating coils or agitator blades.
Also transmitter shall have adjustable damping
circuitry
13. Range Range of transmitter shall be capable of

covering the complete level span of tank
taking care of blocking distance, frequency
attenuation due to surface, obstructions,
vapors etc
14. Display Minimum 4 character display with integral

keypad, access protected by user code.
15. Diagnostics Loss of echo alarm etc
16. Load Impedance 500 ohms minimum
17. Electrical Connection Plug and socket
18. Accessories • All weather canopy for protection from

direct sunlight and direct rain.
• All mounting hardware and accessories

required for erection and commissioning
mounting fittings material shall be SS 316.

SECTION-VI
PART-B
• For hazardous areas, explosion proof

enclosure as described in NEC article 500.
Note:-
Contractor can also provide Radar type transmitter in place of ultrasonic

transmitters subject to approval by Employer during detailed Engineering.
3.00.00 TEMPERATURE ELEMENTS
3.01.00 RESISTANCE TEMPERATURE DETECTOR ( RTD )
Sr. Features Essential/Minimum Requirements

No.
1 Type of RTD. : Pt-100 (100 Ohms resistance at zero

degree centigrade)
2 No. of element : Duplex
3 Housing/Head : IP-55/Diecast Aluminium. Plug in

connectors are to be provided for
external signal cable connection.
4 Sheathing of RTD : Metal sheathed, ceramic packed
5 Calibration and accuracy : As per DIN-43760 Class-A
6 Characteristic : Linear with respect to temp, within ±1/2

percent of top range value.
7 Accessories : Thermo well (as specified below) and

shall be spring loaded for positive
contacts with the well.
8 Standard : DIN-43760 for RTD and ASME PTC-19.3

for Thermo-well.
3.02.00 THERMO WELL
Thermo well shall be one piece solid bored type of 316SS of Step-less tapered
design (as per ASME PTC 19.3, 1974).

SECTION-VI
PART-B
3.03.00 TEMPERATURE TRANSMITTER
Following type of 2-wire temperature transmitter (directly powered from 4-20mA

input cards of DDCMIS) shall be provided. The temperature transmitter shall be
fully compatible with thermocouples and RTDs being provided by the contractor.
Temperature compensation of the thermocouples shall be performed in the
temperature transmitter itself.
Single Input DIN-rail mounted Temperature Transmitter
These shall be suitable for mounting on DIN-rails in JBs. The specifications of the
JBs shall be same as indicated in Subsection INST CABLE with additional DIN-
rails and IP 65 Protection class. This temperature transmitter shall be the ones
which are especially designed for DIN-rail mounting with IP 20 protection class.
These shall have terminals for input/output provided on front side when mounted
on DIN-rail. Head mounted temperature transmitter with clamps to make it suitable
for DIN-rail mounting shall not be acceptable under this category.
Requirements for each of the above type of temperature transmitters
Output : 2-wire (power supply from input card of

Control System) with 4-20mA output with
superimposed HART protocol signal.
Input : Same transmitter shall be capable to handle

Pt-100 RTD , Thermocouples –K&R types
(input type to be selectable at site through
HART terminal)
Isolation : min. 500 V AC
EMC compatibility : as per EN 61326
Operating ambient : 0 to 85 deg C (without indicator)

temperature
0 to 70 deg C (with indicator)
Power supply compatible with input module of Control

System
Accessories Mounting arrangements including clamps etc.
Composite Accuracy
(Refer note 2) RTD =<0.4% of 0-250 deg C span

SECTION-VI
PART-B
T/C-K type =<0.4% of 0-600 deg C span
T/C-R type =<0.4% of 0-1000 deg C span
CJC accuracy (for thermocouples) shall be =<

1 deg C
Notes:-
1. In case of failure (open or burn-out) of RTD/thermocouple, temp. Transmitter

shall provide low temperature output.
2. Composite Accuracy is to be calculated as summation of all applicable

accuracies of temp transmitter, for converting sensor input to output in 4-20
mA (e.g., basic accuracy, digital accuracy, D/A accuracy, etc.) and
temperature effect on these accuracies at ambient temperature of 50 deg C,
based on the figure/ formula given in the standard product catalogue for span
as specified above for various types of Temperature Elements specified. All
such accuracy/ temp effect figures in catalogue shall be first converted to deg
C, and then percentage of this converted accuracy in specified span shall be
calculated to compare with the specified composite accuracy figures.
3.04.00 Hand held calibrator
Hand held calibrators (2 nos) shall be provided for adjustment/calibration/

maintenance of the HART compatible temperature transmitters.
4.00.00 SPECIFICATIONS FOR PR. GAUGE, D.P. GAUGE, TEMP. GAUGE AND LEVEL
GAUGE.
Sl. FEATURES ESSENTIAL/MINIMUM REQUIREMENTS

No
Pr. Gauge/ DP Temperature Level Gauge

Gauge/ Gauge
Draught
gauges
1 Sensing Bourdon for Mercury in steel Tempered * toughened

Element and high pressure, for below 450°C Borosilicate gauge
material Diaphragm/Bel and inert gas glass steel armoured
low for low pr. actuated for reflex or transparent
Of 316 SS above 450°C of type.
SS bulb and
capillary.

SECTION-VI
PART-B
2 Body Die-cast Die-cast Forged carbon

material aluminium aluminium steel/304 SS
3 Dial size 150mm 150 mm Tubular covering entire

range
4 End 1/2 inch NPT 3/4" NPT (M) Process connection as

connection (M) per ASME PTC and
drain/vent 15 NB
5 Accuracy ±1% of span ± 1% of span ± 2%
6 Scale Linear, 270° Linear, 270° arc Linear vertical

arc graduated graduated in °C
in metric units
7 Range Cover 125% of Cover 125% of Cover 125% of max. of

selection max. of scale max. of scale scale
8 Over range Test pr. for the assembly shall be1.5 to the max. Design pr.
test at 38°C.
9 Housing Weather and Weather and dust CS/304 SS leak proof

dust proof as proof as per IP-55
per IP-55
10 Zero/span Provided Provided --

adjustment
11 Identification Engraved with service legend or laminated Phenolic name

plate
12 Accessories Blow out disc, SS Thermo well Gasket for all KEL-F
siphon, shields for transparent
snubber, type vent and drain
pulsation valves of Steel/SS as
dampener, per CS/Alloy process
chemical seal Requirement.
(if required by
process)
gauge
isolation valve

SECTION-VI
PART-B
13 Material of 316 SS / 304 316 SS / 304 SS

Bourdon/ SS
movement
Notes:-
*Bicolor type level gauges will be provided for applications involving steam and
water except for condensate and feed water services.
Length of gauge glass shall not be more than 1400 mm. If the vessel is higher,
multiple gauge glasses with 50 mm overlapping shall be provided.
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be removable
for cleaning. The entire volume above the diaphragm shall be completely filled
with an inert liquid suitable for the application.
5.00.00 ROTAMETERS
Sr. Features Essential / minimum requirements

No.
1. Type Variable Area Metal Tube
2. Fluid media Water/oil
3. Tube body SS316
4. Material of float 316 SS
5. Indicator Linear scale
6. Accessories Flange orifice in case of bypass rotameter (for line size

above 100 mm)
7. Housing IP-55
protection class
8. Accuracy + 2% of measured value.

SECTION-VI
PART-B
6.00.00 PROCESS ACTUATED SWITCHES
FEATURES ESSENTIAL / MINIMUM REQUIREMENTS
Pressure/ Temperature Level switches

Draft switches
Switches/
DP
Switches
Sensing Piston Vapor pressure Capacitance types for oil and

Element actuated for sensing, liquid dirty medium, water,
high filled bellow type condensate application.
pressure with SS bulb and
and capillary (10 m Float type switches for
diaphragm minimum) applications as decided by
or bellows Employer during detailed
for low pr./ engineering.
vacuum
Capacitance/ Conductivity/
Ultrasonic type for acid and
alkali application.
Material 316 SS Bulb 316 SS/ 316 SS

capillary 304 SS
End ½ inch NPT ½ inch NPT (F) Manufacturer standard

connection (F)
Over range 150% of - 150% of max. design

proof max. design pressure
pressure pr.
Repeat-ability + 0.5% of full range
No. of 2 No.+2NC. SPDT snap action dry contact

contacts
Rating of 60 V DC, 6 VA (or more if required by DDCMIS or PLC)*

contacts
Elect. Plug in socket

Connection

SECTION-VI
PART-B
Set point/ Provided over full range

dead band
adjustment
Enclosure Weather and dust proof as per IP-55
Accessories Siphon, Thermo well of All mounting accessories

snubber, 316 SS and
chemical packing glands
seal,
pulsation
dampeners
as required
by process
Mounting Suitable for Suitable for rack -

enclosure/ mounting or
rack direct mounting
mounting or
direct
mounting
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be
removable for cleaning. The entire volume above the diaphragm shall be
completely filled with an inert liquid suitable for the application.

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIB-10
HT LOAD BREAK SWITCH AND

JUNCTION BOX

H.T. LOAD BREAK SWITCH AND JUNCTION BOX
1.00.00 CODE AND STANDARDS
IS:3427, IS:2208, IS:9920
2.00.00 TYPE
2.01.01 6.6KV LOAD BREAK SWITCH PANEL
Metal enclosed, free standing, indoor, non draw-out type, IP-55 enclosure protection,
paint shade: RAL 9002. The panel shall be located in the MCC room of S/R machine
and shall be suitable for the fault level of the system.
2.02.00 JUNCTION BOX
Metal enclosed, free standing, suitable for outdoor location, I.P-65 enclosure
protection, paint shade-RAL-9002. 6.6 KV Junction Box shall be located at the
centre of the travel length of S/R machine and shall be suitable for the fault level of
the system.
Temperature rise of busbars shall not exceed 55 deg.C for silver plated joints and 40
deg.C for other joints, over an ambient temperature of 50 deg.C.
4.00.00 OPERATIONAL REQUIREMENT
4.01.00 Load break Switch
a) Load break switch unit shall be provided with hinged front door and suitable
for front execution. The switch shall be mechanically interlocked with the door
so that the door can not be opened while the switch is in closed position.
b) Constructional details, sheet steel thickness etc. shall be as per technical

specification of MCCs.
c) The switch unit shall perform satisfactorily even with the vibrations and jerks
due to operation of the machine.
d) Load break switch shall have shunt trip coil, ON indicating lamp, on/OFF
position mechanical indication, internal earth bus and earth switch which shall
be interlocked with the main switch.
e) Panel shall be identified on front as well as back side by large engraved plate
MUZAFFARPUR THERMAL POWER PROJECT SUB-SECTION-IIIB-10

STAGE-II (2X195 MW) HT LOAD BREAK PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE SWITCH AND 1 OF 3
PART-B
BID DOCUMENT NO. : CS-0350-155(R)-2 JUNCTION BOX
giving detailed feeder description. Identification labels/painted (Not stickers)

plates shall be provided inside the panel.
f) The panel shall be designed to offer adequate level of safety to

operating/maintenance personnel. Means shall be provided to prevent
access to the live part to avoid accidents during service as well as
maintenance period. Contractor shall bring out the safety means provided to
achieve the same. A detailed instruction plate suitable for wall mounting shall
be provided for mounting on wall describing various safety
procedure/precautions for safe operation and maintenance. Rubber mats
shall be provided in front of the panels.
4.02.00 H.T. Junction box
a) Junction shall be adequately sized to facilitate the HT XLPE cable on one side
and EPR insulated trailing cable on the other side.
b) Constructional details, sheet steel thickness etc. shall be as per technical

specification of MCCs.
5.00.00 TYPE TESTS:
equipment price.

SECTION-VI
PART-B
5.01.00 Type test reports for the following type tests on HT load break switch panel shall
be submitted:
1) Short circuit test
2) Degree of protection test
3) Power frequency withstand test
4) Impulse voltage withstand test

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIB-11
BATTERY

BATTERY
1.00.00 BATTERY RATINGS
DC systems of 220V voltage level shall be provided for coal handling plant. The
system shall comprise of two batteries and two float-cum-boost chargers. CHP
battery shall be sized for a period of at least 30 minutes for the CHP DC loads. The
O
battery shall also be sized considering a minimum electrolyte temperature of 15 C
and an ageing factor of 1.2.
In addition to the above following criteria shall be followed for CHP batteries:
Battery sizing shall take into account the emergency lighting in CHP equipment
buildings as detailed elsewhere in technical specifications, in addition to continuous
DC loads of various Macs/Swgr and control panels. 220V DC load of 10 KW for
employer’s use shall also be considered for battery sizing.
PART-A: NICKEL-CADMIUM BATTERY
2.01.00 All standards, specifications and codes of practice referred to herein, shall be the
of opening of bid.
In case of conflict between this specification and those (IS codes, Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per the
following standards and codes:
IS : 10918 Specification for vented type Nickel Cadmium Batteries.
IS : 1069 Quality tolerances for water for storage batteries
Indian electricity rules
Indian Electricity Acts.
2.02.00 Equipment complying with other internationally accepted standards such as IEC.,
BS, VDE etc. will also be considered if they ensure performance and constructional
features equivalent or superior to standards listed above. In such a case, the Bidder
shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest
revision of the standards along with copies of all official amendments and revisions in
force as on date of opening of bid and shall clearly bring out the salient features for
comparison.

SECTION-VI
COAL HANDLING PLANT PACKAGE BATTERY 1 OF 10
PART-B
3.00.00 GENERAL TECHNICAL REQUIREMENT
3.01.00 Equipments
(a.) DC Batteries shall be stationary Nickel Cadmium Pocket plate type

conforming to IS:10918. For the purpose of design an ambient temperature of
50 degree centigrade and relative humidity of 85% shall be considered.
(b.) DC batteries shall be suitable for standby duty. The batteries shall normally
be permanently connected to the load in parallel with a charger and shall
supply the load during emergency conditions when AC supplies are lost.
Batteries shall be suitable for a long life under continuous float operations
and occasional discharges. The batteries shall be boost charged at about
1.54 to 1.7 volts per cell maximum and float charged at about 1.42 V/cell.
(c.) The number of cells for the 220 Volts shall be 169.
(d.) Batteries should be suitable for continuous operation for the maximum
ambient temperature as defined in technical parameters.
3.02.00 Construction Features
3.02.01 Containers
Containers shall be made of polypropylene plastic material. Containers shall be

robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging type
and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level
lines shall be marked on container in case of translucent containers.
3.02.02 Vent Plugs
Vent plugs shall be provided in each cells. They shall be anti splash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent alkali
from coming out. The design shall be such that the water loss due to evaporation is
kept to minimum. In addition the ventilator shall be easily removed for topping up the
cells and of such dimensions that the syringe type hydrometer can be inserted into
the vent to take electrolyte samples.
3.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS:10918.

SECTION-VI
PART-B
The separators shall maintain the electrical insulation between the plates and shall
allow the electrolyte to flow freely. Separators should be suitable for continuous
immersion in the electrolyte without distortion.
The positive and negative terminal posts shall be clearly marked.
3.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be cleaned
during normal life and prevent shorts within the cells.
3.02.05 Cell Insulator
Each cell shall be separately supported on PVC/porcelain/hard rubber insulators

fixed on to the racks with adequate clearance between adjacent cells. Minimum
distance between the adjacent cells shall be more than the budge allowed for two
cells in accordance with IS: 1146.
3.02.06 Electrolyte
The electrolyte shall be prepared from battery grade potassium hydroxide

conforming to BS: 1069.
The cells can be shipped either in charged condition or in dry condition
Necessary electrolyte for make-up shall be supplied separately.
3.02.07 Connectors and Fasteners
Nickel coated copper connectors shall be used for connecting up adjacent cells and
rows. Bolts, nuts and washers shall be effectively Nickel coated to prevent corrosion.
The thickness of Nickel coating of connectors should be not less than 0.02 mm. All
the terminals and cells inter-connectors shall be fully insulated or have insulation
shrouds. End take off connections from positive and negative poles of batteries shall
be made by single core cables having stranded aluminium conductors and XLPE
insulation. Necessary supports and lugs for termination of these cables on batteries
shall also be supplied by the contractor. All connectors and lugs shall be capable of
continuously carrying the 30 minutes discharge current of the respective batteries
and through fault short circuit current which the battery can produce and withstand
for the period declared. Contractor shall furnish necessary sizing calculations to
prove compliance to the same. Suitable number of Inter-rack connectors shall be
supplied by the Bidder to suit the battery room layout during detailed engineering.

SECTION-VI
PART-B
3.02.08 Battery racks
Mild steel racks for all the batteries shall be provided. They shall be free standing
type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall
preferably be located in the single tier arrangement. However, batteries having a
complete cell weight of lower than 50 Kg could be located in the double tier
arrangement. The batteries racks and supports for cable termination shall be coated
with three (3) coats of anti-alkali paint of approved shade. Name plates, resistant to
alkali, for each cell shall be attached on to the necessary racks. The bottom tier of
the stand shall not be less than 150 mm above the floor.
Wherever racks are transported in dismantled conditions, match markings shall be

provided to facilitate easy assembly.
3.02.09 Manufacturer’s Identification System
The following information shall be indelibly marked on outside of each cell.
(a.) Manufacturers’ name and trade marks
(b.) Country and year of manufacture.
(c.) Manufacturer type designation.
(d.) AH capacity at 5 hour discharge rate.
(e.) Serial number
4.00.00 THE FOLLOWING INFORMATION SHALL BE GIVEN ON THE INSTRUCTION

CARDS SUPPLIED WITH THE BATTERY:
(a.) Manufacturer's instructions for filling and initial charging of the battery
together with starting and finishing charging rate.
(b.) Maintenance instructions.
(c.) Designation of cell in accordance with IS:10918.
(d.) Storing conditions of electrolyte.

SECTION-VI
PART-B
5.00.00 TESTS
5.01.00 GENERAL
(a.) All equipment to be supplied shall be of type test design. During detailed
all the type tests as per latest IS-1146 (for all applicable tests for containers) /
IS-10918 (for Ni-Cd Batteries) and carried out within last ten years from the
equipment similar to those proposed to be supplied under this contract and
the test(s) should have been either conducted at an independent laboratory
or should have been witnessed by a client. The complete type tests shall be
for any rating of battery in a particular group, based on plate dimensions.
(b.) However if the contractor is not able to submit reports of the type test(s)
the contractor shall conduct all such tests under this contract at no additional
cost to the owner either at third party lab or in presence of client/owners
(c.) All acceptance and routine tests shall be as per Quality assurance and
Inspection table of batteries.
furnished by the manufacturer confirming similarity and “No design Change”.
5.02.00 Commissioning checks.
All tests as listed below shall be carried out on sample cell selected at random by the
employer at site after completion of installation.
(a.) Physical Examination
(b.) Dimensions, Mass & layout
(c.) MARKING
(d.) Polarity and absence of short circuit.
(e.) Air pressure test
(f.) Ampere - hour capacity
(g.) Retention of charge
(h.) Insulation resistance
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments.

SECTION-VI
PART-B
PART-B: LEAD –ACID PLANTE BATTERY
6.01.00 All standards, specification and codes of practice, referred to herein, shall be the
latest edition including all applicable official amendments and revisions as on
date of opening of bid.
In case of conflict between this specification and those (IS Codes Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per
the following standards and codes :
IS : 266 Specification for sulphuric acid
IS : 1069 Specification for water for storage batteries
IS : 1146 Specification for rubber & plastic containers for lead acid storage
batteries.
IS : 1652 Specification for stationary cells and batteries, lead acid type (with
plant positive plates).
IS : 3116 Specification for sealing compound for lead acid batteries.
IS : 8320 General requirements and methods of tests for lead acid storage
batteries.
IS : 6071 Specification for synthetic separators for lead acid batteries.
Indian Electricity Rules
Indian Electricity Acts
6.02.00 Equipment complying with other internationally accepted standards such as IEC,
BS, VDE etc. will also be considered if they ensure performance and
constructional features equivalent or superior to standards listed above. In such a
case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in
English of the latest revision of the standards alongwith copies of all official
amendments and revisions in force as on date of opening of bid and shall clearly
bring out the salient features for comparison.

SECTION-VI
PART-B
7.00.00 GENERAL TECHNICAL REQUIREMENTS
7.01.00 Equipments
DC Batteries shall be stationary lead acid Plante positive plate type conforming to
IS:1652. For the purpose of design an ambient temperature of 50 degree
centigrate and relative humidity of 85% shall be considered.
DC Batteries shall be suitable for standby duty. The Batteries shall normally be
permanently connected to the load in parallel with a charger and shall supply the
load during emergency conditions when AC supplies are lost. Batteries shall be
suitable for a long life under continuous float operations and occasional
discharges. The batteries shall be boost charged at about 2.7 volts per cell
maximum and float charged at about 2.2 V/cell:
The number of cells for the 220 Volts shall be 109.
Batteries should be suitable for continuous operation for the maximum ambient
temperature as defined in technical parameters.
7.02.00 Construction Features
7.02.01 Containers
Containers shall be made of transparent glass, hard rubber, suitable robust, heat
resistance, leak proof, non absorbent, acid resistant, non-bulging type and free
from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines
shall be marked on container in case of transparent containers. Float type level
indicator shall be provided in case of opaque containers. The stem portion of the
float should be long enough to prevent falling of the float inside the container
even if there is no electrolyte in the container. The marking for the electrolyte
level should be for the upper and lower limits. The material of level indicator shall
be acid proof and oxidation proof. Container shall be closed/sealed lid type. Lid
and sealing compound shall be non-cracking type. The container made of hard
rubber and plastics shall be type tested as per IS : 1146. All type tests shall be
carried out for sealing compound as per IS:3116.
The pole sealing arrangement should be such that no acid particle gets
entrapped due to acid creep as a result of capillary action and it should be
possible to remove and refix the sealing to carry out the maintenance.
7.02.02 Vent Plugs
Vent plugs shall be provided in each cell. They shall be antisplash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent
acid from coming out. The design shall be such that the water loss due to
evaporation is kept to minimum. In addition the ventilator shall be easily removed

SECTION-VI
PART-B
for topping up the cells and of such dimensions that the syringe type hydrometer
can be inserted into the vent to take electrolyte sample.
7.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS: 1652 as applicable.
The separators shall maintain the electrical insulation between the plates and
shall allow the electrolyte to flow freely. Separators should be suitable for
continuous immersion in the electrolyte without distortion. The positive and
negative post shall be clearly marked.
7.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be
cleaned during normal life and prevent shorts within the cells.
7.02.05 Cell Insulator
Each cell shall be separately supported on PVC/porcelain/hard rubber insulators

fixed on the racks with adequate clearance between adjacent cells. Minimum
distance between adjacent cells shall be more than the buldge allowed for two
cells in accordance with IS: 1146.
7.02.06 Electrolyte
The electrolyte shall be prepared from battery grade sulphuric acid conforming to
IS:266 and distilled water conforming to IS:1069. The cells shall be shipped dry
uncharged. The electrolyte shall be supplied separately.
7.02.07 Connectors and Fasteners
Lead or Lead coated copper connectors shall be used for connecting up adjacent
cells and rows. Bolts, nuts and washers shall be effectively lead coated to prevent
corrosion. The thickness of lead-coating of connectors should not be less than
0.025 mm. The lead coating thickness shall be measured in accordance with
APPENDIX F of IS: 6848 (latest edition). All the terminals and cells inter-
connectors shall be fully insulated or have insulation shrouds. End take off
connections from positive and negative poles of batteries shall be made by single
core cables having stranded aluminium conductors and XLPE insulation.
Necessary supports and lugs for termination of these cables on batteries shall
also be supplied by the contractor. All connectors and lugs shall be capable of
continuously carrying the 30 minutes discharge current of the respective Batteries

SECTION-VI
PART-B
and through fault short circuit current which the battery can produce and
withstand for the period declared. Contractor shall furnish necessary sizing
calculations to prove compliance to the same.
7.02.08 Battery racks
Wooden racks for all the batteries shall be provided. These racks shall be made
of good quality first class seasoned teak wood in line with CPWD specification.
They shall be free standing type mounted on porcelain/hard rubber/PVC pads
insulators. Batteries shall preferably be located in the single tier arrangement.
However, batteries having a complete cell weight of lower than 50 Kg could be
located in the double tier arrangement. The batteries rack and wooden support
for cable termination shall be coated with three (3) coats of anti-acid paint of
approved shade. Numbering tags, resistant to acid, for each cell shall be
attached on to the necessary racks. The bottom tier of the stand shall not be less
than 150 mm above the floor. Wherever racks are transported in dismantled
condition, suitable match markings shall be provided to facilitate easy assembly.
7.02.09 Manufacturer’s Identification Systems
The following information shall be indelibly marked on outside of each cell.
(a.) Manufacturer's name and trade marks
(b.) Country and year of manufacture.
(c.) Manufacturer type designation.
(d.) AH capacity at 10 hour discharge rate.
(e.) Serial number
8.00.00 TESTS
8.01.00 GENERAL
(a) All equipment to be supplied shall be of type test design. During detailed
all the type tests as per latest IS-1146 (for rubber & plastic containers for
Lead – acid storage batteries) and carried out within last ten years from the
equipment similar to those proposed to be supplied under this contract and
the test(s) should have been either conducted at an independent laboratory
or should have been witnessed by a client. The complete type tests shall be
for any rating of battery in a particular group, based on plate dimensions.

SECTION-VI
PART-B
(b) However if the contractor is not able to submit reports of the type test(s)
the contractor shall conduct all such tests under this contract at no additional
cost to the owner either at third party lab or in presence of client/owners
(c) All acceptance and routine tests shall be as per Quality assurance and
Inspection table of batteries.
(d) The type test reports once approved for any projects shall be treated as
8.02.00 Commissioning checks
All tests as listed below shall be carried out on sample cell selected at random by
the employer at site after completion of installation.
1) Verification of markings.
2) Verification of dimensions.
3) Test for capacities for 10 hrs discharge rate alongwith the test for voltage
during discharge.
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed
requirements the Employer shall have the option of asking the Contractor to
replace the same.

SECTION-VI
PART-B
PART - B
SUB-SECTION-IIIB-12
BATTERY CHARGER

CLAUSE NO.
BATTERY CHARGER
of opening of bid. In case of conflict between this specification and those (IS codes,
standards etc.) referred to herein, the former shall prevail. All work shall be carried
out as per the following standards and codes.
ANSI-C Guide for surge withstand capability tests

37.90a
IS:5 Colours for ready mix paints.
IS : 694 PVC Insulated Cable for working voltages upto and including 1100 V.
IS : 1248 Specification for Direct acting indicating analogue electrical
measuring instruments.
IS:13947 Degree of protection provided by enclosures for low voltage switch
Part-1 gear and control gear.
IS : 13947 Specification for low voltage switch gear and control gear
IS : 3231 Electrical relays for power system protection.
IS : 3842 Application guide for Electrical relays for AC System
IS : 3895 Mono-crystalline semi-conductor Rectifier Cells and Stacks
IS : 4540 Mono crystalline semi-conductor Rectifier assemblies and equipment.
IS:6005 Code of practice for phosphating of Iron and Steel.
IS:6619 Safety Code for Semi-conductor Rectifier Equipment.
IS:6875 Control switches (switching devices for control and auxiliary circuits
including contactor relays) for voltages upto 1000 V AC or 1200 V
DC.
IS : 9000 Basic environmental testing procedures for electronic and electrical
items.
IS:13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V
DC.
EEUA-45D Performance requirements for electrical Alarm Annunciation System
Indian Electricity Rules
Indian Electricity Act.

STAGE-II (2X195 MW) TECHNICAL SPECIFICATION SUB-SECTION-IIIB-12 PAGE
COAL HANDLING PLANT PACKAGE SECTION-VI BATTERY CHARGER 1 OF 13
BID DOCUMENT NO. : CS-0350-155(R)-2 PART-B
CLAUSE NO.
1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS,
VDE. etc. will also be considered if they ensure performance and constructional
features equivalent or superior to standards listed above. In such a case, the Bidder
shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest
revision of the standards alongwith copies of all official amendments and revisions in
force as on date of opening of bid and shall clearly bring out the salient features for
comparison.
2.00.00 EQUIPMENT DESCRIPTION
2.01.00 PART-I BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY
(a.) The Battery Chargers as well as their automatic regulators shall be of static
type. Battery chargers shall be capable of continuous operation at the
respective rated load in Trickle mode i.e. Trickle charging the associated DC
lead-acid Batteries while supplying the D.C. loads. The Batteries shall be
Trickle charged at 2.25 Volts per cell. All chargers shall also be capable of
Boost charging the associated D.C. Battery at 2.0 to 2.7 Volts per cell at the
desired rate. The Chargers shall be designed to operate, as mentioned
above, at an ambient air temperature of 50°C.
(b.) Battery Chargers shall have a selector switch for selecting the battery
charging mode i.e. whether Trickle or Boost charging.
(c.) All Battery Chargers shall be provided with facility for both automatic and
manual control of output voltage and current. A selector switch shall be
provided for selecting the mode of output voltage/current control, whether
automatic or manual. Means shall be provided to avoid current/voltage
surges of harmful magnitude/nature which may arise during changeover from
Auto to Manual mode or vice-versa under normal operating condition.
(d.) Soft start feature shall be provided to build up the voltage to the set value
slowly within fifteen seconds. The chargers shall have load limiters which
shall cause, when the voltage control is in automatic mode, a gradual
lowering of the output voltage when the DC load current exceeds the load
limiter setting of the Charger. The load limiter characteristic shall be such that
any sustained overload or short circuit in DC system shall neither damage the
Charger nor shall it cause blowing of any of the changer fuses. The Charger
shall not trip on overload or external short circuit. After clearance of fault, the
Charger voltage shall build up automatically when working in automatic
mode.
(e.) When on automatic control mode during Trickle charging, the Charger output
voltage shall remain within +/-1% of the set value for AC input voltage
variation of +/-10%, frequency variation of +3/-5%, a combined voltage and

CLAUSE NO.
frequency (absolute sum) variation of 10% and a continuous DC load

variation from zero to full load. Uniform and stepless adjustments of voltage
setting (in both manual and automatic modes) shall be provided on the front
of the Charger panel covering the entire Trickle charging output range
specified. Stepless adjustment of the load limiter setting shall also be
possible from 80% to 100% of the rated output current for Trickle charging
mode.
(f.) During Boost charging, the Battery Chargers shall operate on constant
current mode (When automatic regulator is in service). It shall be possible to
adjust the Boost charging current continuously over a range of 50 to 100% of
the rated output current for Boost charging mode. The charger output voltage
shall automatically go on rising, when it is operating on boost mode, as the
battery charges up. For limiting the output voltage of the charger, a
potentiometer shall be provided on the front of the panel, whereby it shall be
possible to set the upper limit of this voltage anywhere in the output range
specified for boost charging mode. All voltage and current setting
potentiometers shall be vernier type.
(g.) Energising the Charger with fully charged battery connected plus 10% load
shall not result in output voltage greater than 110% of the voltage setting.
Time taken to stabilise, to within the specified limits as mentioned elsewhere,
shall be less than fifteen seconds.
(h.) Momentary output voltage of the Charger, without the Battery connected shall
be within 94% to 106% of the voltage setting during sudden load Change
from 100% to 20% of full load or vice-versa. Output voltage shall return to,
and remain, within the limits specified as mentioned elsewhere in less than 2
seconds after the above mentioned change.
(i.) The Charger manufacturer may offer an arrangement in which the voltage
setting device for Trickle charging mode is also used as output voltage limit
setting device for Boost charging mode, and the load limiter of the trickle
charging mode is also used as Boost charging current setting device.
(j.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple
content (peak to peak) in the output voltage to 1% irrespective of the DC
load, even when they are not connected to a battery.
(k.) The DC System shall be ungrounded and float with respect to the ground
potential when healthy. An earth fault relay shall be provided by the Employer
in the DC distribution board for remote annunciation.

CLAUSE NO.
2.02.00 PART-II BATTERY CHARGER FOR NICKEL-CADMIUM TYPE BATTERY
(a.) The Battery Chargers as well as their automatic regulators shall be of static
type. Battery chargers shall be capable of continuous operation at the
respective rated load in Trickle mode i.e. Trickle charging the associated DC
Nickel-Cadmium Batteries while supplying the D.C. loads. The Batteries shall
be Trickle charged at 1.4 to 1.42 Volts per cell. All chargers shall be capable
of Boost charging the associated D.C. Battery at 1.53 to 1.7 Volts per cell at
the desired rate. The Chargers shall be designed to operate, as mentioned
above, at an ambient air temperature of 50°C.
(b.) Battery Chargers shall have a selector switch for selecting the battery
charging mode i.e. whether Trickle or Boost charging.
(c.) All Battery Chargers shall be provided with facility for both automatic and
manual control of output voltage and current. A selector switch shall be
provided for selecting the mode of output voltage/current control, whether
automatic or manual. Means shall be provided to avoid current/voltage
surges of harmful magnitude/nature which may arise during changeover from
Auto to Manual mode or vice-versa under normal operating condition.
(d.) Soft start features shall be provided to build up the voltage to the set value
slowly within fifteen seconds. The chargers shall have load limiters which
shall cause, when the voltage control is in automatic mode, a gradual
lowering of the output voltage when the DC load current exceeds the load
limiter setting of the Charger. The load limiter characteristic shall be such that
any sustained overload or short circuit in DC system shall not damage the
Charger, nor shall it cause blowing of any of the charger fuses. The Charger
shall not trip on overload or external short circuit. After clearance of fault, the
Charger voltage shall build up automatically when working in automatic
mode.
(e.) When on automatic control mode during Trickle charging, the Charger output
voltage shall remain within +/-1% of the set value for AC input voltage
variation of +/-10%, frequency variation of +3 to -5%, a combined voltage and
frequency (absolute sum) variation of 10% and a continuous DC load
variation from zero to full load. Uniform and stepless adjustments of voltage
setting (in both manual and automatic modes) shall be provided on the front
of the Charger panel covering the entire Trickle charging output range
specified. Stepless adjustment of the load limiter setting shall also be
possible from 80% to 100% of the rated output current for Trickle charging
mode.

CLAUSE NO.
(f.) During Boost charging, the Battery Chargers shall operate on constant
current mode (When automatic regulator is in service). It shall be possible to
adjust the Boost charging current continuously over a range of 50 to 100% of
the rated output current for Boost charging mode. The charger output voltage
shall automatically go on rising, when it is operating on boost mode, as the
battery charges up. For limiting the output voltage of the charger, a
potentiometer shall be provided on the front of the panel, whereby it shall be
possible to set the upper limit of this voltage anywhere in the output range
specified for boost charging mode. All voltage and current setting
potentiometers shall be vernier type.
(g.) Energising the Charger with fully charged battery connected plus 10% load
shall not result in output voltage greater than 110% of the voltage setting.
Time taken to stabilise, to within the specified limits as mentioned elsewhere
shall be less than fifteen seconds.
(h.) Momentary output voltage of the Charger, without the Battery connected shall
be within 94% to 106% of the voltage setting during sudden load Change
from 100% to 20% of full load or vice-versa. Output voltage shall return to,
and remain, within the limits specified as mentioned elsewhere in less than 2
seconds after the above mentioned change.
(i.) The Charger manufacturer may offer an arrangement in which the voltage
setting device for Trickle charging mode is also used as output voltage limit
setting device for Boost charging mode, and the load limiter of the trickle
charging mode is also used as Boost charging current setting device.
(j.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple
content (peak to peak) in the output voltage to 1% irrespective of the DC
load, even when they are not connected to a battery.
(k.) The DC System shall be ungrounded and float with respect to the ground
potential when healthy. An earth fault relay shall be provided by the Employer
in the DC distribution board for remote annunciation.
2.03.00 Printed Circuits Boards (PCB)
PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8%
pure copper foil, free of wrinkles, blisters, scratches and pinholes. The contact
surface of the edge connectors of the PCBs shall be plated with hard gold to a
minimum thickness of 5 microns. Component identification shall be printed on PCB
by silk screen method. All PCBs shall be tropicalised and masked.

CLAUSE NO.
2.04.00 CONTACTORS
All Battery Chargers shall have an AC contactor on the input side. It shall be of air
break type and suitable for continuous duty. The operating coil shall be rated for 415
Volts AC.
2.05.00 Thermal Overload Relay
A thermal overload relay incorporating a distinct single phasing protection (using

differential movement of bimetal strips) shall also be provided for the AC input. The
relay shall trip the above contactor.
2.06.00 Rectifier-Transformers and Chokes
The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating
of the rectifier-transformers and chokes shall correspond to the rating of the
associated rectifier assembly. The rectifier-transformers and chokes shall have
class-B insulation with temperature rise limited to class-A insulation value.
2.07.00 Rectifier Assembly
The rectifier assembly shall be full wave bridge type and designed to meet the duty
as required by the respective Charger. The rectifier cells shall be provided with their
own heat dissipation arrangement with natural air cooling. The rectifier shall utilise
diodes/thyristors and heat sinks rated to carry 200% of the load current continuously
and the temperature of the heat sink shall not be permitted to exceed 85°C absolute
duly considering the maximum charger panel inside temperature. The Contractor
shall submit calculations to show what maximum junction temperature will be and
what the heat sink temperature will be when operating at 200% and 100% load
current continuously duly considering the maximum surrounding air temperature for
these devices inside the charger panel assuming air ambient temperature of 50°C
outside the panel. Necessary surge protection devices and rectifier type fast acting
fuses shall be provided in each arm of the rectifier connections.
2.08.00 DIGITAL INDICATING INSTRUMENTS
Digital indicating instruments with built in communication port for remote data
transfer shall be provided for all chargers. The instruments shall indicate DC current,
DC voltage & AC voltage and instrument shall be 96 x 96 sqmm, with display
accuracy 0.5%, 4 digit – 7 segment LED/LCD display and RS 485 serial Bus port.
2.09.00 AIR BREAK SWITCHES
All Chargers shall have AC input and DC output switches of air break, single throw,
load break and fault make type. The contacts of the switches shall open and close

CLAUSE NO.
with a snap action. Switches shall be rated for 120% of the maximum continuous
load. ‘ON’ & ‘OFF’ position of the switch shall be clearly indicated.
2.10.00 CONTROL AND SELECTOR SWITCHES
Control and selector switches shall be of rotory stayput type with escutcheon plates
showing the functions and positions. The switches shall be of sturdy construction and
suitable for mounting on panel front. Switches with shrouding of live parts and
sealing of contacts against dust ingress shall be preferred. The contact ratings shall
be atleast the following :
(a.) Make and carry continuously – 10 Amps.
(b.) Breaking current at 220 V DC – 0.5 Amp. (inductive)
(c.) Breaking current at 240 V AC – 5 Amp. At 0.3 p.f.
2.11.00 FUSES
Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse
carriers which are mounted on fuse bases. Wherever it is not possible to mount
fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such
cases one insulated fuse pulling handle shall be supplied for each charger. Kick-off
fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses.
2.12.00 Indicating Lamps
Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The
indicating lamp shall be of panel mounting, filament type low wattage or LEDs and
capable of clear status indication under the normal room illumination. The lamps
shall be provided with series resistors (non-hygroscopic) preferably built in the lamp
assembly and replaceable from front. The lamp covers shall be preferably screwed
type, unbreakable and moulded from heat resistant material
2.13.00 Blocking Diode
Blocking diode shall be provided in the output circuit of each Charger to prevent
current flow from the D.C. Battery into the Charger.
2.14.00 Annunciation System
Visual indications through indicating lamps/LEDs or annunciation facia as per

EEUA-45D shall be provided in all Chargers for the following:
(a.) A.C. supply failure

CLAUSE NO.
(b.) Rectifier fuse failure
(c.) Surge circuit fuse failure
(d.) Filter fuse failure
(e.) Load limiter operated
(f.) Charger trip
(g.) Battery on Boost
Potential free NO contacts of all above conditions shall be provided for

following remote alarms in the Employer’s Unit Control Board:
(h.) Battery on Boost
(i.) Charger trouble (this being a group alarm initiated by any of the faults other
than ‘Battery on Boost’)
2.15.00 Name Plates and Marking
The name plates shall be made of non-rusting metal/3 ply Lamicoid and shall have
black back-ground with white engraved letters and secured by screws. These shall
be provided near top edge on the front as well as on rear side of Charger. Name
plates with full and clear inscriptions shall also be provided on and inside the panels
for identification of the various equipments.
3.00.00 CONSTRUCTION
3.01.00 The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed
cubicle type. The Contractor shall supply all necessary base frames, anchor bolts
and hardware. The Charger shall be fabricated using cold rolled sheet steel shall not
less than 1.6 mm and shall have folded type of construction. The panel frame shall
be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm.
Removable undrilled gland plates of at least 3.0 mm sheet steel and lugs for all
cables shall be supplied by the Contractor. The lugs for cables shall be made of
electrolytic copper with tin coat. Cable sizes shall be advised to the Contractor at a
later date for provision of suitable lugs and gland plates. The Charger shall be
tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire
mesh. All doors and covers shall be fitted with synthetic rubber gaskets. The
Chargers shall have hinged double leaf doors provided on front and/or backside for
adequate access to the Charger internals. All the Charger cubicle doors shall be
properly earthed. The degree of protection of Charger enclosure shall be atleast IP-
42.

CLAUSE NO.
3.02.00 All indicating instruments, control & selector switches and indicating lamps shall be
mounted on the front side of the Charger. Design of panels shall be based on the
following dimensions.
1) Overall height - Maximum 2350 mm
2) Operating handles - Maximum 1800 mm

(highest and lowest Minimum 350 mm
positions reached by
operator’s hands),
protective mechanical
indicators
3) Doors and panel - Maximum 1800 mm

handles and locks Minimum 300 mm
3.03.00 Electronic equipments shall be of modular design consisting of plug in modules in
standard 19 inches metallic racks with metallic card guides. The cards should be
provided with proper handles. Card to card wiring should be preferably through a
mother board. Unplanned jumpering and track modifications are not permitted.
Mechanical interlocks to prevent wrong insertion of cards should be provided. Each
card shall have its junction and test points identified. Maintenance aids such as
extension printed wiring boards and jumper leads shall be provided.
3.04.00 The layout of Charger components shall be such that their heat losses do not give
rise to excessive temperature within the Charger panel surface. Location of the
electronic modules will be such that temperature rise of the location, in no case, will
exceed 10°C over ambient air temperature outside the Charger.
3.05.00 Each Charger panel shall be provided with an illuminating lamp and one 5 Amp.
Socket. Switches and fuses shall be provided separately for each of the above.
3.06.00 Locking facilities shall be provided as following:
(a.) For locking Trickle/Boost selector switch in the trickle position only. This
would be used for having key mechanical interlock between Trickle/Boost
selector switch and isolator in D.C. distribution board which is being procured
separately by the employer.
(b.) The Charger enclosure door locking requirements shall be met by the
application of padlocks. Padlocking arrangement shall allow ready insertion of
the padlock shackle but shall not permit excessive movement of the locked
parts with the padlock in position.

CLAUSE NO.
3.07.00 Wiring
3.07.01 Each Charger shall be furnished completely wired upto power cable lugs and
terminal blocks ready for external connection. The power wiring shall be carried out
with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part-I). The control
wiring shall be of 1.1KV grade PVC insulated stranded copper conductors of 2.5
sq.mm. conforming to IS:694. Control wiring terminating at electronic cards shall not
be less than 1.0 sq. mm. Control terminal shall be suitable for connecting two wires
with 2.5 sq.mm. stranded copper conductors. All terminals shall be numbered for
ease of connections and identification. At least 20% spare terminals shall be
provided for circuits.
3.07.02 Power and control wiring within panels shall be kept separate. Any terminal or metal
work which remains alive at greater than 415 V, when panel door is opened, shall be
fully protected by shrouding.
3.07.03 An air clearance of at least ten (10) mm shall be maintained throughout all circuits,
except low voltage electronic circuits, right upto the terminal lugs. Whenever this
clearance is not available, the live parts should be insulated or shrouded.
3.08.00 PAINTING
Treatment as per IS:6005. Two coats of lead oxide primer followed by powder
painting with final shade of RAL9002 for complete panel except end covers & RAL
5012 for end covers.
4.00.00 TESTS
4.01.00 GENERAL
1. All equipment to be supplied shall be of type test design. During detailed

a) Complete physical examination
b) Temperature rise test at full load.
c) Temperature rise test of rectifier assembly at 200% of full load.

CLAUSE NO.
d) Insulation resistance test.
e) High voltage (power frequency) test on power and control circuits

except low voltage electronic circuits.
f) Ripple content test at
i) No load
ii) Half load
iii) Full load
g) Automatic voltage regulator operation test at specified A.C. supply

variations at
i) No load
ii) Half load
iii) Full load
h) Load limiter operation test
i) Efficiency and power factor measurement.
j) Input and output surge withstand capability test. Surge Voltage as per
ANSI-C37.90a shall be applied for period not less than 2 sec. At the
following points of the Charger operating at 50 deg. C at full load :
i) Across each A.C. input phase
ii) Across AC input line to ground.
iii) Across D.C. output terminals.
iv) Across each D.C. output terminal to ground
The Charger shall not exhibit any component damage

and there shall be no change in performance as per (g)
and (h).

CLAUSE NO.
k) Environmental Tests
Steady state performance tests (g) and (h))shall be carried out before
and after each of the following tests.
i) Soak Test
The electronic modules shall be subjected to

continuous operation for a minimum period of 72
hours. During last 48 hours, the ambient temperature
shall be maintained at 50 deg. C. The 48 hour test
period shall be divided into four equal 12 hour
segments. The input voltage during each 12 hours
shall be nominal voltage for 11 hours followed by
110% of nominal voltage for 30 minutes, followed by
90% of nominal voltage for 30 minutes.
ii) Degree of protection test.
2. However if the Contractor is not able to submit report of the type test(s)
type test report(s) are not found to be meeting the specification
requirements, the Contractor shall conduct all such tests under this contract
at no additional cost to the Owner either at third party lab or in presence of
client/owners representative and submit the reports for approval.
3. All routine tests as per QA table and relevant standards shall be carried out.
Charges for these shall be deemed to be included in the equipment price.
4. The type test reports once approved for any projects shall be treated as
5.00.00 COMMISSIONING
5.01.00 The contractor shall carryout the following commissioning tests and checks after
installation of the equipment at site:
(a.) Complete physical examination.
(b.) Checking of proper operation of annunciation system.
(c.) Temperature rise test at full load.

CLAUSE NO.
(d.) Insulation resistance test.
(e.) Automatic voltage regulator operation.
(f.) Load limiter operation.
(g.) Dynamic response test.
Overshoot/Undershoot in output voltage of the Charger as a result of sudden

change in load from 100% to 20% and 20% to 100% shall be measured with the
Batteries connected/disconnected. Output voltage of the Charger connected with
Battery shall be within 94% to 106% of the voltage setting in above conditions and
shall return to, and remain, within the limits specified as mentioned elsewhere, in
less than 2 seconds (as applicable).

PART - B
SUB-SECTION-IIIB-13
CONTROL PANEL

CLAUSE NO.
CONTROL PANELS
Programmable Logic Controller IEC: 1131
2.00.00 CONTROL TYPE
PLC based
3.00.00 PANEL CONFIGURATION
3.01.00 Stacker Reclaimer control system
Stacker / Reclaimer control desk having necessary push buttons, switches, joy sticks
etc. to operate the entire machine shall be provided in two parts, one part on the left
side and the other part on the right side of the operator in the operator cabin. OWS
shall be mounted in front of the operator so that he can control the machine through
key board / mouse also. The other OWS, PLC processor panel and I/O panel along
with printer shall be housed in the MCC room on the S/R machine. No remote I/O
panel is envisaged in the operator cabin.
3.02.00 Wagon Tippler control system
Wagon tippler control desk having necessary push buttons, switches, OWS etc. shall
be provided for the wagon tippler system being supplied by the contractor. Operator
shall be able to operate the Wagon tippler from control desk as well of from OWS.
Remote I/O panels are to be provided in the Control rooms and in the MCC rooms as
per the requirement.
3.03.00 Separate, vertical, free standing PLC & RIO panels with Perspex/glass door for
visual access to LEDs shall be provided for each stacker reclaimer machine and for
each wagon tippler.
3.04.00 Power distribution equipment i.e. Control transformers/ UPS/Power Supplies/Backup

Batteries/ MCBs etc shall be housed in a separate free standing vertical panels.
3.05.00 Local control panels for Coal handling plant:
Local control panels for traveling trippers, paddle feeders, metal detectors, sump
pumps, SM & ILMS, belt weighers and hoists shall be free standing, floor/wall
mounting type. They shall be provided with the necessary power equipment like
switches, fuses, contactors etc. and the required control equipment like selector
switches, meters, push buttons, indications, and annunciations etc.

SECTION-VI PAGE 1 OF 11
COAL HANDLING PLANT PACKAGE CONTROL PANEL
PART-B
CLAUSE NO.
Local control panels shall be provided for Coal sampling units, hydraulic scoop
coupling and dust suppression system. However control of these systems shall be
through main DDCMIS with starters located in the main MCCs only.
Necessary controls, indications and annunciations, as described elsewhere, for all

the above equipment shall be provided in main CHP control desk and DDCMIS being
procured by the employer under a separate package.
4.00.00 SYSTEM CONFIGURATION
4.01.00 Control shall be normally affected through OWS. Facilities to operate HT load
break isolator switch of S/R & LT breakers of S/R & WT shall be provided on the
respective control desk also.
All indicating instruments (i.e. Ammeters/ Voltmeters) shall be digital type and of
accuracy class 1. Ammeters shall be provided on control desk for all motors rated
30 kW and above and for I/Cs and B/Cs of LT switchgear. Voltmeters shall be
provided on control desk for LT bus voltages.
4.02.00 Ammeters and Voltmeters shall be suitable for 4-20mA DC signals.
5.00.00 CONTROL SYSTEM
1). The control system for all the coal handling drives including conveyors, Dust
Suppression System, etc except for the Stacker Reclaimer and wagon tippler
shall be DCS based being procured by the employer under a separate
package.
2). The control system for stacker reclaimer and wagon tippler shall be PLC
based. The PLC system shall be provided with 2x100% processors in hot
standby mode. Standby processor shall be energised and continuously
monitored for healthiness. In case a failure of working processor, the standby
processor shall take over the operation automatically by bumpless transfer
and necessary failure alarm shall be provided. Both the work stations of a
PLC system shall be suitable for operation and also for programming hence
software shall be provided accordingly. The processor along with their
accessories shall be housed in a free standing vertical type PLC panel
separate from control desk. The operation and supervisory system shall
consist of PC (latest model), TFT monitors with key boards which shall be
mounted as an integral part of the control desk.
3). The processor along with OWS, printer etc. and control panels shall be
interlinked through independent dual data highway and dual I/O
communication links. The hot standby shall be hardware based and there

PART-B
CLAUSE NO.
shall be dedicated link between the two processors for data and program
equalization.
4). The push button and selector switches mounted on control desk shall send
necessary signals through PLC.
5). The list of required annunciations shall be finalised during detail engineering.
Detailed alarms shall be displayed on OWS.
6). In addition to the controls from the control desk/keyboard/local control panels,
each drive shall be provided with local stop push button station near the drive
and shall be wired to PLC.
7). The PLC shall provide supervisory information for alarm, various types of
displays, status information, trending, historical storage of data etc. and also
perform self monitoring and diagnostic functions.
6.00.00 CONTROL PHILOSOPHY
1). Normal / local mode of operation shall be selected from the key board.
(a) In normal mode of operation, which shall be the default mode, all
drives shall be operated from control desk through keyboard.
Whenever required for maintenance, maintenance mode for equipment
will be selected through keyboard . Operation interlocks, except trip
interlocks shall be locked using a unique password. After
maintenance, the drives shall be started through keyboard, with all
process interlocks, by re-entering the password. Normal mode of
operation can be selected then. Irrespective of any PLC mode of
operation, the running equipment can be stopped from keyboard or
from desk/panel or from emergency stop push button.
7.00.00 TRAINING
Further to the relevant clause regarding training specified elsewhere, Bidder's

experienced personnel/engineers shall also provide training courses on offered
PLC system to Employer's engineers in the following areas:
(a.) Operator training
(b.) Hardware Maintenance training
(c.) Software training

PART-B
CLAUSE NO.
(d.) Any other specialized training as required for system operation and
maintenance.
The maintenance training shall include lectures and hands on experience on similar
type of equipment / system at manufacturer works and recently commissioned
operating plant and / or training simulator. The Owner shall require training of two
hardware and two software engineers and the duration of each course shall be
minimum two weeks.
The details of hardware and software training shall be finalised during detailed
engineering and shall be subject to Employer's approval.
8.00.00 PLC EQUIPMENT AND SYSTEM REQUIREMENTS
8.01.00 Each PLC system shall consist of redundant processors, PCs with CRT (latest
version with latest application software) & keyboard, I/O modules, UPS / power
supply with battery backup, printer etc. Each PC based operating and programming
workstation shall be fully equipped for operation and control of the various systems.
The configuration of PLC shall be as per enclosed drawing. Details of various
components shall be as given below :
a) Processor Two (2) numbers. one as hot standby
b) Memory Non volatile EPROM, Lithium or Ni-Cd battery for 360

hours backup, 20% spare capacity for future use.
c) Selection Normal/Test/Program/Off facility shall be provided. In

test mode all outputs shall be blocked.
d) Monitor & Keyboard Twenty inches (20 inches) TFT flat monitor with
resolution of 1280 x 1024 pixels non interfaced,
refresh rate min. 75Hz, with flat membrane type
keyboard/ mouse. Provision for erasing and
duplicating the user program and long storage facility,
forcing facility for changing the status of inputs and
outputs, timers and flags to facilitate fault finding and
other testing requirements shall be provided. The
numbers of OWS shall be as per PLC configuration
diagram.
e) Processors & I/O Modular design. Possible to change any module

racks without disconnection of any wire. Keying in of
individual wire connectors shall be provided to ensure
that only the correct card is plugged on the I/O

PART-B
CLAUSE NO.
module. Wiring between I/O cards & terminal blocks

shall be through prefab cables. Twenty (20%) percent
spare capacity in input output and CPU memory
modules shall be provided in each rack over and
above system requirement. One additional Ethernet
port shall be made available in each PLC system so
that wireless communication modem can be
connected by the Employer in future. All Output cards
shall be sourcing type and Input cards shall be sinking
type.
f) Isolation between 1.5 KV with opto couplers.

Input, Output and
controller
g) Indication Individual signal status of each Input / Output, power

supply status.
h) Fail safe mode On power supply failure / both PLCs failure /

communication failure etc. the output shall be
automatically switched over to fail safe mode. In CPU,
memory should exist where the sequence was
aborted. Further, in case of such failures, operating
drives / equipment shall be tripped or kept running as
per a pre-determined programmable requirement
finalised during detail engineering.
i) Fusing philosophy Individual fuses with blown fuse indicator for each
output. Individual fuses for each input/ group of inputs,
keeping in view of system availability.
j) Switching capacity Output modules shall be rated to switch on/off

coupling relays of 2.5 VA at 24V DC and solenoid
valves at 110 V AC. Coupling relays are provided in
HT/LT Switchgears.
k) CRT/CPU and Input Hundred percent redundant Communication links

output through routed in separate GI conduits.
communication links
l) Printer Color laser printer shall be suitable for A4 size paper,

4 pages per minite, 600 dpi (black) and heavy duty(>_
30000 pages per month)

PART-B
CLAUSE NO.
Number of printers shall be as shown in the tender

drawing ‘PLC Configuration’.
m) Power supply i) Two (2) nos 415V AC feeders shall be provided for
each control panel / desk and remotely located I/O
panels.
ii) Power supply to stacker reclaimer control system i.e.,

PLCs, I/Os, printer, OWS, and control desk shall be
fed through 2x100% UPS with battery back-up rated
for 30 minutes at full load. The UPS shall be smart
type line interactive complete with software &
hardware for remote management along with features
of surge suppression & AVR facility. The UPS and
batteries shall be rated for 20% spare capacity.
Redundant DC power packs shall be provided for DC
loads.
iii) Power supply to Wagon tippler control system shall

also be same as given for stacker reclaimer as
indicated above.
iv) All the batteries shall be sealed maintenance free Ni-

Cd type.
n) Command Manual command shall prevail over auto command.

hierarchy Protection command shall have priority over all other
commands.
o) Databus Hundred percent redundant. Necessary interface

hardware and software for dual fibre connectivity and
interconnection with employer’s DDCMIS for two way
transfer of signals through OPC compliant Ethernet
link following TCP/IP standards.
p) Time To be synchronised with DDCMIS

Synchronisation
system.
q) Date No disturbance due to change of date/year.

Insensitivity

PART-B
CLAUSE NO.
r) System reaction Less than 100 msec. from input signal to output signal
time including logic processing.
s) Display Max 1 sec for control related displays. 2 to 3 sec for

response other displays.
t) Feedback/field By 24V DC. Status feedback from MCC/field shall be

interrogation in the form of one changeover contact. Discrepancy
shall be alarmed. All analog signals shall be routed
through analog cards.
u) Programming Flow chart/Block logic ladder diagram. Tag based

format addressing format shall be used for programming.
The same shall be submitted for owner's review
before programming of the system.
v) Long time 168 hours latest data on hard disc. Data to be stored:
storage &
retrieval
i) Alarm list.
ii) Five analog points at scan rate.
iii) Fifteen analog points at one secs rate.
iv) Balance analog points at 5 minutes rate.
v) Binary points on status change.
vi) Log reports.
w) Software All application software with locks and passwords for

PLC functioning like input/output scanning,
acquisitions, condition processing, control and
communication, operator interface of monitors, display
trends, curves, bar charts, historical storage/ retrieval
and alarm functions. Complete set of documents for
modifications / editing / additions/ deletions of features
in software. Comprehensive list of all
application/system software.

PART-B
CLAUSE NO.
x) Accessories Industrial grade furniture shall be provided along with

Control desk/OWS/printer.
y) Software The contractor shall provide software license for all

license software being used in PLC based control system
including HMI. The software licenses shall be
provided for the project and shall not be
hardware/machine specific. All licenses shall be valid
for the continuous service life of the plant.
z) Software As a customer support the contractor shall periodically

upgrades inform the designated officer of the employer about
the software upgrades / new releases that would be
taking place after the system is commissioned so that
if required, same can be procured and implemented at
site.
8.02.00 Annunciation System
i) Facia Translucent glass/plastic window with engraving.
ii) Operation Through PLC.
a) On occurrence Audible horn and flashing of facia lamp.

of trouble
b) Acknowledge Audible horn and flashing of facia lamp shall stop.

button pressed Facia lamp will become steady.
c) Reset button If fault is removed then facia lamp will go off.

pressed
d) Test button All lamps will glow.

pressed
iii) Monitoring Power supply to annunciator shall be monitored.
9.00.00 DESK/PANEL CONSTRUCTION
a) Type Fabricated from cold rolled sheet steel
Frame thickness 2.0 mm

PART-B
CLAUSE NO.
Enclosure thickness 1.6 mm
Gland plate thickness 3.0 mm
b) Switches AC22 category
c) Fuses HRC cartridge with visual operation indicator.
d) Name Plates & Each panel shall be identified by a name plate. Panel
Labels internal equipment shall be identified by paint marking.
Nameplates shall be non rusting metal or 3-ply
lamicoid, with engraved lettering and shall be subjected
to Owner’s approval.
e) Grounding 25 x 3 mm copper ground bus to be provided for each

panel
f) Space heater 240V AC, single phase, thermostatically controlled

space heaters to be provided.
g) Terminal block 650V grade. clip-on type.
h) Type Elmex - CATD type for CTs. Elmex - CSLT for other
application.
i) Spare 20 percent.
j) Wiring 650V grade. PVC insulated stranded copper wire.
k) Panel Lighting Each free standing panel shall be provided with a door
switch operated fluorescent lamp and a 240V AC plug
point.
l) Painting Treatment as per IS: 6005. Two coats of lead oxide

primer followed by powder painting with final paint
shade of RAL 9002.
m) Degree of For panels located in

enclosure
protection i) Air conditioned areas : IP-32
ii)Other indoor areas : IP-52
iii)Outdoor areas : IP-55

PART-B
CLAUSE NO.
iv)Dusty areas like : IP-65
Conveyor galleries, Transfer points,
Bunker area, Track hopper area,
Crusher house etc.
10.00.00 TYPE TESTS
equipment price.
furnished by the manufacturer confirming similarity and “No Design
Change”. Minor changes if any shall be highlighted on the endorsement
sheet
10.01.00 Programmable logic controller
10.01.01 Following test reports shall be submitted for the equipment:
a). Dry heat withstand test
b). Variation of temperature immunity test
c). Variation immunity test

PART-B
CLAUSE NO.
d). Temperature cycle test
e). Noise immunity test
f). Dielectric test.
10.01.02 Following tests shall be conducted under this contract as routine tests:
a). Tests on internal and external wiring.
b). Incoming power supply voltage and frequency variation test.
c). Test for verification of functional characteristics of I/Os.
d). Task transition test (for each task, the contractor will list out the user
accessible conditions which shall be used in the simulation of the task).
e). Functional testing of software and hardware in accordance with the

approved block logic diagram with simulation of the system with switches,
relays and solenoid valves etc. or equivalent loads.

PART-B
PART - B
CIVIL

PART - B
SUB-SECTION-IIID-01
CIVIL WORKS

1.00.00 GENERAL
1.01.00 This section of the bidding document deals mainly with the technical specification
needed for the design and preparation of detailed drawings, getting the design and
drawings approved by the Engineering, fabrication, erection and construction of the
necessary civil, structural and architectural works associated with the coal handling
plant to be installed at Muzaffarpur Thermal Power Project, Stage-II (2x195 MW) .
The work shall have to be carried out both below and above ground level and shall
be involving, basements, equipment foundations, slabs, beams, columns, footings,
rafts, walls, steel frames, brick walls, stairs, trenches, pits, finishes, complete
architectural aspects, drainage, sanitation, water supply (from terminal points to
various buildings, conveyor galleries), and all other civil and structural works
associated with the Coal Handling Plant.
1.02.00 The specifications are intended for the general description of the work, quality and
workmanship. The specifications are not, however, intended to cover minutest details
and the work shall be executed according to the relevant latest Indian Standard
Codes / I. R. S. / I. R. C. specifications. In absence of the above, the work shall be
executed according to the best prevailing local Public Works Department practices or
to the recommendations of relevant American and British Standards or to the
instructions of the Engineer. List of I. S. Codes to be followed is mentioned in the
Technical Specifications. The Contractor is expected to get clarified on any doubts
about the specifications, etc. before bidding, in writing with the Employer in respect of
interpretation of any portions of this document.
1.03.00 The civil and steel structural design for the works under the scope of this contract
shall be carried out by an agency who should have designed the following works
within the preceding seven (7) years, reckoned as on date of techno-commercial bid
opening.
1) The civil & steel structural works associated with at least one bulk material
handling plant.
2) The civil & steel structural works associated with structures like track hopper,
wagon tippler, underground tunnels, etc.
The bidder may engage a consulting agency which meets the above requirements for
design, either in same or separate contracts.
The bidder is required to furnish in the bid documents, details regarding the design
experience of himself or the consulting agency engaged by him, meeting the above
requirements. The consulting agency proposed by the bidder for design shall be
subject to Owner’s approval.
2.00.00 LAYOUT AND LEVELS
2.01.00 The layout and levels of all structures, etc. shall be made by the Contractor at his
own cost from the general grid of the plot and bench mark given by the Engineer. He
shall provide all instrument, materials and men to the Engineer for checking the
layout and levels. However, the Contractor shall be fully responsible for correctness
of layout and levels.
MUZAFFARPUR TPP TECHNICAL SPECIFICATIONS Sub-Section - IIID-01 Page 1 of 54

STAGE-II (2X195 MW)
COAL HANDLING PLANT PACKAGE SECTION VI, PART-B CHP CIVIL WORKS
BID DOC. NO.:CS-0350-155(R)-2
3.00.00 DRAWINGS / DOCUMENTS
3.01.00 The drawings included in the Bidding Document provide a general idea about the
work to be performed under the scope of this contract. These are preliminary
drawings for bidding purposes only and are by no means the final drawings or show
the full range of the work under the scope. Work has to be executed according to
drawings prepared by the contractor and approved by the Engineering.
3.02.00 Conceptual arrangement of civil works supported by calculations shall be submitted

along with tender bids. Later on, detailed construction drawings and design
calculations for all civil works for static as well as dynamic analysis (wherever
essential) shall be submitted for approval prior to undertaking construction work.
3.03.00 Design calculations shall be done in STRAPP / M.S. Office (latest version) and
Drawings shall be prepared in Auto Cad (latest version). The analysis shall be done
by using STADD PRO / ANSYS / STRAPP (latest version). However design may be
carried out by manually, using computer work sheets or by using suitable software
programmes, as mutually agreed by Employer. Final calculations and drawings shall
be submitted in Compact Disc (CD) (2 Sets)
3.04.00 Civil Task drawings indicating various equipment loading and supporting
arrangement and floor loads shall be submitted along with design calculations. Soft
copies of all STAAD input files shall be submitted along with the design calculations
for all revisions.
3.05.00 Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works
shall be submitted structure wise and area wise for N.T.P.C. record. However each
drawing shall indicate approximate quantity of structure (Sectionwise) Concrete
(Grade wise) and reinforcement (Diameterwise.)
3.06.00 Structural steel fabrication drawings to be prepared by the contractor will not be
approved by the Employer. However, the Contractor for Employer’s reference shall
submit all fabrication drawings. Copy of detailed bar bending schedule as prepared
by contractor shall also be submitted to the Engineering and also to Engineer in
charge for the reference.
3.07.00 Approval of construction drawings prepared by the contractor shall not relieve the
Contractor of his responsibility regarding the adequacy of design and correctness of
the drawing.
4.00.00 WORK DESCRIPTION
It includes the Civil, Structural and Architectural works related mainly to the following
areas (but not limited to):
4.01.00 Track Hopper, Wagon Tippler, Machinery Hatches, Underground TP’s & Tunnel
4.01.01 Deep underground structures like Track hopper, Machinery hatches, WT-3&4 and
tunnel for Conv. 1A/B are coming very close to the existing rail track (in operating
condition) and boundary wall. To ensure complete safety and no damage/interruption
of existing rail track/boundary wall during construction, following measures shall be
taken by bidder:-

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
i) For track hopper, machinery hatches, WT-3&4 and tunnel for Conv. 1A/B,
excavation shall be carried out by using either sheet piling/ diaphragm wall/
secant piling/ contiguous piling or their combination from FGL. Sheet piling/
diaphragm wall/ secant piling/ contiguous piling shall not be considered as part of
permanent structure.
The excavation scheme & design for (i) above shall be developed by a specialized
agency and submitted for owner’s approval.
4.01.02 Track hopper and machinery hatches shall consist of underground portion, which
shall be of R. C. C., and above ground portion, which shall be of structural steel shed
covered with permanently Colour coated profiled steel sheets.
The structural arrangement to be adopted for the design and construction of

underground portion of track hopper and machinery hatches shall be as shown in
tender drawing. It essentially consists of R. C. C. frames spaced at approx. 3.0M
centers with R. C. C. wall panels on the sides and R. C. C. raft at the bottom, fixed to
the frames. The top beam of the R. C. C. frame supports the rail supporting beams
and the coal hopper. Minimum thickness of R. C. C. raft at bottom shall be 600 mm.
Minimum thickness of RCC side walls shall be 600 mm at bottom and 300 mm at top.
No columns shall be provided inside the Machinery Hatches.
The vertical and inclined portion of coal hopper, the beams and top of coal tray in the
track hopper structure as shown in the tender drawing shall be provided with 50 mm
thick guniting (shotcreting). Complete inside surfaces of Wagon tippler & reclaim
hopper shall also be provided with 50mm thick guniting. Details of shotcreting
have been given elsewhere in this specification.
Expansion joints shall be provided at a maximum distance of 40m unless otherwise

shown in the tender drawing. 600 mm wide water stop fabricated with 22G copper
plate with bitumen board fillers and polysulphide sealing compound as specified
elsewhere shall be used as expansion joint material. Detailing of expansion joints
shall be as per details in the tender drawing. Construction joints shall also be
provided with 600 mm wide water stop 22 G copper plate.
Floor shall be provided with cross slope not flatter than 1 in 50 towards side drains.
Side drains shall be sloped towards sump where sump pumps as specified
elsewhere, shall be provided. The slope of side drains shall not be flatter than 1 in
400. Side drains and sump shall have removable type steel grating cover. Gratings
shall be galvanized to grade 610 gm/m2.
Water proofing / Damp proofing of under ground portion of track hopper and
machinery hatches, Wagon tippler, tunnels, underground (i. e. basement) portion of
transfer houses shall be done by providing the following treatments:
(a.) Chemical injection grouting for inner faces (details as specified elsewhere).
(b.) Polymer modified cementitious coating on earth side face as per the following :
(1.) On the outer surface of walls, frames and roof slabs coming in contact
with earth, polymer modified cementitious coating in two layers as

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
specified and as per manufacturer’s specifications shall be provided

directly on the concrete surface.
(2.) 50 mm thick P. C. C. (1 : 2 : 4 with 10 mm nominal size stone aggregates)

shall be provided under the raft i.e. over the lean concrete, followed by
polymer modified cementitious coating in two layers ( slurry mix
application ) as per manufacturer’s specification. 50 mm thick P. C. C. ( 1 :
2 : 4 ) with 10 mm nominal size stone aggregates shall then be laid over
the polymer modified cementitious coating before laying the raft.
Track hopper shall have removable type steel grating cover. The opening size for the
grating shall be 350 mm x 320 mm. Machinery hatches shall have removable steel
chequered plate cover. Track hopper grating shall be built of min. 100mm x 20mm
thick flats in one direction and 100mm x 16mm thick flats in other direction. No
painting/galvanization shall be provided in gratings. However, two coats of red oxide
primer to be provided immediately after fabrication.
Steel gratings of mesh size 350mmx320mm for wagon tippler hopper shall be
provided. The grating shall be built of min. 200mm x 28mm thick flats in main
direction and min. 100mm x 20mm thick in secondary direction. The hopper and
gratings shall be designed for movement of front end loader/ bulldozer over them.
Bull-dozer weight shall be considered as about 35T. No painting/galvanization
shall be provided in gratings. However, two coats of Red oxide Primer to be
provided immediately after fabrication.
Catwalk shall be provided along the track hopper as shown in the tender drawing.
Each machinery hatch shall be provided with a pair of R. C. C. stair for providing
access to the base of track hopper / machinery hatch. Both the stairs shall be
interconnected at suitable height.
Plinth protection along with drains shall be provided along the Track Hopper and
around machinery hatches. However, 5m wide paving shall also be provided around
machinery hatches.
The track hopper, wagon tippler are deep underground structures which are
subjected to direct load from the loaded wagons / loco due to the rake movement
over it, in addition to load due to coal filled hopper and lateral earth pressure. The
railway loads, analysis and design of track hopper, machinery hatches, wagon
tippler, transfer point and the portion of tunnel subjected to rail loads shall be as
specified in design criteria. Coefficient of dynamic augmentation shall be worked out
for a train speed of 30 kms per hour
Earth pressure to be considered for design shall be due to earth pressure at rest (Ko)
condition only. Earth pressure due to surcharge intensity of Railway Loads (where
applicable) or Uniformly Distributed Load (U. D. L) of intensity 2 T / Sq. M. whichever
is critical, shall be considered in the design.
A minimum safety factor of 1.2 against uplift of track hopper, machinery hatches,
wagon tippler, transfer points (underground or with basement) and tunnels, due to
ground water shall be ensured during execution and after execution, considering
dead weight of the structure to be 0.9 times only, ground water table at adjoining
formation level and soil wedge angle of not more than 15 degrees.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
Also, FOS against uplift, to be taken as 1.0, considering the dead wt. of structure and
soil resting on side projections if any in the vertical plane. Inclined wedge action of
soil shall not be considered in this case.
Walkway width and hand railing shall be provided as specified in the tender drawing.
Wherever, slope of tunnel exceeds 10o, R. C. C. steps shall be provided for the entire
width of each walkway.
Track hopper structure shall be analyzed and designed for the worst load
combinations. However, it shall be analyzed for the following load combinations also.
(a.) Load Combination - I
(1.) Hopper full
(2.) Maximum load from Railway Track
(3.) Earth pressure without surcharge and subsoil water pressure
(4.) Maximum load from steel columns for shed
(5.) Maximum load from paddle feeder support
(6.) Maximum load from coal tray.
(b.) Load Combination - II
(1.) Hopper full
(2.) Maximum load from Railway Track
(3.) Earth pressure with surcharge and subsoil water pressure
(4.) Maximum load from steel columns for shed
(5.) Maximum load from paddle feeder support
(6.) Maximum load from coal tray.
(c.) Load Combination - III
(1.) Hopper empty
(2.) No load on Railway Track
(3.) Earth pressure with surcharge and subsoil water pressure
(4.) No load from steel columns for shed
(5.) Dead load only from paddle feeder supporting structure

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
(6.) Dead load only from coal tray.
4.02.00 Overhead / Ground Conveyor Galleries and Trestles
Overhead conveyors shall be located in a suitably enclosed gallery of structural steel.

The overhead gallery shall consist of two vertical latticed girders having rigid jointed
portal frame at both ends. Cross beams at floor level supporting conveyor stringer
beams shall be made of single rolled steel beam or single channel section (ISMB or
ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of
the gallery (latticed girders shall be braced together in plan at the top and bottom).
Common end portal frame shall not be used for adjacent conveyor spans. Roof truss
shall be provided at upper node points of latticed girders to form an enclosure. The
maximum span of overhead gallery shall be limited to 25 meters unless higher span
is required due to site conditions, which shall be subject to approval of the Engineer.
The gallery should as far as possible be erected as a box section keeping all the
vertical and horizontal bracing tied in proper position. The gallery should be checked
for all erection stresses that are likely to develop during handling and erection and if
required, temporary strengthening of gallery members during erection shall be made.
Seal plates under the conveyor galleries shall be provided in such a way that
complete gallery bottom shall form a leak proof floor.
The ground conveyors shall be located in suitably enclosed gallery of structural steel
consisting of rigid portal frames spaced at regular intervals and suitably braced.
Plinth protection along with drains shall be routed along the ground conveyors.
For double stream conveyor gallery, two side and one central walkway of width 800
mm and 1100 mm respectively shall be provided. The width of two side walkways for
single stream conveyor gallery shall be 800 mm and 1100 mm respectively. Both
sides of central and side walkways shall be provided with pipe handrails all along the
conveyor gallery. Hand railing should not be supported on conveyor supporting
stringers. The walkways shall be chequered plate construction with anti - skid
arrangement. The anti - skid arrangement will consist of welding of 10 mm square
steel bars at a maximum spacing of 500 mm along the length of the gallery. Where
the slope of walkway is more than 10o, chequered plate steps with nosing and toe
guard shall be provided. The floor of conveyor gallery all along the gallery length,
shall be provided with minimum 12 gauge thick seal plates and other drainage
arrangements as specified elsewhere
Conveyor gallery shall have permanently colour coated steel sheet covers on roof
and both sides. However in roof, a panel of minimum 1.5 m x 1.5 m area at about 6.0
m center shall be provided with translucent sheets of polycarbonate material for
natural lighting. A continuous slit opening of 500 mm shall be provided on both sides
just below the roof sheeting. Adequate provision of windows shall be kept on both
sides of conveyor gallery as appended in Mechanical Section (Belt conveyor
system). Windows shall be provided with wire mesh as specified elsewhere in this
specification.
Cross - over with chequered plate platform and ladder for crossing over the
conveyors shall be provided at approximately every 100 M intervals of conveyor.
Crossover shall preferably be located over four-legged rigid trestle location.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
For railway tracks passing below overhead conveyor gallery and along conveyors,
the railway clearances both underground as well as over ground shall have to be
adhered to for design, execution and erection of foundations, trestles, galleries etc.,
so that movement of locomotives and wagons is not hampered in any way during
execution and afterwards. However at the location where the overhead conveyor
gallery crosses road / rail line, minimum clearance of 8.0m above the road crest / rail
top shall be provided.
For calculation of coal load on moving conveyor, a multiplication factor 1.6 shall be
used to take care of inertia force, casual over burden and impact factor etc.
Thus coal load per unit length of each moving conveyor shall be
Rated Capacity of Conveyor system 1100
1.6 X ------------------------------------------------ X ---------
Conveyor Belt Speed 800
It should be noted that for structural design, unit weight of coal shall be assumed as
1100 Kgs. / Cu. M. instead of 800 Kgs. / Cu. M. considered for system sizing
purpose.
Conveyor Gallery structure shall be designed considering both conveyors operating

simultaneously.
Conveyor gallery and supporting trestles located between transfer houses / buildings
shall be arranged in any one of the following ways.
a) All gallery supporting trestles shall be four legged type only. One end of each
gallery span shall be hinged to the supporting trestle and the other end shall
be slide type. Slide type support shall be with P. T. F. E. bearings to allow
both rotation & longitudinal movements.
b) In between transfer houses / buildings, four legged trestles shall be placed at

a maximum interval of 90 metres. The arrangement shall be such so as to
ensure that force in the longitudinal direction (i. e. along the conveyor length)
of conveyor gallery of length not more than 90 m is transferred to any four
legged trestle. In the space between each successive four legged trestles,
two legged trestles shall be provided at regular intervals. The end supports
resting on the four-legged trestle can have either ends hinged or one hinge
and the other on slide type depending on the arrangements. Slide type
support shall be with P. T. F. E. bearings to allow both rotation & longitudinal
movements.
End of conveyor gallery which will be supported over transfer house, shall be so
detailed that only vertical reaction is transferred from conveyor gallery and no
horizontal force in longitudinal direction is transferred from conveyor gallery to
transfer house structure and vice - versa.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
For trestles and trestle foundations for conveyor galleries located adjacent to existing
structures, over ground and under ground facilities, location and details of these
trestles and foundations shall have to be decided such that there is no interference
both underground as well as over ground with existing structures and facilities.
Trestle columns / ground conveyor portal column base shall be kept 300 mm higher
than the existing ground level.
4.03.00 Transfer Houses
The over ground portion of the transfer house shall be framed structure of structural
steel work with permanently colour coated profiled steel sheet side cladding and R.
C. C. floors over structural beams. However the lower portion of side cladding for a
minimum height of 0.9 m above the finished floor level shall be one brick thick wall
plastered on both side. In some areas like MCC floors etc., one brick thick wall
cladding shall be provided. Brick wall cladding shall be supported on encased wall
beams and suitably anchored to adjoining columns and beams.
Adequate steel doors and windows for proper natural lighting and ventilation shall be
provided. In addition to steel windows, panels of suitable size to suit the architectural
treatment and made of translucent sheets of polycarbonate material shall also be
provided on the side cladding for natural lighting.
Roof shall be provided with troughed profile permanently colour coated sheet on
outside and plain permanently colour coated sheet on inside with 50mm thick mineral
wool insulation in between the two sheets. A slope of 1 in 5 shall be provided for
quick drainage of rain water. Mineral wool insulation (as per IS: 8183) having a
density of 32 kg/cum for glass wool or 48 kg/cum for rock wool, bound in polythene
bags shall be used, with or without framed strips 25x3mm (min.) at maximum 300mm
c/c to hold the insulation between the runners, keeping in position with galvanized
hexagonal wire netting of 0.3mm wire dia. & 19mm mesh size as per manufacturer’s
recommendations.
4.04.00 Crusher House
The crusher house shall be framed structure of structural steel work with permanently
colour coated profiled steel sheet side cladding. However, panels of suitable size to
suit the architectural treatment and made of translucent sheets of polycarbonate
material shall also be provided on the side cladding for natural lighting. The lower
portion of side cladding for a height of minimum 0.9m above the finished floor level
shall be of one brick thick wall plastered on both faces. Floors shall be of R. C. C.
supported on steel beams. Within this building cubicles are to be provided for resting
room of operators and these shall be constructed with one brick thick brickwork
having both sides plastered and roof slab. Adequate steel doors and windows for
natural lighting and ventilation shall be provided.
Roof shall be provided with troughed profile permanently colour coated sheet on
outside and plain permanently colour coated sheet on inside with 50mm thick mineral
wool insulation in between the two sheets. A slope of 1 in 5 shall be provided for
quick drainage of rain water. Mineral wool insulation (as per IS: 8183) having a
density of 32 kg/cum for glass wool or 48 kg/cum for rock wool, bound in polythene
bags shall be used, with or without framed strips 25x3mm (min.) at maximum 300mm
c/c to hold the insulation between the runners, keeping in position with galvanized

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
hexagonal wire netting of 0.3mm wire dia. & 19mm mesh size as per manufacturer’s
recommendations.
Ring Granulator type Crushers shall be supported on R. C. C. deck, which in turn will
rest on suitable vibration isolation system consisting of springs and dampers. This R.
C. C. deck shall be isolated from the floor. However, the vibration isolation system
consisting of springs and dampers may rest on main building framework. Detailed
specification of vibration isolation system including the unbalanced force (due to ring
granulator), frequency and amplitude criteria and other design requirements are
appended elsewhere in this specification.
4.05.00 Stacker Reclaimer Foundation
Stacker - Reclaimer foundation shall be in R. C. C. and shall be designed as a

continuous wall or R. C. C. framed structures (in longitudinal & transverse direction).
Lateral tie beams between two rail supporting elements shall be provided at a regular
interval of approx. 3.0 m center. The foundation shall be designed for the most critical
combination of loads as furnished by the equipment supplier. R.C.C retaining wall on
both sides of the S/R foundation shall be provided as shown in the tender drawing.
The portion between the two rails and between the retaining wall & rail on both sides
shall be paved in concrete as per specification for grade slab of ground level
specified elsewhere. However no metallic hardener finish over R. C. C. slabs is to be
provided. Drains shall be provided along the rails for drainage of rain / dust
suppression / floor washing water. Drains shall be routed on both sides of the
foundation along the rail as shown in Tender Drawing. Drains shall be connected to
the network drainage system for finally discharge into coal settling tank. RCC drains
shall be provided in Coal stockyard area with precast RCC covers.
4.06.00 Control building, M. C. C. Buildings
These shall be R. C. C. framed structures with columns, beams, slabs and

foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof
shall be provided with roof water proofing treatment, as specified elsewhere in the
Technical specification.
All air - conditioned areas, shall be provided with the suspended permanently colour
coated aluminium false ceiling system (details specified elsewhere) with under deck
insulation.
Adequate aluminium doors and windows shall be provided for natural lighting,
ventilation and view. All windows in air conditioned rooms shall have hermetically
sealed double glazing.
4.07.00 Pump Houses
These shall be of R.C.C. or steel framed structure with columns, beams, slab and
foundations etc. cladding shall be of brick work with plastering on both sides. Roof
shall be provided with roof water proofing treatment as specified elsewhere.
Underground sump and water tanks shall be of R.C.C. Adequate number of doors,
Windows and Rolling Shutters shall be provided.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
Galvanized steel ladder / rung ladder shall be provided for access to the roof level of
the pump house and water tanks.
4.08.00 Pent House
These shall be of R. C. C. framed structures with columns, beams, slabs and

foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof
shall be provided with roof water proofing treatment as specified elsewhere.
Adequate nos. of steel doors and windows shall be provided for natural lighting and
ventilation.
4.09.00 Toilets
Toilet with potable water line facilities shall be provided in each of the following
locations:
(a.) Crusher House (Ground & Drive Floor)
(b.) In all M. C. C. Rooms
(c.) Control Building
Each unit shall have brick enclosure, and the following fittings.
i) Squatting type, white, vitreous china Orissa 1 No.
pattern, W.C. pan with flush valve
and all requisite fittings. In

addition, for control building one
no. wall mounted glazed vitreous
china European water closet with
flushing valve shall be provided.
ii ) White glazed vitreous china flat back lipped 1 No.
urinal with photovoltaic control system for

flushing and all requisite fittings
iii ) Wash Basin 630 mm x 450 mm mounted 1 No.
over granite beveled edge counter fitted

with photovoltaic control system for water
controls, bottle trap with two taps and all
requisite items
iv ) Mirror 600 mm x 450 mm x 5.5 mm thick 1 No.
with bevelled edges ( Superior sheet glass )
v) C.P. Brass Towel Rod 600 x 20 mm 1 No.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
vi ) Liquid Soap Container 2 Nos.
vii ) Washing Tap ( CP Brass ) 1 No.
viii ) Overhead Polyethylene water tank 1 No.
(min. 500 litres capacity)
ix ) Suitable provision for installation of water coolers.
x) For control room buildings, pantry with granite top 1 No.
counter & stainless steel sink.
4.10.00 Staircases
All floors of transfer house and crusher house and roof/floor of MCC rooms shall be
accessible through staircase. However, for the pump houses, access to the roof will
be provided by cage ladder
All stairs other than those of M. C. C. rooms and control rooms shall be of steel
(minimum 1000 mm wide)and maximum rise should not be more than 180 mm and
minimum tread width 250 mm. Stringers shall be of rolled steel channel( minimum
ISMC 250 )and tread shall be of steel gratings. Stairs shall be provided with 32 mm
dia nominal bore medium duty M. S. pipe hand rail.
Handrails (for staircases, around openings, in walkways etc.) shall be of standard

weight steel pipe of flush welded constructions, ground smooth using 32 mm nominal
bore medium class pipe provided with double rail, top rail about 1.0 metre above
platform level and pipe posts spaced not more than 1.5 metres apart. Angle handrail
post may be provided when specifically called for in drawings approved by
Engineering. Handrails around openings should have toe plates.
Smooth uniform curves and bends shall be provided at stair returns and also where
so ever required. Posts connected to curb plates shall have a neat closure at the
bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All
necessary fittings including inner dowels at splices, brackets, belts, bends, flanges
and chains, where required shall be plugged and welded. A minimum radius of 3
times the pipe diameter shall be provided at all points of direction changes in the
handrail.
Treads and landing shall be suitable for the prescribed loading. The maximum width
of openings in gratings shall not exceed 40 mm. The minimum thickness of main bars
shall be 6 mm. The usual span of grating will not generally exceed 1.5 meters. Stair
case gratings shall be galvanized to grade 610g/m2.
Out side stairs to transfer points shall be open type. However sheeting shall be
provided at the top.
Stairs of control room and M. C. C. room shall be of R. C. C. construction, and

minimum 1200 mm wide, maximum rise should not be more than 180 mm and
minimum tread with 250 mm.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
Numbers and arrangement (including enclosures etc.) of stair cases shall be such as
to meet the fire safety requirement as per guide lines of statutory regulatory bodies.
4.11.00 Trenches
All trenches for cables or any other underground facility as detailed out elsewhere
shall be of R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers /
chequered plate cover. Cable trenches as well as pre - cast covers shall be provided
with edge protection angles and lifting hooks. All embedments / block outs as
required and specified elsewhere in these specifications shall be provided. Proper
drainage arrangement shall be provided. Trench pre - cast cover weight shall not be
more than 65 Kgs. Trench covers near entry or at road crossings shall be designed
for 10 T wheel load at centre. Pre - cast covers shall be designed for central point
load of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection of
cables, up to top level and covered with pre - cast R. C. C. covers. For cable
trenches outside buildings, top level shall be 200 mm above G. L.
Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protection

all around cut outs / openings in floor slabs, edges of drains supporting
grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast covers,
supported edges of pre - cast cover, treads of RCC stairs.
4.12.00 Cable gallery/trestles
Cable galleries/trestles shall be made of tubular steel sections only. The tubular steel
section shall be of circular/rectangular/square shape. The circular steel tube shall
conform to IS:1161 and rectangular/square steel sections shall confirm to IS:4923.
The steel structures using tubular sections shall be designed and fabricated as per
IS:806 – “Code of Practice for use of steel tubes in general building construction.”
and EN 1993-1-8:2005.
5.00.00 Drainage & Water Supply Works
5.01.00 Drainage System:-
The drainage arrangements shall be so planned so as to ensure quick disposal of

drainage water without stagnation and / or overflow. It is envisaged to clean the
conveyor galleries, transfer points, crusher building, penthouse etc. with water
periodically.
Minimum 4 nos. down comers shall be provided in each transfer house / crusher
house. In case of conveyor galleries, the down comer shall be provided at every
trestle location.
Drainage of the complete coal stock pile, area around stacker reclaimer rails etc.
shall be discharged into the coal slurry settling pond.
For Conveyors 1A/B, 2 A/B, 5 A/B, 6 A/B, 7 A/B, 8 A/B, 9 A/B, 12A/B, 13 & 14 each
down comer shall lead the water / coal slurry to pit (of 2 Cu.M capacity) to allow
settling of coal. The water from the pit shall overflow into contractor‟s R.C.C drain,
which will lead the discharge finally into nearest owner‟s drain.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
For Conveyors 3 A/B, 4 A/B, & 10 A/B each down comer shall lead the water / coal
slurry into a R.C.C drain, which will lead the discharge finally to the coal settling
pond.
For Crusher House & TP-7, each down comer shall lead the water / coal slurry into
the peripheral drains (Brick drains with steel gratings provided around the building)
which will lead the water / coal slurry to contractor‟s RCC drain and finally to the coal
settling pond.
For TP-1, TP-2, TP-3, TP-4, TP-5, TP-6 & TP-8 TP-9, TP-4A, Pent Houses & MCC-
IIC each down comer shall lead the water / coal slurry into the peripheral drains
(Brick drains with steel gratings provided around the building) which will lead the
water / coal slurry to contractor‟s RCC drain and finally into nearest owner‟s drain.
For Track Hopper, machinery hatches, wagon tipplers, peripheral drains (Brick drains
with steel gratings provided around the building) shall lead the water / coal slurry to a
local pit (of 10 Cu. M. capacity) near each facility to allow settling of coal. The water
from the pit shall overflow into contractor‟s R.C.C drain, and finally to the nearest
owner‟s drain.
In case of Control rooms and M. C. C. buildings Pump houses, etc, water / coal slurry
coming from down comers shall discharge into peripheral drains (Brick drains with
steel gratings provided around the building) which will lead the water / coal slurry into
contractor‟s R.C.C drain, which will lead the discharge finally into owner‟s drain
routed alongside the nearby road.
Suitable kick plates/Curb beams shall be provided around the floor openings, stair
case landings, in the transfer points, crusher house and other buildings.
Contractor‟s scope shall also include construction of necessary culverts under the rail
lines / roads as per railway / I. R. C. standards and approval of Railway culverts from
concern Railway authorities.
5.02.00 Internal and external water supply, drainage etc.:-
The scope for potable water supply includes all distribution systems, tanks, pipes,
fittings etc. as required and as described here or elsewhere in these specifications.
The scope for service water supply and dust control water supply shall be as
described elsewhere in these specifications.
For water supply, medium class galvanized mild steel pipes conforming to IS: 1239
shall be used.
The scope for drainage of surface water shall include design, layout and construction
of drains for and from buildings and drains required for coal stockyard area, drainage
up to main coal slurry settling tank including connection with the tank. Drainage
system shall be designed for maximum intensity of rainfall as 75 mm/hr and 60 %
runoff coefficient. All buildings (including transfer houses and crusher house) shall be
provided with open surface brick drains of minimum size of 300 mm width and 300
mm depth all around the periphery. All drains excepting the peripheral drains around
the transfer points, crusher house, control / M. C. C. buildings, pumps house etc.,
shall be of R. C. C. construction. All open drains shall have removable steel grating
designed for loads as specified under loading clause. Minimum thickness of grating

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
(Galvanised to 610 gm/m2) shall be 12 mm. However at entry or road crossing point’s
minimum thickness shall be 40 mm. The opening size of grating shall not be more
than 90 mm x 35 mm. All drains as well as pre - cast covers shall be provided with
edge protection angles and lifting hooks.
However, drains in coal stockyard area shall have pre cast R. C. C. covers. RCC pre
- cast cover weight shall not be more than 65 Kgs. RCC pre-cast covers near entry or
at road crossings shall be designed for 10 T wheel load at centre. RCC pre - cast
covers shall be designed for central point load of 75 Kgs.
The scope for foul water from toilets shall include layout and laying of sewers up to
the Employer’s main sewer line for sewerage system together with all fittings and
fixtures and inclusive of ancillary works such as connections, manholes and
inspection chambers within the building and from the building to the Employer’s
sewer line.
For rain water down comer and those to be used for conveying water / coal slurry
generated from cleaning of conveyor gallery and buildings floors, Galvanised MS
pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes) with welded
joints shall be used for MCC buildings, pump houses, penthouse, control rooms.
Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330
conforming to IS: 3589 with welded joints shall be used for all TP’s, Crusher house,
and Conveyor galleries.
Galvanising shall be as per IS: 4736. The minimum mass of zinc coating shall not be
less than 400 gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall
be subjected to testing as per IS: 2633, for uniformity of coating. The zinc coating
shall be free from all defects as per IS: 2629.
All rain water down comers shall be provided with roof drain heads and complete with
shoes bends, junctions, sockets, adapters, brackets and finished with anti corrosive
painting over a coat or primer.
For design of building drainage system IS: 1742 shall be followed.
For sanitary / sewerage pipes above ground, sand cast iron pipes conforming to IS :
1729 with leak proof lead joints.
For underground drain pipes, minimum class NP - 2 pipes conforming to IS: 458. At
road crossings, concrete pipes of class NP 3 conforming to IS: 458 and at rail
crossing R.C.C. box culvert to be provided.
For sewerage below ground stoneware pipes conforming to IS: 651 with concrete
bedding and haunch.
6.00.00 COLOUR COATED AND OTHER SHEETING WORK
6.01.00 For floor/roof decking, troughed permanently colour coated metal decking sheet,
shall conform to any one of the following –
(i) of steel with zinc coated to class Z275 with minimum bare metal thickness (
i.e. excluding the thickness of coating and painting) of 0.8mm of grade G250

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per
EN 10326.
(ii) of steel with zinc coated to class Z275 with minimum bare metal thickness (
i.e. excluding the thickness of coating and painting) of 0.6mm of grade G350
as per AS1397 / grade SS340 class 4 as per ASTM A653M / grade S350GD
as per EN 10326 / grade G550 as per AS1397 / grade SS550 as per ASTM
A653M / grade S550GD as per EN 10326.
6.02.00 For roofing & side cladding, troughed permanently colour coated sheets (internal or
external) shall conform to any one of the following –
(i) of steel with zinc coated to class Z275 with minimum bare metal thickness
(i.e. excluding the thickness of coating and painting) of 0.6mm of grade G250
as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per
EN 10326.
(ii) of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare
metal thickness (i.e. excluding the thickness of coating and painting) of
0.5mm of grade G350 as per AS1397 / grade SS340 class 4 as per ASTM
A792M / grade S350GD as per EN 10326.
(iii) of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare
metal thickness (i.e. excluding the thickness of coating and painting) of
0.4mm of grade G550 as per AS1397 / grade SS550 as per ASTM A792M /
grade S550GD as per EN 10326.
6.03.00 Steel shall be colour coated with total coating thickness of 35 microns (nominal) dry
film thickness (DFT) comprising of Silicon Modified Polyester paint (SMP with silicon
content of 30% to 50%) or Polyester paint, of 20 microns (nominal) SMP or polyester
paint on one side (exposed side) over 5 micron (nominal) primer coat and 5 micron
(nominal) SMP or Polyester paint over 5 micron (nominal) primer coat on other
side,(SMP and Polyester paint shall conform to Product type 4 of AS/ANZ 2728.
Coated surface (exposed side) shall be provided with a protected guard film
(polyethylene) of about 40 microns to avoid any damage to the coating during
handling.
6.04.00 Sheet shall be of approved profile, sectional properties, colour and shade.
6.05.00 Chemical composition of troughed permanently colour coated metal decking sheets
and metal sheet for roofing and side cladding, shall conform to the provisions of the
same reference code to which the mechanical properties conform to. Mechanical
properties shall be confirmed by relevant tests.
6.06.00 Tolerance on minimum BMT (bare metal thickness) shall be (-)0.00mm and
(+)0.06mm.
6.07.00 Plain permanently colour coated steel metal sheets for ridge and hips, flashings,
trimmings, closure for vertical and horizontal joints, capping etc shall confirm to the
same requirements as those of troughed permanently colour coated metal sheet for
roofing and side cladding.
6.08.00 For metal decking the sectional modulus and moment of inertia of troughed profile
per meter width shall be so as to limit the deflection of sheets to span/250 for two

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
span condition. The sectional modulus and moment of inertia of troughed profile shall
be computed as per the provisions of IS:801 for satisfying the deflection and strength
requirements.
6.09.00 For metal roofing and side cladding, the sectional modulus and moment of inertia of
troughed profile per metre width shall be such that the deflection of sheets is limited
to span/250 for two span condition. The sectional modulus and moment of inertia of
troughed profile shall be computed as per the provisions of IS: 801 for satisfying the
deflection and strength requirements. No increase in allowable stress is permissible
under wind load condition.
6.10.00 Maximum spacing of the fasteners shall be 390 mm c/c along the length of
beams/purlins / runners. However exact spacing shall be as per the design done by
the bidder for the fasteners considering the wind load, self load and other associated
loads. Minimum diameter of the fastener shall be 5.5 mm and at least 3 nos. of
fasteners shall be used per sheet.
6.11.00 Sealant used for cladding shall be butyl based, two parts poly sulphide or equivalent
approved, non-staining material and shall be flexible enough not to interface with fit of
the sheets.
6.12.00 Filler blocks as a trough filler shall be used to seal cavities formed between the
profiled sheet and the support or flashing. The filler blocks shall be manufactured
from black synthetic rubber or any other material approved by the Engineer.
6.13.00 For insulation of cladding, mineral wool conforming to IS: 8183 shall be used. The
density shall be 32 or 48 kg. /Cu.M. for glass or rock wool respectively. The nominal
thickness of insulation shall be 50mm.
6.14.00 Special coated fasteners shall be used conforming to corrosion resistant class 3 as
per AS3566 and shall be tested to 1000 hours salt spray test.
6.15.00 The dimensional tolerances of profiled sheets for sheet length, sheet cover width,
straightness, squareness, depth of profile, radius and angle of curved sheets, ripple
of side lap, etc. shall be as per “Manufacturing tolerances for profiled metal roof and
wall cladding & roofing” by The Metal Cladding & Roofing Manufacturers Association
Limited, UK.
6.16.00 Sheets shall be laid with a minimum overlap of 15 cm at the ends and side laps shall
be of one trough length subject to a minimum of 50 mm, having a proper water tight
arrangement. The minimum lap of sheets with ridges, hips and valleys shall be 15 cm
measured at right angles to the line of the ridge, hip and valley respectively.
6.17.00 Metal decking sheets shall be laid over the supporting beams/purlins with a minimum
bearing of 50 mm and end projection of 75 mm at lap joints.
6.18.00 Flashings, cappings, trimming, closure for vertical/horizontal joints, ridge and hips etc.
shall be provided with a minimum lap of 15 cm. The lapping of sheets shall provide
the dust free, airtight enclosure. If required, this may be achieved by using 2-parts
polysulphide sealing compound or butyl tape.
6.19.00 Distorted, blemished or water stained sheets shall not be used.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
6.20.00 Side and end laps of the sheets shall be made weather proof by securing them with
the fasteners not less than 4.8mm dia with 2.0 mm thick neoprene washer. Maximum
spacing of the fasteners should not exceed 500 mm.
6.21.00 Precautions shall be taken during the erection of the sheets to ensure that partially
erected sheets are protected from damage at all times and particularly during
inclement weather. Sheets shall be laid over the supporting purlins/runners with a
minimum bearing of 50 mm and end projection of 75 mm at lap joints.
6.22.00 Side cladding for Crusher House, Transfer points & conveyor galleries(including roof)
shall have single skin troughed profile permanently colour coated sheets. However,
roof of Crusher House and transfer points shall be provided with troughed profile
permanently colour coated sheet on outside and plain permanently coated sheet on
inside with 50mm thick mineral wool insulation in between the two sheets.
6.23.00 The polycarbonate sheet to be used for cladding and glazing purpose in conveyor
galleries shall have toughed profile to match with the metal cladding profile. Minimum
2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of GE plastic
or equivalent approved make shall be used. The polycarbonate sheet shall be
installed along with the metal cladding so as to have a watertight lapping
arrangement. Suitable detailing shall be made to cater for the thermal expansion.
IS:14434 to be referred for other details.
6.24.00 Polycarbonate sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous
use under temperature 100oC), impact resistant and ultraviolet resistant sheet shall
be provided (as glazing) in transfer houses, crusher house, etc.
7.00.00 Roof Details
Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD
reinforcement bars placed at 200 mm center both ways at top and bottom.
900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided
over roofs of all buildings. Parapet wall shall have suitable coping. External face of
parapet wall of the buildings provided with metal cladding shall also be finished with
metal cladding of design and colour as per approved architectural drawings.
Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet.
Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness
of 30 mm of M-15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished
with 12 mm 1 : 3 cement : sand plaster.
Roofs of all M. C. C./control rooms, penthouse, pumphouse etc., shall have roof
water proofing treatment. Roof water proofing treatment shall be as follows:
1) Application of polymerised mastic over the RCC roof to achieve smooth surface
as primer coat.
2) Application of high solid content liquid applied urethane based elastomeric water
proofing membrane, over the primer coat, to give uniform joint less dry film
thickness of minimum 1.5 mm (as per ASTM C 836 and C 898).

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
3) For efficient disposal of rain water, the run off gradient for the roof shall not be
less than 1: 100. This gradient shall be provided by screed concrete M-15 (using
12.5 mm coarse aggregate) and / or cement mortar (1: 4) over the elastomeric
water proofing membrane with 25mm thick cement mortar (1:4) topping.
4) Wearing course at top, shall consist of 25 mm thick P. C. C. (M-15) cast in panels
of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized
chicken wire mesh and sealing of joints using sealing compound / elastomeric
water proofing membrane. Pathways for handling of materials and movement of
personnel shall be provided with 22 mm thick chequered cement concrete tiles as
per IS : 13801 for a width of 1000 mm in place of P. C. C.
Roof of transfer points and crusher house shall be provided with troughed profile
permanently colour coated sheet on outside and plain permanently colour coated
sheet on inside with 50mm thick mineral wool insulation in between the two sheets. A
slope of 1 in 5 shall be provided for quick drainage of rain water.
8.00.00 Floors and Grade level details
The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia
HYSD reinforcement bars placed at 200 mm center both ways at top and bottom
Floors of transfer points shall have cross slope of not flatter than 1: 80, towards the
floor washing drainage outlets, for efficient drainage. For ground conveyor & crusher
house slope shall be 1:100.
Chequered plates (used for floors, walkways etc.) shall be minimum 6 mm thick o/p
or as indicated on drawings. The chequered plate pattern shall be approved by
Employer / Engineer. Mild steel flats/angles of suitable size shall be welded to the
bottom portion of chequered plates at a designed spacing to stiffen chequered plates
suitably. Chequered plates shall be fixed by staggered welding of suitable size.
Floors of trenches shall have integral finish to concrete base.
Toe guard of size 100 x 6 mm shall be provided at various openings provided in

floors e.g. around stair case openings, chute openings and other similar cutouts. For
conveyor walkways, angle runner to act as toe guard shall be provided.
All along the periphery of R. C. C. floors (where no brick masonry walls are provided)
shall be provided with one brick thick 300 mm high brick wall and 700 mm high steel
hand rails all around over this brick work.
The grade slab shall consists of 230 mm thick rubble soling (63 mm downgraded
hard stone aggregate as per IRC specification, watering and compaction to minimum
of 90% Standard Proctor density, including filling the interstices of stone aggregates
with sand), over well compacted earth, overlaid by 75 mm thick P. C. C. M-7.5 and
100 mm thick R. C. C. of grade M-20 with minimum 8 mm dia bars placed at 200 mm
C / C in either direction respectively. There will be minimum 50 mm thick metallic
hardener finish over the R. C. C. slab.
All buildings (including track hopper and machinery hatches, penthouse, transfer
houses and crusher house) and ground conveyors shall be provided with 750 mm
wide plinth protection all around. It consists of 50 mm thick P.C.C. M-20 grade with
12 mm maximum size aggregate over 200 mm thick stone soling using 40 mm
nominal size rammed, consolidated and grouted with fine sand.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
An area of 5 m width all round the transfer houses and crusher house shall be paved.
This paving will be in addition to plinth protection. The paving construction shall be as
per specifications for the grade slab at ground level. However, 50 mm thick metallic
hardener finish is not required to be provided in paved area.
Plinth level of all buildings shall be kept at least 500 mm above the finished grade /
formation level.
9.00.00 Brickwork and allied masonry works
All brick walls shall be non - load bearing in-filled panel walls.
All brickwork shall be designed as per Indian Standards and shall be plastered on
both faces. All external walls shall be minimum one brick thick in 1: 6 cement: sand
mortar. Brick walls shall be provided with 12 mm and 18 mm thick 1: 6 cement: sand
plaster on smooth and rough face of the brick work respectively.
Bricks to be used in brickwork shall be of minimum Class designation 50.
Brickwork cladding for various structures shall be so provided that there is a clear
gap of 40 mm between inside face of external brick wall and outside face of column
flange. Structural steel wall beams supporting brickwork shall be suitably encased
with plaster or 1: 2: 4 concrete as the case may be. In case of box type steel beam,
encasement shall be done with cement sand plaster in specified thickness and
proportions over G. I. wire netting of 0.9 mm thickness.
Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be
provided with drip course in 1 : 4 cement sand mortar.
50 mm thick Damp proof course shall be provided at plinth level for all brick wall.
All R. C. C. ceilings shall be rendered smooth and finished with whitewash unless
otherwise specified. Ceiling of control rooms, M. C. C. rooms (except areas provided
with false ceiling) shall be provided with 6 mm thick plaster.
10.00.00 Earthing Mat
40 mm Dia MS Rods as earthing mat, placed at a distance of 1.0M away and at

depths between 0.60M and 1.00M shall be supplied and laid all around the periphery
of buildings, structures, and outdoor equipment, as per the approved drawings.
Risers of 40 mm Dia MS Rods and connecting to the above Earthing mat shall also
be supplied and laid in position by the Contractor, as per the approved drawings.
Risers shall be laid up to a height of 300 mm above the local Ground level, at each of
the columns of the buildings on outside of the buildings, and minimum 2 (Two)
numbers for structures and outdoor equipment. The contractor also supply and lay
necessary number of 3.0 M deep vertical 40 mm Dia MS Rods Earthing electrodes
and connecting them to the Earthing mat, as per the approved drawings and the
supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing
mat with the Employer's earthing mat separately at two locations.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
11.00.00 Fencing
Fencing with toe wall and steel gates shall be provided around the transformers.
Fencing shall comprise of PVC coated GI chain link fencing of minimum 8G
(including PVC coating) of mesh size 75 mm and of height 2.4 m above the toe wall.
The diameter of the steel wire for chain link fence (excluding PVC coating) shall not
be less than 12G. Fence posts shall be of pre – cast R. C. C. of minimum M20 grade.
All corner posts will have two stay posts and every tenth post will have transverse
stay post. Suitable R. C. C. foundation for the post and stays shall be provided based
on prevailing soil conditions. Gates shall be sturdy with locking provisions.
Toe walls of brick masonry shall be provided between fence posts all along the run of
the fence with suitable foundation. Toe wall shall be minimum 200 mm above the
formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend
minimum 300 mm below the formation level. Toe wall shall be plastered on both
sides and painted with two coats of cement paint of approved colour and shade. Toe
wall shall be provided with weep holes at suitable spacing.
12.00.00 LOADING
For consideration of loads on structures IS : 875 - ‘Code of practice for structural

safety of buildings’ shall be followed. In addition to the dead load, live load,
equipment load (including impact / vibration). Temperature loads etc. various loading
conditions arising due to operation and maintenance of equipment shall be
considered in the design. The structure and equipment shall also be designed for
seismic loads as per the “Criteria for Earthquake Resistant Design of Structures and
equipment" and the “Criteria for Wind Resistant Design of Structures and equipment"
specified in the Annexure A and B respectively in Civil Section, whichever is
governing. Wind and seismic forces shall not be considered to act simultaneously.
The following minimum live loads shall be adopted for the design of various
structures. If actual expected load is more than the specified load, then actual load is
to be considered.
a ) Roofs 150 Kgs. / Sq. M. for accessible roofs

and 75 Kgs. / Sq. M. for non -
accessible roofs.
In addition to this coal dust load (Dead
load) of 150 Kgs. / sq. m. on flat roofs &
75 Kgs. / sq. m. on inclined roofs shall
also be considered.
b ) R. C. C. floors 500 Kgs. / Sq. M.
c ) Stair and balconies 500 Kgs. / Sq. M.
d ) Toilet rooms 200 Kgs. / Sq. M.
e ) Chequered plate floors 400 Kgs. / Sq. M.
f ) Walkways ( including walkways in 300 Kgs. / Sq. M.

conveyor galleries )
g ) Conveyor galleries In addition to the live loads, loads due

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
to cable trays, fire fighting / service

water pipes shall also be considered @
125 Kgs. / m ( minimum ) on each of
the longitudinal girder.
Roof-truss members are to be checked
for supporting fire fighting pipes/
Service water pipes. Tentative locations
and diameter for pipes are shown in
Tender Drawing.
h ) Road Culverts and its allied For class 'AA' loading and checked for
structures including R. C. C. pipe class A loading as per IRC standard.
crossing & road crossing of
trenches.
i ) Channels / trenches In addition to earth pressure and water

pressure, etc. additional earth pressure
due to surcharge of 2T / Sq. M. shall
also be considered for design.
j ) Covers for trenches / channels Covers for channels & trenches, shall
be designed for a live load of 0.4T Sq.
M. and loading as mentioned under
clause in trenches, whichever is critical.
k ) Sumps and tanks and other In addition to earth pressure with a

underground basement type surcharge of 2T / Sq. M. (or surcharge
structures due to Railway loading whichever is
critical for Railway load bearing
structures etc.) and sub - soil water
pressure etc. These are also to be
designed for the following conditions :
i) Water / liquid inside and no
earth outside (applicable only to such
structures which are liable to be filled
up with water or any liquid ).
ii ) Earth with surcharge outside
and no water / liquid inside
iii ) For underground (basement)
structures protection against buoyancy
during execution and after execution
shall be ensured without superimposed
loadings with minimum factor of safety
of 1.2 against buoyancy.
l ) Unit weight of coal shall

be taken as 1100 Kgs. / cum. for
design purposes.
If the erection load is higher than the specified live loads on any floor or part thereof,
then the erection loads are to be considered for the design.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
Permissible increase in stresses of materials and bearing pressure of soil due to wind
load or seismic load shall be as per relevant I. R. S. and I. S. code.
13.00.00 DESIGN CRITERIA
The loads for all railway load bearing structures e. g. track hopper including
machinery hatches, wagon tippler, tunnel, culverts and under ground transfer houses
etc. and the analysis and the design of these structures shall be made strictly in
accordance with the provisions of Indian Railway Bridge rules (latest edition), and
Indian Railway Codes of practice (latest edition) with all amendments up to the date
of opening of bids. The axle load for analysis and design shall be considered as
“DFC loading (32.5t axle load)” of Heavy mineral loading as per Indian railway
standard. Coal heap of 1.2m height shall be considered above hopper top for design
of coal tray, hopper and supporting elements of track hopper. The analysis, design
and detailed drawing for the structure coming below the railway track shall be
got approved by the contractor from the concerned railway authorities before
taking up construction. All necessary payment for the above work shall be
made by the bidder to the railway authority.
The design of all R. C. C. structures shall be carried out as per ‘code of practice for
plain and reinforced concrete for general building construction’, IS : 456 ( latest ).
The steel structures shall be designed and fabricated as per ‘code of practice for use
of structural steel in general building construction’, IS : 800 and other relevant IS
Standards. Minimum size of the angle section to be used as structural members shall
be 50 X 50 X 6. Minimum weld size shall be 6 mm.
The building shall conform to local bye - laws, rules and regulations for industrial
buildings and also B. I. S. publications, SP 32 and 41.
Slotted holes shall not be assumed to act as expansion joint for relieving of stresses
and suitable bearings shall be provided at the supports.
All gallery supporting trestles shall be so proportioned that the transverse deflection
of gallery due to wind / seismic load should not exceed trestle height / 1000 as
stipulated in IS: 11592. This deflection condition shall be strictly followed. Peak wind
speed method shall be considered for checking the transverse deflection.
The crusher and transfer house structures shall be so designed that transverse
deflection at places where conveyor galleries meet, should be equal to the respective
transverse deflection of conveyor supporting trestles.
Stresses for all CHP structures shall be checked for the higher of the forces obtained
from gust factor method and the peak wind speed method.
The permissible vertical deflection for beams supporting drive machinery shall be
restricted to span / 500 and for other beams it shall be within span / 325.
Horizontal bracing system shall be provided at floor levels around the openings.
Shear force in steel columns shall be transferred to the pedestals / foundations

exclusively either through foundation bolts or the shear key arrangement.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
For design of liquid retaining structures, IS: 3370 ( Part - I to IV ) ( latest ) shall be
followed. Face of the structure in contact with liquid shall be designed as un -
cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458,
IS : 783 should be followed.
For design of all underground structures / foundations, ground water table shall be
assumed at the formation level ( i. e. the adjoining ground level ).
Design of Hopper walls shall be done for both Static & Dynamic flow condition using
Walker’s theory.
Design of masonry walls shall be made as per IS : 1905.
Civil task drawing indicating various equipment loading and supporting arrangement
and floor loads to be submitted along with the design calculation.
For metal roofing and side cladding, the spacing of purlins/runners shall be such that
the deflection of metal sheet used is limited to span/250 under adverse loading
condition.
Minimum reinforcement shall be provided at the top face of the footing, even if, no
reinforcements are required as per design.
14.00.00 CONCRETE
All R. C. C. works to the done under this specification, unless specified otherwise
shall be design mix concrete. Minimum grade of concrete for various structures shall
be as follows:
a) M35 - For railway load bearing structures like Track hopper, wagon
tipplers, etc.
b) M25 - For all other underground / sub structural R. C. C. work.
C) M20 - For R. C. C. superstructure works including ground floor slabs,

trenches & drains.
Minimum 75 mm thick P.C.C M-7.5 shall be provided as mud mat below all
foundations.
For concreting of underground structures requiring water tightness, plasticizer cum

water proofing admixture shall be added to the concrete mix.
Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting
etc. unless otherwise mentioned.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
15.00.00 Excavation Details
15.01.00 Excavation in soil
Excavation for foundation shall be to the bottom of lean concrete and as shown on
drawing or as directed by the Engineer. The bottom of all excavations shall be
trimmed to required levels and when excavation is carried below such levels by error,
it shall be brought back to the specified level by filling with concrete of nominal mix 1
: 3 : 6 (cement: coarse sand: 40 mm down aggregates ), as directed by the Engineer.
The Contractor shall ascertain for himself the nature of materials to be excavated and
the difficulties, if any, likely to be encountered in executing this work. Cofferdams,
sheet piling, shoring, bracing to maintain suitable slopes, draining etc. shall be
provided and installed by the contractor, to the satisfaction of the Engineer.
Surplus excavated materials shall be disposed off by the contractor at locations up to

a lead of 5 kms from the plant boundary wall as directed by the engineer.
The Contractor shall have to constantly pump out any water collected in excavated
pits and other areas due to rain water, springs etc. and maintain dry working
conditions at all times until the excavation, placement of reinforcement, shuttering,
concreting, Backfilling is completed. The Contractor shall remove all slush/muck from
the excavated areas to keep the work area dry. The Contractor, if required, shall
employ sludge pumps, for this purpose.
For other details, excavation clauses as given in Sub-Section III-D-02 are to be

referred.
15.02.00 Excavation in rock
For the work of excavation in rock, Contractor shall engage specialised agency
having experience of excavation in rock involving wedging and blasting. The agency
shall be subject to approval of Engineer and the Contractor shall furnish details of
relevant experience in support while seeking approval for the agency.
Blasting shall be resorted to only with the written permission of the Engineer. All the
statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc.
pertaining to the acquisition, transport, storage, handling and use of explosives etc.
shall be strictly followed.
The contractor shall obtain Licenses from Competent Authorities for undertaking
blasting work as well as for procuring, transporting to site and storing the explosives
as per Explosives Act. The Contractor shall be responsible for the safe transport,
use, custody and proper accounting of the explosive materials.
Surplus excavated materials shall be disposed off by the contractor at locations up to

a lead of 5 kms from the plant boundary wall as directed by the engineer.
The Contractor shall have to constantly pump out any water collected in excavated
pits and other areas due to rain water, springs etc. and maintain dry working
conditions at all times until the excavation, placement of reinforcement, shuttering,
concreting, backfilling is completed.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
15.03.00 De-watering of Deep Excavations
For deep underground structures like track hopper, machinery hatches, tunnels and
underground transfer houses, requiring open excavation with extensive de - watering,
completely dry working conditions during excavation, shuttering, placement of
reinforcement, concreting, water proofing of structures, backfilling and any other
operation shall be maintained by suitable de - watering method of suitable capacity.
15.04.00 Backfilling, Disposal and Stacking of materials
Backfilled earth shall be compacted to minimum 90 % of the standard proctor density

at OMC. Sand filling shall be compacted to minimum 80 % of the relative density.
Also refer Sub-section III D-02 for more details.
However, the backfill under the rail lines and roads shall be compacted to minimum
95 % of the standard proctor density at OMC unless otherwise stated by rail
Authorities.
The contractor is required to excavate upto any depth as shown on the drawings or
as directed by the Engineer. Lifting of excavated materials shall be done either by
manual or mechanical or both means if called for by the Engineer.
The disposal / stacking areas for excavated materials shall be indicated by the
Engineer. The carriage of excavated materials shall be done by the methods
mentioned below:
The excavated materials shall be carried beyond the initial lead of 50 m but upto 500
m by manual / animal labour or by mechanical means. If directed by the Engineer this
material shall be used directly for filling purposes.
For leads exceeding 500 m the Contractor shall transport the excavated materials by
mechanical means only and as directed by the Engineer. The Contractor may be
allowed to carry materials through Kuccha roads. Providing and maintaining of the
Kuccha roads shall be the responsibility of the Contractor. The transported material
shall be neatly stacked as directed by the Engineer.
Some excavated materials required for filling purposes, may have to be carried upto
a lead of 500 m and stacked as per instructions of the Engineer. Excavated materials
carried beyond 500 m shall normally be for disposal purpose only. Double handling of
materials shall be avoided as far as possible. However, depending on site condition
excavated materials carried beyond a lead of 500 m may also be required to be
brought back for filling purpose.
Materials to be used for filling purpose shall be stone, sand or other inorganic
materials and they shall be clean and free from shingle, salts, organic matter, large
roots and excessive amount of sod, lumps, concrete or any other foreign substances
which could harm or impair the strength of the substances in any manner. All clods
shall be suitably broken to small pieces. When the materials are mostly rock
boulders, these shall be broken into pieces not larger then 150 mm size. Sand used
for filling shall be clean, medium grained and free from impurities. Fines less than 75
microns shall not be more than 20%. In any case, the materials to be used for filling
purposes shall have the prior written approval of the Engineer.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
In case the materials have to be brought from pits / quarries, then it shall be the
Contractor’s responsibility for identification of such quarry areas, obtaining approval
from their use from concerned authorities, excavation / quarrying loading and
carriage of such material, unloading and filling at specified locations. The Contractor
shall pay any fees, royalties etc. that may have to be pain for utilisation of borrow
areas.
16.00.00 GALVANISING
All burrs and irregular edges of the structural steel members to be galvanised shall
be ground smooth before galvanising.
Purity of Zinc to be used for galvanising shall be 99.5 % as per IS : 209 ( latest
edition ).
The weight of the zinc coating shall be at least 610 Gms. / m2 unless noted
otherwise.
17.00.00 CHEMICAL INJECTION GROUTING
Minimum, 12 mm dia ( NB ) threaded nozzle of suitable length, shall be provided over

the surface and along the construction joint line in a grid pattern at a spacing not
exceeding 1.5 m c / c before concreting operation. Adequate precaution shall be
taken to keep the nozzles plugged at both ends to prevent them from getting closed
by concrete.
For fixing of any nozzle in set concrete suitable size hole shall be drilled, preferably
by using repercussive hammer drill electrically operated, in grid pattern and grouting
nozzle shall be fixed in these holes.
After the nozzles are fully set, neat cement slurry admixed with water soluble non -
shrink polymer / monomer based chemical shall be injected through the net - work of
nozzles with low pressure grout pumps at a pressure of about 2.0 Kgs. / cm2. Cement
slurry shall be prepared by mixing cement with non-shrink polymer/monomer @ 500
gm/50 kg bag of cement and water, ensuring that Water: Cement ratio does not
exceed 2 (by weight). Wetter the structure, lesser should be the water cement ratio.
The property of the polymer/monomer should be such that when it is mixed with
water @0.5% by weight of water, the viscosity of the resultant solution (water and
polymer/monomer) should not be more than 1.2 centipoises. Plasticizing agent shall
be added wherever required. The grouting shall be started at very low pressure and
increased gradually to a required pressure. The grouting shall continue, till the hole
refuses to take any further grout, even at an increased pressure. Applied pressure
shall not be more than the designed strength of the concrete. After completion of
grouting operation, the nozzles shall be sealed properly to the satisfaction of the
Engineer.
18.00.00 POLYMER MODIFIED CEMENTITIOUS COATING
18.01.00 Materials
Modified liquid polymer blend shall be a dispersion containing 100 % acrylic based
polymer solids. Polymer shall be mixed in the ratio of 1 cement: 0.5 polymer (for
minimum solid content of polymer 30%).

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
Portland cement based dry powder.
Clean, fine specially prepared quartz sand approximately 0.6 mm size.
18.02.00 Mixing
The liquid polymer shall be stirred well and cement based powder shall then be
added slowly to make a Slurry Mix. For preparation of Brush Topping Mix, quartz
sand shall be added slowly and mixed well till a homogeneous mixture is obtained.
The mix shall be used within half an hour of the preparation. Addition of quartz sand
may not be necessary, in case dry power contains the same.
18.03.00 Properties of Coating
It must adhere to wet surface.
It should develop adequate bond strength, with the concrete surface, not less than 2
N / Sq. mm.
Co - efficient of permeability shall be about 5x10-10 Cm / Sec.
Water absorption after continuous soaking shall not be more than 1 %.
The materials shall be permeable under water vapour.
The material shall be resistant to acids and alkalies present in the soil and
underground water with normal pH value between 4 and 14.
The co - efficient of thermal expansion of the material shall be close to that of

concrete.
18.04.00 Application
The concrete surface shall be cleaned and made free from grease, oils or loosely
adhered particles. The surface shall be damp without any free water. For exterior
underground part, application (b) pertaining to Brush topping Mix shall be followed.
(d.) For Slurry Mix
A minimum of 2 coats shall be applied on the surface. The first coat being applied,
when the surface is still damp and left to harden for 4 to 6 hours. After 4 to 6 hours of
the application of second coat, it shall be finished by rubbing down with a soft dry
sponge. The coverage shall not be less than 1 : 1 Kgs. / m2 in the 2 coats. A lap of 75
mm shall be provided at the joints.
The coating shall be air dried for 4 to 6 hours and, thereafter, cured for 7 days after
the application of last coat.
(e.) For Brush Topping Mix
This shall be applied in two coats. A primary coat of slurry mix can also be first
applied on the surface as first coat. After the coating has dried up, a coat of Brush

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
Topping Mix shall be applied over it with a push broom or any other similar brush. It
shall be left in broom finished condition. The nominal thickness shall be 1.5 mm and
minimum thickness shall be 1.0 mm. A lap of 75 mm shall be provided at the joints. It
shall be ensured that no pinhole exists and rebrushing shall be done to cover the
pinholes, if any.
The Coating shall be air dried for 4 to 6 hours and thereafter cured for 7 days after
the application of last coat.
Rate of application of coating shall be established to achieve the required thickness.
19.00.00 Architectural Features
All architectural features of buildings like control rooms, crusher houses, M. C. C.

rooms, transfer houses and conveyor galleries etc. shall have a unified, harmonious
architectural character and shall be detailed by contractor’s qualified architect. All
buildings shall be designed as per the provisions in National Building code and as
per TAC requirements. Necessary projections, fins etc. in addition to the minimum
specified elsewhere in this specification shall be provided as required. The
Contractor for Employer’s approval shall submit detailed architectural drawings
including door-window details, toilet details, stair details & finish schedules with
colour schemes. Nothing extra shall be payable for any changes required while
getting the drawings / schemes approved and for executing the same.
In case structural column base plates are proposed below the floor level, the same
shall be encased with adequate cover up to the finished floor level with minimum M -
20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skin
reinforcement of the encasing.
19.01.00 Glazing
Window glazing for various locations shall be as below:
(i) In transfer houses, crusher house and pump houses etc:
6mm. thick toughened float glass & Polycarbonate sheet (Details described
elsewhere).
(ii) In Switchgear / M. C. C. buildings
(a) In air conditioned (A / C) areas:
Composite double glazing with clear float glass of 6 mm thick on one side and 6mm
thick tinted glass on the other side hermetically sealed and separated by 12 mm thick
gap for thermal insulation at partition of A / C and non A / C areas.
Composite double glazing with clear float glass of 6 mm thick on inside and 6mm
thick toughened reflective glass hermetically sealed and separated by 12 mm thick
gap for exterior windows.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
(b) In toilets:
Frosted glass of minimum thickness 6 mm.
(c) In other areas:
Toughened glass of minimum thickness 6 mm
The above mentioned glass thickness are bare minimum only and actual thickness
will depend on the panel size of the glazing to be provided.
19.02.00 False Ceiling
All air - conditioned areas, shall be provided with the suspended permanently colour
coated aluminium false ceiling system with corrosion resistance aluminium alloy
panels of minimum thickness 0.5 mm. The suspension system for false ceiling shall
be as per manufacturers guidelines.
Additional hangers and height adjustment clips shall be provided for returns air grills,
light fixtures, A. C. ducts etc.
Under deck insulation shall be provided on the ceiling (underside of roof slab) and
underside of floor slab of air - conditioned areas depending upon the functional
requirements. This under deck insulation shall consist of 50 mm thick mineral wool
insulation mat conforming to IS: 8183 having a density of 32 kg/cum for glass wool or
48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G x 25 mm
mesh wire netting and shall be fixed to the ceiling with 14G wire ties.
19.03.00 Acid / Alkali Resistant Lining
Battery Room
Acid, alkali and oil resistant high build self smoothing, seamless epoxy resin floor
finish, on horizontal and vertical surfaces, at all levels, for all types of works,
including all labour, material, equipment, scaffolding, handling, transportation,
preparation of surface, application of epoxy based primer coat, of approved colour,
quality and make to give minimum thickness of 300 micron (in two coats) and dado
upto 1200 mm, etc., all complete, shall be provided.
19.04.00 FINISHING SCHEDULE
The contractor's scope also includes all doors, windows, glazing, rolling shutters,
finishes, damp proofing, inserts, anchor bolts, embedments, stairs, nosing, railings,
toe - guards, ladders, edge protection angles, etc.
The Contractor shall adhere to the finishing schedule as given.
19.04.01 Flooring
I. P. S. (cement concrete flooring) with metallic hardener topping shall be provided for
all floors in track hopper, wagon tipplers, transfer houses, including ground floors of
transfer houses, ground conveyors, operating floor of pump houses, M. C. C. rooms,

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
cable vault / cable spreader rooms, maintenance and unloading areas, general
storage areas and all other areas in plant buildings where heavy duty flooring is
required.
Heavy Duty Ceramic Tiles (matt finish), 300mm x 300mm x 7mm of approved colour
shade & finish, shall be provided for floors of toilets, pantry, etc with 300 x 200mm
designer wall ceramic tiles for dado in toilets & pantries.
Vitrified ceramic tile (mirror polished) 600 x 600 x 10mm thick shall be provided for
floors of office rooms, conference room, laboratories, control room & control
equipment room and for dado upto false ceiling.
The nominal total thickness of floor finish shall be 50 mm i.e. under bed and topping.
The floor shall be laid on an already laid and matured concrete base.
Sunken R. C. C. slab shall be provided in toilet area so as to keep the finished floor
level of these areas same as that of the surrounding area.
Wherever specified metallic hardener topping shall be 12 mm with ordinary grey

cement.
Paving details shall be similar to grade slab excluding metallic hardener.
Skirting in general shall be 150 mm high. Dado in toilets and pantries shall be up to
2.1 m height from finished floor level. Skirting and dado shall match with the floor
finish.
19.04.02 Interior Wall / Ceiling Finish
For all air conditioned control room, 600 x 600 x 10mm th. Vitrified ceramic tile dado
shall be provided upto false ceiling and for other air - conditioned areas acrylic
emulsion paint of approved make and shade over 2 mm thick plaster of paris punning
shall be provided.
For toilets and pantries minimum 300 x 200 mm thick decorative coloured ceramic
tiles of approved make and shade with approved pattern up to 2.10 m. height from
finished floor level shall be provided. Oil bound distemper over plaster of paris
punning above 2.10 m height shall be provided.
For all other areas oil bound distemper ( IS : 428 ) of approved shade over 2 mm
thick plaster of paris punning shall be provided.
For battery room and other areas coming in contact with acid / alkali fumes, chemical
resistant chlorinated rubber paint shall be provided above 2.1 m height. Up to 2.1 m
height from finished floor level acid alkali resistant epoxy resin finish shall be
provided as specified elsewhere.
All R. C. C. ceilings shall be finished with acrylic distemper.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
19.04.03 Exterior Finish
Permanently colour coated M. S. / High tensile steel metal cladding ( non - insulated )
of approved colour combination shall be provided for transfer points, conveyor
galleries, elevator shafts, and parapet walls of buildings where metal cladding is
specified. The cladding sheets shall be coated with silicon modified paint as specified
elsewhere.
Solvent based acrylic exterior paint in combination with textured paint with 2.5mm
stone chips in the ratio of 3 : 1 shall be provided for the under mentioned areas :
(a.) All buildings with R. C. C. framework unless specified otherwise in this

specification.
(b.) Brick work in the lower portion of metal cladding.
(c.) Fire walls
(d.) Projections and facia : R. C. C. parapets ( excepting parapets of buildings

where metal cladding is specified )
(e.) Exterior brick walls.
19.05.00 DOORS, WINDOWS AND ROLLING SHUTTERS.
19.05.01 Doors and Windows
All doors, windows and ventilators of control room building, S and T control room and
M. C. C. buildings shall have Electro colour coated (anodised) aluminium frame work
with glazing. All doors of office and toilet areas shall be of factory made pre-
laminated particle board (M D F exterior grade). All other buildings shall have steel
doors, windows and ventilators.
Single glazed panels with aluminium framework shall be provided as partition

between two air - conditioned areas wherever clear view is necessary.
Coal conveyor galleries shall have steel windows of openable type. The window
shutters shall be provided with M. S. louvers.
All steel doors shall consist of double plate flush door shutters. The door shutter shall
be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous
vertical 20 G stiffeners at the rate 150 mm centre to centre. Side, top and bottom
edges of shutters shall be reinforced by continuous pressed steel channel with
minimum 18G. The door shall be sound deadened by filling the inside void with
mineral wool. Doors shall be complete with all hardware and fixtures like door closer,
tower bolts, handles, stoppers aldrops, etc.
Windows of coal galleries shall be provided with welded wire fabric of 1.6 mm thick
wire as per IS: 4948 and 12 mm x 30 mm mesh size.
Wherever functionally required rolling shutters shall be provided and these shall be
either electrically operated or manually operated or with geared arrangement.

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In transfer points, windows near floors shall be steel and openable types. The
window shutters shall be provided with MS louvers. Windows / ventilators at higher
level can be of steel with fixed glazing. All openable windows shall be provided with
suitable stays.
All windows and ventilators on ground floor of all switchgear and M. C. C. buildings
shall be provided with suitable anodized aluminium grill.
Fire - Proof doors with panic devices and all necessary fixtures shall be provided at
all fire exit points as per the recommendations of statutory regulatory bodies These
doors shall generally be as per IS : 3614 ( Part I and Part II ) meeting TAC
requirements. Fire rating of the doors shall be as per requirements of statutory
regulatory bodies. However minimum rating shall be 2 hours. These doors shall be
double cover-plated types with mineral wool insulation.
Hollow extruded section of minimum 2 mm wall thickness as manufactured by INDAL

or equivalent shall be used for all aluminium doors, windows, and ventilators.
All doors should have opening as indicated in the drawings. Doors and windows on
external walls of the buildings having brick enclosures i.e. enclosure other than with
permanently colour coated steel sheet cladding, shall be provided with sunshade
over the openings with width 600 mm more than the opening width. Projections from
the wall for the sunshade shall be 500 mm over window openings and 500 mm over
door openings. Minimum size of door provided should be 2.1 m high and 1.2 m wide,
except for toiler rooms, where door may be 0.75 m wide. All doors ( other than those
in W/C and urinal area ) shall be double plate flush door shutters. For W/C and
urinals area, wooden panel doors shall be provided. Area of windows shall be at least
10 % of the floor area of the respective building. The area of translucent
polycarbonate sheet panels shall also be at least 10 % of the floor area of the
respective building.
Monorail doors shall be provided with steel stays / chains etc for convenient
operation of the shutters.
The louvre blade shall be ‘Z’ shaped and made out of 18G sheets in EZ7 steel
frames. The frames shall be of ISMC 100.
19.05.02 Rolling Shutters
Rolling Shutters/ grills shall be with motor drives, gear arrangement including all
accessories and shall conform to IS: 6248. All electrical work shall be in strict
accordance with the relevant Indian Electricity Rules.
After installing the shutters, the Contractor shall test the performance of the shutter in
presence of the Engineer. The shutters shall be smoothly operable under all ambient
conditions. All control and locking devices shall give fault free performance.
20.00.00 PAINTING
Painting of all steel structures, including seal plates, hand rails, steel doors &
windows, ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc.
shall be with paints as per following:

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20.01.00 Materials
Zinc silicate primer (minimum 75 micron Dry Film Thickness - DFT) shall be inorganic
(Ethyl) self curing high built (Solid by volume minimum 60%) formulation as per BS :
5493 (Inorganic Zinc rich systems).
Intermediate (Under) coat (minimum 75 micron DFT) shall be of epoxy based

titanium di-oxide / micaceous iron oxide pigmented high performance (solid by
volume minimum 60%) epoxy coating as per BS : 5493 ( two pack chemical resistant
under coats).
Finish coat (minimum 75 micron DFT) shall be of epoxy based colored pigmented
high performance (solid by volume minimum 60%) epoxy coating as per BS: 5493
(two pack chemical resistant finishes).
Final finish coat (minimum 25 Micron DFT) shall be of polyurethane colour pigmented
(solid by volume minimum 40%) as per BS: 5493 (two pack chemical resistant
finishes).
All paints including primer shall be of reputed brand / manufacturer and as approved
by the engineer.
20.02.00 Preparation of Surface
The surfaces shall be blast cleaned to near white metal surface (Sa 2 ½) i.e. 2nd
quality (requiring at least 95% of the surface completely cleaned) as given in BS :
4232 . For blast cleaning shot blasting shall be used.
Approved type of abrasives shall only be used for blast cleaning of steel surfaces by
shot blasting. Suitable enclosure shall be provided to carry out the blast cleaning
operation. If required prior approval from the factory inspector / pollution control
board etc. shall be obtained regarding the method of blast cleaning and abrasives
used therein.
Immediately after blast cleaning of the steel surfaces, primer coat shall be applied
onto the surfaces.
20.03.00 Application of paint
The contractor shall submit the total painting scheme and works shall be started after
the approval of the scheme, from the engineer.
Painting works shall be carried out on structural as per the approved scheme. The
total painting scheme to be submitted to the engineer shall include the following:
i) Method of blast cleaning giving the details and sizing of various equipment
required, abrasive used, enclosure provided to avoid contamination of the
adjoining area, expected productivity on an eight (08) hour shift working etc.
ii) Arrangement of airless spray with the equipment rating.
iii) Drying time to be allowed before the application of subsequent coat.

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iv) Recommended paint for primer, intermediate (under) coat, finish coat and
final finish coat with their brand name and designation, considering the
requirements of BS : 5493 for long range (typical time to first maintenance 10
to 20 years), life for exterior exposed non polluted inland atmosphere.
v) Number of coat and the thickness of each coat to be applied to achieve the
specified thickness of each coat i.e. primer, intermediate (under), finish and
final finish coats.
vi) Environmental conditions i.e. ambient temperature and humidity at the time of
application of the paint.
vii) Quality control setup for painting i.e. checking of surface preparation,
thickness of each coat, quality of applied paints vis-à-vis the approved sample
etc.
viii) Method of touch up painting for surfaces damaged during handling, transit,
erection, welding, subsequent to painting, removal of the temporary supports
etc.
ix) Reference of relevant Indian / International standards for the testing and
acceptance.
Before application of inorganic zinc silicate primer, the steel surfaces shall be blast
cleaned to near white metal surface (Sa 2 ½).
Primer paint and intermediate (Under) coat shall be done by airless spray. However
finish coat and final finish coat can be applied either by spray and or brush.
All subsequent coats shall be applied only after acceptance of the previous applied
coat. Inaccessible surfaces shall be primer painted before shop assembly.
For final touch up painting of surfaces, which are damaged during handling, transit,
erection, etc. surfaces shall be well prepared, by rubbing the entire damaged area
using wire brush, emery paper etc. and shall be provided with minimum 100 micron
(DFT) of self priming high build epoxy based primer followed by intermediate, finish
and final finish coats as described elsewhere in this document. Touch up painting of
areas welded subsequent to painting and areas exposed after removal of temporary
supports shall also be carried out in same way.
Rectification of the damaged painted surfaces on account of welding / handling etc.

of each coat shall be done by touch up painting, before the application of next coat,
using minimum 100 micron (DFT) self priming high build epoxy based primer
followed by various coats in sequence of thickness as specified elsewhere.
20.04.00 Acceptance Criteria
All painted surfaces shall be uniform and pleasing in appearance.
Dry film thickness of each coat shall be checked and measured by using elcho-
meter. The thickness as measured shall not be less than the minimum thickness
specified for the coat of paint under relevant clauses of the technical specification.

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BID DOC. NO.:CS-0350-155(R)-2
Measurement of paint thickness shall be as per “SSPC : The society for Protective
Coatings Paint Application Standard no. 2” titled “Measurement of Dry Coating
thickness with magnetic gages”.
Colour, texture shall match exactly with the approved sample.
21.00.00 Miscellaneous
21.01.00 Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings,
pedestals, cable trenches, pits etc., Plywood form work shall be used for all over
ground exposed work like columns, beams, floors and ceilings in control room and M.
C. C. buildings.
21.02.00 Monorail girders and fixtures shall be provided for monorails at the locations as
required and as described elsewhere in these specifications or drawings. Monorail
openings in the walls shall be provided with steel frame doors preferably sliding type
or otherwise open able inside, access platforms and ladders.
21.03.00 Steel frame around openings in roof and on external walls for mounting of exhaust
fans shall be provided.
21.04.00 Ready mix non - shrink cementitious grout of reputed manufacturer as approved by
the Employer shall be used for grouting of block outs and foundation bolts,
underpinning of base plates and machine bases. Crushing strength of grout shall be
one grade higher than the foundation concrete. Minimum crushing strength shall be
30 N / mm2 unless higher strength requirement is specified by the equipment supplier
or the grout manufacturers.
21.05.00 The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m
above the ground except for rail / road crossing where it shall be 8m above the rail
top / road crest/ground. Further in bunker areas it shall be 8 m above the ground.
21.06.00 Polysulphide Sealing Compound shall be two-part polysulphide sealant and shall be
from approved manufacturer, conforming to IS : 12118. Materials shall consist of
polysulphide polymer and a curing agent. Gun grade material shall be used unless
otherwise specified. The application of the sealant shall be strictly followed as per
manufacturer’s guidelines.
22.00.00 SHOTCRETING

22.01.01 Generally, shotcreting shall be done in accordance with IS : 9012.
22.01.02 Reinforcement for shotcreting shall be as detailed below, unless specified otherwise.
(a.) Reinforcement in one direction consisting of 6 mm M. S. bars at 750 mm c / c

shall be connected to the lugs for fastening of the wire fabric. This shall be used
in case of 50 mm or above thick shotcreting.
(b.) Wire fabric conforming to IS : 1566 shall be used as reinforcement and shall
consist of wire, 3 mm diameter, spaced 50 mm both ways and shall be
electrically cross welded. Wire fabric shall be securely tied to 6 mm bars for 50

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BID DOC. NO.:CS-0350-155(R)-2
mm thickness. Adjacent sheet of wire fabric shall be lapped at least 100 mm

and tied.
(c.) Clear cover to reinforcement mesh shall not be less than 15 mm.
22.01.03 Minimum thickness of shotcreting shall be 50 mm. for abrasion resistant work and 25
mm for ordinary surface protection work.
22.02.00 Material
Generally, the materials shall be in accordance with aggregates specification

given hereunder.
22.02.01 Fine aggregate shall consist of natural sand or crushed stone from a known source
and shall be strong, hard, coarse, sharp, chemically inert, clean and free from any
coating. It shall be free from clay, coal or coal residue, organic or any other impurities
that may impair the strength or durability of the concrete and shall conform to IS :
383.
22.02.02 Fine aggregate (Sand) shall be well graded and particles shall range in size within
the following limits. The Engineer, may approved the use of any other grading as per
requirement or as per IS : 9012.
23.01.02 The fineness modulus shall be preferably between 2.5 and 3.3. Any other value can
be used, with prior approval of the Engineer.
22.03.00 Application
22.03.01 After the placement of reinforcement and / or welded mesh and not more than six
hours prior to the application of shotcrete, the surface shall be thoroughly cleaned of
all loose materials and dirt. The Contractor shall properly prepare the surfaces,
reinforcement and / or welded mesh to receive the shotcrete. Cleaned surfaces shall
be wetted not more than hour prior to shotcreting.
22.03.02 The mix as placed on surface shall be one part cement to three parts approved sand
by mass. Cement and sand shall be dry mixed; not water shall be added after mixing
and before using in the gun. The quantity of water when added shall be only that
which is sufficient to hydrate the cement. For average atmospheric conditions, the
water cement ratio for shotcrete in place shall be between 0.35 and 0.5 by mass.
Suitable admixture shall be used wherever required.
22.03.03 A uniform pressure of not less than 25 Kgf / Cm2 at the nozzle shall be maintained.
Necessary adjustments shall be made to ensure this pressure, taking into account
the length of hose and height of the place to be shotcreted, above location of the
machine.
22.03.04 The application shall proceed in an upward direction. Beams, stiffeners and
intermediate walls, if any, shall be wrapped with wire fabric and completely covered
with shotcreting. All rebound shall be removed from the area of application as the
work progresses and such rebound material shall not be reused.
22.03.05 As soon as the freshly shotcreted surface shows the first dry patches, a fine spray of
water shall be applied to keep too moist. After the surface has hardened, it shall be

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kept continuously moist for minimum seven days. If there is extreme heat, especially
when accompanied by hot winds, the shotcreted surface, immediately upon
completion, shall be covered with burlap or similar covering, which must be kept
continuously moist for 14 days after shotcreting. The temperature of the lining shall
not be permitted to exceed 38oC during placing and curing.
23.00.00 VIBRATION ISOLATION SYSTEM
These specifications are meant for the design, supply and erection of vibration isolation system for
supporting coal crushers ( ring granulators ).
23.01.00 Supporting Arrangement

23.01.02 The crushers shall be supported on vibration isolation system consisting of steel
helical springs and viscous dampers. The supporting arrangement for each crusher
shall consist of an R. C. C. deck supported on steel helical spring units and viscous
damper units which in turn shall be supported on girders. The girders shall be an
integral part of the crusher house building.
The part of the structure consisting of the R. C. C. deck, springs and viscous
dampers shall hitherto be referred to as “spring supported foundation”. The part of
the structure, which is below the spring shall hitherto be called “supporting structure”.
23.01.00 The Contractor should do the Engineering / design, supply and erection of vibration
isolation system consisting of steel helical spring units and viscous dampers
supporting the top deck which in turn would support the coal crushers. The vibrations
isolation system supplied shall be of a proven make. The Contractor or his sub -
contractor who designs and supplies the system should have designed, supplied and
installed such systems for not less than five machines of speeds and unbalance
forces comparable to the machine proposed by the vendor. The vibration isolation
systems installed by the contractor or his sub - contractor in such machines should
have been working satisfactorily for atleast five years.
23.01.00 Scope of Work
23.01.02 Scope of work shall include the following :
(a.) Engineering
(1.) Design of the vibration isolation system using steel helical springs and
viscous dampers to support an R. C. C. top deck supporting the coal
crusher. This includes the static and dynamic analysis of the vibration
isolation system with the R. C. C. top deck and the coal crusher.
(2.) Structural design of the R. C. C. top deck including preparation of General

Arrangement drawings, detailed reinforcement drawings, bar - bending
schedules etc.
(3.) Calculation of loads on the structure supporting the springs and viscous
dampers, their points of application and the stiffness requirements of the
supporting structure.
(4.) Drawings showing embedments and their locations and details on the R.
C. C. top deck.

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BID DOC. NO.:CS-0350-155(R)-2
(5.) Drawings showing blockouts, recesses etc. on the top deck.
(6.) Design of the supporting structure, including preparation of detailed

drawings and bill of materials.
(b.) Supply including packing and transportation to site
(1.) Steel helical spring units and viscous dampers, including associated
auxiliaries for installation of the spring units and dampers like steel shims,
adhesive pads etc.
(2.) Frame ( s ) for pre-stressing of spring elements.
(3.) Suitable hydraulic jacks system including electric pumps, high pressure
tubes etc. required for the installation, alignment etc. of the spring units,
two extra hydraulic jacks, one hand operated pump and spares for the
hydraulic jack system as required.
(c.) Erection and Commissioning
(1.) Complete erection and commissioning of the vibration isolation system

including :
(2.) Pre-stressing of spring elements, placing of spring elements in position,

checking clearances on the shuttering of the R. C. C. top deck,
construction of the supporting structure and the R. C. C. top deck,
releasing to pre-stress in spring elements and making final adjustments
and alignments after machine installation etc.
(3.) The scope of work shall be deemed to include all activities which may not
have been explicitly mentioned but are reasonably implied for the
successful completion of the work for which these specifications are
intended.
(4.) This part of the specifications is for vibration isolation system. For the
construction of the supporting structure for the crusher and the top deck,
the relevant parts of the specification should be referred to.
(d.) Documentation
(1.) Submission of detailed design calculation, analysis ( static and dynamic )

and drawings for Employer’s acceptance and approval.
(2.) Furnishing methodology of providing shuttering and its removal as well as

concreting of deck slab, installation of springs and dampers and the
sequence of operation.
(3.) Furnishing installation and maintenance manual indicating equipment,

procedure etc., necessary for installation, maintenance of vibration
isolation system.

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BID DOC. NO.:CS-0350-155(R)-2
(4.) Furnishing a check list for confirming the readiness of the civil fronts for
the installation of vibration isolation system and equipment required at
each stage installation.
(5.) Bill of materials of various elements such as springs, visco-dampers, with

their rating, stiffness etc., included in supply.
(6.) Detailed specifications of the vibration isolation system and various items
included in the supply and the standard (local or international) to which
they conform.
(7.) Proposed erection strategy of the entire system.
23.01.00 Design Requirements for Crusher ( Ring Granulator ) Foundation
23.01.02 Dynamic Analysis
Detailed dynamic analysis shall be done for the top deck together with springs and
dampers and the natural frequencies and amplitudes of vibration shall be
determined. A mathematical model of the top deck shall be formulated with three -
dimensional beam / plate finite elements for the purpose of analysis with the spring
idealised with vertical and horizontal stiffnesses. The mass of the machine together
with that of the top deck shall be considered for the analysis.
Natural frequencies upto at least 10 % above the operating speed shall be

determined and these frequencies shall be checked against the design criteria.
Forced response dynamic analysis shall be carried out for the operating condition
unbalance forces using a sinusoidal forcing function. Unbalance forces as given by
this specifications shall be used for his purpose. The amplitudes shall be checked
against the design criteria. The dynamic forces from this analysis shall be used for
structural design with a suitable fatigue factor.
23.01.02 Isolation Efficiency
The vibration isolation system shall be designed for about 90 % isolation efficiency.
23.01.02 De-coupling
A ratio of the least 10 ( ten ) shall be ensured between the stiffness of the supporting
structure and the stiffness of the spring system in the vertical direction to achieve de-
coupling between the two ( the stiffness of the spring system being lower ). This
ensures that dynamic analysis of the supporting structure need not be carried out.
23.01.02 Frequency Criteria
The frequency criterion has already been laid down implicitly by the isolation
efficiency criteria and de-coupling required.
The first bending mode frequency of the top deck shall be at least 20 % above the
operating speed.

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23.01.02 Unbalance Forces
Unbalance forces arising out of all the following cases shall be considered for
checking the design and amplitudes.
(a.) Balance quality grade Q 40 as per VDI 2060 - 1966.
(b.) One hammer broken condition. The missing hammer shall be assumed to be
closest to the crusher non - drive end of the crusher.
(c.) Three hammers broken condition. All the three hammers broken shall be
assumed to be from the same suspension bar and located at the non - drive
end of the crusher.
23.01.02 Amplitude Criteria
The calculated amplitudes (mean to peak values) shall not exceed following limits
under the specified conditions.
1) Operating speed of 750 RPM
(a.) 150 microns for an unbalance force arising out of balance quality
grade Q 40 as per VDI 2060 - 1966.
(b.) 300 microns in case of a one hammer broken condition.
(c.) Amplitudes need not be checked for a three hammer broken condition.
Operating speed of 450 RPM
200 microns for an imbalance force arising out of balance quality grade Q-40 as per
VDI -2060-1966.
400 microns in case of a one hammers broken condition.
Amplitude need not be checked for a three hammer broken condition.
For intermediate operating speed between 450 to 750 RPM the amplitude limits can
be linearly interpolated.
The amplitude limits mentioned above are in both vertical and horizontal directions.
The amplitudes shall be calculated at critical points on the top surface of the R. C. C.
deck. The amplitudes shall be checked for the most unfavorable superposition of
modes in any direction. However, phase difference between the maximum amplitude
occurring in different directions due to the rotating vetor may be considered while
superimposing the modes.
23.01.02 Transient Resonance
Transient resonance, which may occur during the start - up or coasting down
condition of the crusher, shall be checked, and the amplitudes in such a condition

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BID DOC. NO.:CS-0350-155(R)-2
should not exceed one - and - half times those at operating speed for each design
condition.
23.01.02 Strength Criteria
The following criteria shall apply for the design of top deck :
(a.) Dead loads, live loads, Seismic loads and dynamic loads shall be considered
for the design. The most unfavorable combination shall considered for design.
(b.) Seismic loads shall be assumed to act together with dynamic loads for a one
millimeter eccentricity in the rotor. However, seismic loads and dynamic loads
arising out of hammer breakage need not be considered together
(c.) Fatigue shall be considered while designing for dynamic forces. A fatigue factor
of 2.0 shall be used on all dynamic forces to arrive at the equivalent static force
for the purpose of design.
(d.) Working stress method shall be used for the design of R. C. C. deck. In survival
condition, 10 % overstressing may be permitted.
(e.) The R. C. C. top deck shall be at least of M25 grade of concrete as per IS : 456
- 1978.
(f.) Fatigue need not be considered for the three hammer broken condition.
(g.) For calculating unbalance forces, the heaviest hammer ( plain or toothed ) shall
be considered.
23.01.00 Approval of Designs and Drawings
All design calculation, drawings and documents shall be in English. All design
calculations and drawings shall be submitted to Employer for approval. However,
approval of such designs and drawings shall not relieve the contractor of his
responsibility regarding the adequacy of the foundation to carry the design forces.
23.01.00 Standards
Latest revisions of the following Codes shall be used for the design of the crusher
foundations.
(a.) IS : 456 Code of Practice for Plain and Reinforced concrete.
(b.) IS : 2974 ( Part IV ) Code of Practice for Design and Construction of Machine
Foundations ( Part IV ) for rotary type machine of low frequency.
(c.) IS : 1893 ( Criteria for Earthquake Resistant Design of Structures ).
(d.) DIN 4024 Machine Foundations :
Flexible supporting structures for machines with rotating masses.

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BID DOC. NO.:CS-0350-155(R)-2
(e.) DIN 2089
Helical Compression Springs out of round wire and rod; calculation and Design.
(f.) DIN 2096
Helical Compression Springs out of round wire and rod; quality requirements for
hot formed compression springs.
(g.) VDI 2056 - Criteria for assessing mechanical vibrations of machines.
(h.) VDI 2060 - Criteria for assessing the state of balance of rotating rigid bodies.
24.00.00 Packaging and Transportation.
All the equipment shall be suitably protected coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at site till the
time of erection. While packing all the materials the limitations from the point of view
of availability of railway wagon sizes in India should be taken into account. The
contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing.
25.00.00 Plant Life
The plant shall be designed for a minimum operating life of 30 years under the
conditions of operation. Assurance shall be given that plant components are
adequate for this lifetime. If there are any exceptional items of the plant on which an
assurance of meeting this clause cannot be given, life of such components and the
difficulties associated with them shall be stated.
26.00.00 PTFE (Poly Tetra Fluoroethylene) Bearing
The bearing shall be of reputed make and manufacturer as approved by the

Engineer, for required vertical load and end displacement/rotation. PTFE bearing
shall be sliding against highly polished stainless steel and the coefficient of friction
between them shall be less than 0.06 at 55 kg/sq.cm. In order to prevent cold flow in
PTFE surface it shall be rigidly bonded by a special high temperature resistance
adhesive to the stainless steel substrata. The stainless steel surface that slides
against the PTFE is mirror polished. The stainless steel shall be bonded to the top
plate by special high strength adhesive. The thickness of stainless steel plate shall
be between 1.0 mm to 1.5 mm.
27.00.00 TESTS FOR MATERIAL / WORKMANSHIP
All tests required for all materials, quality of workmanship or any other tests as
desired by the Engineer shall be at contractor’s cost.
28.00.00 MATERIALS
28.01.00 For Civil, Structural and Architectural works
Employer will not supply any material. All materials including cement, reinforcement
steel and structural steel, whatsoever required for execution and completion of the
entire scope of work covered under this specification shall be arranged by the
contractor at his own cost. All materials procured by the contractor shall meet the
quality requirements specified in this specification.

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The contractor shall keep sufficient stock of cement and steel at site at any point of
time when the work is in progress excluding what has been already incorporated in
the works, so that any disruption / delay in availability of these materials during
procurement will not affect the progress of work at site. The minimum quantity of
such materials in stock at site shall not be less then the Requirement of one ( 1 )
month in case of Cement and Requirement of two ( 2 ) Consecutive months in case
of Steel.
28.02.00 Structural steel
28.02.01 Mild Steel
(i.) Rolled sections shall conform to E250A of IS 2062:2006 in as rolled and semi
killed condition.
(j.) Plates up to 20mm thickness shall conform to E250A of IS 2062:2006 in as

rolled and semi killed condition.
(k.) Plates beyond 20mm and up to 40 mm shall conform to E250B of IS 2062:2006

as rolled in killed condition.
(l.) Plates beyond 40mm shall conform to E250B of IS 2062:2006 in normalized

and ultrasonically tested quality.
(m.) Pipes for handrail shall conform to medium grade of IS : 1161.
(n.) Chequered plates shall conform to IS : 3502. Tensile properties shall conform
to E250A of IS 2062:2006.
(o.) Seal plates shall conform to IS : 1079 ( semi - skilled quality )
28.02.02 Medium & High Tensile Steel
(a.) Rolled section shall conform to Grade E350 of IS 2062:2006, Semi Killed.
(b.) Plates up to 20 mm thickness shall conform to Grade E350 of IS 2062:2006,
Semi Killed.
(c.) Plates beyond 20 mm and 40mm shall be as per Grade E350 of IS 2062:2006,
Killed type.
(d.) Beyond 40mm shall conform to Grade E350 of IS 2062:2006, in normalized
condition and ultrasonically tested quality.
28.02.03 All plates up to and including 40mm thickness shall be ultrasonically tested on audit
basis to check the laminations.
28.02.04 Tubular steel sections shall be used for cable galleries/trestles only. The tubular steel
section shall be of circular/rectangular/square shape. The circular steel tube shall
conform to IS:1161 and rectangular/square steel sections shall confirm to IS:4923.
28.03.00 Fly ash based Portland pozzolona cement conforming to IS: 1489 Part - I shall
preferably be used. However, the contractor may use other types of cements
conforming to IS: 269, IS: 8112, IS: 12269, & IS: 455. However Ordinary Portland

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BID DOC. NO.:CS-0350-155(R)-2
cement conforming to IS: 269 or IS: 8112 shall necessarily be used for Crusher
Deck.
28.04.00 Reinforcement steel shall conform to:
a) Mild steel grade I of IS: 432 Part – I and grade A of IS: 2062.
b) High yield strength deformed bar of Gr. Fe 415/ Fe 500 produced by thermo-
mechanical treatment process, having elongation more than 14.5 percent and
conforming to other requirements of IS 1786 shall be used for the
reinforcement.
All standards, specifications, acts and code of practice referred to herein shall
be the latest editions including all applicable official amendments and
revisions. Other Indian, foreign Codes and Standards not listed here but
referred to elsewhere within this specification shall also be deemed to be part
of this list.
In case of conflict between this specification and those (IS standards, codes
etc.) referred to herein, the former shall prevail.
Some of the relevant Indian standards, Acts and Codes applicable to this
section of the specification are listed below
IS : 383 Specification for coarse and fine aggregates from

natural sources for Concrete.
IS : 432 Specification for mild steel and medium tensile steel

bars and hard drawn steel wire for concrete
reinforcement.
IS : 456 Code of practice for plain and reinforced concrete.
IS : 458 Specification for concrete pipes.
IS : 516 Method of test for strength of concrete.
IS : 800 Code of practice for use of structural steel in general

building construction.
IS : 814 Specification for covered electrodes for metal arc

welding for weld steel.
IS : 816 Code of practice for use of metal arc welding for

general construction.
IS : 817 Code of practice for training and testing of metal arc

welders.
IS : 875 (Pt. I to V) Code of practice for design loads other than

earthquake) for buildings and structures.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
IS : 1038 Steel doors, windows and ventilators.
IS : 1172 Basic requirements for water supply, drainage and

sanitation.
IS : 1361 Steel windows for industrial buildings.
IS : 1786 Specification for high strength deformed steel bars and

wires for concrete reinforcement.
IS : 1892 Code of practice for subsurface investigation for

foundation.
IS : 1893 Criteria for earthquake resistant design of structures.
IS : 1904 Code of practice for design and construction of

foundations in soils; general requirements.
IS : 1905 Code of practice for structural safety of buildings -

Masonry walls.
IS : 1948 Specification for aluminium doors, windows and

ventilators.
IS : 2062 Steel for general structural purposes.
IS : 2131 Method of standard penetration test for soils.
IS : 2212 Code of practice for brickwork.
IS : 2645 Specification for Integral cement water proofing

compounds.
IS:2720 (Part-II, Methods of test for soils - determination for water

IV TO VIII, XIV, content etc code of practice for earth work on canals.
XXI, XXIII, XXIV,
XXVII TO XXIX,
XL)
IS : 2911 Code of practice for design and construction of pile

foundations.
(Part-1/Sec.1) Driven cast in situ concrete piles.
(Part-1/Sec.2) Bored cast-in-situ concrete piles.
(Part-IV) Load test on piles.
IS : 2974 (Part - I Code of practice for design and construction of

TO V) machine foundations.
IS : 3370 (Part I Code of practice for concrete structures for the storage
to IV) of liquids.
IS : 3658 Code of practice for liquid penetrant flaw detection.
IS : 3664 Code of practice for ultra sonic testing by pulse echo

method.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
IS : 4326 Code of practice for earthquake resistant design and

construction of buildings.
IS : 4990 Specification for plywood for concrete shuttering work.
IS : 5624 Specification for foundation bolts.
IS : 7215 Tolerances for fabrication steel structures.
IS : 8112 Specification for 43 grade Ordinary Portland Cement.
IS : 9103 Specification for admixtures for concrete.
IS : 9595 Code of procedure of manual metal arc welding of mild

steel.
IS : 10262 Recommended guidelines for concrete mix design.
IS : 13311 Method of non - destructive testing of concrete.
IS : 13755 Dust pressed ceramic tiles with water absorption of 3%,

E6% (Group B11a)
ASTM 898 -89 Standard guide for use of high solid content, cold
liquid-applied elastomeric water proofing membrane
for use with separate wearing course.
AS/NZS 2728 Pre finished / pre painted sheet metal product for
interior / exterior building applications – Performance
requirements.
AS : 1365 Standards for steel manufacturing.
AS : 1397 A steel sheet & strip – hot – dipped-zinc-coated or

Aluminium-Zinc coated.
AS : 3566 Self drilling screws for building and construction

industry.
IRC : 37 Guidelines for the design of flexible pavements.
- Manual on sewerage and sewage treatment (Published

by CPH & EEO) As updated.
Indian Explosives Act. 1940 as updated.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
ANNEXURE A
CRITERIA FOR EARTHQUAKE RESISTANT

DESIGN OF STRUCTURES AND EQUIPMENT
All structures and equipment shall be designed for seismic forces adopting the site
specific seismic information provided in this document and using the other provisions
in accordance with IS:1893 (Part 1):2002 and IS:1893 (Part 4):2005. Pending
finalisation of Parts 2, 3 and 5 of IS:1893, provisions of part 1 shall be read along
with the relevant clauses of IS:1893:1984, for structures other than the buildings and
industrial structures including stack-like structures.
A site specific seismic study has been conducted for the project site. The peak
ground horizontal acceleration for the project site, the site specific acceleration
spectral coefficients (in units of gravity acceleration ‘g’) in the horizontal direction for
the various damping values and the multiplying factor (to be used over the spectral
coefficients) for evaluating the design acceleration spectra are as given at Annexure-
I.
Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding

horizontal values.
The site specific design acceleration spectra shall be used in place of the response
acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893
(Part 4). The site specific acceleration spectra along with multiplying factors specified
in Annexure-I includes the effect of the seismic environment of the site, the
importance factor related to the structures and the response reduction factor. Hence,
the design spectra do not require any further consideration of the zone factor (Z), the
importance factor (I) and response reduction factor (R) as used in the IS:1893 (Part 1
and Part 4).
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:
a) Steel structures : 2%
b) Reinforced Concrete structures : 5%
c) Reinforced Concrete Stacks : 3%
d) Steel stacks : 2%

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
Method of Analysis
Since most structures in a power plant are irregular in shape and have irregular
distribution of mass and stiffness, dynamic analysis for obtaining the design seismic
forces shall be carried out using the response spectrum method. The number of
vibration modes used in the analysis should be such that the sum total of modal
masses of all modes considered is at least 90 percent of the total seismic mass and
shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak
response quantities shall be performed as per Complete Quadratic Combination
(CQC) method or by an acceptable alternative as per IS:1893 (Part 1).
In general, seismic analysis shall be performed for the three orthogonal (two principal
horizontal and one vertical) components of earthquake motion. The seismic response
from the three components shall be combined as specified in IS:1893 (Part 1).
For buildings, if the design base shear (VB) obtained from modal combination is less
than the base shear (⎯VB) computed using the approximate fundamental period (Ta)
given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate
multiplying factor, the response quantities (e.g. member forces, displacements,
storey forces, storey shears and base reactions) shall be enhanced in the ratio of
⎯VB/ VB. However, no reduction is permitted if ⎯VB is less than VB.
For regular buildings less than 12m in height, design seismic base shear and its
distribution to different floor levels along the height of the building may be carried out
as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1) and using site specific
design acceleration spectra. The design horizontal acceleration spectrum value (Ah)
shall be computed for the fundamental natural period as per clause 7.6 of IS:1893
(Part 1) using site specific spectral acceleration coefficients with appropriate
multiplying factor given in Annexure-I. Further, the spectral acceleration coefficient
shall get restricted to the peak spectral value if the fundamental natural period of the
building falls to the left of the peak in the spectral acceleration curve.
Design/Detailing for Ductility for Structures
The site specific design acceleration spectra is a reduced spectra and has an in-built
allowance for ductility. Structures shall be engineered and detailed in accordance
with relevant Indian/International standards to achieve ductility.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
ANNEXURE – I
SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND

EQUIPMENT
The various site specific seismic parameters for the project site shall be as follows:
1) Peak ground horizontal acceleration (MCE) : 0.24g
2) Multiplying factor to be applied to the site specific

horizontal acceleration spectral coefficients (in units of
gravity acceleration ‘g’) to obtain the design acceleration
spectra
a) for ordinary moment resisting steel frames designed and

detailed as per IS:800 : 0.070
b) for braced steel frames designed and detailed as per : 0.053

IS:800
c) For special moment resisting RC frames designed and

detailed as per IS:456 and IS:13920 : 0.042
d) for steel chimney : 0.105
e) for design of structures not covered under 2 (a) to 2 (d)

above and under 3 below : 0.070
3) Multiplying factor to be applied to the site specific

horizontal acceleration spectral coefficients (in units of
gravity acceleration ‘g’) for design of equipment and
structures where inelastic action is not relevant or not : 0.140
permitted
Note: g = Acceleration due to gravity
The horizontal seismic acceleration spectral coefficients are furnished in subsequent

pages.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
ANNEXURE – I
HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS

(In units of ‘g’)
Damping Factor (as a percentage of critical damping)

Time Period
(Sec) 2% 3% 5%
0.000 1.000 1.000 1.000
0.030 1.000 1.000 1.000
0.040 1.327 1.263 1.207
0.050 1.653 1.515 1.396
0.060 1.978 1.757 1.572
0.070 2.302 1.991 1.739
0.080 2.625 2.220 1.897
0.090 2.948 2.443 2.049
0.100 3.270 2.661 2.195
0.110 3.591 2.876 2.336
0.108 3.527 2.833 2.308
0.110 3.591 2.876 2.336
0.115 3.752 2.982 2.405
0.120 3.912 3.087 2.473
0.125 4.073 3.191 2.539
0.130 4.230 3.294 2.605
0.134 4.230 3.376 2.657
0.140 4.230 3.500 2.734
0.147 4.230 3.500 2.823
0.150 4.230 3.500 2.860
0.200 4.230 3.500 2.860
0.250 4.230 3.500 2.860
0.300 4.230 3.500 2.860
0.350 4.230 3.500 2.860
0.410 4.230 3.500 2.860
0.430 4.230 3.500 2.860
0.450 4.230 3.500 2.860
0.520 4.230 3.500 2.860
0.555 4.193 3.500 2.860
0.560 4.155 3.500 2.860
0.565 4.119 3.500 2.860
0.570 4.082 3.500 2.860
0.575 4.047 3.500 2.860
0.580 4.012 3.500 2.860
0.585 3.978 3.500 2.860
0.590 3.944 3.500 2.860
0.595 3.911 3.500 2.860
0.600 3.878 3.500 2.860

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
ANNEXURE – I


Time Period
(Sec) 2% 3% 5%
0.650 3.580 3.231 2.640
0.700 3.324 3.000 2.451
0.750 3.103 2.800 2.288
0.800 2.909 2.625 2.145
0.850 2.738 2.471 2.019
0.900 2.586 2.333 1.907
0.950 2.449 2.211 1.806
1.000 2.327 2.100 1.716
1.050 2.216 2.000 1.634
1.100 2.115 1.909 1.560
1.150 2.023 1.826 1.492
1.200 1.939 1.750 1.430
1.250 1.862 1.680 1.373
1.300 1.790 1.615 1.320
1.350 1.724 1.556 1.271
1.400 1.662 1.500 1.226
1.450 1.605 1.448 1.183
1.500 1.551 1.400 1.144
1.550 1.501 1.355 1.107
1.600 1.454 1.313 1.073
1.650 1.410 1.273 1.040
1.700 1.369 1.235 1.009
1.750 1.330 1.200 0.981
1.800 1.293 1.167 0.953
1.850 1.258 1.135 0.928
1.900 1.225 1.105 0.903
1.950 1.193 1.077 0.880
2.000 1.164 1.050 0.858
2.050 1.135 1.024 0.837
2.100 1.108 1.000 0.817
2.150 1.082 0.977 0.798
2.200 1.058 0.955 0.780
2.250 1.034 0.933 0.763
2.300 1.012 0.913 0.746
2.350 0.990 0.894 0.730
2.400 0.970 0.875 0.715
2.450 0.950 0.857 0.700
2.500 0.931 0.840 0.686
2.550 0.913 0.824 0.673

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
ANNEXURE – I


Time Period
(Sec) 2% 3% 5%
2.600 0.895 0.808 0.660
2.650 0.878 0.792 0.648
2.700 0.862 0.778 0.636
2.750 0.846 0.764 0.624
2.800 0.831 0.750 0.613
2.850 0.816 0.737 0.602
2.900 0.802 0.724 0.592
2.950 0.789 0.712 0.582
3.000 0.776 0.700 0.572
3.050 0.763 0.689 0.563
3.100 0.751 0.677 0.554
3.150 0.739 0.667 0.545
3.200 0.727 0.656 0.536
3.250 0.716 0.646 0.528
3.300 0.705 0.636 0.520
3.350 0.695 0.627 0.512
3.400 0.684 0.618 0.505
3.450 0.665 0.609 0.497
3.500 0.646 0.600 0.490

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
ANNEXURE-B
CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT
All structures shall be designed for wind forces in accordance with IS: 875 (Part-3)
and as specified in this document. See Annexure – B for site specific information.
Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind
Speed method as defined in the standard.
Along wind forces on slender and wind sensitive structures and structural elements
shall also be computed, for dynamic effects, using the Gust Factor or Gust
Effectiveness Factor Method as defined in the standard. The structures shall be
designed for the higher of the forces obtained from Gust Factor method and the Peak
Wind Speed method.
Analysis for dynamic effects of wind must be undertaken for any structure which has
a height to minimum lateral dimension ratio greater than “5” and/or if the fundamental
frequency of the structure is less than 1 Hz.
Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc.

should be examined and designed/detailed accordingly following the
recommendations of IS:875(Part-3) and other relevant Indian standards.
It should be estimated if size and relative position of other structures are likely to
enhance the wind loading on the structure under consideration. Enhancement factor,
if necessary, shall suitably be estimated and applied to the wind loading to account
for the interference effects.
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:
a) Welded steel structures : 1.0%
b) Bolted steel structures : 2.0%
c) Reinforced concrete structures : 1.6%
d) Steel stacks : As per IS:6533 &

CICIND Model Code
whichever is more
critical.

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
SITE SPECIFIC DESIGN PARAMETERS
The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the
project site shall be as follows:
a) The basic wind speed “Vb” at ten

metres above the mean ground level : 47 metres/second
b) The risk coefficient “K1” : 1.07
c) Category of terrain : Category-2
Note: Notwithstanding the values of the above mentioned parameters, the design
wind pressure so computed at any point shall not be taken less than 1500 N/Sq.
meter for all classes of structures, i.e. A, B & C, as defined in IS: 875 (Part-3).

STAGE-II (2X195 MW)
BID DOC. NO.:CS-0350-155(R)-2
PART - B
SUB-SECTION-IIID-02
FOUNDATION SYSTEM AND

GEOTECHNICAL DATA

FOUNDATION SYSTEM AND GEOTECHNICAL DATA
1.00.00 SOIL DATA AND FOUNDATION SYSTEM
Bearing capacity for design of foundations and Borelogs data are given at
Annexure - I of this specification.
1.01.00 Soil Data
1.01.01 Employer has carried out detailed geotechnical investigation in the areas
pertaining to this package. The detailed geotechnical investigation report
comprising of Boreholes, Laboratory tests, Chemical analysis, etc. in respect
of the sub-strata prevailing at site will be made available for the Bidder's
study at the Employer's office, if required. The onus of correct assessment /
interpretation and understanding of the existing subsoil condition / data is on
the Bidder. The natural ground level is varying from RL (+) 53.3 to RL (+)
54.5m and finished ground level shall be RL (+) 56.0m. Ash/ soil filling has
been done over natural ground level (NGL) to achieve FGL as indicated
above. Ground water level is at a depth of about 2.45m to 3.50m below
natural ground level at the time of investigation and may fluctuate with
season.
1.02.00 Foundation System
The requirements for the foundation system to be adopted are as given in

subsequent clauses.
(a.) All structures/equipment shall be supported either on suitable open

foundations (isolated, combined, raft) or on pile foundations.
(b.) The ground floor slabs, trenches, pipe pedestals, channels/drains and
staircase foundation with foundation loading intensity less than 4T/M2
may be supported on open/ shallow foundations resting on
i) In case of controlled compacted filled up soil/ash, foundations shall
rest on 100mm PCC which will be rested on 200mm stone soling/
hard crust.
ii) In case of natural ground foundations shall rest on 100mm PCC.
iii) Minimum depth of pipe pedestals and staircase shall be 1.0 m.
(c.) No other foundation shall rest on the filled up ground / soil.
(d.) All foundations shall be designed in accordance with relevant parts of the
latest revisions of Indian Standards. The water table for design purpose
shall be considered at Finished Ground Level.
MUZAFFARPUR TPP Sub-section IIID-02
STAGE-II (2X195 MW) Foundation & Geotechnical
SECTION VI, PART-B Page 1 of 8
COAL HANDLING PLANT PACKAGE Data
BID DOC. NO.:CS-0350-155(R)-2
(e.) A combination of open and pile foundations shall not be permitted under
the same equipment / structure / building.
1.02.02 Open Foundations
In case open foundations are adopted, following shall be adhered to.

(a.) The minimum width of foundation shall be 1.0 m.
(b.) The minimum depth of foundation shall be 1.0 m below natural ground
level.
(c.) Minimum founding level, bearing capacity and permissible settlements
shall be as given in the Annexure - 1 to this specification.
Incase pile foundations are to be adopted the requirements under para "pile
foundations" shall be adhered to.
1.02.03 Pile Foundations
In case piles are adopted, following shall be adhered to :

i) The pile foundation shall be of RCC, Cast-in-situ bored piles as per
IS:2911. Pile boring shall be done using Rotary Hydraulic Rigs. Two
stage flushing of pile bore shall be ensured by airlift technique duly
approved by the Employer.
ii) The minimum diameter of pile shall be 600 mm. The allowable load
capacity of the pile in vertical compression, uplift and lateral load shall
be limited to the values given at Annexure - I. However, the pile
capacities to be adopted shall be the least of the estimated design
values, values given at Annexure - I and that obtained from the initial
pile load tests.
iii) Only straight shaft piles shall be used. Minimum cast length of pile
above cutoff level shall be 1.0 m.
iv) The bidder shall furnish design of piles (in terms of rated capacity,
length, diameter, termination criteria to locate the founding level for
construction of pile in terms of measurable parameter, reinforcement
for job as well as test piles, locations of initial test piles etc.) for
Engineer’s approval.
v) The piling work shall be carried out in accordance with IS:2911
(Relevant part) and accepted construction methodology. The
construction methodology shall be submitted by the Contractor for
Engineer's approval.
vi) Number of initial load tests to be performed for each diameter &
length and rated capacity of pile shall be subject to minimum as
under.

BID DOC. NO.:CS-0350-155(R)-2
Vertical
Lateral Minimum of 2 Nos. in each mode.
Uplift
vii) The initial pile load test shall be conducted with test load upto three
times the estimated pile capacity. In case of compression test (initial
test) the method of loading shall be cyclic as per IS:2911 (relevant
part).
viii) Load test shall be conducted at pile cut of level (COL). If the water
table is above the COL the test pit shall be kept dry through out the
test period by suitable de-watering methods. Alternatively the vertical
load test may be conducted at a level higher than COL. In such a
case, an annular space shall be created to remove the effect of skin
friction above COL by providing an outer casing of suitable diameter
larger than the pile diameter.
ix) Number of routine pile load tests to be performed for each
diameter/allowable capacity of pile shall be as under :
i) Vertical : 0.5% of the total number of piles provided.
ii) Lateral : 0.5% of the total number of piles provided.
x) The routine tests on piles shall be conducted upto test load of one
and half times the allowable pile capacity. Piles for routine load tests
shall be approved by the Employer.
xi) In case, routine pile load test shows that the pile has not achieved the
desired capacity or pile(s) have been rejected due to any other
reason, then the Contractor shall install additional pile(s) as required
and the pile cap design shall accordingly be reviewed and modified, if
required.
xii) Testing of piles and interpretation of pile load test results shall be
carried out as per IS:2911 (Part-4). Contractor shall ensure that all the
measuring equipment and instruments are properly calibrated at a
reputed laboratory / institute prior to their use. Settlement /
movement of the pile top shall be made by Linear Variable Differential
Transducers (LVDT) having a least count of 0.01mm.
xiii) The test load on initial test piles shall be applied by means of reaction
from anchor piles / rock anchors alone or combination of anchor piles
/ rock anchors and kentledge.
xiv) Low Strain Pile Integrity test shall be conducted on all test piles and
job piles by the agency approved by Engg dept of owner. This test
shall be used to identify the routine load test and not intended to
replace the use of static load test. This test is limited to assess the
imperfection of the pile shaft and shall be undertaken by an
independent specialist agency. The test equipment shall be of TNO
or PDI make or equivalent. The process shall confirm to ASTM.

BID DOC. NO.:CS-0350-155(R)-2
xv) Contribution of frictional resistance of filled up soil if any, shall not be
considered for computation of frictional resistance of piles.
1.03.00 Special Requirements
1.03.01 Details of treatment for foundations / underground structures required to

counteract soil / water chemical environment, cement type, grade of concrete,
type of reinforcement, cover to reinforcement and protective coating to
foundations, etc. shall be as mentioned in Annexure-1 of this specification.
1.04.00 Excavation, Filling and Dewatering
1.04.01 For excavation works, comprehensive dewatering with well point or deep
wells arrangement wherever required shall be adopted. Scheme for
dewatering and design carried out by specialized agency with all
computations and backup data for dewatering shall be submitted for the
owner’s information. The water table shall be maintained at 0.5m below the
founding depth .
1.04.02 Excavation for shallow foundations shall be covered with PCC immediately
after reaching the founding level. In case of any local loosening of soil or
pockets are encountered at founding level during excavation the same shall
be removed and compensated by PCC M 7.5. The final layer of about 300
mm thickness above the founding level shall be excavated by suitable
means, so as to avoid disturbance to founding stratum.
1.04.03 Backfilling around foundations, pipes, trenches, sumps, pits, plinths, etc. shall
be carried out with approved material in layers not exceeding 300 mm
compacted thickness and each layer shall be compacted to 90% of standard
proctor density for cohesive soils and to 75% of relative density for non
cohesive soils.
1.04.04 The founding level for trenches/channels shall be decided as per functional
requirement. The bottom of excavation shall be properly compacted prior to
casting of bottom slab of trenches / channels.
1.04.05 CBR tests for pavement/road design shall be carried out by the Contractor
after earth filling (if applicable) has been completed upto the formation level.
1.04.06 Following details shall be submitted by the Bidder before start of work at site.
Scheme for initial pile load tests in vertical, lateral and uplift modes along with
supporting design calculations and methodology for installation of working
piles and the complete piles installation data for individual pile including the
pile test result for all piles (for reference only).

BID DOC. NO.:CS-0350-155(R)-2
1.05.00 Sheeting & Shoring
1.05.01 Deep underground structures like Track hopper, Machinery hatches, WT-3&4
and tunnel for Conv. 1A/B are coming very close to the existing rail track (in
operating condition) and boundary wall. To ensure complete safety and no
damage/interruption of existing rail track/boundary wall during construction,
following measures shall be taken by bidder:-
i) For track hopper, machinery hatches, WT-3&4 and tunnel for Conv. 1A/B,
excavation shall be carried out by using either sheet piling/ diaphragm wall/
secant piling/ contiguous piling or their combination from FGL. Sheet piling/
diaphragm wall/ secant piling/ contiguous piling shall not be considered as
part of permanent structure.
ii) The excavation scheme & design for (i) above shall be developed by a
specialized agency and submitted for owner’s approval.
1.05.02 For excavation of all other foundations, contractor shall provide coffer dams,
sheeting and shoring, bracing and maintaining suitable slopes, draining etc. to
the satisfaction of the Engineer.

BID DOC. NO.:CS-0350-155(R)-2
Annexure-I
SOIL DATA AND FOUNDATION SYSTEM
a) Logs of representative boreholes and laboratory test results from this area
are enclosed with this Annexure.
b) The foundation system to be adopted for different structures shall be as given
in Table – 1 below
Table – 1: Net Allowable Bearing Pressure

STRUCTURE TYPE OF
FOUNDATION TO
BE ADOPTED
Over Ground TPs, Crusher House, Stacker Piles
Reclaimer, Conveyor trestles
Wagon Tippler, CHP Office, MCC room, Track

Open
hopper, TP-6, Pent House, Cable Trestles
c) The minimum founding level and the corresponding net allowable bearing
pressure shall be as given in Table – 2 below.
Table – 2: Net Allowable Bearing Pressure
Founding Net Allowable Bearing Pressure

Structure Level in T/m2
RL Isolated / Strip for a Rafts (width > & =
permissible settlement of 50 6m) for a
mm permissible
width upto 3.0 width >3 & < settlement of
m 6m 75mm
53.0 5.0 - -
52.5 7.0 5.0 5.5
WT-3&4, TP-
6, Tunnel for 51.5 8.0 5.5 6.0
Conv. 8A/B & 48.5 10.0 6.5 7.0
9A/B, MCC 47.5 11.0 7.0 7.5
room, CHP
42.5 15.0 9.0 10.0
Office, Cable
Trestles 41.5 16.0 10.0 11.0
38.5 18.0 11.0 12.0
37.5 19.0 12.0 14.0
Track hopper, 53.0 6.0 5.0 5.5
Tunnel for 52.0 7.0 5.5 6.0
Conv. 1A/B,
51.0 9.0 6.5 7.0
Pent House,
Pump houses 49.0 10.0 7.5 8.5

BID DOC. NO.:CS-0350-155(R)-2
48.0 11.0 8.5 9.0
47.0 13.0 9.5 10.0
45.0 16.0 10.0 11.0
The net allowable bearing pressure higher than above mentioned values shall
not be permitted. At intermediate levels the bearing capacity shall be same as
the net allowable bearing pressure corresponding to the immediate shallower
level mentioned above.
d) Permissible Settlement of Foundations:

For open foundations, the total permissible settlement and differential
settlement shall be governed by IS: 1904 and from functional requirements
whichever is more stringent. However, total settlement shall be restricted to
the following:
Isolated & Strip 50 mm
Raft (widths greater than 6 m) 75 mm
In case the total permissible settlement is to be restricted to less than as
above specified from functional requirements, then the net allowable bearing
pressure shall be reduced after review in consultation with Engineer.
e) The diameter of pile, minimum length and maximum allowable capacity of
piles shall be as given below:
Area/ Pile Ref. Minimum Safe Load Capacity in
Location Diame Ground Length of Vertical Uplift Lateral
ter Level (m) Bored Pile Comp. (MT) (MT)
(mm) Below Cut- (MT)
off Level
(m)
Crusher
House,
Stacker
Reclaimer, 600 56.00 30.0 120.0 36.0 5.0
Over
Ground
TPs,
Conveyor,
- Cut off Level (COL) is assumed at 3.0 m below Ref. Ground Level.
f) The criteria for Pile Termination (founding level) shall be as given below:
i) Minimum length of the pile below COL (cut off level) shall be as
specified at (e) above.

BID DOC. NO.:CS-0350-155(R)-2
ii) Pile shall be terminated in the strata with STP ‘N’ value > 20.
For ensuring pile termination as per the criteria specified above, bidder
shall conduct SPT in a separate borehole at 100mm dia as per IS
1892. In this borehole SPT shall be conducted at 3.0m interval upto
30.0m and at 1.5 m interval beyond 30.0 m to at least 5.0 m below the
estimated pile termination level. The estimated pile termination level
can be assessed based on the nearest borelog details available in the
specification. For job piles one borehole shall be done for 50-70 piles
or in pile group as decided in consultation with engineer-In-Charge.
For test piles one borehole shall be done for each test pile group.
However, in no case the length of pile shall be less than the minimum
length as specified in (i) above.
g) Special Requirements:
1) Chemicals in ground water and subsoil, as observed during investigation
are:
Chemical SO3 Chlorides pH
Ground Water Below Detection 6.0 - 6.4 mg/ml 7.0

Sub-soil 0.01-0.015 0.012-0.031 8.1
2) In view of the above, the following shall be adopted for all foundations and
sub-structures,
Cement Type As specified elsewhere in the specifications
Concrete Grade As specified elsewhere in the specifications
Type of Reinforcement As specified elsewhere in the specifications
Cover to As specified elsewhere in the specifications
Reinforcement

BID DOC. NO.:CS-0350-155(R)-2
BORE LOG DETAILS
Client KBUNL Type of Sampler used UDS/Split spoon/Core barrel
Project MTPS - Stage - II Dia Of Bore 150mm in Soil,
Location Muzaffarpur Inclination of Borehole Vertical
Borehole No BH-141 Type of Boring Rotary Drilling
Coordinate of Borehole S-348.563,E-195.6Conducted By L.Mohapatra
RLof ground bore ( m ) 54.942 Date started 09.12.09
RL of Ground Water table(m) 0.000 Date Completed 12.12.09
Depth
Symbolic SPT Results Grain Size Analysis Bulk
Description Of from Type of IS Liquid Plastic Plasticity
Represen RL (m) Gravel( Silt(% Clay( Density(gm
Starata Ground Sample Observed Classification Sand(%) Limit(%) Limit(%) Index
tation %) ) %) /cc)
surface
Coal dust filling
materials 0.5 54.442 DS
1.0 53.942 UDS
1.5 53.442 DS
2.0 52.942 SPT 5
2.5 52.442 DS
Clay
3.0 51.942 DS
3.5 51.442 UDS
4.0 50.942 DS
4.5 50.442 DS
5.0 49.942 SPT 7
5.5 49.442 DS
6.0 48.942 DS
Silty clay
6.5 48.442 UDS
7.0 47.942 DS
7.5 47.442 DS
8.0 46.942 SPT 8
8.5 46.442 DS
9.0 45.942 DS
9.5 45.442 UDS
10.0 44.942 DS
10.5 44.442 DS
11.0 43.942 SPT 11
11.5 43.442 DS
12.0 42.942 DS
Clay
12.5 42.442 UDS
13.0 41.942 DS
13.5 41.442 DS
14.0 40.942 SPT 11
14.5 40.442 DS
15.0 39.942 DS
15.5 39.442 UDS
16.0 38.942 DS
16.5 38.442 DS
17.0 37.942 SPT 12
17.5 37.442 DS
18.0 36.942 DS
18.5 36.442 UDS
19.0 35.942 DS
19.5 35.442 DS
Silty clay
20.0 34.942 SPT 15
20.5 34.442 DS
21.0 33.942 DS
21.5 33.442 UDS
22.0 32.942 DS
22.5 32.442 DS
23.0 31.942 SPT 62
23.5 31.442 DS
24.0 30.942 DS
24.5 30.442 UDS FAIL
25.0 29.942 SPT 65
25.5 29.442 DS
26.0 28.942 SPT 57
Fine sand 26.5 28.442 DS
27.0 27.942 DS
27.5 27.442 UDS FAIL
28.0 26.942 SPT 61
28.5 26.442 DS
29.0 25.942 SPT 52
29.5 25.442 DS
30.0 24.942 DS
30.5 24.442 UDS FAIL
31.0 23.942 SPT 54
Fine sand
31.5 23.442 DS
Coordinate of Borehole S-348.563,E-195.6Conducted By L.Mohapatra
Depth
Represen RL (m) Gravel( Silt(% Clay( Limit(%) Limit(%) Index Density(gm
Starata Ground Sample Observed Classification Sand(%)
tation %) ) %) /cc)
surface
32.0 22.942 SPT 44
32.5 22.442 DS
Clay with granular 33.0 21.942 DS
materials 33.5 21.442 UDS
34.0 20.942 DS
34.5 20.442 DS
Silty sand 35.0 19.942 SPT 58
BORE LOG DETAILS
Client KBUNL Type of Sampler used UDS/Split spoon /Core barrel
Borehole No BH -85 Type of Boring Rotary
Coordinate of Borehole S -748,E -102 Conducted By T.K.Das
Depth
Represen RL (m) Gravel Sand Silt(% Clay( Density(gm
Starata Ground Sample Observed Classification Limit(%) Limit(%) Index
tation (%) (%) ) %) /cc)
surface
0.5 53.744 DS
1.0 53.244 UDS
1.5 52.744 DS
2.0 52.244 SPT 10 CI 0 14.2 18.6 67 36 18 18
2.5 51.744 DS
3.0 51.244 DS
3.5 50.744 DS
4.0 50.244 UDS
4.5 49.744 DS
Clay 5.0 49.244 SPT 11
5.5 48.744 DS
6.0 48.244 DS
6.5 47.744 DS
7.0 47.244 UDS 1.91
7.5 46.744 DS
8.0 46.244 SPT 16
8.5 45.744 DS
9.0 45.244 DS
9.5 44.744 DS
10.0 44.244 UDS FAIL
10.5 43.744 SPT 14 CL 0 22.6 77.4 32 15 17
11.0 43.244 SPT 19
Silty Clay 11.5 42.744 DS
12.0 42.244 DS
12.5 41.744 DS
13.0 41.244 UDS FAIL
13.5 40.744 SPT 35
14.0 40.244 SPT 44
14.5 39.744 DS
15.0 39.244 DS
15.5 38.744 SPT 45 CL 11.8 18.3 26.7 43.2 33 15 18
16.0 38.244 DS
16.5 37.744 DS
17.0 37.244 SPT 47
17.5 36.744 DS
18.0 36.244 DS
18.5 35.744 SPT 47
19.0 35.244 DS
19.5 34.744 DS
20.0 34.244 SPT 46
20.5 33.744 DS
21.0 33.244 DS
Silty Clay with 21.5 32.744 SPT 49 CL 10.8 16.3 72.9 31 16 15
Granular Material 22.0 32.244 DS
22.5 31.744 DS
23.0 31.244 SPT 47
23.5 30.744 DS
24.0 30.244 DS
24.5 29.744 SPT 49
25.0 29.244 DS
25.5 28.744 DS
26.0 28.244 SPT 53
26.5 27.744 DS
27.0 27.244 DS
27.5 26.744 SPT 54 CI 9.4 19.3 17.75 53.6 36 17 19
28.0 26.244 DS
28.5 25.744 DS
29.0 25.244 SPT 57
29.5 24.744 DS
30.0 24.244 SPT 58
BORE LOG DETAILS
Borehole No BH-91 Type of Boring Rotary
Coordinate of Borehole S-862,E-510 Conducted By L Mohapatra
Depth
Represen RL (m) Density(gm
Starata Ground Sample Observed Classification Gravel( Sand(%) Silt(% Clay( Limit(%) Limit(%) Index
tation %) ) %) /cc)
surface
0.5 53.560 UDS
Clay
1.0 53.060 DS
1.5 52.560 SPT 13
Sandy Silt 2.0 52.060 DS
2.5 51.560 DS
3.0 51.060 UDS
3.5 50.560 DS
4.0 50.060 DS
4.5 49.560 SPT 8
5.0 49.060 DS
5.5 48.560 DS
6.0 48.060 UDS
6.5 47.560 DS
7.0 47.060 DS
Clay
7.5 46.560 SPT 11
8.0 46.060 DS
8.5 45.560 DS
9.0 45.060 UDS
9.5 44.560 DS
10.0 44.060 DS
10.5 43.560 SPT 15
11.0 43.060 DS
11.5 42.560 DS
12.0 42.060 UDS FAIL
Clayey Silt 12.5 41.560 SPT 15
13.0 41.060 DS
13.5 40.560 SPT 16
14.0 40.060 DS
14.5 39.560 DS
15.0 39.060 UDS
15.5 38.560 DS
16.0 38.060 DS
16.5 37.560 SPT 35
17.0 37.060 DS
17.5 36.560 DS
Silty Clay
18.0 36.060 UDS
18.5 35.560 DS
19.0 35.060 DS
19.5 34.560 SPT 33
20.0 34.060 DS
20.5 33.560 DS
21.0 33.060 UDS
21.5 32.560 DS
22.0 32.060 DS
22.5 31.560 SPT 12
23.0 31.060 DS
23.5 30.560 DS
24.0 30.060 UDS
24.5 29.560 DS
25.0 29.060 DS
25.5 28.560 SPT 14
26.0 28.060 DS
Clay
26.5 27.560 DS
27.0 27.060 UDS
27.5 26.560 DS
28.0 26.060 DS
28.5 25.560 SPT 18
29.0 25.060 DS
29.5 24.560 DS
30.0 24.060 SPT 21
BORE LOG DETAILS
Client KBUNL Type of Sampler used UDS/Split spoon /Core barrel
Coordinate of Borehole S-855,E-257 Conducted By N.JENA
Depth
Starata Ground Sample Observed Classification Gravel Sand Silt(% Clay( Limit(%) Limit(%) Index
tation (%) (%) ) %) /cc)
surface
0.5 54.641 UDS
1.0 54.141 DS
1.5 53.641 SPT 5 CL 0 22.4 31.3 46.3 34 18 16
2.0 53.141 DS
2.5 52.641 DS
3.0 52.141 DS
3.5 51.641 UDS
4.0 51.141 DS
4.5 50.641 SPT 8
5.0 50.141 DS
Silty Clay
5.5 49.641 DS
6.0 49.141 UDS CL 0 21.8 33.4 44.8 32 17 15
6.5 48.641 DS
7.0 48.141 DS
7.5 47.641 SPT 11
8.0 47.141 DS
8.5 46.641 DS
9.0 46.141 UDS
9.5 45.641 DS
10.0 45.141 DS
10.5 44.641 SPT 12
11.0 44.141 DS
11.5 43.641 DS
Clayey Sand 0 51.4 27.6 21
12.00 43.141 UDS
12.50 42.641 DS
13.00 42.141 DS
13.5 41.641 SPT 20
14.0 41.141 DS
14.5 40.641 DS
Silty Clay 0 28.2 71.8
15.0 40.141 UDS
15.5 39.641 DS
16.0 39.141 DS
16.5 38.641 SPT 28
17.0 38.141 DS
17.5 37.641 DS
18.0 37.141 UDS
18.5 36.641 DS
19.0 36.141 DS
19.5 35.641 SPT 33
20.0 35.141 DS
20.5 34.641 DS
21.0 34.141 UDS
21.5 33.641 DS
22.0 33.141 DS
22.5 32.641 SPT 36
Silty Clay with 23.0 32.141 DS
Granular 23.5 31.641 DS
Material 24.0 31.141 UDS
24.5 30.641 DS
25.0 30.141 DS
25.5 29.641 SPT 41 CI 11.8 18.3 16.7 53.2 39 18 21
25.7 29.441 DS
26.0 29.141 DS
26.5 28.641 DS
27.0 28.141 UDS
27.5 27.641 DS
28.0 27.141 DS
28.5 26.641 SPT 45
29.0 26.141 DS
29.5 25.641 DS
30 25.141 SPT 48
BORE LOG DETAILS
Coordinate of Borehole S-347,E-437 Conducted By T. K. Das
Depth
Represen RL (m) Density(g
Starata Ground Sample Observed Classification Gravel( Sand(%) Silt(% Clay Limit(%) Limit(%) Index
tation %) ) (%) m/cc)
surface
0.5 53.635 DS
1.0 53.135 UDS
1.5 52.635 DS
2.0 52.135 SPT 5
2.5 51.635 DS
3.0 51.135 DS
3.5 50.635 UDS
4.0 50.135 DS
4.5 49.635 DS
5.0 49.135 SPT 8
Clay 5.5 48.635 DS
6.0 48.135 DS
6.5 47.635 UDS
7.0 47.135 DS
7.5 46.635 DS
8.0 46.135 SPT 13
8.5 45.635 DS
9.0 45.135 DS
9.5 44.635 UDS
10.0 44.135 DS
10.5 43.635 DS
11.0 43.135 SPT 21
11.5 42.635 DS
12.0 42.135 DS
12.5 41.635 UDS
Clayey silt 13.0 41.135 DS
13.5 40.635 DS
14.0 40.135 SPT 24
14.5 39.635 DS
15.0 39.135 DS
15.5 38.635 UDS
16.0 38.135 DS
16.5 37.635 DS
17.0 37.135 SPT 19
Clay 17.5 36.635 DS
18.0 36.135 DS
18.5 35.635 UDS
19.0 35.135 DS
19.5 34.635 DS
20.0 34.135 SPT 41
20.5 33.635 DS
21.0 33.135 DS
21.5 32.635 UDS FAIL/DS TAKEN
22.0 32.135 SPT 43
22.5 31.635 DS
23.0 31.135 SPT 46
23.5 30.635 DS
24.0 30.135 DS
Silty sand
25.0 29.135 SPT 40
25.5 28.635 DS
26.0 28.135 SPT 49
26.5 27.635 DS
27.0 27.135 DS
28.0 26.135 SPT 55
28.5 25.635 DS
29.0 25.135 SPT 27
29.5 24.635 DS
Clay 30.0 24.135 DS
30.5 23.635 UDS
31.0 23.135 DS
31.5 22.635 DS
32.0 22.135 SPT 29
32.5 21.635 DS
33.0 21.135 DS
Clay
33.5 20.635 UDS
34.0 20.135 DS
34.5 19.635 DS
35.0 19.135 SPT 26
BORE LOG DETAILS
Client KBUNL Type of Sampler used UDS/Split spoon
Borehole No BH -147 Type of Boring Rotary Drilling
Coordinate of Borehole S -557,E - 511 Conducted By R.N Mohanty
Depth SPT Results GRAIN SIZE ANALYSIS
Symbolic IS
Description Of from Type of Liquid Plastic Plasticity
Represent RL (m) Classificat
Starata ation
Ground Sample Observed Gravel( Sand( Silt(%) Clay(%) Limit(%) Limit(%) Index
%) %) ion
surface
0.5 52.648 UDS
Clay 1.0 52.148 DS
1.5 51.648 DS
2.0 51.148 SPT 7
2.5 50.648 DS
3.0 50.148 DS
3.5 49.648 UDS
Silty clay 4.0 49.148 DS
4.5 48.648 DS
5.0 48.148 SPT 8
5.5 47.648 DS
6.0 47.148 DS
6.5 46.648 UDS
Clay 7.0 46.148 DS
7.5 45.648 DS
8.0 45.148 SPT 28
8.5 44.648 DS
9.0 44.148 DS
10.0 43.148 SPT 30
10.5 42.648 DS
11.0 42.148 SPT 31
11.5 41.648 DS
12.0 41.148 DS
13.0 40.148 SPT 32
13.5 39.648 DS
14.0 39.148 SPT 34
14.5 38.648 DS
15.0 38.148 DS
16.0 37.148 SPT 33
16.5 36.648 DS
17.0 36.148 SPT 40
17.5 35.648 DS
18.0 35.148 DS
Silty sand
19.0 34.148 SPT 43
19.5 33.648 DS
20.0 33.148 SPT 44
20.5 32.648 DS
21.0 32.148 DS
22.0 31.148 SPT 45
22.5 30.648 DS
23.0 30.148 SPT 48
23.5 29.648 DS
24.0 29.148 DS
25.0 28.148 SPT 51
25.5 27.648 DS
26.0 27.148 SPT 52
26.5 26.648 DS
27.0 26.148 DS
28.0 25.148 SPT 54
28.5 24.648 DS
29.0 24.148 SPT 59
29.5 23.648 DS
30.0 23.148 SPT 74
BORE LOG DETAILS
Coordinate of Borehole S-493.532,E-436 Conducted By R.N Mohanty
Depth
Starata Ground Sample Observed Classification Gravel( Sand(%) Silt(%) Clay( Limit(%) Limit(%) Index
tation %) %) /cc)
surface
0.5 53.388 DS
1.0 52.888 UDS
1.5 52.388 DS
2.0 51.888 SPT 5
2.5 51.388 DS
3.0 50.888 DS
3.5 50.388 UDS
Clay 4.0 49.888 DS
4.5 49.388 DS
5.0 48.888 SPT 7
5.5 48.388 DS
6.0 47.888 DS
6.5 47.388 UDS
7.0 46.888 DS
7.5 46.388 DS
8.0 45.888 SPT 27
8.5 45.388 DS
9.0 44.888 DS
Silty sand
9.5 44.388 UDS FAIL
10.0 43.888 SPT 26
10.5 43.388 DS
Upper 20cm of
11.0 42.888 SPT 29
SPT is silty sand &
Lower 14 cm is
blackish clay 11.5 42.388 DS
12.0 41.888 DS
Silty sand 13.0 40.888 SPT 32
13.5 40.388 DS
14.0 39.888 SPT 14
14.5 39.388 DS
15.0 38.888 DS
15.5 38.388 UDS
16.0 37.888 DS
16.5 37.388 DS
17.0 36.888 SPT 13
17.5 36.388 DS
18.0 35.888 DS
Clay
18.5 35.388 UDS
19.0 34.888 DS
19.5 34.388 DS
20.0 33.888 SPT 17
20.5 33.388 DS
21.0 32.888 DS
21.5 32.388 UDS
22.0 31.888 DS
22.5 31.388 DS
23.0 30.888 SPT 31
23.5 30.388 DS
24.0 29.888 DS
Silty sand
24.5 29.388 UDS FAIL
25.0 28.888 SPT 34
25.5 28.388 DS
26.0 27.888 SPT 22
26.5 27.388 DS
27.0 26.888 DS
Clay 27.5 26.388 UDS
28.0 25.888 DS
28.5 25.388 DS
29.0 24.888 SPT 24
29.5 24.388 DS
Clay
30.0 23.888 SPT 23
BORE LOG DETAILS
Coordinate of Borehole S-660,E-437 Conducted By T.K.Das
Depth
tation %) ) %) /cc)
surface
0.5 52.410 DS
1.0 51.910 UDS
1.5 51.410 DS
2.0 50.910 SPT 7
2.5 50.410 DS
3.0 49.910 DS
Silty clay
3.5 49.410 UDS
4.0 48.910 DS
4.5 48.410 DS
5.0 47.910 SPT 10
5.5 47.410 DS
6.0 46.910 DS
6.5 46.410 UDS
7.0 45.910 DS
7.5 45.410 DS
8.0 44.910 SPT 12
8.5 44.410 DS
9.0 43.910 DS
9.5 43.410 UDS
10.0 42.910 DS
10.5 42.410 DS
11.0 41.910 SPT 15
11.5 41.410 DS
12.0 40.910 DS
12.5 40.410 UDS
13.5 39.410 DS
14.0 38.910 SPT 18
14.5 38.410 DS
15.0 37.910 DS
15.5 37.410 UDS
16.0 36.910 DS
16.5 36.410 DS
17.0 35.910 SPT 19
17.5 35.410 DS
18.0 34.910 DS
18.5 34.410 UDS
19.0 33.910 DS
19.5 33.410 DS
20.0 32.910 SPT 17
20.5 32.410 DS
21.0 31.910 DS
21.5 31.410 UDS
22.0 30.910 DS
22.5 30.410 DS
23.0 29.910 SPT 20
23.5 29.410 DS
24.0 28.910 DS
24.5 28.410 UDS
25.0 27.910 DS
Clay 25.5 27.410 DS
26.0 26.910 SPT 28
26.5 26.410 DS
27.0 25.910 DS
27.5 25.410 UDS
28.0 24.910 DS
28.5 24.410 DS
29.0 23.910 SPT 27
29.5 23.410 DS
30.0 22.910 DS
30.5 22.410 UDS
31.0 21.910 DS
31.5 21.410 DS
32.0 20.910 SPT 30
32.5 20.410 DS
Clay 33.0 19.910 DS
33.5 19.410 UDS
34.0 18.910 DS
34.5 18.410 DS
Upper 7cm of SPT
sampler is clay &
lower 19cm is fine 35.0 17.910 SPT 37
sand
BORE LOG DETAILS
Client KBUNL Type of Sampler used UDS/Split spoon
Borehole No BH -150 Type of Boring Rotary Drilling
Coordinate of Borehole S -502,E - 550 Conducted By R.N Mohanty
Depth SPT Results GRAIN SIZE ANALYSIS
Symbolic IS
Description Of from Type of Liquid Plastic Plasticity
Represent RL (m) Gravel( Sand( Classificat
Starata ation
Ground Sample Observed Silt(%) Clay(%) Limit(%) Limit(%) Index
%) %) ion
surface
0.5 52.410 DS
Clay 1.0 51.910 UDS
1.5 51.410 DS
2.0 50.910 SPT 5
2.5 50.410 DS
3.0 49.910 DS
3.5 49.410 UDS
4.0 48.910 DS
4.5 48.410 DS
Silty clay
5.0 47.910 SPT 7
5.5 47.410 DS
6.0 46.910 DS
6.5 46.410 UDS
7.0 45.910 DS
7.5 45.410 DS
8.0 44.910 SPT 11
8.5 44.410 DS
9.0 43.910 DS
9.5 43.410 UDS
10.0 42.910 DS
10.5 42.410 DS
Clay
11.0 41.910 SPT 13
11.5 41.410 DS
12.0 40.910 DS
12.5 40.410 UDS
13.0 39.910 DS
13.5 39.410 DS
14.0 38.910 SPT 15
14.5 38.410 DS
15.0 37.910 DS
15.5 37.410 UDS
16.0 36.910 DS
16.5 36.410 DS
17.0 35.910 SPT 17
17.5 35.410 DS
18.0 34.910 DS
18.5 34.410 UDS
19.0 33.910 DS
19.5 33.410 DS
20.0 32.910 SPT 20
20.5 32.410 DS
21.0 31.910 DS
Silty clay 21.5 31.410 UDS
22.0 30.910 DS
22.5 30.410 DS
23.0 29.910 SPT 22
23.5 29.410 DS
24.0 28.910 DS
24.5 28.410 UDS
25.0 27.910 DS
25.5 27.410 DS
26.0 26.910 SPT 23
26.5 26.410 DS
27.0 25.910 DS
27.5 25.410 UDS
28.0 24.910 DS
28.5 24.410 DS
29.0 23.910 SPT 26
29.5 23.410 DS
Clay 30.0 22.910 SPT 17
BORE LOG DETAILS
Depth
tation %) ) %) /cc)
surface
0.5 52.957 UDS
1.0 52.457 DS
1.5 51.957 DS
2.0 51.457 SPT 7
Clay
2.5 50.957 DS
3.0 50.457 UDS
3.5 49.957 DS
4.0 49.457 DS
4.5 48.957 SPT 10
5.0 48.457 DS
5.5 47.957 DS
6.0 47.457 UDS
6.5 46.957 DS
7.0 46.457 DS
7.5 45.957 SPT 13
8.0 45.457 DS
8.5 44.957 DS
9.0 44.457 UDS
9.5 43.957 DS
10.0 43.457 DS
Clayey silt/Silty clay
10.5 42.957 SPT 15
11.0 42.457 DS
11.5 41.957 DS
12.0 41.457 UDS
12.5 40.957 DS
13.0 40.457 DS
13.5 39.957 SPT 17
14.0 39.457 DS
14.5 38.957 DS
15.0 38.457 UDS
15.5 37.957 DS
16.0 37.457 DS
16.5 36.957 SPT 19
17.0 36.457 DS
17.5 35.957 DS
18.0 35.457 UDS
18.5 34.957 DS
19.0 34.457 DS
19.5 33.957 SPT 16
20.0 33.457 DS
20.5 32.957 DS
21.0 32.457 UDS
22.0 31.457 DS
22.5 30.957 SPT 20
23.0 30.457 DS
23.5 29.957 DS
24.0 29.457 UDS
24.5 28.957 DS
25.0 28.457 DS
25.5 27.957 SPT 18
26.0 27.457 DS
26.5 26.957 DS
27.0 26.457 UDS
27.5 25.957 SPT 32
28.0 25.457 DS
Silty sand
28.5 24.957 SPT 38
29.0 24.457 DS
29.5 23.957 DS
Clay 30.0 23.457 SPT 29
BORE LOG DETAILS
Depth
tation %) ) %) /cc)
surface
0.5 52.772 DS
1.0 52.272 UDS
1.5 51.772 DS
2.0 51.272 DS
2.5 50.772 SPT 6
3.0 50.272 DS
3.5 49.772 DS
4.0 49.272 UDS
4.5 48.772 DS
5.0 48.272 DS
5.5 47.772 SPT 7
6.0 47.272 DS
6.5 46.772 DS
7.0 46.272 UDS
7.5 45.772 DS
8.0 45.272 DS
8.5 44.772 SPT 10
Clay
9.0 44.272 DS
9.5 43.772 DS
10.0 43.272 UDS
10.5 42.772 DS
11.0 42.272 DS
11.5 41.772 SPT 11
12.0 41.272 DS
12.5 40.772 DS
13.0 40.272 UDS
13.5 39.772 DS
14.0 39.272 DS
14.5 38.772 SPT 15
15.0 38.272 DS
15.5 37.772 DS
16.0 37.272 UDS
16.5 36.772 DS
17.0 36.272 DS
17.5 35.772 SPT 16
18.0 35.272 DS
18.5 34.772 DS
19.0 34.272 UDS
19.5 33.772 DS
20.0 33.272 DS
Silty clay
20.5 32.772 SPT 19
21.0 32.272 DS
21.5 31.772 DS
22.0 31.272 UDS
22.5 30.772 DS
23.0 30.272 DS
23.5 29.772 SPT 17
Clay 24.0 29.272 DS
24.5 28.772 DS
Silty clay/Clayey silt 25.0 28.272 SPT 20
BORE LOG DETAILS
Coordinate of Borehole S-954,E-437 Conducted By N. Barik
Depth
tation %) ) %) /cc)
surface
0.5 53.032 DS
1.0 52.532 UDS
1.5 52.032 DS
2.0 51.532 SPT 5
2.5 51.032 DS
3.0 50.532 DS
3.5 50.032 UDS
4.0 49.532 DS
4.5 49.032 DS
5.0 48.532 SPT 8
Clay 5.5 48.032 DS
6.0 47.532 DS
6.5 47.032 UDS
7.0 46.532 DS
7.5 46.032 DS
8.0 45.532 SPT 9
8.5 45.032 DS
9.0 44.532 DS
9.5 44.032 UDS
10.0 43.532 DS
10.5 43.032 DS
11.0 42.532 SPT 11
11.5 42.032 DS
12.0 41.532 DS
Blackish clay
12.5 41.032 UDS
13.0 40.532 DS
13.5 40.032 DS
14.0 39.532 SPT 17
14.5 39.032 DS
15.0 38.532 DS
15.5 38.032 UDS
16.0 37.532 DS
16.5 37.032 DS
17.0 36.532 SPT 20
17.5 36.032 DS
18.0 35.532 DS
18.5 35.032 UDS
19.0 34.532 DS
19.5 34.032 DS
20.0 33.532 SPT 21
20.5 33.032 DS
21.0 32.532 DS
Clay
21.5 32.032 UDS
22.0 31.532 DS
22.5 31.032 DS
23.0 30.532 SPT 28
23.5 30.032 DS
24.0 29.532 DS
24.5 29.032 UDS
25.0 28.532 DS
25.5 28.032 DS
26.0 27.532 SPT 24
26.5 27.032 DS
27.0 26.532 DS
27.5 26.032 UDS
28.0 25.532 DS
28.5 25.032 DS
29.0 24.532 SPT 31
29.5 24.032 DS
Silty clay
30.0 23.532 DS
30.5 23.032 UDS
31.0 22.532 DS
Silty clay
31.5 22.032 DS
Depth
tation %) ) %) /cc)
surface
32.0 21.532 SPT 19
32.5 21.032 DS
33.0 20.532 DS
Clay 33.5 20.032 UDS
34.0 19.532 DS
34.5 19.032 DS
35.0 18.532 SPT 24
BORE LOG DETAILS
Coordinate of Borehole S-1002,E-439 Conducted By T.K Das
Depth
tation %) ) %) /cc)
surface
0.5 53.191 UDS
1.0 52.691 DS
1.5 52.191 SPT 4
2.0 51.691 DS
2.5 51.191 DS
3.0 50.691 UDS
3.5 50.191 DS
4.0 49.691 DS
4.5 49.191 SPT 8
5.0 48.691 DS
5.5 48.191 DS
6.0 47.691 UDS
6.5 47.191 DS
7.0 46.691 DS
7.5 46.191 SPT 10
8.0 45.691 DS
8.5 45.191 DS
9.0 44.691 UDS
9.5 44.191 DS
10.0 43.691 DS
10.5 43.191 SPT 13
11.0 42.691 DS
11.5 42.191 DS
12.0 41.691 UDS
12.5 41.191 DS
13.0 40.691 DS
13.5 40.191 SPT 12
14.0 39.691 DS
14.5 39.191 DS
15.0 38.691 UDS
Clay 15.5 38.191 DS
16.0 37.691 DS
16.5 37.191 SPT 17
17.0 36.691 DS
17.5 36.191 DS
18.0 35.691 UDS
18.5 35.191 DS
19.0 34.691 DS
19.5 34.191 SPT 20
20.0 33.691 DS
20.5 33.191 DS
21.0 32.691 UDS
21.5 32.191 DS
22.0 31.691 DS
22.5 31.191 SPT 21
23.0 30.691 DS
23.5 30.191 DS
24.0 29.691 UDS
24.5 29.191 DS
25.0 28.691 DS
25.5 28.191 SPT 18
26.0 27.691 DS
26.5 27.191 DS
27.0 26.691 UDS
27.5 26.191 DS
28.0 25.691 DS
28.5 25.191 SPT 23
29.0 24.691 DS
29.5 24.191 DS
30.0 23.691 UDS
30.5 23.191 DS
Coordinate of Borehole S-1002,E-439 Conducted By T.K Das
Depth
tation %) ) %) /cc)
surface
31.0 22.691 DS
31.5 22.191 SPT 25
32.0 21.691 DS
32.5 21.191 DS
Clay 33.0 20.691 UDS
33.5 20.191 DS
34.0 19.691 DS
34.5 19.191 SPT 29
35.0 18.691 SPT 31
BORE LOG DETAILS
Coordinate of Borehole S-1040,E-509 Conducted By R.N Mohanty
Depth
tation %) ) %) /cc)
surface
0.5 53.448 DS
1.0 52.948 UDS
1.5 52.448 DS
2.0 51.948 SPT 5
2.5 51.448 DS
3.0 50.948 DS
3.5 50.448 UDS
4.0 49.948 DS
4.5 49.448 DS
5.0 48.948 SPT 8
Clay 5.5 48.448 DS
6.0 47.948 DS
6.5 47.448 UDS
7.0 46.948 DS
7.5 46.448 DS
8.0 45.948 SPT 10
8.5 45.448 DS
9.0 44.948 DS
9.5 44.448 UDS
10.0 43.948 DS
10.5 43.448 DS
11.0 42.948 SPT 14
11.5 42.448 DS
12.0 41.948 DS
Clayey silt
12.5 41.448 UDS
13.0 40.948 DS
13.5 40.448 DS
14.0 39.948 SPT 12
14.5 39.448 DS
15.0 38.948 DS
15.5 38.448 UDS
16.0 37.948 DS
16.5 37.448 DS
17.0 36.948 SPT 13
17.5 36.448 DS
18.0 35.948 DS
Clay
18.5 35.448 UDS
19.0 34.948 DS
19.5 34.448 DS
20.0 33.948 SPT 14
20.5 33.448 DS
21.0 32.948 DS
21.5 32.448 UDS
22.0 31.948 DS
22.5 31.448 DS
23.0 30.948 SPT 17
23.5 30.448 DS
24.0 29.948 DS
Silty clay
24.5 29.448 UDS
25.0 28.948 DS
25.5 28.448 DS
26.0 27.948 SPT 83
26.5 27.448 DS
27.0 26.948 DS
Clayey silt
27.5 26.448 UDS
28.0 25.948 DS
28.5 25.448 DS
29.0 24.948 SPT 58
29.5 24.448 DS
Silty sand
30.0 23.948 DS
Coordinate of Borehole S-1040,E-509 Conducted By R.N Mohanty
Depth
tation %) ) %) /cc)
surface
31.0 22.948 SPT 59
31.5 22.448 DS
32.0 21.948 SPT 59
32.5 21.448 DS
Silty sand
33.0 20.948 DS
34.0 19.948 SPT 81
34.5 19.448 DS
Clayey silt 35.0 18.948 SPT 48
BORE LOG DETAILS
Depth
Represen RL (m) Density(g
Starata Ground Sample Observed Classification Gravel( Sand(%) Silt(% Clay Limit(%) Limit(%) Index
surface
0.5 53.196 DS
Clay 1.0 52.696 UDS
1.5 52.196 DS
2.0 51.696 SPT 5
2.5 51.196 DS
3.0 50.696 DS
Silty clay
3.5 50.196 UDS
4.0 49.696 DS
4.5 49.196 DS
5.0 48.696 SPT 12
5.5 48.196 DS
6.0 47.696 DS
6.5 47.196 UDS
7.0 46.696 DS
7.5 46.196 DS
Clay
8.0 45.696 SPT 16
8.5 45.196 DS
9.0 44.696 DS
9.5 44.196 UDS
10.0 43.696 DS
10.5 43.196 DS
11.0 42.696 SPT 18
11.5 42.196 DS
12.0 41.696 DS
Silty clay
12.5 41.196 UDS
13.0 40.696 DS
13.5 40.196 DS
14.0 39.696 SPT 21
14.5 39.196 DS
15.0 38.696 DS
15.5 38.196 UDS
16.5 37.196 DS
17.0 36.696 SPT 26
17.5 36.196 DS
18.0 35.696 DS
18.5 35.196 UDS FAIL
19.0 34.696 SPT 38
19.5 34.196 DS
20.0 33.696 SPT 41
20.5 33.196 DS
21.0 32.696 DS
21.5 32.196 UDS FAIL
22.0 31.696 SPT 51
22.5 31.196 DS
23.0 30.696 SPT 58
23.5 30.196 DS
24.0 29.696 DS
Silty sand 24.5 29.196 UDS FAIL
25.0 28.696 SPT 48
25.5 28.196 DS
26.0 27.696 SPT 82
26.5 27.196 DS
27.0 26.696 DS
27.5 26.196 UDS FAIL
28.0 25.696 SPT 64
28.5 25.196 DS
29.0 24.696 SPT 71
29.5 24.196 DS
30.0 23.696 DS
30.5 23.196 UDS FAIL
31.0 22.696 SPT 58
Silty sand
31.5 22.196 DS
32.0 21.696 SPT 34
32.5 21.196 DS
33.0 20.696 DS
Clayey silt
33.5 20.196 UDS
Depth
Represen RL (m) Gravel( Silt(% Clay Density(g
surface
34.0 19.696 DS
34.5 19.196 DS
Clay 35.0 18.696 SPT 36
BORE LOG DETAILS
Depth
tation %) ) %) /cc)
surface
0.5 53.090 UDS
1.0 52.590 DS
1.5 52.090 SPT 5
2.0 51.590 DS
2.5 51.090 DS
Clayey silt 3.0 50.590 UDS
3.5 50.090 DS
4.0 49.590 DS
4.5 49.090 SPT 7
5.0 48.590 DS
5.5 48.090 DS
6.0 47.590 UDS
6.5 47.090 DS
7.0 46.590 DS
7.5 46.090 SPT 4
8.0 45.590 DS
8.5 45.090 DS
9.0 44.590 UDS
9.5 44.090 DS
10.0 43.590 DS
10.5 43.090 SPT 7
11.0 42.590 DS
11.5 42.090 DS
12.0 41.590 UDS
12.5 41.090 DS
13.0 40.590 DS
13.5 40.090 SPT 18
Clay 14.0 39.590 DS
14.5 39.090 DS
15.0 38.590 UDS
15.5 38.090 DS
16.0 37.590 DS
16.5 37.090 SPT 20
17.0 36.590 DS
17.5 36.090 DS
18.0 35.590 UDS
18.5 35.090 DS
19.0 34.590 DS
19.5 34.090 SPT 23
20.0 33.590 DS
20.5 33.090 DS
21.0 32.590 UDS
21.5 32.090 DS
22.0 31.590 DS
22.5 31.090 SPT 35
23.0 30.590 DS
23.5 30.090 DS
Silty sand
24.0 29.590 UDS FAIL
24.5 29.090 SPT 39
25.0 28.590 DS
25.5 28.090 SPT 15
26.0 27.590 DS
26.5 27.090 DS
27.0 26.590 UDS
27.5 26.090 DS
Silty clay
28.0 25.590 DS
28.5 25.090 SPT 19
29.0 24.590 DS
29.5 24.090 DS
30.0 23.590 UDS
30.5 23.090 DS
Silty clay
31.0 22.590 DS
31.5 22.090 SPT 22
32.0 21.590 DS
Depth
tation %) ) %) /cc)
surface
32.5 21.090 DS
Clayey silt
33.0 20.590 UDS
33.5 20.090 DS
34.0 19.590 DS
Silty clay 34.5 19.090 SPT 23
Clay 35.0 18.590 SPT 26
BORE LOG DETAILS
Depth
tation %) ) %) /cc)
surface
Coal ash filling
0.5 53.481 DS
material
1.0 52.981 UDS
1.5 52.481 DS
2.0 51.981 SPT 6
2.5 51.481 DS
3.0 50.981 DS
3.5 50.481 UDS
4.0 49.981 DS
4.5 49.481 DS
5.0 48.981 SPT 6
5.5 48.481 DS
Clay
6.0 47.981 DS
6.5 47.481 UDS
7.0 46.981 DS
7.5 46.481 DS
8.0 45.981 SPT 9
8.5 45.481 DS
9.0 44.981 DS
9.5 44.481 UDS
10.0 43.981 DS
10.5 43.481 DS
11.0 42.981 SPT 11
11.5 42.481 DS
12.0 41.981 DS
Silty clay
12.5 41.481 UDS
13.0 40.981 DS
13.5 40.481 DS
14.0 39.981 SPT 22
14.5 39.481 DS
15.0 38.981 DS
15.5 38.481 UDS
16.0 37.981 DS
16.5 37.481 DS
Clay
17.0 36.981 SPT 18
17.5 36.481 DS
18.0 35.981 DS
18.5 35.481 UDS
19.0 34.981 DS
19.5 34.481 DS
20.0 33.981 SPT 31
20.5 33.481 DS
21.0 32.981 DS
21.5 32.481 UDS FAIL
Sandy silt 22.0 31.981 SPT 34
22.5 31.481 DS
23.0 30.981 SPT 35
23.5 30.481 DS
24.0 29.981 DS
24.5 29.481 UDS
25.0 28.981 DS
25.5 28.481 DS
26.0 27.981 SPT 28
26.5 27.481 DS
27.0 26.981 DS
Clayey silt
27.5 26.481 UDS
28.0 25.981 DS
28.5 25.481 DS
29.0 24.981 SPT 26
29.5 24.481 DS
30.0 23.981 SPT 30
BORE LOG DETAILS
Depth
tation %) ) %) /cc)
surface
Coal ash filling
0.5 53.241 UDS FAIL
materials
Upper 9cm of SPT
sampler is coal ash
1.0 52.741 SPT 6
and lower 11cm is
clay
1.5 52.241 DS
2.0 51.741 DS
2.5 51.241 UDS
3.0 50.741 DS
3.5 50.241 DS
4.0 49.741 SPT 6
4.5 49.241 DS
5.0 48.741 DS
Clay 5.5 48.241 UDS
6.0 47.741 DS
6.5 47.241 DS
7.0 46.741 SPT 7
7.5 46.241 DS
8.0 45.741 DS
8.5 45.241 UDS
9.0 44.741 DS
9.5 44.241 DS
10.0 43.741 SPT 12
10.5 43.241 DS
11.0 42.741 DS
11.5 42.241 UDS
12.5 41.241 DS
13.0 40.741 SPT 14
13.5 40.241 DS
14.0 39.741 DS
14.5 39.241 UDS
15.0 38.741 DS
15.5 38.241 DS
16.0 37.741 SPT 20
17.0 36.741 DS
17.5 36.241 UDS
18.0 35.741 DS
18.5 35.241 DS
19.0 34.741 SPT 19
19.5 34.241 DS
20.0 33.741 DS
20.5 33.241 UDS
21.0 32.741 DS
21.5 32.241 DS
Clay
22.0 31.741 SPT 20
22.5 31.241 DS
23.0 30.741 DS
23.5 30.241 UDS
24.0 29.741 DS
24.5 29.241 DS
25.5 28.241 DS
26.0 27.741 DS
26.5 27.241 UDS
27.0 26.741 DS
Clay
27.5 26.241 DS
28.0 25.741 SPT 14
28.5 25.241 DS
29.0 24.741 DS
29.5 24.241 UDS
Clay
30.0 23.741 DS
Depth
tation %) ) %) /cc)
surface
31.0 22.741 SPT 25
32.0 21.741 DS
32.5 21.241 UDS FAIL
33.0 20.741 SPT 37
Silty sand 33.5 20.241 DS
34.0 19.741 SPT 39
34.5 19.241 DS
Upper 27cm of SPT
sampler is silty sand 35.0 18.741 SPT 10
and lower 7cm is clay
BORE LOG DETAILS
Depth
tation %) ) %) /cc)
surface
Coal Ash Filling 0.5 53.719 DS
Material 1.0 53.219 UDS FAIL
Upper 10cm of
SPT is Coal Ash
1.5 52.719 SPT 6
and Lower 8cm is
Clay
2.0 52.219 DS
2.5 51.719 DS
3.0 51.219 UDS
3.5 50.719 DS
4.0 50.219 DS
Clay 4.5 49.719 SPT 9 CI 0 12.7 27.3 60 44 18 26
5.0 49.219 DS
5.5 48.719 DS
6.0 48.219 UDS 1.9
6.5 47.719 DS
7.0 47.219 DS
Upper 9cm of SPT
is Clay and Lower 7.5 46.719 SPT 13
17cm is Clayey Silt
8.0 46.219 DS
8.5 45.719 DS
9.0 45.219 UDS
9.5 44.719 DS
Clayey Silt
10.0 44.219 DS
10.5 43.719 SPT 15
11.0 43.219 DS
11.5 42.719 DS
12.0 42.219 UDS CI 0 14.6 23.7 61.7 42 17 25
12.5 41.719 DS
13.0 41.219 DS
13.5 40.719 SPT 6
14.0 40.219 DS
14.5 39.719 DS
15.0 39.219 UDS
Silty Clay 15.5 38.719 DS
16.0 38.219 DS
16.5 37.719 SPT 9
17.0 37.219 DS
17.5 36.719 DS
18.0 36.219 UDS CI 0 16.3 21.8 61.9 40 18 22
18.5 35.719 DS
19.0 35.219 DS
19.5 34.719 SPT 34
20.0 34.219 DS
20.5 33.719 DS
21.0 33.219 UDS FAIL
21.5 32.719 SPT 40
Fine Sand
22.0 32.219 DS
22.5 31.719 SPT 37
23.0 31.219 DS
23.5 30.719 DS
24.0 30.219 UDS FAIL
24.5 29.719 SPT 14
Clay
25.0 29.219 DS
25.5 28.719 SPT 21 0 21.8 34.6 43.6
26.0 28.219 DS
26.5 27.719 DS
27.0 27.219 UDS
Clayey Silt 27.5 26.719 DS
28.0 26.219 DS
28.5 25.719 SPT 25
29.0 25.219 DS
29.5 24.719 DS
Depth
tation %) ) %) /cc)
surface
Clay with Granular
30.0 24.219 SPT 30
Material
BORE LOG DETAILS
Coordinate of Borehole S-946,E-179 Conducted By T.K. Das
Depth
Represen RL (m) Gravel( Silt(% Clay Limit(%) Limit(%) Index Density(gm
tation %) ) (%) /cc)
surface
0.5 53.921 DS
1.0 53.421 UDS
Clay 1.5 52.921 DS
2.0 52.421 SPT 6
2.5 51.921 DS
3.0 51.421 DS
3.5 50.921 UDS
4.0 50.421 DS
4.5 49.921 DS
5.0 49.421 SPT 9
5.5 48.921 DS
6.0 48.421 DS
6.5 47.921 UDS
7.0 47.421 DS
7.5 46.921 DS
8.0 46.421 SPT 11
8.5 45.921 DS
9.0 45.421 DS
9.5 44.921 UDS
10.5 43.921 DS
11.0 43.421 SPT 10
11.5 42.921 DS
12.0 42.421 DS
12.5 41.921 UDS
13.0 41.421 DS
13.5 40.921 DS
14.0 40.421 SPT 13
14.5 39.921 DS
15.0 39.421 DS
15.5 38.921 UDS
16.0 38.421 DS
16.5 37.921 DS
17.0 37.421 SPT 21
Clay 17.5 36.921 DS
18.0 36.421 DS
19.0 35.421 SPT 30
19.5 34.921 DS
20.0 34.421 SPT 35
20.5 33.921 DS
21.0 33.421 DS
Silty sand 21.5 32.921 UDS FAIL/DS TAKEN
22.0 32.421 SPT 38
22.5 31.921 DS
23.0 31.421 SPT 41
23.5 30.921 DS
24.0 30.421 DS
25.0 29.421 SPT 12
25.5 28.921 DS
26.0 28.421 SPT 13
26.5 27.921 DS
27.0 27.421 DS
Clay
27.5 26.921 UDS
28.0 26.421 DS
28.5 25.921 DS
29.0 25.421 SPT 16
29.5 24.921 DS
Sandy silt 30.0 24.421 SPT 52
BORE LOG DETAILS
Coordinate of Borehole S-806,E-244 Conducted By L.Mohapatra
Depth
tation %) ) %) /cc)
surface
0.5 52.959 DS
1.0 52.459 UDS
1.5 51.959 DS
2.0 51.459 SPT 6
2.5 50.959 DS
3.0 50.459 DS
3.5 49.959 UDS
4.0 49.459 DS
4.5 48.959 DS
Clay
5.0 48.459 SPT 8
5.5 47.959 DS
6.0 47.459 DS
6.5 46.959 UDS
7.0 46.459 DS
7.5 45.959 DS
8.0 45.459 SPT 12
8.5 44.959 DS
9.0 44.459 DS
9.5 43.959 UDS
10.0 43.459 DS
10.5 42.959 DS
11.0 42.459 SPT 15
11.5 41.959 DS
12.0 41.459 DS
12.5 40.959 UDS
13.0 40.459 DS
13.5 39.959 DS
14.0 39.459 SPT 20
15.0 38.459 DS
15.5 37.959 UDS
16.0 37.459 DS
16.5 36.959 DS
17.0 36.459 SPT 18
17.5 35.959 DS
18.0 35.459 DS
18.5 34.959 UDS
19.0 34.459 DS
19.5 33.959 DS
20.0 33.459 SPT 19
20.5 32.959 DS
21.0 32.459 DS
Clay 21.5 31.959 UDS
22.0 31.459 DS
22.5 30.959 DS
23.0 30.459 SPT 23
23.5 29.959 DS
Silty clay/Clayey 24.0 29.459 DS
silt 24.5 28.959 UDS
25.0 28.459 DS
25.5 27.959 DS
26.0 27.459 SPT 35
26.5 26.959 DS
27.0 26.459 DS
27.5 25.959 UDS FAIL
Silty sand
28.0 25.459 SPT 34
28.5 24.959 DS
29.0 24.459 SPT 39
29.5 23.959 DS
BORE LOG DETAILS
Coordinate of Borehole S-683,E-84 Conducted By Nilambar Barik
Depth
tation %) ) %) /cc)
surface
0.5 53.990 DS
Clay 1.0 53.490 UDS
1.5 52.990 DS
2.0 52.490 SPT 8
2.5 51.990 DS
3.0 51.490 DS
Clayey silt
3.5 50.990 UDS
4.0 50.490 DS
4.5 49.990 DS
5.0 49.490 SPT 11
5.5 48.990 DS
6.0 48.490 DS
6.5 47.990 UDS
7.0 47.490 DS
7.5 46.990 DS
Silty clay
8.0 46.490 SPT 17
8.5 45.990 DS
9.0 45.490 DS
9.5 44.990 UDS
10.0 44.490 DS
10.5 43.990 DS
11.0 43.490 SPT 21
11.5 42.990 DS
12.0 42.490 DS
12.5 41.990 UDS
13.0 41.490 DS
13.5 40.990 DS
Clay
14.0 40.490 SPT 24
14.5 39.990 DS
15.0 39.490 DS
15.5 38.990 UDS
16.0 38.490 DS
16.5 37.990 DS
17.0 37.490 SPT 18
17.5 36.990 DS
18.0 36.490 DS
18.5 35.990 UDS
19.0 35.490 DS
20.0 34.490 SPT 24
20.5 33.990 DS
21.0 33.490 DS
21.5 32.990 UDS
22.0 32.490 DS
22.5 31.990 DS
23.0 31.490 SPT 23
23.5 30.990 DS
24.0 30.490 DS
24.5 29.990 UDS
25.0 29.490 DS
25.5 28.990 DS
26.0 28.490 SPT 26
26.5 27.990 DS
27.0 27.490 DS
Clay
27.5 26.990 UDS
28.0 26.490 DS
28.5 25.990 DS
29.0 25.490 SPT 25
29.5 24.990 DS
30.0 24.490 DS
30.5 23.990 UDS
31.0 23.490 DS
31.5 22.990 DS
32.0 22.490 SPT 28
32.5 21.990 DS
Coordinate of Borehole S-683,E-84 Conducted By Nilambar Barik
Depth
tation %) ) %) /cc)
surface
33.0 21.490 DS
Silty clay
33.5 20.990 UDS
34.0 20.490 DS
34.5 19.990 DS
Clayey silt 35.0 19.490 SPT 35
BORE LOG DETAILS
Coordinate of Borehole S-747,E-25 Conducted By L.Mohapatra
Depth
tation %) ) %) /cc)
surface
0.5 53.835 UDS
1.0 53.335 DS
1.5 52.835 SPT 4
2.0 52.335 DS
Clay
2.5 51.835 DS
3.0 51.335 UDS
3.5 50.835 DS
4.0 50.335 DS
4.5 49.835 SPT 10
Silty clay/Clayey
5.0 49.335 DS
silt
5.5 48.835 DS
6.0 48.335 UDS
7.0 47.335 DS
7.5 46.835 SPT 6
8.0 46.335 DS
8.5 45.835 DS
9.0 45.335 UDS
9.5 44.835 DS
10.0 44.335 DS
Clay
10.5 43.835 SPT 7
11.0 43.335 DS
11.5 42.835 DS
12.0 42.335 UDS
12.5 41.835 DS
13.0 41.335 DS
13.5 40.835 SPT 10
14.0 40.335 DS
14.5 39.835 DS
Silty clay
15.0 39.335 UDS
15.5 38.835 DS
16.0 38.335 DS
16.5 37.835 SPT 14
17.0 37.335 DS
17.5 36.835 DS
18.0 36.335 UDS
18.5 35.835 DS
19.0 35.335 DS
19.5 34.835 SPT 15
20.0 34.335 DS
20.5 33.835 DS
Clay
21.0 33.335 UDS
21.5 32.835 DS
22.0 32.335 DS
22.5 31.835 SPT 18
23.0 31.335 DS
23.5 30.835 DS
24.0 30.335 UDS
24.5 29.835 DS
25.0 29.335 DS
25.5 28.835 SPT 62
26.0 28.335 DS
26.5 27.835 DS
27.0 27.335 UDS FAIL
27.5 26.835 SPT 54
Fine sand 28.0 26.335 DS
28.5 25.835 SPT 57
29.0 25.335 DS
29.5 24.835 DS
30.0 24.335 SPT 51
PART - B
QUALITY ASSURANCE

PART-B
PART - B
SUB-SECTION-IIIE-01
COAL HANDLING PLANT

PART-B
CLAUSE NO. QUALITY ASSURANCE
1.01.01 Shaft and wheel forgings – Chemical, Mechanical, Hardness and Ultrasonic Test
shall be conducted.
1.01.02 Following minimum NDT on Weld Joint shall be carried out
(a) Butt Welds - 10% UT/RT & 100% MPI/DPT
(b) Fillet Welds - 10% MPI/DPT
1.01.03 Shop trial run shall be conducted to check for movement and RPM of Paddle wheel &
Travel wheel, function of P/F in locked rotor condition, noise and vibration etc.
1.02.00 Brakes and Clamps
1.02.01 Final testing of brakes shall include load, HV/IR & heat run tests.
1.03.00 Monorails and Hoists
1.03.01 All electric hoist shall be tested as per IS 3938 and chain pulley block shall be tested
as per IS 3832.
1.04.00 Hoppers & Liners
1.04.01 Rack & Pinion Gates/Flap Gates/Rod Gates
a) MPI/DP test shall be conducted on rack and pinion / rod / weld joint
b) Functional checks on the gates shall be carried out alongwith respective

actuator, if applicable.
1.05.00 Belt Conveyor System
The details of the checks to be carried out in the various equipments are to be
submitted by the Contractor for Owner’s approval. However, some indicative checks
on different items are given below which should necessarily form a part of the Quality
Assurance Plan to be agreed with the Owner.
1.05.01 Idlers
a) Check for run out and free movement shall be carried out on idlers. Run out
shall be restricted as per IS:8598
b) Test for dust proofness, water proofness and dynamic friction factor of the
Idlers shall be conducted at shop. The detailed procedures for the same shall
be submitted for review and approval.
MUZAFFARPUR TPP
STAGE-II (2X195 MW) SUB-SECTION-IIIE-01
PADDLE FEEDER
BID DOCUMENT NO. : CS-0350-155(R)-2 PART – B
1.05.02 Belting
(a) Rubber cover of finished belt shall be checked for tensile strength and
elongation at break before and after ageing. Rubber cover shall also be
checked for abrasion, tear strength and hardness.
(b) For finished belts, checks for elongation at 10% nominal tensile strength,
tensile and elongation at break in longitudinal (warp) direction and tensile in
transverse (weft) direction shall be carried out.
(c) Adhesion test between ply to ply and cover to ply shall be carried out.
(d) Troughability test and Test for fire resistance shall be carried out.
(e) Test for procedure qualification for belt vulcanizing joint (at site) shall be done.
Procedure for belt vulcanizing joint shall be discussed and finalized during
FQP finalization.
(f) There will be a limitation on the no. of repairs allowed on the belts. Following
will be the acceptance norm for the cover repairs.
i) The maximum size of a repair shall be limited to a size equivalent to

one fifth the belt width. No single dimension shall exceed one fifth(1/5)
of belt width.
ii) Small local repair by dough filling of size 25mm x 25mm to a limited
extent shall not be counted of repairs. However, in case of cluster of
repairs, same shall be counted as a patch repair.
iii) The maximum number of patch repair shall not exceed 5 per 100 mts.
However, the total number of patch and dough filling repairs shall not
exceed 10 per 100 meters.
(g) In addition to above, Steel Cord belt shall also be tested for following.
i. Cord dia and breaking strength
ii. Finished belt shall be tested for cord pull-out strength before and after
aeging, peeling resistance.
iii. Dynamic cord pull out test
iv. Cord dia, pitch and number of cords
(h) In no case shall the cover thickness or the width of belt be less than that given
in specification.
(i) For testing purpose, belt sample shall be taken from anywhere of the belt roll
length offered
MUZAFFARPUR TPP
PADDLE FEEDER
1.05.03 Belt Vulcanizing Machine
a) Check for tensile strength shall be carried out on a sample vulcanized belt
joint for each type of belt in shop. However if such test has been done earlier,
the report for same shall be submitted for verification.
b) Complete assembly shall be tested at shop for temp. and pressure developed
1.05.04 Pulleys
a) In addition to chemical, mechanical, hardness, microstructure as per

applicable material specification, pulleys shaft forgings shall be subjected to
ultrasonic testing.
b) 100% MPI/DPT on all welds shall be conducted and 10% RT/UT on butt
welds shall be conducted.
c) Static balancing of pulleys shall be carried out after rubber lagging.
d) Checks on rubber lagging to include abrasion loss, shore hardness test, peel-
off strength test and physical properties. Peel-off strength shall be 10 Kg/Cm,
Abrasion loss shall be less than 250 cubic mm when tested as per DIN 53516.
1.05.05 Pull Chord & Belt Sway Switches
a. Acceptance tests
i) Over all dimension and functional test.
ii) HV & IR test
iii) Degree of protection test report.
1.05.06 Zero Speed Switch, Under Belt Switch and Chute Blockage Switch
a Acceptance test
i) Burn in test at 50 degree C for 48 hours shall be done for electronic

switches.
ii) Over all dimension and functional test shall be carried out.
iii) HV & IR
iv) Degree of protection test
MUZAFFARPUR TPP
PADDLE FEEDER
1.06.00 Drive Equipments
1.06.01 Gear Boxes :
(a) In addition to checks for physical, chemical, hardness, microstructure as per

relevant standard, the shaft and gear/pinion forgings shall be subjected to
ultrasonic testing .
(b) MPI to be carried out on Gears/Pinions after machining. Case depth,

hardness and MPI after hardfacing shall be checked to ensure freedom from
defects.
(c) Gear reducer shall be checked for reduction ratio, backlash and contact
pattern. No load shop trial run to be conducted on gear boxes to check for oil
leakage, temperature rise, noise level and vibration .
1.06.02 Flexible Coupling
(a) Ultrasonic testing shall be conducted on forgings for gear sleeve and gear
hub, if gear coupling is provided.
(b) MPI shall be carried out after machining to ensure freedom from cracks.
1.06.03 Fluid Coupling
(a) Dynamic balancing shall be carried out for the rotating parts.
(b) Check for leak tightness of the coupling shall be carried out.
(c) Functional test on fusible plug for each type of coupling shall be conducted at
shop.
(d) All couplings to be run tested at shop on no load
(e) Check for temperature rise, torque-speed, torque-slip characteristics and over
speed test shall be included during performance test of one coupling of each
type preferably at full load.
1.07.00 Belt Scales
submitted by the Contractor for Employer’s approval. However, some indicative
checks are given below which should necessarily form a part of the quality assurance
plan to be agreed with the Employer.
1.07.01 Mounting arrangement/Overall dimensional check shall be carried out on the Belt
Scales.
1.07.02 Belt scale shall be calibrated with test weight/test chain in static at works and with
test weight for dynamic condition at site.
MUZAFFARPUR TPP
PADDLE FEEDER
1.07.03 All electronic modules shall be subjected to burn in test at 50 Degree C for 48
hours.
1.07.04 General check for load cell shall be carried out.
1.07.05 Test report for degree of protection on enclosure shall be furnished.
1.07.06 Accuracy/performance check shall be demonstrated at site.
1.08.00 Dust Control & Miscellaneous Systems(Dust Suppression & Dry Fog Dust
Suppression System)
The details of the checks to be carried out on the various equipments are to be
submitted by the Contractor for Owners approval. However some indicative checks
on different items are given below which should necessarily form a part of the Quality
Assurance Plan to be agreed with by the Owner.
1.08.01 Pumps
(a) All materials should be of tested quality and test certificates to be provided.
(b) DPT of machined shaft and impeller shall be done.
(c) Shaft forgings to be also subjected to ultrasonic testing.
(d) Impellers to be dynamically balanced to ISO 1940 Gr.6.3
(e) All pressure parts shall be hydraulically tested at 150% of the shut-off head or
200% of rated head, whichever is higher for 30 minutes. No leakage is
allowed.
(f) All pumps to be performance tested as per Hydraulic Institute Standard/Indian

Standard. Performance test to include check for noise, vibration level and
temperature rise.
1.08.02 Valves & Specialities
(a) Valves and Specialities shall be tested as per relevant standards / codes.
(b) Seat Leakage and hydraulic test to be carried out as per relevant standards /
codes.
1.08.03 Pipes and Fittings
Pipes and fittings shall be tested as per relevant standards / codes.
1.08.04 Air Compressor
a) All pressure parts shall be hydraulically tested at not less than 150% of design
pressure for a duration of 30 minutes prior to painting.
MUZAFFARPUR TPP
PADDLE FEEDER
b) All other parts including inter-connecting piping shall be hydraulically tested

wherever possible, as per relevant codes.
c) Ultrasonic testing shall be carried out on all forgings and rotor for dia 50mm
and above. MPI/DPT shall be done on machined area of the components.
d) During assembly all clearances and alignments shall also be checked and
recorded
e) Rotor shall be statically and dynamically balanced
f) Performance Test(Shop Test)
i. Performance test on the compressor shall becarried out in accordance

with ISO:1217/Eq. The test shall also include demonstration of loading
and unloading mechanism(Capacity control) and operation of safety
valve
ii. Vibration and Noise level measurement shall be done during shop
performance test.
1.08.05 Air Receiver
a) Each finished vessel shall be hydraulically tested at 150% of the design

pressure for a duration of 30 minutes
b) NDT on weld joints shall be as per respective code requirements or the

minimum as specified below
i. 100% DPT on root run of butt welds
ii. 100% DPT on all finished butt welds and fillet welds
iii. 10% RT on butt welds which shall include all T-Joints
1.09.00 Dust Extraction and Ventilation Systems
1.09.01 Fan
(a) All materials should be of tested quality and test certificates should be
provided.
(b) Dynamic balancing of the fan impellers to be carried out.
(c) Shop run test shall be conducted on all centrifugal fans including check for
noise and vibration level.
(d) Performance test shall be conducted on one fan of each type at shop for
capacity, pressure, efficiency and power consumption.
MUZAFFARPUR TPP
PADDLE FEEDER
1.09.02 Valves and Specialities
Refer 1.08.02 above
1.09.03 Pipes and Fittings
Refer 1.08.03 above
1.10.00 Vibrating Grizzly Feeders and Vibrating Feeders
(a) Shaft forgings to be checked for ultrasonic testing in addition to check for
chemical, mechanical, hardness, microstructure etc. as per applicable
material specification
(b) Following minimum NDT requirements to be ensured for welds:
i) Butt welds - 10% UT/RT and 100% MPI/DPT.
ii) Fillet Welds - 10% MPI/DPT.
(c) Shop trial run test shall be conducted to checks for speed (RPM),
amplitude(stroke), temperature rise and noise level.
1.11.00 Crushers(Ring Granulators)
The details of the checks to be carried out for various components are to be
submitted by the Contractor for Owner’s approval. However, some indicative checks
on different items are given below which should necessarily form part of the Quality
Assurance Plan to be agreed with the Owner.
(a) All plates equal to or above 25mm thickness shall be ultrasonically tested.
(b) Shaft forgings and suspension bars to be checked for ultrasonic testing in
addition to check for chemical, mechanical, hardness, microstructure etc. as
per applicable material specification.
(c) Following minimum NDT requirements to be ensured for welds:
(d) Crusher rotor to be dynamically balanced. Procedure to be submitted for

approval.
(e) No-load trial run test to be carried out at shop to check for speed (RPM),
temperature rise, noise level and vibration.
MUZAFFARPUR TPP
PADDLE FEEDER
1.12.00 Travelling Trippers & Bunker Sealing Arrangement
Mobile Trippers
(a) Shaft and wheel forgings – Ultrasonic test in addition to check for
chemical,mechanical,hardness,microstructure etc. as per applicable material
specification shall be conducted.
(b) Following minimum NDT requirements to be ensured for welds:
(c) Shop trial run test shall be carried out and shall include check for noise level
and vibration.
1.13.00 In-Line Magnetic Separators
i) Overall Dimensional, Visual check alongwith control panel.
ii) HV & IR.
iii) Operation, temperature rise, lifting capacity, force index and gauss strength.
1.14.00 Metal Detectors
i) Functional test including sensitivity, Burn in test, operation of liquid spray

marker, detection of smallest piece of different materials as specified.
ii) Test report for Degree of protection test to be furnished.
1.15.00 Coal Sampling Units
(a) Free carriage and cutter movement, speed of cutter and dust door closing and
sealing shall be tested for samplers.
(b) “No load test” shall be carried out for crushers.
1.16.00 Elevators (Rack and Pinion Type)
submitted by the contractor for owner’s approval. However, some indicative checks
on different items are given below which should necessarily form part of the quality
assurance plan to be agreed with the owner.
1.16.01 All forgings shall be subjected to ultrasonic test to ensure free from internal defects in
addition to check for chemical and mechanical properties.
1.16.02 10% of the welds selected at random shall be subject to DP test.
1.16.03 All forged components shall be subjected to DPI/MPI after machining.
MUZAFFARPUR TPP
PADDLE FEEDER
1.16.04 Gear Reducer shall be checked for gear ratio, backlash, contact pattern. No load
shop trial run shall be conducted on gear boxes to check for oil leakage, temperature
rise, noise and vibration.
1.16.05 Buffer springs shall be subjected to load test as per relevant specifications. Material
certificates for springs shall also be furnished.
1.16.06 All components prior to assembly shall be checked for dimensions.
1.16.07 Function test of Elevator assembly shall be carried out.
1.16.08 All electrical equipments shall be of proven quality.
1.16.09 Galvanized components/parts shall be checked for weight of Zn coating, thickness of

coating, uniformity of coating and adhesion test and visual examination as per IS
2633 and IS 2629.
1.17.00 Reversible Stacker Cum Reclaimer
1.17.01 All plates equal to or above 25mm thickness shall be ultrasonically tested.
1.17.02 Forgings/Castings for Shaft, Gears/Pinion, Axles, Rail Wheels, Bucket

Hub/Teeth/Blade etc., shall be subject to ultrasonic testing in addition to check for
chemical, mechanical, hardness and micro structure as per applicable material
specification
1.17.03 MPI/DPT shall be carried out on forgings/casting after machining/hardfacing if

applicable.
1.17.04 Following minimum NDT requirements shall be followed for welds:
i) Butt Welds in Tension- 100% UT/RT and 100% MPI/DPT.
ii) Butt Welds in Compression- 10% UT/RT and 10% MPI/DPT.
iii) Fillet Welds - 10% MPI/DPT.
1.17.06 Trial assembly of Stacker/Reclaimer, Sub-assemblies shall be carried out at shop.

Manufacturer shall furnish detail procedure for various sub assemblies such as wheel
bogies, base frame, slew deck, bucket wheel, boom, bucket wheel with shaft and
sample bucket etc. for NTPC approval.
1.18.00 WAGON TIPPLER ALONGWITH SIDE ARM CHARGER
1.18.01 All plates equal to or above 25 mm thickness shall be ultrasonically tested.
1.18.02 Casting and forgings/bars (Shafts, Racks, Pinion wheels, Arm etc.) shall be subjected
to ultrasonically test in addition to check for chemical, mechanical, hardness,
microstructure etc. as per applicable material specification.
1.18.03 Machined and hardfaced surface of casting/forging shall be subjected to DPT/MPI.
MUZAFFARPUR TPP
PADDLE FEEDER
1.18.04 Following minimum NDT requirements shall be followed for welds:
1.18.05 Trial assembly of various sub-assemblies of Wagon Tippler alongwith Side Arm
Charger shall be carried out in shop. Manufacturer shall furnish detail procedure for
the same for NTPC approval.
APRON FEEDER
1. All plates equal to or above 25 mm thickness shall be ultrasonically tested.
2. Castings and forgings, forged/rolled bar/section shall be subjected to

ultrasonically test in addition to check for chemical, mechanical, hardness,
microstructure etc. as per applicable material specification.
3. Machined and hardfaced surface of casting/forging and other hardened,

stellited parts shall be subjected to DPT/MPI in addition to check for case
depth, hardness as applicable for chain/sprocket/gear
reducer/rollers/wheel/pan etc.
4. Suitable check for life time sealing of rollers for protection from dust and water
shall be done
5 Following minimum NDT requirements shall be followed for welds:
6. For other items like drive system, motor, pulley, belt relevant portion of
specification shall be applicable
7. No load trial run test shall be carried out at shop on completely assembled
apron feeder to check for trouble free operation, temperature rise, Noise &
Vibration.
MUZAFFARPUR TPP
PADDLE FEEDER
PART - B
SUB-SECTION-IIIE-02
INDUCTION MOTORS

PART-B
CLAUSE NO.
QUALITY ASSURANCE
MOTOR
TESTS/CHECKS
Welding/Brazing(WPS/PQR)
Make/Type/Rating /General
Electrical Characteristics
Mech/Chem. Properties
Physical Inspection
NDT /DP/MPI/UT
Heat Treatment
Metallography
Dimensional
Visual
TEMS/COMPONENTS
Plates for stator frame, end Y Y Y Y Y Y

shield, spider etc.
Shaft Y Y Y Y Y Y Y
Magnetic Material Y Y Y Y Y
Rotor Copper/Aluminium Y Y Y Y Y Y
Stator copper Y Y Y Y Y Y
SC Ring Y Y Y Y Y Y Y Y
Insulating Material Y Y Y Y
Tubes, for Cooler Y Y Y Y Y Y
Sleeve Bearing Y Y Y Y Y Y
Stator/Rotor, Exciter Coils Y Y Y Y Y
Castings, stator frame, terminal Y Y Y Y Y Y
box and bearing housing etc.
Fabrication & machining of Y Y Y Y Y
stator, rotor, terminal box
Wound stator Y Y Y Y
Wound Exciter Y Y Y Y
Rotor complete Y Y Y
Exciter, Stator, Rotor, Terminal Y Y Y
Box assembly
Accessories, RTD, BTD,CT, Y Y Y
Space heater, antifriction
bearing, gaskets etc.
Complete Motor Y Y Y
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a
detailed
Quality Plan indicating the practices & Procedure followed along with
relevant
supporting documents during QP finalization. However, No QP for LT motor
upto
50KW.
2. Additional routine tests for Flame proof motors shall be applicable as per
relevant
standard
3. Makes of major bought out items for HT motors will be subject to NTPC
approval.
Y1 = for HT Motor / Machines only.
MUZAFFARPUR TPP
MOTORS
CLAUSE NO.
QUALITY ASSURANCE
MOTOR
TESTS/CHECKS
per IS-325/IS-4722 /IS- 9283/IS

Routine & Acceptance tests as
Hydraulic/Leak/Pressure Test
2148/IEC60034\IEC 60079-I
Tan delta, shaft voltage &

Magnetic Characteristics
Paint shade, thickness &

Thermal Characteristics
polarization index test

Dynamic Balancing
Over speed
adhesion
Vibration
Run out
ITEMS/COMPONENTS
Plates for stator frame,

end shield, spider etc.
Shaft
Magnetic Material Y Y
Rotor Copper/Aluminium
Stator copper Y
SC Ring
Insulating Material Y
Tubes for Cooler Y
Sleeve Bearing Y
Stator/Rotor, Exciter Coils
Castings, stator frame,
terminal box and bearing
housing etc.
Fabrication & machining of
stator, rotor, terminal box
Wound stator
Wound Exciter
Rotor complete Y Y
Exciter, Stator, Rotor,
Terminal Box assembly
Accessories, RTD,
BTD,CT, , Space heater,
antifriction bearing,
gaskets etc.
Complete Motor Y Y Y Y1 Y
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed
Quality Plan indicating the practices & Procedure followed along with relevant
supporting documents during QP finalization. However, No QP for LT motor upto
50KW.
2. Additional routine tests for Flame proof motors shall be applicable as per relevant
standard
3. Makes of major bought out items for HT motors will be subject to NTPC approval.
Y1 = for HT Motor / Machines only.
MUZAFFARPUR TPP
MOTORS
PART - B
SUB-SECTION-IIIE-03
LT SWITCHGEAR & BUSDUCT

PART-B
LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION,
LOCAL MOTOR STARTERS)
ATTRIBUTES /
Functional & Operational Features as
Paint Shade, Adhesion, Thickness &
Degree of Protection Routine test as
All Routine tests as per NTPC spec.

CHARACTERISTICS
Make, Model, Type, Rating & TC
Pretreatment as per IS 6005

Item to conform to relevant
Mechanical Properties
Dimensions & Finish
Chemical properties
Electrical properties
Functional Checks
Milli-volt drop Test
IR – HV – IR Test
per NTPC Spec.
per NTPC spec

ITEMS/ COMPONENTS/
SUB SYSTEM
ASSEMBLIY
Sheet Steel (IS : 513) Y Y Y Y Y
Aluminum Bus bar Y Y Y Y Y Y

Material
(IS : 5082)
Copper Bus bar Material Y Y Y Y Y Y
(IS : 613)
Support Insulator Y Y Y Y Y
Air Circuit Breaker ( IS: Y Y Y Y Y Y Y
13947)
Energy Meters ( IS : Y Y Y Y Y Y
13010, 13779 )
Power & Aux. Contactors Y Y Y Y Y
(IS : 13947 )
Protection & Aux. Relays Y Y Y Y Y Y
(IS : 3231)
Control & Selector Y Y Y Y Y
Switches
( IS : 13947)
CT’s & PT’s ( IS 2705 / Y Y Y Y
3156)
MCCB ( IS : 13947 ) Y Y Y Y
Indicating Meters ( IS : Y Y Y Y Y Y
1248 )
Indicating Lamps ( IS : Y Y Y Y Y
13947 )
Air Break Switches Y Y Y Y Y
( IS : 13947 )
Control Terminal Blocks Y Y Y Y
MUZAFFARPUR TPP
LT SWGR BUSDUCT
LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
ATTRIBUTES /
CHARACTERISTIC
Paint Shade, Adhesion, Thickness & Finish

Functional & Operational Features as per
All Routine tests as per NTPC spec. & IS

Degree of Protection Routine test as per
S
Item to conform to relevant Standards

Make, Model, Type, Rating & TC
Pretreatment as per IS 6005

Dimensions & Finish
Chemical properties
Electrical properties
Functional Checks
Milli-volt drop Test

NTPC Spec.
NTPC spec
ITEMS/ COMPONENTS/
SUB SYSTEM
ASSEMBLIY
Fuse ( IS 13703) Y Y Y Y
Control Transformer Y Y Y Y Y Y
( IS : 12021)
Push Buttons ( IS : 4794 Y Y Y Y Y
)
Transducer ( IEC : Y Y Y Y Y Y
60688)
MCB ( IS : 8828) Y Y Y Y Y
Breaker Handling Trolley Y Y Y Y Y Y
Synthetic Rubber Y Y Y Y Y
Gasket
(IS : 11149 )
LT SWITCHGEAR Y Y Y Y Y Y Y Y Y Y Y
( IS : 8623 )
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed

Quality Plan indicating the practice and procedure along with relevant supporting
documents.
2. Makes of all major Bought Out Items will be subject to NTPC approval.
MUZAFFARPUR TPP
LT SWGR BUSDUCT
LT BUSDUCT
ATTRIBUTES ,
Paint Shade, Thickness, Adhesion & Finish

CHARACTERISTICS
Degree of Protection routine test as per

Galvanizing Test as per IS 2629/ 2633/
Weld Quality Check ( DP test & x-ray
WPS Approval, Welder Qualification
Tightness by Torque measurement

Item to conform to relevant IS
Dimension & Surface Finish
Make, Type, Rating & TC
Phase Sequence Check

Electrical Clearances
Chemical Properties
Electrical Properties
NTPC spec.
ITEM,
COMPONENTS, SUB
SYSTEM ASSEMBLY
Aluminum Sheets / Y Y Y Y Y Y Y
Plates / Strips /
Flexibles / tubes
( IS : 5082 / 737 )
CRCA Flats / ISMC ( Y Y Y Y Y
IS 2062 )
Neoprene / Synthetic Y Y Y Y
Rubber Gaskets ( IS
11149 / 3400 )
Rubber Bellows (IS : Y Y Y Y
3400)
Support Insulator ( BS Y Y Y Y
: 2782,
IEC : 660, IS : 10912 )
Galvanized Structure Y Y Y Y
& GI Earthing Flat
(IS : 2629 / 2633 /
4749 )
Space Heater & Y Y Y
Thermostat
LT Busduct (IS : 8623 Y Y Y Y Y Y Y Y Y Y Y
PART 2)
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed

Quality Plan indicating the practice and
procedure along with relevant supporting documents.
MUZAFFARPUR TPP
LT SWGR BUSDUCT
PART - B
SUB-SECTION-IIIE-04
LT POWER CABLE

PART-B
QUALITY ASSURANCE & INSPECTION MODULE NO. SQE 13
L.T POWER CABLES Page 1 of 3

(1.1 KV PVC & XLPE CABLES)
Attributes /
Tensile strength, elongation before & after ageing of

Characteristics
Thermal Stability of insulation and outer sheath *
Constructional / requirement as per NTPC Spec.

Sequential marking/surface finish /cable length
Armour coverage, Cross over, looseness, Gap
Relevant Standard and NTPC specification

Anti ternite treatment on wooden drums
Routine and acceptance test as per

between two armour wire/strip
Make, Rating, Type & TC
insulation & outer sheath

Dimension/surface finish
Chemical Composition
Lay length / Sequence

Hot set test (XLPE)

Item / Components /
FRLS Test
Spark Test
Sub System Assembly
Aluminum (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
XLPE Compound(IS-7098 Part-I) Y Y Y Y Y
FRLS PVC Compound(IS-5831 ) Y Y Y
ASTM-D-2843/ ASTM-D-2863
IEC-754 Part-I
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554 & 7098 – Part-1) Y Y Y Y Y Y Y Y Y
ASTM-D-2843/ IS 10810 ( Part- - 58 )
IEC-754 Part-I
Swedish Chimney SS 4241475 for (F3
category)
Flammability test IEC-332 Part –3 Cat-
B
Wooden drum (IS-10418) / Steel drum Y Y
Note: 1.This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and procedure
along with relevant supporting documents. All major BoIs to be of makes approved from owner.
∗ 2. Not applicable for XLPE insulation
MUZAFFARPUR TPP
LT POWER CABLES
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for
all types & sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
2) High voltage test at room temperature
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of
the cables on the cable drums selected at random as per sampling plan
mentioned in IS: 1554 Part 1 & IS 7098 Part-I
A) For Conductor
1) Annealing test For copper conductor only
2) Tensile test For aluminium conductor only
3) Wrapping test For aluminium conductor only
4) Resistance test
B) For Armour Wires / Formed Wires ( If applicable )

1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires
only
8) Uniformity of Zinc coating For G S wires / Formed wires
only
9) Adhesion test For G S wires / Formed wires
only
10) Freedom from defects
C) For PVC / XLPE insulation & PVC Sheath

1) Test for thickness
2) Hot set test For XLPE insulation only
3) Tensile strength & Elongation before ageing
MUZAFFARPUR TPP
LT POWER CABLES
D) For completed cables

1) Insulation resistance test ( Volume resistivity method )
E) Following tests shall be carried out and only one sample shall be taken
from each offered lot of all sizes for these tests:-
1) Tensile strength & elongation after ageing on PVC / XLPE insulation and PVC outer
sheath
2) Thermal stability test on PVC insulation and outer sheath
3) Oxygen index test on outer sheath
4) Smoke density rating test on outer sheath as per ASTM –D 2843
5) Acid gas generation test on outer sheath as per IEC – 754 (Part 1)
6) Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed cable
7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable
F) Following tests shall be carried on one length of each size of offered lot:
1) Surface finish, length measurement, sequence of cores, armour coverage, Gap between two
consecutive armour wires / formed wires
MUZAFFARPUR TPP
LT POWER CABLES
PART - B
SUB-SECTION-IIIE-05
LT CONTROL CABLES

PART-B
QUALITY ASSURANCE & INSPECTION MODULE NO. SQE 14
L.T CONTROL CABLES Page 1 of 3

(1.1 KV PVC CABLES)
Attributes /
Routine & Acceptance test as per relevant

Constructional feature as per NTPC Spec.
Characteristics
Armour coverage, cross over, looseness,
Thermal stability of insulation and outer

after ageing of insulation &outer sheath
Sequential marking/surface finish/cable
Tensile strength, elongation before &
Anti termite treatment on wooden drums
standard & page 2 & 3 of this table

gap between two armour wire
Dimension/surface finish
Make, Type, Rating, T.C
Chemical Composition
Lay length/Sequence
FRLS Test
Spark Test
Item / Components /
Sub System Assembly
sheath
length
Copper Conductor (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
FRLS PVC Compound IS-5831 Y Y Y Y
ASTM-D-2843/ IS 10810 (Part-58
)
IEC-754 Part-1
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554- 1 ) Y Y Y Y Y Y Y Y Y
ASTM-D-2843/ IS 10810 (Part-58
)
IEC-754 Part-1
Swedish Chimney: SEN SS 424-
1475( F3 category)
Flammability test IEC-332 Part-3
Cat-B
Wooden drum( IS : 10418) / Steel Y Y
drum
• 1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating
the Practice and procedure along with relevant supporting documents.
MUZAFFARPUR TPP
TECHNICAL SPECIFICATION SUB-SECTION-IIIE-05
STAGE-II (2X195 MW)
COAL HANDLING PLANT PACKAGE SECTION-VI LT CONTROL PAGE 1 OF 3
BID DOCUMENT NO. : CS-0350-155(R)-2 PART – B CABLES
CONTROL CABLE
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all
types & sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of
the cables on the cable drums selected at random as per sampling plan
mentioned in IS: 1554 Part 1
A) For Conductor
1) Annealing test For copper conductor only
2) Resistance test
B) For Armour Wires / Formed Wires ( If applicable )

1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires
only
8) Uniformity of Zinc coating For G S wires / Formed wires
only
9) Adhesion test For G S wires / Formed wires
only
10) Freedom from defects
C) For PVC insulation & PVC Sheath

1) Test for thickness
2) Tensile strength & Elongation before ageing
D) For completed cables

1) Insulation resistance test ( Volume resistivity method )
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
E) Following tests shall be carried out and only one sample shall be taken
from each offered lot of all sizes for these tests:-
1) Tensile strength & elongation after ageing on PVC insulation and PVC outer sheath
2) Thermal stability test on PVC insulation and outer sheath
3) Oxygen index test on outer sheath
4) Smoke density rating test on outer sheath as per ASTM –D 2843
5) Acid gas generation test on outer sheath as per IEC – 754 (Part 1)
6) Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed cable
7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable
F) Following tests shall be carried on one length of each size of offered lot:
1) Surface finish, length measurement, sequence of cores, armour coverage, Gap between two
consecutive armour wires / formed wires
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
PART - B
SUB-SECTION-IIIE-06

PART-B
INSTRUMENTATION CABLE
TESTS
Vol. Resistivity. at room & Elevated Temp. (A) ++

Tensile & Elongation before & after aging (A) ++
Swidesh chimney Test (SS-4241475) (A) ++
Outer-Sheathe/core marking, end sealing (A)
ITEMS
Constructional detail, dimensions (A)
Overall/Coverage/Continuity (A)
Conductor Resistance ® & (A)
Electrical Parameters ** (A) +

Insulation Resistance ® & (A)
Visual, Surface finish (A) +
Spark test report review ®

Thermal Stability (A) +
High Voltage ® & (A)
Persulphate Test (A) +
FRLS Test * (A) ++

1. Instrument cable
twisted and shielded
Conductor(IS-8130) Y Y Y
Insulation(VDE-207) Y Y Y Y Y Y
Pairing/Twisting Y Y Y
Shielding Y Y Y
Drain wire Y Y Y Y Y
Inner Sheath Y Y Y Y Y Y
Outer Sheath Y Y Y Y Y Y
Over all cable Y Y Y Y Y Y Y Y Y
Cable Drums(IS-10418) Y Y
Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6) Compensating cables shall
be checked for Thermal EMF/Endurance test as per IS 8784.
Note : This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan
indicating his practice & Procedure along with relevant supporting documents during QP finalization for
all items.
Note : ® - Routine Test A - Acceptance Test Y - Test Applicable
Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable)
• * FRLS Tests: Oxygen / Temp Index ( ASTM D-2863), Smoke Density Rating ( ASTM – D 2843),
HCL Emission ( IEC-754-1)
• ** Characterisitic Impedence, Attenuation, Mutual Capacitance, Cross Talk ( As applicable)
+ Sample size will be One No. of each size/type per lot.
++ Sample size will be One No. sample for complete lot offered irrespective of size/type.
MUZAFFARPUR TPP
INSTRUMENTATION
PART - B
SUB-SECTION-IIIE-07
STATION LIGHTING

PART-B
STATION LIGHTING SQE_17

Item Components
Routine Test as per relevant std aad

Paint Shade Thickness Adhesion &
Bought Out Items/ Bill of Material

Sub System
Acceptance Test as per relevant

Functional Check as per spec.
Assembly
Constructional Feature as per
Item to conform to relevant

Make, Type , Rating/ TC
Pre-Treatment of sheat
Attributes
Characteristics
Galvanise Test
std and spec

NTPC spec.
Dimension
HV & IR
standard
IP Test
Finish
spec
Luminaries (IS-10322 Part- Y Y Y Y Y
5 Sec.1)
Electronic Ballast Y Y Y
Y
Lighting Wire (IS-694) Y
Y
Fans (IS-374) Y
Y
Pole (IS-2713) Y Y Y Y
Y
Lamps (IS-9800, IS-9974) Y Y Y
Lighting Mast (with raise Y Y Y Y Y
& lower lantern type) Y
Wall Mounted Lighting Y Y Y Y Y Y Y Y Y Y Y Y
Panel (IS-513, IS-5)
Switch Box/ Junction Y Y Y Y Y Y Y Y Y Y Y Y
Box/Receptacles/ Local
Push Button
Station,Lighting Panel (IS-
513, 2629, 2633, 4759,
6745)
Cable Gland (BS-6121) Y Y Y
Cable Lug (IS-8309) Y Y Y
Flexible Conduit Y
Y
Lighting Transformer (IS- Y Y Y
1117)
Epoxy & Galvanised Y Y Y
Conduit (IS-9537, 2629, Y
2633, 4759, 6745)
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan
indicating the practice and procedure along with relevant supporting documents.
2. Make of all major Bought Out Items will be subject to NTPC approval.
MUZAFFARPUR TPP
STATION LIGHTING
PART - B
SUB-SECTION-IIIE-08
CABLING, EARTHING & LIGHTNING

PROTECTION

PART-B
QUALITY ASSURANCE & INSPECTION MODULE NO. SQE-16

Page 1 of 1
CABLING, EARTHING, LIGHTNING PROTECTION
ATTRIBUTES /
CHARACTERISTICS
Constructional feature as per NTPC Specification

Acceptance tests as per relevant standard &
Routine tests as per relevant standard &
Paint shade, paint thickness, adhesion
Bought out items/Bill of material

Galvanise Test (If Applicable)
Pre-treatment of sheet
Deflection test*
Surface finish
IP protection
specification
specification
Proof load*
Dimension
Functional
HV & IR
ITEMS/COMPONENTS /
SUB SYSTEMS
Wall Mounted-Lighting Panel (IS- Y Y Y Y Y Y Y Y Y Y Y Y

513, IS:5, IS:2629, 2633, 6745)
Switch box/junction box/ Y Y Y Y Y Y Y Y Y Y Y Y
Receptacles Panel (IS-513, IS:5,
IS:2629, 2633, 6745)
Cable glands(BS-6121) Y Y
Cable lug(IS-8309) Y Y
Lighting wire(IS-694) Y Y
Flexible conduits Y Y Y
Conduits(Galvanise & Epoxy) IS- Y Y Y Y Y
9537 & IS-2629,2633 ,6745
RCC Hume Pipe (IS-458) Y
Cable termination & straight Y Y Y
through joint (VDE-0278)
Cable Trays, Flexible supports Y Y Y Y Y Y Y Y Y Y Y
system & accessories IS-513,
2629,2633,6745
Trefoil clamp Y Y
GI flats for earthing & lighting Y Y Y Y Y
protection (IS 2062, 2629,
6745,2633)
GI wire (IS-280) Y Y
Fire Sealing System ( BS –476) Y Y Y
.Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan indicating the
practice and procedure along with relevant supporting documents.
2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as per details given in
the NTPC technical specification & approved MQP. The above acceptance tests shall be done only on one sample
from each size of offered lot.
3. Make of all items will be subject to NTPC approval.
MUZAFFARPUR TPP SUB-SECTION-IIIE-08

STAGE-II (2X195 MW) CABLING, EARTHING
& LIGHTNING
PROTECTION
PART - B
SUB-SECTION-IIIE-09
CONTROL PANELS

PART-B
CONTROL PANEL ( AHP & CHP) SQE_25
Attributes
Routine test as per relevant std.

Characteristics
Interlock Functional & Operation

Type/ Rating/Functional check
Paint finish/ shade/thickness

IS:6005 ,Seven tank process
Testing / Simulation check

Mountings / BOM/ Make,
Degree of Protection Test

Specification requirement
Constructional Features
Chemical Properties
Dimensions / Finish
Item Components
Sub System Assembly
Completeness
HV/IR
Sheet Steel (IS-513) Y Y Y
Aluminum / Copper Bus- Y Y Y Y
bar(IS-5082/IS-613/IS-
1987)
Support Insulator (BS- Y Y Y Y
2782/IEC-660/IS-10912)
Control / Selector Y Y Y
Switch(IS-6875)
Contractor/ MCB(IS-13947) Y Y Y
O/L Protection relays(IS- Y Y
3231)
C.T /V.T/ Indicating Y Y Y
Meter(IS-2705/3156/1248)
Fuse/ Fuse carrier(IS- Y Y Y
13703)
Terminals/lugs/pvc Y Y Y Y Y
wires(IS-13947//IS-694)
Timers(IS-3231) Y Y Y
LVS, Mosaics Y
Push Button/ Lamp/ (IS- Y Y Y
6875)
Control Transformer (IS- Y Y Y
12021)
Mimic, Annunciater Y Y
GASKET(IS-11149) Y Y Y Y Y
Fabrication Y
Pretreatment & Painting Y Y
Control panel Y Y Y Y Y
MUZAFFARPUR TPP
CONTROL PANEL
NOTE:
1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan
2. All major Bought Out Items will be subject to NTPC approval.
MUZAFFARPUR TPP
CONTROL PANEL
PART - B
SUB-SECTION-IIIE-10
PROGRAMMABLE LOGIC CONTROLLER

PART-B
PROGRAMMABLE LOGIC CONTRLLER

TESTS
Review of TC for instruments/ Devices/ Recorders, Indicators/ Mosaic Items/
Functional Check for Control Element , Annunciation ®

ITEMS
GA, BOM ,Lay Out of components ®
Component Rating/ Make / Type ®
Accessibility of TBS/ Devices ®
Test as per IEC 1131 ® *
Test as per Std ® & ( A)

Alignment of Section ®
Thickness/Adhesion ®
Transducers ®
Dimensions ®
Illumination ®
Paint Shade/
IR & HV ®
Wiring ®
Visual ®
Mimic ®
1. PLC Panel Y Y Y Y Y Y Y Y Y Y Y Y
2. Control Desk With PLC Y Y Y Y Y Y Y Y Y Y Y Y Y
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance
Programme in General Technical Conditions
2) This is an indicative list of test/ checks. The manufacturer is to furnish a detailed quality plan
indicating the Practice and Procedure alongwith relevant supporting documents.
*Applicable for PLC Y - Test Applicable , ® - Routine Test (A) - Acceptance Test
MUZAFFARPUR TPP
PLC
PART - B
SUB-SECTION-IIIE-11
BATTERY CHARGER & BATTERIES

PART-B
DC SYSTEM SQE_19
LEAD ACID BATTERY
ATTRIBUTES /
CHARACTERISTICS
Lead Coating Thickness (min. 25 microns,
Constructional requirements as per NTPC
rate along with the test for voltage during

Test for Capacities for 10 hrs. discharge
Checking of Polarity & absence of short
Conformance to CPWD Spec. for Teak
Marking ( Routine & Acceptance Test)

Conformance to relevant part drg. &
Paint Process checks, Paint Shade,
circuit (Routine & Acceptance Test)

IS: 6848 App.F) & Adhesion Check
Thickness, Adhesion & Finish
discharge ( Acceptance Test)

Manufacturer’s standards
Chemical composition
Insulation Resistance
Dimensions & Finish
Spec
ITEMS, COMPONENTS, SUB
SYSTEM ASSEMBLY
Container & Lids ( IS : 1146) Y Y
Vent Plugs Y Y
Sealing Compound Y Y
( IS : 3116 )
Positive & Negative Plates Y Y
Separators ( IS : 6071 ) Y Y
Electrolyte Y Y
( Water / Sulphuric Acid )
( IS : 1069 / 266 )
Inter-cell Connectors & Fasteners Y Y Y
Battery Stand Y Y Y Y
Cell Insulators Y Y Y
Stack Assembly Y Y
Lead Acid Battery Y Y Y Y Y
( IS : 1652 )
Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality
Plan indicating the practice and procedure along with relevant supporting documents.
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
COAL HANDLING PLANT PACKAGE SECTION-VI BATTER & BATTERY PAGE 1 OF 4
BID DOCUMENT NO. : CS-0350-155(R)-2 PART – B CHARGER
Ni- Cd BATTERY
ATTRIBUTES /
Polarity & absence of short circuit (Routine & Acceptance

CHARACTERISTICS
Conformance to relevant part drg. & Manufacturer’s
Marking & Mass (Routine & Acceptance Test)
Retention of Charge Test ( Acceptance Test)

Paint Shade, Thickness, Adhesion & Finish
Air Pressure Test (Acceptance Test)

Air Pressure Test after heat sealing
AH Test (Acceptance Test)

Nickel Plating thickness
Chemical composition
Insulation Resistance
Dimensions & Finish
Resistance to Alkali
(Acceptance Test)
Impact Strength
standards
Test)
ITEMS, COMPONENTS, SUB
SYSTEM ASSEMBLY
Container & Lids Y Y Y Y
Vent Plugs Y Y Y
Perforated Steel Strips Y Y Y Y
Active Material for Positive & Y Y
Negative Plates
Separators Y Y Y
Electrolyte Y Y
Inter-cell Connectors & Fasteners Y Y Y Y
Battery Stand Y Y Y
Cell Insulators Y Y Y
Stack Assembly Y Y Y Y Y Y
Ni-Cd Battery Y Y Y Y Y Y Y
( IS : 10918)
Notes:
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
BATTERY CHARGER
Temperature Rise Test on one unit of each rating if

Verification of Routine test reports as per relevant
Attributes / Characteristics
Complete physical examination for constructional

Dimensional check and Paint shade, thickness,
Degree of Protection Test as per NTCP Spec.

Sheet Steel Pretreatment & Painting process
Conform to relevant Standard & NTPC spec
Burn-In Test at 50^C for 48 hrs in energised

Ripple Content Test, Load Limiter & AVR
features as per NTPC approved drgs &
Alternating current measurement test

Make, Model, Type, Rating & Finish
Operational & Functional Checks

adhesion & Finish checks
Type testing is waived off
Dynamic Response Test

Operation Test
HV & IR Test
Items / Components /
Sub- assembly
condition
f
IS
Rectifier Transformer and Y Y Y Y Y

Reactors IS : 4540, 2026)
Electronic Components Y Y Y
including Potentiometer
( Vernier Type)
Electronic Cards Y Y Y
PCB & racks for electronic Y Y
cards
Control & Selector Y Y Y
Switches
( IS : 6875)
Indicating Meters (IS : Y Y Y
1248 )
Indicating Lamps (IS: Y Y Y
13947)
Air Break Switches / Fuses Y Y Y
( IS : 13947 / 13703 )
Control Terminal Blocks Y Y
(IS : 13947)
Control Transformer Y Y Y
( IS : 12021)
Push Buttons ( IS : 4794 ) Y Y Y
MCB ( IS : 8828) Y Y Y
PVC insulated Copper Y Y
control wires (IS : 694 )
Sheet Steel ( IS : 513 ) Y Y Y
Synthetic Rubber Gaskets Y Y
Annunciator Y Y Y
Battery Charger Y Y Y Y Y Y Y Y Y Y Y
Notes:
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
BATTERY CHARGER
Attributes / Characteristics
Complete physical examination for constructional
Operational & Functional Checks of aux. Devices

Dimensional check and Paint shade, thickness,
Ripple Content Test, Load Limiter operation &
like annunciator, switches, indiactors etc.

features as per approved drgs
Make, Model, Type, Rating
adhesion & Finish checks
AVR Operation Test
HV & IR Test
Burn-In Test
Items / Components /
Sub- assembly
Battery Charger Y Y Y Y Y Y Y
Note 1 : This check list is applicable for Battery Charger of capacity upto 24 V / 48 V , 150
A DC.
2 : Separate approval of QP is not envisaged. Main Contractor / nominated

inspection agency will carry out the inspection as per above check-list and submit
inspection report to NTPC for their review / acceptance of the same.
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
PART - B
SUB-SECTION-IIIE-12
L.T. INDOOR TRANSFORMER (DRY TYPE)

PART-B
LT INDOOR TRANSFORMER Table: QE-5
Attributes /
Measurement of capacitance & tan

Characteristics
Make / Type / Rating / Model /TC /

Voltage Ratio, Vector Gorup &
Routine Test as per relevant

General Physical Inspection
Visual & Dimensional check
delta between winding

Mechanical properties
Chemical Properties
Thermal Properties
Electrical strength
NDT / DP / MPI
WPS & PQR
Routine Test
standard
Items/Components
Polarity
Sub Systems
Enclosure door, H.V. &

L.V. Cable Box / Flange Y Y Y
Throat
Copper Conductor Y Y Y Y
Insulating Material Y Y Y
CRGO Lamination &
Y
Built Core
Bushing /Insulator
Y Y Y
( IS:2544 / 5621)
Gasket Y Y Y
Off-Circuit Tap Changer Y Y
Core Coil Assembly Y Y
Marshalling Box Y Y
WTI, Thermister,
Y Y
Terminal Connector
Welding Y
Complete Transformer
Y Y Y
(IS:11171 / IEC 60076)
Notes: 1) This is an indicative List of test/checks. The manufacturer is to furnish a
detailed Quality Plan indicating his practice and procedure along with
relevant supporting documents during QP finalisation for all item.
2) All major Bought Out Items will be subject to NTPC approval.
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
COAL HANDLING PLANT PACKAGE SECTION-VI LT INDOOR PAGE 1 OF 1
BID DOCUMENT NO. : CS-0350-155(R)-2 PART – B TRANSFORMER
PART - B
SUB-SECTION-IIIE-13
PROCESS CONNECTION & PIPING

PART-B
CLAUSE NO.
QUALITY ASSURANCE
PROCESS CONNECTION & PIPING
TESTS
GA, BOM, Layout of component &
Flattening,flaring,hydrotest,hardnes
s check as per ASTM standard (A)
Proof pressure test,Dismantling &

reassembly test,Hydrulic impulse
Chemical/physical properties of
Accessability of TBs/Devices ®
Make, Model, Type, Rating®
Illumination,grounding ®
Tests as per standards &

Paint Shade/thickness ®
Component Ratings ®
instrument/devices (R)
construction feature®
and vibration test (R)

Leak/Hydro test(A)
Review of TC for
Dimension ®
specification
material (A)
IR & HV ®
Tubing ®
Wiring ®
Visual ®
ITEMS
Local Instrument Y Y Y Y Y Y Y Y Y Y Y Y Y
enclosure
Local instruments Y Y Y Y Y Y Y Y Y Y Y Y Y
racks
Junction Box Y Y Y Y Y Y Y
*
Gauge Board Y Y Y Y Y Y Y YY
Impulse pipes and Y Y Y Y Y
tubes
Socket weld fittings Y Y Y Y Y
ANSI B-16.11
Compression fittings Y Y Y Y Y Y
Instrument valves & Y Y Y Y Y
Valve manifolds
Copper tubings Y Y Y
ASTM B75
*-applicable for painted junction boxes.
Note: R-Routine Test A- Acceptance Test Y – Test
applicable
Note: This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan
indicating the Practices and Procedure adopted alongwith relevant supporting documents.
PART-B
MUZAFFARPUR TPP
STAGE-II (2X195 MW)
SECTION-VI PROCESS PAGE 1 OF 1
BID DOCUMENT NO.: CS-9560-156-2 CONNECTION &
PIPING
PART - B
SUB-SECTION-IIIE-14
MEASURING INSTRUMENTS
(PRIMARY & SECONDARY)

PART-B
CLAUSE NO.
QUALITY ASSURANCE
MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)

TESTS
Process / Electrical connection (R)
IBR Certification (if applicable )(R)

Make, Model, Type, Rating (R)
Material Test certificate ®

ITEMS
Insulation Resistance (R)

Test as per standard(R)
Dimensions (R)
Calibration (R)
Hydro Test(R)
1. PR Gauge (IS-3624) Y Y Y Y Y
2. Temp. Gauge (BS-5235) Y Y Y Y Y
3. Pr./D.P.Switch(BS-6134) Y Y Y Y Y Y
4. Electronic Y Y Y Y Y Y
Transmitter(IEC-770)
5. Temp. Switch Y Y Y Y Y Y
6. Recorder(IS-9319/ANSI Y Y Y Y Y Y
C-39.4)
7. Vertical indicators Y Y Y Y Y
8. Digital Indicators Y Y Y Y Y
9. Integrators Y Y Y Y
10. Electrical Metering Y Y Y Y Y Y
Instrument (IS-1248)
11. Transducer (IEC-688) Y Y Y Y Y Y
12. Thermocouples (ANSI- Y Y Y Y Y Y
MC-96.1)
13. RTD(IEC-751) Y Y Y Y Y Y
14. Thermowell Y Y Y Y Y
R-Routine Test A- Acceptance Test Y – Test applicable
: Note: 1) Detailed procedure of Environmental Stress Screening shall be as per
Quality Assurance Programme in General Technical Conditions
2) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted
alongwith relevant supporting documents.
MUZAFFARPUR TPP PART-B
COAL HANDLING PLANT PACKAGE (MEASURING
BID DOCUMENT NO.: CS-9560-156-2
BID DOCUMENT NO. : CS-0350-155(R)-2 INSTRUMENTS)
CLAUSE NO.
QUALITY ASSURANCE
TESTS
Process / Electrical connection (R)
IBR Certification as applicable (R)

Requirement as per standard (R)
Make, Model, Type, Rating (R)
Calculation for accuracy (R)

Non-destructive testing (R)
Material test certificate (A)

Insulation Resistance (R)
ITEMS
WPS approval (A)

Dimensions (R)
Calibration (R)
Hydro test (R)

15. Cold junction Y Y Y Y Y
compensation box
16. Orifice plate(BS-1042) Y Y Y Y Y Y Y Y Y Y
* ** ** **
17. Flow nozzle(BS-1042) Y Y Y Y Y Y Y Y Y Y
*
18. Impact head type element Y Y Y Y Y
19. Level transmitter/float Y Y Y Y Y Y Y Y
type switch
20. Flue Gas analyser Y Y Y Y
21. Dust emission monitors Y Y Y Y
*Calibration to be carried out
on one flow element of each
type and size if calibration
carried out as type test same
shall not be repeated.
** If applicable
Note: 1) Detailed procedure of Environmental Stress screening test shall be as per

COAL HANDLING PLANT PACKAGE (MEASURING
BID DOCUMENT NO. : CS-0350-155(R)-2 INSTRUMENTS)
PART - B
SUB-SECTION-IIIE-15
POWER SUPPLY SYSTEM

PART-B
CLAUSE NO.
QUALITY ASSURANCE
POWER SUPPLY FOR C&I SYSTEMS (UPS/BATTERY/BATTERY

CHARGER/ACDB/DCDB)
TESTS
General arrangement/BOM/make of components

Visual/dimension/rating/ Paint Adhesion/ Thickness
Restart with PRI A.C and battery (separately)(R)
Tests as per standard &specification (R)&(A)

Out put voltage and frequency adj.range(A)
Parralel operation and current divison(R)
System transfer and retransfer (R)*

AC input faliure and return test (R)
Load transfer retransfer test (R) *
Relative harmonic content(R)

Premilinary light load test(R)
Input voltage variation (A)
Asynchronous transfer(R)
Load limiter operation (R)

Efficiency ,regulation(R)
Ripple content(R)
IR/HV(R)
/Mimic ®
ITEMS
(R)
UPS/CONVERTER
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
(IEC-146 PT-4)
VOLTAGE
Y Y Y Y Y Y Y Y
STABILISER
LEAD ACID
BATTERY(TUBLAR Y
)-IS-1651
LEAD ACID
BATTERY Y
(PLANTE)-IS-1652
NICKEL CADMIUM
BATTERY(IS- Y
10918/IEC-623)
SMF BATTERY Y
ACDB/DCDB Y Y Y Y
BATTERY
Y Y Y Y Y Y Y Y Y Y
CHARGER
* Transfer time and Over shoot /under shoot during load & system transfer shall be
recorded .
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per

COAL HANDLING PLANT PACKAGE POWER SUPPLY
PART - B
SUB-SECTION-IIIE-16
SAMPLING TESTING & QUALITY

ASSURANCE FOR – CIVIL WORKS

PART-B
CLAUSE NO.
QUALITY ASSURANCE
SAMPLING, TESTING AND QUALITY ASSURANCE FOR CIVIL WORKS
1.00.00 INTRODUCTION
1.01.00 This part of the specification covers the sampling, testing and quality assurance
requirement (including construction tolerances and acceptance criteria) for all civil
and structural works covered in this specification including excavation and filling,
cast in situ concrete and allied works, fabrication and erection of structural steel
works, masonry / sheeting and allied works, finishing items etc.
1.02.00 This part of the technical specification shall be read in conjunction with other Parts of
the technical specifications, general technical requirements & erection conditions of
the contract. Wherever IS code or standards have been referred they shall be the
latest revisions.
1.03.00 All tests required for all materials (bought by Contractor) and workmanship shall be
done / got done by the contractor at his own cost. The rate for respective items of
work or price shall include the cost for all works, activities, equipment, instrument,
personnel, material etc. whatsoever associated to comply with sampling, testing and
quality assurance requirement including construction tolerances and acceptance
criteria and as specified in subsequent clauses of this part.
2.00.00 QUALITY ASSURANCE PROGRAMME (QAP)
2.01.00 The Contractor shall adopt suitable Quality Assurance Programme (QAP) to ensure
that the equipments and services under the scope of contract whether manufactured
or performed within Contractor’s works or at his sub-Contractor’s premises or at the
Owner’s site or at any other place of work are in accordance with the specifications.
Such QAP shall be outlined by the Contractor and shall be finally accepted by the
Owner or his authorized representative after discussions before the start of work.
The QAP shall be generally in line with IS/ISO Systems. The QAP of the Contractor
shall generally indicate the following:
z His organization structure for the management and implementation of the

proposed quality assurance programme
z Quality System Manual
z Design Control System
z Documentation and Data Control System
z Qualification data / details for Contractor’s key personnel.

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COAL HANDLING PLANT PACKAGE SECTION-VI SAMPLING TESTING PAGE 1 OF 36
BID DOCUMENT NO. : CS-0350-155(R)-2 PART - B FOR CIVIL WORKS
CLAUSE NO.
QUALITY ASSURANCE
z The procedure for purchase of materials, parts, components and selection of

sub-contractor’s services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.
z System for shop manufacturing and site erection controls including process,
fabrication and assembly.
z Control of non-conforming items and system for corrective actions and

resolution of deviations.
z Inspection and test procedure both for manufacture and field activities.
z Control of calibration and testing of measuring testing equipment.
z System for Quality Audits.
z System for identification and appraisal of inspection status.
z System for authorizing release of manufactured product to the Owner.
z System for handling, storage and delivery.
z System for maintenance of records, and
z Quality plans for manufacturing and field activities detailing out the specific
quality control procedure adopted for controlling the quality characteristics
relevant to each item of work/ equipment/component.
3.00.00 SAMPLING, LABORATORY AND FIELD TESTING
3.01.00 The Contractor shall provide the facilities whatsoever required and also bear the cost
for all sampling, testing and quality assurance in the field and in the laboratory. The
Contractor shall carry out all sampling and testing in accordance with the relevant
Indian standards and / or international standards and this technical specification.
Where no specific testing procedure is mentioned, the tests shall be carried out as
per the best prevalent engineering practices and to the directions of the Engineer. All
sampling shall be done in the presence of the Engineer or his authorized
representative. The Contractor shall establish the QA&QC laboratory at site and all
field tests shall be done in the presence of the Engineer and / or his authorized
representative. The tests which cannot be carried out in the field laboratory shall be
done at a laboratory of repute such as CSMRS, NCBM, IITs, National Test House,
Kolkata etc. as agreed by the Engineer. The test samples for such test shall be jointly
selected and sealed by the engineer and thereafter these shall be sent to the
concerned laboratory through the covering letter signed by FQA representative of the
engineer. The cost of transportation and other associative cost including the test
charges shall be borne by the contractor. These cost shall deemed to be included in
the respective item of work in the contract. If the Engineer desires to witness such

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
tests at laboratory, Contractor shall arrange to conduct the test in his presence. At
least one set of mix design shall be carried out by contractor at NCB,Ballabgarh/
CSMRS, Delhi.
Before execution of any civil work the Contractor shall conduct full-scale suitability
tests on various construction and building material such as fine and coarse
aggregates, Cement, Reinforcement, construction chemicals, supplementary
cementitious Materials and Construction water to check their suitability for use from
reputed institutes such as NCB-Ballabhgarh, CSMRS-Delhi, IIT’s.
3.02.00 The recommendations and suitability of material for concreting and other building
materials like brick, cement, aggregates etc., shall be ascertained by contractor prior
to start of work.
Preliminary evaluation of aggregate and its evaluation for potential alkali-aggregate

reactivity as per following scope of work shall be done:-
A. Evaluation of Aggregates:
I. To carry out different tests on coarse aggregate sample i.e. specific

gravity, water absorption, sieve analysis, deleterious material;
soundness, crushing value, impact value, abrasion value, elongation
index and flakiness index, as per IS: 2386.
II. To carry out different tests on fine aggregate sample i.e. specific
gravity, water absorption, sieve analysis soundness, deleterious
material, silt content, clay content and organic impurities as per IS:
2386.
III. To prepare evaluation report based on test results of I) and II) above
and to advise regarding suitability of fine and coarse aggregates.
B. Evaluation of Aggregates for Potential Alkali-Aggregate Reactivity:
Evaluation for Potential Alkali-Aggregate reactivity as per following scope of

work:
I. To carry out petrographic analysis and accelerated Mortar bar Test on

aggregate samples (1N NaOH at 80 deg. Centigrade for 14 days as
per ASTM 1260, or the method established/ developed by CSMRS for
22days test).
II. To prepare a report based on test results of I) above and to advise

regarding suitability of aggregates and further testing required if any.
The contractor shall initiate the action with regard to the above mentioned evaluation
of aggregates and other building material, so as to ensure timely completion of these

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
tests thereby not affecting any project work. All records shall be submitted, unless
specified otherwise, as per the format developed by the Contractor and approved by
the Engineer.
3.03.00 The FQA laboratory set-up shall be constructed by the Contractor at his own cost at
site in line with the indicative field QA&QC laboratory set-up enclosed at Annexure-I.
The Laboratory building shall be constructed and installed with the adequate facilities
to meet the requirement of envisaged test setup. Temperature and humidity controls
shall be available wherever necessary during testing of samples. The Quality Plan
shall identify the testing equipments/ instrument, which the Contractor shall deploy
and equip the Field quality Laboratory for meeting the Field Quality Plan
requirements. The Contractor shall furnish a comprehensive list of testing
equipments/ instrument required to meet the planned/scheduled tests for the
execution of works for Owner acceptance/ approval. The contractor shall mobilize the
requisite laboratory equipment and QA&QC manpower at least 15 days prior to the
planned test activity as per the schedule of tests.
If any facility for testing or the trained personnel for conducting any special test is not
available with the Contractor then the Contractor may get the test done from reputed/
approved laboratory or out source the personnel as approved by Owner.
All equipments and instruments shall be calibrated before the commencement of

tests and then at regular intervals, as per the manufacturer’s recommendation and as
directed by the Owner. Contractor shall arrange for having the instruments/
equipments tested for their calibration at an NABL/NPL accredited agency and the
test report shall be submitted to the Owner.
Based on the schedule of work agreed with the Engineer-in-charge and the approved
FQP, the Contractor shall prepare a schedule of tests and submit them to the
Engineer-in-charge and organize to carry out the tests as scheduled/ agreed.
4.00.00 QA & QC MANPOWER
4.01.00 The Contractor shall appoint a dedicated, experienced and competent QA&QC in-
charge at site, preferably directly reporting to the Project Manager, supported as
necessary by experienced personnel, to ensure the effective implementation of the
approved QAP. An indicative structure of Contractors QA&QC manpower required to
be deployed at site is enclosed at Annexure-II. Based on the finalized L-2 network
and the approved Field Quality plan the Contractor shall finalize and submit a
deployment schedule of QA&QC personnel along with their details to Owner for
approval/ acceptance and further shall ensure their availability well before the start of
the concern activity.
The QA&QC in-charge shall have the organizational freedom and authority to
implement the requirements of these quality assurance arrangements, free from
commercial and programme restraints. The QA&QC setup of the Contractor shall

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
consist of qualified and experienced Civil, Electrical, Mechanical Engineers and

Laboratory assistants with their supporting staff both at their works and site.
4.02.00 The deployment of man power for QA & QC set up shall be affected on the basis of
agreed manpower deployment schedule, which shall be prepared by the contractor
based on the L-2 network and the same shall be submitted to the Engineer-in-charge
for acceptance.
5.00.00 FIELD QUALITY PLAN (FQP) AND MANUFACTURING QUALITY PLAN (MQP)
5.01.00 Well before the start of the work, the Contractor shall prepare the Field Quality Plans
(FQP) and obtain approval of Owner, which shall detail out for all the works,
equipments, services, quality practices and procedures etc in line with the
requirement of the technical specifications to be followed by the Contractor at site.
This FQP shall cover for all the items / activities covered in the contract/schedule of
items and required right from material procurement to completion of the work. The
Field Quality Plan (FQP) submission shall be furnished on the format No. QS-01-QAI-
P-09/F2-R1 for Owner approval. An Indicative Field Quality Plan for civil works is
enclosed at Annexure – IV.
5.02.00 All materials / components and equipment covered under the scope of work, shall be
procured by the Contractor for the purpose of the contract, after obtaining the written
approval of the Owner, which are to be manufactured at shop/ factory of the
vendor/sub vendor shall be covered under a comprehensive quality assurance
programme. The Contractor’s purchase specifications and inquiries shall call for
Manufacturing Quality Plans (MQP) to be submitted by the sub-contractor/ sub-
supplier/ sub-vendor. The MQPs called for from the sub-contractor shall detail out for
all the components and equipment-various tests/inspection, to be carried out as per
the requirements of this specification and standards mentioned therein, quality
practices and procedures followed by contractor’s/ sub-contractor’s/ sub-supplier’s
Quality Control Organization, the relevant reference documents and standards,
acceptance norms, inspection documents raised etc., during all stages of materials
procurement, manufacture, assembly and final testing/performance testing. Such
quality plans of the vendors shall be submitted to the Owner for approval in the
prescribed format No. QS-01-QAI-P-09/F1-R1 for Manufacturing Quality Plan and
such approved Quality Plans shall form a part of the purchase order/contract between
the Contractor and sub-contractor. The Quality Plans shall be submitted on electronic
form e.g. CD or E-mail in addition to hard copy, for review and approval of Owner.
After approval the same shall be submitted in compiled form on CD in addition to
hard copy.
5.03.00 The Contractor shall furnish copies of the reference documents/plant standards
/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans.
These Quality Plans and reference documents/standards etc. will be subject to
Owner approval without which manufacturer shall not proceed. These approved
documents shall form a part of the contract. In these approved Quality Plans, Owner

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
shall identify customer hold points (CHP), i.e. test/checks which shall be carried out in
presence of the Owner Engineer or his authorized representative and beyond which
the work shall not proceed without consent of Owner in writing. All deviations to this
specification, approved quality plans and applicable standards must be documented
and referred to Owner along with technical justification for approval and
dispositioning.
5.04.00 With in three weeks of the release of the purchase orders /contracts for such bought
out items /components, a copy of the same without price details but together with the
detailed purchase specifications, quality plans and delivery conditions shall be
furnished to the Owner for reference/record by the Contractor along with a report of
the Purchase Orders placed so far for the contract.
5.05.00 Monthly progress reports on MQP/FQP submission/approval shall be furnished by the

Contractor on the format No. QS-01-QAI-P-02/F1-R0. List of items requiring Quality
Plans and Sub-supplier approval shall be finalized with the Contractor on the format
No. QS-01-QAI-P-01/F3-R1 during the post bid discussions.
6.00.00 BOUGHT OUT ITEMS (BOIs) AND SUB-VENDORS/ SUB-MANUFACTURERS /

SUB-SUPPLIERS
6.01.00 The Contractor shall enclose a comprehensive list of bought out items (BOIs)
envisaged in the contract for carrying out fabrication/ manufacturing/ erection/
construction/ commissioning activities etc and shall indicate the names of reputed
manufacturers for each of them in their bid proposal. The items envisaged by the
Contractor to be procured from these manufacturers shall meet the specification
requirement. Some of these major bought out items list (not exhaustive) is enclosed
at Annexure- III for which the Contractor shall submit the requisite details / lists of
manufacturer’s in their bid proposal.
6.02.00 The contractor shall identify the bought out items as per owner’s specification and
shall finalize the list of manufacturers/ vendors for each bought out items envisaged
in the contract during the post bid discussions stage. The BOI’s shall conform to the
relevant IS/technical referred specifications for the highest quality/ grade of material
unless otherwise specified. All bought out items shall be procured from the
manufacturer’s approved by Owner and tested as per relevant IS Codes/Owner
Specification. To facilitate advance planning (well before the start of activity as per L-
2 network) of material testing/ approval of bought out items, representative samples
shall be procured by the Contractor (from approved vendors) and submitted to the
Engineer for his approval before bulk procurement at least two months prior to start of
works. In case of manufacturers test certificate is submitted for acceptance, it shall be
clearly traceable and correlated with the consignment received at site. Approval of
material / sample by the Engineer shall not relieve the Contractor of his responsibility,
for their conformance to the specification, as well as the requisite quality and
performance of material.

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
6.03.00 The list of manufacturers / sub-vendors of each of the BOIs identified / indicated by
the Contractor shall be discussed / reviewed by the Owner during post bid
discussions and the list of proposed manufacturers / sub-vendors for each of the BOI
shall be agreed/ approved. The list of manufacturers for all the BOIs envisaged in
contract shall be included in the bid proposal and the same shall be discussed for
finalization during the post bid discussions before placement of award. Where the
manufacturers are placed in “DR” (Details required) category, the details of the
manufacturers / sub-vendors placed in the “DR” category shall be submitted to the
Owner for approval within the period agreed at the time of post bid discussions. The
Contractor’s proposal shall include vendor’s site facilities, expertise, facilities
established at the respective works, the process capability, process stabilization, QC
systems followed, experience list, etc. along with his own technical evaluation for
identified sub-Contractors proposed. The formats for furnishing above details shall be
given to the Contractor at post bid discussion stage. Monthly progress reports on
sub-Contractor detail submission / approval shall be furnished on format no. QS-01-
QAI-P-02/F1. The Owner shall furnish other relevant formats for information/
clarification for manufacturers / sub-vendors approval to the Contractor at the time of
post bid discussions (Main supplier’s evaluation report Format No: QA-01-QAI-P-
04/F1-R0 and Sub supplier questionnaire Format no: QA-01-QAI-P-04/F2-R0). Such
manufacturers / sub-vendors approval shall not relieve the Contractor from any
obligation, duty or responsibility under the contract.
6.04.00 Structural Steel for site procurement shall be procured from main steel producers like
SAIL, TISCO, IISCO, RINL, Jindal Steels etc. In case some of the sections are not
available with main Producers and are proposed to be supplied from the re-rollers of
main steel producers, the name of such re-rollers will have to be cleared by corporate
quality assurance of NTPC for which details such as –BIS approval, Main steel
producer’s approval, Past experience for production of sections of specified material,
details of machines plants testing facilities etc., confirmation that the process control
and manufacturing of steel sections by re-rollers shall be same as that of main steel
producers, that billets for re-rolling will be sourced from main steel producers only
shall be furnished with regards to re-roller.
Even after clearance of re-rollers, induction of billets with identified and correlated Mill
test certificates (TC’s) in the process of re-rolling, sampling of steel, quality checks
thereof and stamping of final product for further identification and correlation with
TC’s prior to dispatch will be in presence of authorised representative of main
Contractor.
Reinforcement steel shall be procured from main steel producers like SAIL, TISCO,
IISCO, RINL, Jindal Steels etc. and mill test certificates (TC) is to be obtained and
submitted to NTPC for co-relation. In case any size /diameter specified is not
available and are proposed to be supplied from the conversion agent of the main
Steel producer – the name of such conversion agent / re roller shall have to be
approved by NTPC for which details such as –BIS approval, Main steel producer’s

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
approval, Past experience for production of sections of specified material, details of

machines, plants testing facilities etc., and confirmation that the process control and
manufacturing of steel sections by re-rollers is the same as that of main steel
producers, that billets for re-rolling are sourced from main steel producers only shall
be furnished with regards to re-roller.
7.00.00 STRUCTURAL STEEL WELDING REQUIREMENTS
7.01.00 The Contractor shall submit to the Owner Field Welding Schedule for field welding
activities in the format No.: QS-01-CQA-W11/F1, this format shall be furnished to the
Contractor at pre-award stage. The field-welding schedule shall be submitted to the
Owner along with all supporting documents, like welding procedures, heat treatment
procedures, NDT procedures etc. at least ninety days before schedule start of
erection work at site. The Contractor shall submit Welding Procedure Specification
(WPS) in the format No: QS-01-QAI-W-06/F1 for Owner approval/ acceptance, this
format shall be furnished to the Contractor during post bid discussion stage.
All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870 or other International
equivalent standard acceptable to the Owner.
All welding/brazing procedures shall be submitted to the Owner or its authorized

representative for approval prior to carrying out the welding/brazing.
All brazers, welders and welding operators employed on any part of the contract
either in the Contractor’s/ sub-Contractor’s works or at site or elsewhere shall be
qualified as per AWSD1.1/ASME Section-IX or BS-4871 or other equivalent
International Standards acceptable to the Owner.
Welding procedure qualification and Welder qualification test results shall be

furnished to the Owner for approval. However, where required by the Owner, tests
shall be conducted in presence of Owner/authorized representative.
No welding shall be carried out on cast iron components for repair.
All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
All Non-destructive examination shall be performed in accordance with written

procedures as per International Standards and as mentioned elsewhere in the
technical specification; The NDT operator shall be qualified as per SNT-TC-IA (of the
American Society of non-destructive examination). NDT shall be recorded in a
report, which includes details of methods and equipment used, result/evaluation, job
data and identification of personnel employed and details of co-relation of the test
report with the job. The records of RT (Films) and UT (inspection records or printed
reports if possible) shall be documented and produced to Owner.

STAGE-II (2X195 MW)
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QUALITY ASSURANCE
8.00.00 QUALITY AUDIT
8.01.00 Owner reserves the right to carry out quality audit and quality surveillance of the
systems and procedures of the Contractor’s or their sub-Contractor’s quality
management and control activities.
The Contractor shall provide all necessary assistance to enable the Owner carry out
such audit and surveillance. The Contractor shall carry out an inspection and testing
Programme during manufacture in his work and that of his sub-Contractor’s and at
site to ensure the mechanical accuracy of components, compliance with drawings,
conformance to functional and performance requirements, identity and acceptability
of all materials parts and equipment. The Contractor shall carry out all
tests/inspection required to establish that the items/equipment conform to
requirements of the specification and the relevant codes/standards specified in the
specification, in addition to carrying out tests as per the approved quality plan.
8.02.00 Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Owner to reject the equipment/ facilities if it does
not comply with the specification when erected or does not give complete satisfaction
in service and the above shall in no way limit the liabilities and responsibilities of the
Contractor in ensuring complete conformance of the materials/equipment supplied to
relevant specification, standard, data sheets, drawings, etc.
9.00.00 GENERAL QA REQUIREMENTS
9.1.0 QA REQUIREMENTS FOR PROPERTIES, STORAGE AND HANDLING OF

COMMON BUILDING MATERIALS
1. All the materials like Bricks, Stones, Concrete Blocks, Lime, Cement, Water,
Aggregates, Sand, Reinforcement Steel, Structural Steel shall conform to the
relevant IS Codes/NTPC Technical Specification requirements.
2. All materials shall be stacked and stored by the Contractor as per IS-4082
and as per the requirements specified in NTPC Technical Specification.
3. All material shall be stacked separately.
4. Lime and cement shall be stored on a raised platform in Weather Proof, Dry &
Leak Proof Conditions stores.
5. Different consignment of different types of cement shall be stored separately

with clear identification mark.
6. Cement stored for more than 60 days in contractors godown shall be retested
to check their suitability for use.

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7. Cement shall be consumed on first in first out basis.
8. Steel shall be stacked and stored consignment wise, on raised wooden

battens size wise and grade wise with identification mark.
9. For properties, storage and handling of all materials used shall comply to the
requirements of NTPC Technical Specification
10. The sheets/ packets(Profiled sheets for decking, roofing and cladding) shall
be stacked neatly clear off the ground at an angle to the ground, over a base
pallet to provide drainage.
11. The sheets/ packets(Profiled sheets for decking, roofing and cladding) must
be covered with water proof covering to protect from moisture rain and foreign
particles.
12. Water / moisture should not be allowed to stagnate on surface, or in between

layers of sheets/ packets(Profiled sheets for decking, roofing and cladding).
This can damage the coating , and cause corrosion.
9.2.0 QA REQUIREMENTS FOR SHEETING WORKS.
1. Colour coated sheet
i) Chemical & physical properties of raw material sheet as per relevant

codes.
ii) Bare Metal Thickness
iii) Thickness of coatings
iv) Type of coating/paint
v) Hardness of painted surface (2H pencil Hardness) (ASTM-D-3363)
vi) Flexibility Test (Bend test) as per IS-14246 ASTMD-328 at 180 degree
bends (twice the thickness of sheet). There should not be any crack.
vii) Dimensional check after profiling of sheets
viii) Salt spray test as per ASTM B-117/ IS:9844 for minimum 1000 hrs.
One sample per batch at random. (For true representative sampling,
three samples shall be taken from each batch out of which one sample
shall be sent for salt spray test .The batches shall be chosen at the
beginning of supply, another at the middle of supply and the third
towards the end of the supply)
ix) Cross hatch adhesion test as per IS: 14246

STAGE-II (2X195 MW)
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QUALITY ASSURANCE
2. Bonded Mineral Wool Insulation
a) Thickness
b) Density
c) Thermal Conductivity
d) All other tests as per IS-8183.
3. Sheeting Installation
a) Workmanship including alignment
b) Level, Slope
c) Side and End Laps
d) Proper Installation of Flashing
e) Fixing including opening,(No gas cut opening shall be allowed at the

site , whenever opening is specified these shall be properly cut in the
factory and shall be filled with lipping/flashing for true shape/
dimension etc.)
f) Location, Installation of Lining & Installation.
4. All bought out items shall be procured from the manufacturer’s approved by
Engineer-in - charge and tested as per relevant IS Codes/ Specification.
5. The sheets/ packets shall be stacked neatly clear off the ground at an angle to
the ground, over a base pallet to provide drainage.
6. The packets/ sheets must be covered with water proof covering to protect
from moisture rain and foreign particles.
7. Water / moisture should not be allowed to stagnate on surface, or in between

layers. This can damage the coating , and cause corrosion.
9.3.0 QA REQUIREMENTS FOR ACID/ALKALI RESISTANT LINING
1. Acid Resistant Bricks/Tiles shall be tested for Water Absorption, Compressive

Strength, Resistance to Acid, Flexural Strength, Dimensions and all other
tests as per IS-4860 and IS-4457.
2. Acid and Alkali Resistant Bitumastic ready mixed paint shall be tested for all
tests as per IS-158.

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3. Bitumastic shall be tested as per IS-9510.
4. Potassium Silicate, Resin type and Sulphur type Mortars shall be tested as
per IS-4832, Part I, II and III.
5. Surface preparation shall be checked as per IS-2395.
6. Application of Primer, laying of Acid Proof Bitumastic layer, Acid/Alkali

Resistant Tiles/Bricks, Chemical Resistant Epoxy Lining and Epoxy Paint shall
be as per NTPC Technical Specification.
7. Thickness of Acid and Alkali Lining shall be checked.
8. Epoxy painting shall be carried for required coating thickness and dry film
thickness.
9.4.0 QA REQUIREMENTS FOR RCC PILES - BORED CAST-IN-SITU PILES
1. Standard Penetration Test (SPT) as per IS-2131 and NTPC Technical

Specification to determine the founding level of piles.
2. Founding level of the piles shall be decided based on the criteria given in
NTPC Technical Specification.
3. Check for control of position and alignment of piles as per IS-2911 Part I/Sec-2
4. Boring & Drilling : Drilling mud shall be tested for the following
Liquid limit of drilling mud (Bentonite Slurry) as per IS-2720 Part V.
Sand content of Bentonite powder (shall not be greater than 7%).
Density of freshly prepared Bentonite suspension shall be checked in

each pile bore before concreting and it should be between 1.034 and
1.10 gm/ml depending upon the pile dimension and type of the soil in
which the pile is to be installed. However, the density of bentonite
suspension after getting mixed with deleterious material in the pile
bore may be up to 1.25 gm/ml.
Marsh viscosity (when tested by marsh cone shall be between 30 to 60

seconds).
Differential free swell index.
pH value of Bentonite suspension (shall be between 9 and 11.5).

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Properties of drilling mud shall be checked prior to commencement of the

piling work and thereafter, minimum once per week or as found necessary by
the engineer. One sample consisting of 3 specimens shall be tested for the
above.
5. Check cleaning of pile bore
6. Concreting: All the checks/tests on concrete and concrete materials shall be

carried out as per FQP and IS-2911 Part I/Sec.2
a) Before starting concreting the contaminated drilled mud at the (slurry

collected in sampler tube) bottom of pile bore shall be tested for
density and sand content. Density should not be more than
1.25T/CuM.
b) For Working Piles: Minimum one sample consisting of 6 test cubes

shall be made for first ten piles. Out of these 3 shall be tested for 7
days cube strength and 3 for 28 days cube strength. Minimum one
sample of 6 test cubes for every 25 nos. of piles shall be tested , out of
these 3 shall be tested for 7 days cube strength and 3 for 28 days
cube strength
7. Reinforcement bars used for concreting of piles shall be of tested quality and
conform to the requirements of relevant IS codes.
a) Check distances between two adjacent main reinforcement bars and it

should be as specified in Technical Specification.
b) Check proper cover and central placement of reinforcement cage in

the pile bore by suitable concrete spacers/rollers. Check minimum
clear cover to reinforcement should be as specified in technical
specification.
8. Check cut off level of piles as per drawing.
9. Check recording of all data during installation of piles in prescribed pile data
sheet.
10. Slumps of concrete shall be tested at every one-hour interval.
11. Checking position and Alignment: Each pile shall be checked for its position
w.r.t. Specified location. Each pile shall be checked for its alignment.
Permissible limits for deviation shall be as specified elsewhere in the
Technical Specification.
12. Check for Pile Bore: On completion of boring and cleaning, the bottom of each
pile bore shall be checked from the samples collected from near the bottom of

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pile bore or any other method approved by the Engineer, to ensure that it is
free from pile bore spoil/debris and any other loose material before
concreting.
13. Low strain pile integrity test on all job piles and test piles shall be conducted
as specified in the Technical Specification. This test shall be suitably used to
identify the piles for routine tests.
16. High Strain dynamic test shall be done as per the technical specification. The
frequency of the test shall be as per the BOQ /technical specification.
9.5.0 QA REQUIREMENTS FOR RCC PILES LOAD TEST ON RCC PILES
1. Pile load testing shall conform to IS-2911 (Part IV) and the Technical
Specification.
2. Check all the equipment and instrument used are properly calibrated.
3. Initial load test shall be conducted to assess the safe load carrying capacity of
pile before start of work.
a) Cyclic vertical (compression) load test to assess safe vertical load

capacity.
b) Lateral load test to assess safe horizontal load capacity.
c) Pull out (Tension) load test to assess safe pull out load capacity.
4. Routine Load Test shall be conducted on Working Piles, to verify their load
carrying capacity.
a) Direct Vertical (Compression) load test for vertical load capacity.
b) Lateral load test for horizontal load capacity
5. All other tests on piles shall be carried out as specified in Technical

Specification.
6. Pile load-testing procedure and the test setup/scheme to be submitted for

approval from NTPC. The contractor shall use the test setup having
arrangement for reaction piles for both vertical compression and uplift
(tension) Load test (initial) on piles. The cost of reaction system/ piles shall
deem to be included in the cost of test piles.
7. All the gauges(pressure etc.) and the instruments shall be calibrated before
the start of the tests on test piles and working piles and the calibration record
shall be verified before start of execution of the test.

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9.6.0 QA REQUIREMENTS FOR PRE CAST CONCRETE WORKS
1. All the materials used in Pre cast Concrete work shall be tested and conform
to the requirements of IS codes and NTPC Tech. Specification. If the material
of the cast-in-situ concrete is already tested and part of the same is used for
precast concrete, further testing is not required, otherwise testing is required
for every 50 Cum. Of Concrete.
2. Concrete mix for Pre cast members shall conform to IS-456-2000 i.e. the
provisions of IS:456 shall apply.
3. All relevant QA requirements pertaining to cast insitu concrete shall be

applicable.
4. Load test on Pre cast members shall be carried out for the type of members
as decided by NTPC Engineer as per IS-456-2000.
5. Pre Cast Concrete member shall be checked for dimensions (length, cross
sectional dimensions, straightness, squareness, and flatness) and tolerances
shall be as per NTPC Technical Specification.
9.7.0 QA REQUIREMENTS FOR PLASTERING & ALLIED WORKS
1. Materials like sand, lime for preparation of putty, coarse aggregate, gypsum
etc. shall confirm to the relevant IS codes specified in NTPC Technical
Specification.
2. Check proper mixing of mortar
3. Plaster surface shall be checked for following defects and the remedial
measures for the same shall be adopted as per IS-1661.
a) Blistering
b) Bond filer or loss of adhesion.
c) Cracking and crazing
d) Efflorescence
e) Grinning
f) Irregularity of Surface Texture
g) Popping or blowing
h) Recurrent surface dampers
i) Softness or chalkiness

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4. Trueness of Plastering System:
Finished plaster surface shall not show any deviation more than 4mm when
checked with straight edge of 2 Mt. length.
5. Check thickness of plaster.
9.8.0 QA REQUIREMENTS FOR CONCRETING
All records of concreting, reinforcement, testing of materials, as-built dimensions, the

details of the rectification, etc, shall be maintained as given below. Copies of such
record shall be submitted to owner for their record and future reference.
a) Testing data / report of aggregates
b) Mix design details.
c) Testing records of admixture including dosage, workability and setting time.
d) Approved scheme for concreting.
f) Hourly records of concreting including pour card.
g) Protocol indicating the dimensional tolerance and details of inserts.
h) Bar bending schedule.
i) Location and details of mechanical anchoring used for reinforcement.
j) Protocol giving the details of checking of reinforcements before concreting

and conformance to the reinforcement details as shown in the construction
drawings.
k) Report on petrographic examination & potential reactivity of aggregate
l) All tests/checks shall be carried out as per FQP.
In addition to the above the following may also be ensured
i. Check temperature control of fresh concrete during hot weather.
ii. Plasticizer cum Retarder type mixture to be added in the concrete shall be
tested as per IS-9103/ ASTM C 494.
iii. REINFORCEMENT :
a) Check conformity of material to relevant IS codes.

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b) Check lapping/spacing of Reinforcement staggered as under no

circumstances more than 50% of bars at cross section shall be lapped.
iv. Sample test for mechanical bars grips shall be carried out upto the yield
strength of reinforcement of bars. The no. of tests to be carried out shall be
3% of the no. of bar grips used subject to a minimum of three.
v. Batching Plant shall be calibrated regularly at least once in a 3 months and

computerized output shall be taken for each batch of production of concrete.
The calibration if the batching plant shall be done by NABL accredited
laboratories/weights of NPL traceability.
vi. All precautions and control as specified in NTPC Technical Specification shall
be taken care of during concreting. IS 456-2000 shall be applicable for
acceptance of execution of concrete works & test results.
STAGING AND FORM WORK
• Automatic climb form scaffolding systems shall be used. Slipform with

proven record for similar towers may be used subject to IS specific approval of
the owner. The design and detailed construction of the form work and the
scaffolding system shall be as described elsewhere in the technical
specification and shall be submitted to NTPC for approval.
Concrete shall have sufficient strength to with stand the anchoring loads of
scaffolding system. The concrete strength shall be continuously checked and
documented during the climbing process of the scaffolding.
• Design and execution of the form work , staging, shuttering and scaffolding
shall conform to National Safety Council and all relevant IS Code provisions,
i.e. IS 2750, IS:4014, IS:4923, IS:800 etc. In case the IS Codes do not cover
the specific type of shuttering system, then any international Code of Practice,
as approved by the engineer, may be followed.
• Deployment of vertical laser ray equipment for measuring the dimensions and
controlling the shape of the tower at all elevations and plan angles shall be
carried out.
9.9.0 QA REQUIREMENTS FOR STRUCTURAL STEEL WORK (SITE FABRICATED)
1. Physical and chemical properties of material as per relevant codes. Review

of correlated Mill Test Certificates or check testing in absence of MTC.
2. Ultrasonic test on plates above 40mm as per ASTM A435.
3. Welding Procedure & Welders Qualification Test as per ASME Section

IX/AWS D1.1

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4. Fillet Welds:
a) Check for size and visual examination.
b) Microetch examination on production test coupons for main fillet welds

with minimum one joint per built up beams, columns and crane girder
etc.
c) 25% weld length of tension member of crane girder shall be subjected

to Dye Penetration Test.
d) On all other fillet welds, DPT on 5% of weld length with minimum

300mm at each location shall be carried out.
5. Butt Welds:
a) DPT on all butt welds after back gouging
b) Mechanical testing of production test coupons with minimum one joint

per built up beam, column and crane girder.
c) 100% radiography test on butt welds of tension flange (bottom flange)

of crane girder. All other butt welds shall be subjected to Radiography
test on 10% weld length of each welder. Wherever RT is not feasible,
UT shall be carried out.
d) Full penetration welds (other than butt welds) shall be subjected to

Ultrasonic Testing in following quantum :
i) 100% UT on web to flange joint of crane girder.
ii) 10% UT on other full penetration joints.
6. Every 1st and further every 10th set of identical structure shall be checked for
control assembly in shop before erection.
7. All structure components/members shall be checked for dimensional

tolerances during fabrication and erection as per IS-7215 and IS-12843
respectively.
8. Check for Surface Preparation and Paint thickness.
9. In case of failure of any welds in SPOT RT/UT, the %age for retesting shall
be doubled at that particular location. Acceptance criteria of NDT on welds
shall be as per AWS D1.1.

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10. Low hydrogen electrode (AWS E-7018) for welding of High/Medium tensile
steel, for M.S (IS 2062 Gr. A/Gr. B, IS 8500) sections thickness above 20mm
shall be used. Preheating and Post weld heat treatment requirements shall be
complied as specified in the technical specs. /approved WPS.
9.10.0 QA REQUIREMENTS FOR STRUCTURAL STEEL WORK (SHOP FABRICATED)
In addition to requirement of Clause 9.9.0 above following provisions shall also apply:
1. Sub-Vendor approval having requisite manufacturing facilities shall be
required from NTPC.
2. Manufacturing Quality Plan indicating stage inspection/CHP shall be

submitted for NTPC review and approval.
3. Pre-dispatch inspection shall be carried out inline with the approval MQP and
the dispatch shall be effected through MDCC.
4. Raw Material including plates and structural shall be procured from the
manufacturers as identified in the contract with MTC and co-relable
traceability.
9.11.0 ARCHITECTURAL & MISC. WORKS
1. Material used for floor finishes and allied work shall conform and tested as per
the requirements of relevant IS Codes specified in NTPC Technical
Specification.
2. Finishes shall be checked for the following:
• Level, Slope, Plumb
• Pattern & Symmetry
• Alignment of joints, dividing strips etc.
• Colour, Texture
• Surface Finish
• Thickness of Paint
• Details of edges, junction etc.
• Performance
• Precautions specified for durability.

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3. For fabricated item like metal doors, windows, ventilators, louvers, rolling
shutters and grills etc. The following checks shall be carried out.
• Overall Dimensions
• Mullions Transoms
• Doors & Windows shall operate without jamming
• Doors, windows & frames etc. shall be on a true plane, free from wrap
or buckle.
• All welds shall be dressed flush on exposed and contact surfaces.
• Correctness of locations and smoothness of operation of all shop

installed hardware and fixtures.
• Provision of hardware & fixtures to be installed at site.
• Glazing beads shall be cut with mitered corners.
• Glazing clips, fixing devices etc. shall be supplied in adequate nos.
• Shop coats shall be properly applied.
• Exposed aluminium surface shall be free from scratches, stains and

discoloration.
9.12.0 ROLLING SHUTTERS/GRILLS
After installing the shutters, the contractor shall test the performance of the shutter in
the presence of the engineer. The shutter shall be smoothly operable under all
ambient conditions. All controls and locking devices shall give fault free performance.
9.13.0 FIRE PROOF DOORS
1. Fire Proof doors shall be tested for the requirements mentioned in IS-3614
Part-I&II and The Technical Specification. The type test of the doors shall be
carried out at CBRI Roorkee for minimum 2 hours fire rating and its
Fabrication drawing shall also be approved by CBRI, Roorkee.
2. DFT of paint of Fire Proof Doors and its fittings and fixtures as per BOQ shall
be checked. The doors shall be finished with suitable fire retardant painting
system.

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9.14.0 GLASS AND GLAZING
1. Materials used in glass and glazing shall conform to the requirements of the
Technical Specification and IS Codes specified in the Technical Specification.
2. All installation shall be free from cracked, broken or damaged glass, edges of
large panes of thicker glass and heat insulating glass be inspected carefully
for chipped, cracked or underground edges.
3. Glazing shall be carefully done to avoid direct contact with metal frames.
4. All glasses shall be embedded in mastic for steel works and fixed by
neoprene gasket for aluminium works to give a leak proof installation.
5. On completion, the panes shall be free from dirt, stains, excess putty etc. to
the complete satisfaction of the engineer.
9.15.0 ROOF WATER PROOFING & ALLIED WORKS
1. Material used shall be tested and conforms to the requirements of IS

Codes/International Codes specified in NTPC Technical Specification.
2. All elastomeric membrane is fully dried to perform testing with water ponds
created on minimum 5% of area of nominal size 6m x 6m for height of 25mm
to 30mm at critical locations for a period of 48 Hrs. No dampness shall be
visible on the underneath side of roof (i.e. ceiling, parapet and wall junction
etc.). The above testing shall be carried out prior to application of wearing
course.
9.16.0 PAINTING & ALLIED WORKS.
1. Various materials used shall conform and tested for the requirements of
Indian/International Codes specified in the Technical Specification.
2. Surface to receive paint shall be prepared as per the requirement of technical

specification.
3. Painting shall be checked for thickness of different coats as specified in

schedule of items and the Technical Specification/Drawing.
10.00.00 CONSTRUCTION TOLERANCE AND ACCEPTANCE CRITERIA
10.1.0 Excavation and Filling
Tolerance
Finished surface level shall be within 20mm of the level shown in the drawing.

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Acceptance Criteria
Following acceptance criteria shall be followed.
a) When only one set of sample is tested, then all individual samples collected
and tested should pass without any deviation
b) For retest of any sample two additional samples shall be collected and tested,
and both should pass without any deviation.
c) Where a large number of samples are tested for a particular test then 9
samples out of every 10 consecutive samples tested shall meet the
specification requirement.
d) Tolerance on finished levels for important filling areas at approved interval

shall be + 20mm. However, for an unimportant area, tolerance upto +75mm
shall be acceptable at the discretion of the Engineer. However, these
tolerances shall be applicable for localised areas only.
10.2.0 Cast-in-situ concrete and Allied works
10.2.01 Tolerances
a) Cast-in-situ concrete
Unless otherwise specified, the tolerance in construction shall be as follows:
The dimensions of concrete as cast when compared with those on the

drawings shall be within the tolerance given below:
-----------------------------------------------------------------------------------------------------------------
Description of Item/ Structural Element Max Min
(mm) (mm)
-----------------------------------------------------------------------------------------------------------------
z Faces of concrete in foundations
and structural members against which
back fill is placed +25 -10
z Eccentricity of footing 2% of footing width in

the direction of placement
but limited to 50mm
z Top surfaces of slabs and of concrete

to receive base plates to be grouted +5 -5

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z Alignment of beams, lintels, columns,

walls, slabs and similar structural
elements +5 -5
z Cross sectional dimensions of walls,

slabs and similar structural elements +5 -5
z Deviation from specified dimensions

of cross-section of columns and beams +12 -6
z Alignment of holding down bolts without

sleeves +1.5 -1.5
z Alignment of holding down bolts with

sleeves +5 -5
z Level of holding down bolt assemblies +10 -10
z Embedded Parts ( in any direction). +5 -5
z Level of embedment for equipment

support +1.5 0
z Level of embedment for other

embedded parts +5 -5
z Centers of pockets or holes

with greatest lateral dimension not
exceeding 150mm +10 -10
z Variation in steps
z Riser +1.5 +3.0
z Tread -1.5 -3.0
(b) Reinforcement
Tolerance on placing of reinforcement and for cover shall be as per clause

12.3 of IS: 456.
Reinforcement shall be placed within the following tolerances:
a) For effective depth 200 mm or less ± 10mm

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b) For effective depth more than 200 mm ± 15mm
Tolerance for cover
Actual concrete cover should not deviate from the required nominal cover by +
10 mm
(c) Pre cast concrete
Tolerance on dimensions of pre-cast units shall be as follows:
1. Length: +/- 0.1 percent subject to minimum of +/- 5 mm and maximum

of + 10 mm.
2. Cross-sectional dimensions: +/- 3 mm or +/- 0.1 percent whichever is

greater.
3. Straightness or Bow: 1/750 of the length subject to minimum of +/- 5

mm and maximum of +/- 10 mm.
4. Squareness: When considering the squareness of the corner the

length of the two adjacent sides being checked shall be taken as the
base line. The shorter side shall not vary in length from the
perpendicular by more than 5 mm.
5. Flatness: The maximum deviation from a 1.5m straight edge placed in

any position on a nominal plant surface shall not exceed 5 mm.
(d) Formwork and staging
(i) Staging shall be checked for its soundness as a whole and for
adequacy of the joints and its foundations. Formwork joints shall be
inspected for soundness of connections. All joints shall be either
vertical or horizontal and shall be such as to avoid loss of liquid
through the formwork.
(ii) Dimensional tolerance for formwork shall be as per Clause 9.6 of IS :

14687 and 11.1 of IS : 456, which is reproduced as given below:
Deviation from specified dimensions of :

cross section of columns and beams : +12mm - 6mm
Deviation from dimensions of footings :
1) Dimensions in plan: + 50mm - 12 mm

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2) Eccentricity: 0.02 times the width of the

footing in the direction of
deviation but not more than
50 mm
3) Thickness ± 0.05 times the specified

thickness
The above tolerances apply to concrete dimensions only, and not to
positioning of vertical reinforcing steel or dowels.
(iii) Checklist for formwork shall be as per Clause 9.9 of IS : 14687.

Format as per Annexure-C of IS : 14687 shall necessarily be made for
all important structures including all machine foundations.
(a) The acceptance criteria of concrete shall be in accordance with clause no.16
of IS : 456. However in exceptional circumstances, and that too in non-critical
areas, the Engineer may accept concrete work which is marginally
unacceptable as per the criteria laid down in IS : 456. For such accepted
work, payment shall be made at a reduced rate pro rate to the concrete cube
strength obtained, against that stipulated.
(b) Unacceptable concrete work shall be dismantled by the Contractor and

replaced by fresh work, meeting the specification requirements. In the course
of dismantling, if any damage is done to the embedded items or adjacent
structures, the same shall be made good, by the Contractor, to the
satisfaction of the Engineer, at no extra cost to the Owner.
(c) Test shall be conducted for the water tightness of the liquid retaining
structures as per IS : 3370 and IS : 6494.
10.3.0 Fabrication and Erection of Structural Steel Work
10.3.1 Tolerances
I. Fabrication tolerances
(a) maximum permissible gap in built up members
(b) maximum permissible deviation in depth and/or width of girder at the

joints
(c) maximum permissible out-of-square of flanges in built-up girders
(d) tolerances on length of beams and girders and their components

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(e) permissible deviation in column heights
All tolerances for above shall be as per drg / IS : 7215
II. Erection tolerances
(a) permissible tolerances in erected steel columns
(b) permissible tolerances in erected steel trusses
(c) permissible tolerances in crane girder and rails
All tolerances for above shall be as per approved drg / IS : 12843
III. Requirement of pre-heating
Thickness of thickest Welding using other Welding using low

part at the area of than low hydrogen hydrogen welding
welding / heat affected welding electrodes IS electrodes or submerged
zone : 2062 arc welding IS:2062
Upto 20 mm (including) None None
Over 20 mm to 40 mm Not allowed 200 C

(including)
Over 40 mm to 63 mm Not allowed 660 C

(including)
Over 63 mm Not allowed 1100 C
(a) The acceptance criteria of Non Destructive Testing (NDTs) on welds shall be
as per AWS D1.1 (Dynamically Loaded Structures - tension welds). In case of
failure of any of the tests, the Contractor at his own cost shall also carry out
rectification of such defective welds. Retesting of the rectified joint, shall also
be carried out by the Contractor at his own cost.
(b) Every 1st and further every 10th set of identical structure shall be checked for
control assembly in shop before erection.
Embedded part
The tolerances for embedded parts shall be as specified under concrete works.

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10.4.0 Masonry & Allied works
11.4.1 Tolerances
(a) All masonry shall be built true and plumb within the tolerances prescribed as
below. Care shall be taken to keep the perpends properly aligned. Unless
specified otherwise the tolerances in construction of masonry works shall be as
below:
i) Deviation in verticality in total height of any wall of a building more than

one storey in height shall not exceed ± 12.5mm.
ii) Deviation from vertical within a storey shall not exceed ± 6mm per 3m
height.
iii) Deviation from the position shown on the plan of any brickwork more
than one storey in height shall not exceed 12.5mm.
iv) Relative displacement between load bearing walls in adjacent storeys

intended to be in vertical alignment shall not exceed 6mm.
v) Deviation of bed joint from horizontal in any length upto 12m shall not
exceed 6mm, and in any length over 12m it shall not exceed 12.5mm
total.
vi) Deviation from the specified thickness of bed-joints, cross-joints or

perpends shall not exceed ± 3mm.
b) The plastered surface shall be checked for
i) Blistering, bond failure or loss of adhesion, cracking, crazing,

efflorescence, grinning, irregularity of surface texture, popping or
blowing, recurrent surface dampness, softness or chalkiness defects
and the remedial measures for the same shall be adopted as per IS:
1661.
ii) The finished plastered surface shall not show any deviation more than
4 mm when checked with a straight edge of 2 metre length placed
against the surface.
iii) The thickness of the plaster shall be measured exclusive of the

thickness of key i.e., grooves or open joints in brickwork. The average
thickness of plaster shall not be less than the specified thickness. The
minimum thickness over any portion of the surface shall not be less
than the specified thickness by more than 3 mm for plaster thickness
above 12mm and 1 mm for ceiling plaster. Extra thickness required in

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dubbing behind rounding of the corners at junctions of wall or in

plastering of masonry cornices etc. shall be ignored.
Following acceptance criteria shall be followed:
General workmanship is being good and as recommended by the manufacturer

and approved by the Engineer.
Tolerances are within the specified limit.
Material test certificate is in compliance with the applicable codes/standards.
Bought out material is from the approved manufacturer / vendor.
Bought out material is matching with the approved sample.
10.5.0 Finishing & Allied works
11.5.1 Tolerances
a) The floor finish shall be checked specially for the following :
i.) Level, slope, plumb as the case may be
ii.) Pattern and symmetry
iii.) Alignment of joints, dividing strips etc.
iv.) Colour, texture
v.) Surface finish
vi.) Thickness of joints
vii.) Details of edges, junction etc.
viii.) Performance
ix.) Precautions specified for durability
Local depressions on account of faulty workmanship shall not be acceptable.

Tiles / natural stones with cracked or broken/chipped edges shall not be
acceptable.
b) The door, window, ventilator, partition during and after fitting and fixing etc
shall be checked for the following:-

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i) Installation shall be at correct locations, elevations and in general on a

true vertical plane.
ii) Fixing details shall be strictly as shown on drawings.
iii) Assembly of composite units shall be strictly as per drawing, with

mastic caulking at transoms and mullions, gaskets, weather strips etc.
complete.
iv) All frames on external wall shall be mastic caulked to prevent leakage
through joint between frames and masonry.
v) All openable sections shall operate smoothly without jamming. Lock,

fasteners, etc, shall engage positively. Keys shall be non-
interchangeable.
vi) Cutting to concrete or masonry shall be made good and all abrasions
to shop paint shall be touched up with paint or same quality as shop
paint.
vii) Aluminium doors, windows, ventilators, partitions etc., shall be free

from scratches, stains or discolouration.
viii) Door and window shutters shall operate without jamming. The
clearance at head and jamb for door shutters shall not exceed 1.5 mm.
For double leaf doors, the gap at the meeting stiles shall not be more
than 2.5 mm.
10.6.0 For False ceiling system the following shall be checked for :-
i) As installed shall be true to shape, level.
ii) Correctness for the opening for the fixtures, colour and shade.
iii) All joints shall be in the same line and cross joints shall be securely fixed to
walls.
iv) There shall not be any sagging and/ or unevenness in the surface
11.6.1 Acceptance criteria
Ceiling panels shall be best quality material in thickness and properties called for in
the specification /schedule of items. Material Test Certificate to be submitted before
bulk supply.
Finished ceiling shall be at the correct plane and prevent an aesthetically pleasing
and uniform appearance, free from sags and warps. Joints and exposed grids shall

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
be in true lines and symmetrically placed in manner as shown in drawings. Cut outs
for light fixtures, diffusers and other relevant services shall be of exact dimensions
and in exact locations.
11.7.0 Water proofing
Water proofing shall be tested for water tightness by creating a pond of water
minimum 25 mm height on area of 6 m x 6 m, for the period of 48 hrs on fully dried
elastomeric membrane surfaces. Minimum 5% area of the roof shall be subjected to
water tightness test. Such test necessarily be conducted on vulnerable areas like
drain channel/ drain head. No dampness shall be visible on the underneath side of
roof (i.e. ceiling), parapet and wall junctions etc. which have been subjected for
testing. The above testing shall be carried out prior to application of wearing course.
11.8.0 Water Supply, Drainage & Sanitation
11.8.1 Tolerances
a) All soil pipes, waste pipes, ventilating pipes and all other pipes, when above
ground, shall be gas tight. All sewers and drain laid below ground shall be
watertight.
b) Obstruction / Straightness Test
The obstructions shall be checked by inserting a smooth ball, of diameter 13

mm less than the pipe bore at the high end of the sewer or drain. If absence
of any obstructions, such as yarn or mortar projecting through the joints, ball
shall roll down the invert of the pipe and emerge at the lower end. The
straightness shall be checked by means of a mirror at one end of the line and
lamp at the other. If the pipeline is straight, the full circle of the light may be
observed. The mirror will also indicate obstruction in the barrel, if the pipeline
is not straight.
c) Service pipes testing with water
The service pipes shall be slowly and carefully charged with water, allowing
all air to escape avoiding all shock or water hammer. The service pipe shall
then be inspected under working condition of pressure and flow, when all
draw off taps are closed. The service pipes shall be checked for satisfactorily
support and protection from damage corrosion and frost.
d) Fixtures etc.
All fixtures and fittings shall be connected by watertight joints. No dripping of

water shall be acceptable.

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
Following acceptance criteria shall be followed:
General workmanship is being good and is recommend by the manufacturer and

approved by the engineer.
Tolerances are within the specified limit.
Material test certificate is in compliance with the applicable IS Codes.
Bought out material is from the approved manufacturer / vendor.
Bought out material is matching with the approved sample.
12.00.00 QA REQUIREMENTS FOR ROAD WORK
Quality Assurance and testing requirements for roadwork shall be as per relevant
IRC Codes for Road .
13.00.00 SPECIAL ITEMS
1. Vibration Isolation System(V.I.S)
• Stiffness values shall be checked. The permissible deviation shall be

as per DIN 2096.
• For accepting values , following acceptance criteria shall be followed:
1. General workmanship is being good and as recommended by

the manufacturer and approved by the Engineer.
2. Tolerances are within the specified limit.
3. Material tests certificate (M.T.C.) is in compliance with the

applicable codes standards.
4. Bought out material is from the approved manufacturer /

vendor.
5. Bought out material is matching with the approved sample.
14.00.00 ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE PROGRAMME:
14.01.00 Indicative list of Field Quality Laboratory and Survey equipment list (Annexure-I)
14.02.00 Indicative QA&QC Manpower requirements (Annexure-II)

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
14.03.00 Indicative list of Bought Out Items for Civil Works (Annexure – III)
14.04.00 Indicative Field Quality Plan for Civil and structural steel works (Annexure-IV) Note:
The field quality plans attached is indicative and minimum required. However any
addition or deletion in the scope of work, during detailed engineering shall be
accordingly added/ deducted from the indicative Field Quality Plan)
14.05.00 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1
14.06.00 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R1
14.07.00 Status of items requiring Quality Plan and sub supplier approval. Format No.: QS-01-
QAI-P-02/F1-R0
14.08.00 List of items requiring quality plan and sub supplier approval. Format No.: QS-01-
QAI-P-01/F3-R0
14.09.00 Field Welding Schedule Format No.: QS-01-CQA-W-11/F1-R0
14.10.00 Welding Procedure Specification (WPS) Format No.: QS-01-QAI-W-06/F1-R0
14.11.00 Main supplier’s evaluation report Format No: QA-01-QAI-P-04/F1-R0
14.12.00 Sub supplier questionnaire Format no: QA-01-QAI-P-04/F2-R0

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
TYPICAL QA/QC LAB EQUIPMENT ANNEXURE - I
INDICATIVE FIELD QA&QC LABORATORY SET-UP
S. No Equipment Nos
1. Standard sieve analysis setup along with the sieve G.I. 1 Set
frame , Motorized sieve shaker, Pans and Covers etc.
2. Slump Testing Equipment - Slump test mould, temping 2 Set

rod etc.
3. Compression test for concrete cubes and bricks – Cube 1 Set

moulds, compression testing machine, cylinders,
temping rods, laboratory concrete mixer etc.
4. Le-chatelier apparatus, Viacat apparatus, balance, 1 Set each

standard weights, gauging trowel
5. Rebound Hammer for NDT testing of concrete 1 Set
6. Thermostatically controlled laboratory Electric ovens 1 Set each

and Portable ovens.
7. Physical balances and Electronic balances. 1 Set each
8. Micro Meter, Vernier Calipers 1 Set each
9. Mhos scale for hardness test 1 Set
10. Electrical moisture meter (IS 287) for timber test 1 Set
11. Digital Elco-meter for paint thickness 1 Set
12. Standard Proctor test set-up and Core cutters for in- 1 Set each
situ density test set-up
13. NDT tests on welding – DPT set-up, UT and RT (with 1 Set each
BARC approved source) set-up
14. Computerized Seismographs for blast vibration 1 Set each

monitoring, if required
15. Glass Jar, sedimentation pipette, Measuring Cylinders, As required

Containers, Evaporating dish, steam bath, desiccators,
muffle furnace, chemicals etc.
16. Thermometer, Steel rules, Measuring wedge for bricks As required

etc.

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
NOTE:
1. The equipments listed above are indicative and required to be mobilised as

minimum requirement. Additional equipment if any, required for successful
completion of work shall be provided /arranged by the contractor.
2. All test reports/ inspection reports have to be computerized and maintained on

LAN with an access to the owner
3. Computers - 2 Nos shall be deployed with Windows operating system and

connected to the NTPC server
4. Based on the schedule (L2/L3 Network), Quality control & Quality Assurance
work plan shall be finalized by the contractor and the same shall be submitted
to the engineer-in-charge for acceptance/approval. The Finalized work plan
shall be maintained on the computer to be accessed by the owner for
database and day to day monitoring.
5. The CC may indicate the tests proposed to be outsourced, if any, to be

conducted at NTPC approved third party laboratories such as NCB, CSMRS,
IIT’s etc.
6. All laboratory / measurement / survey equipments to be used at site shall be

calibrated by NABL/NPL accredited laboratory / agency.

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
Annexure – II
INDICATIVE FIELD QA & QC MANPOWER STRUCTURE
PROJECT MANAGER
QA & QC MANAGER
QC ENGINEER-IN-CHARGE QA&QC
QUALITY ASSURANCE
LABORATORY
• DOCUMENTATIO IN-CHARGE
N- QAP, FQP,
MQP, MONTHLY/
QUARTERLY EXCAVATION, FILLLING,
REPORTS ETC. FOUNDATIONS, PILING -
• CO-ORDINATION GEOTECHNICAL ENGINEERS
AND
INTERACTION
WITH NTPC AND SUPPROTING FIELD
SUB- CONCRETE & BUILDING MATERIALS AND LAB.STAFFF
CONTRACTORS EVALUATION/ TESTING, CONCRETE
• TEST ON MIX DESIGN, PRODUCTION, AND
BOUGHT OUT PLACING AND OTHER MISC WORKS-
ITEMS CIVIL ENGINEERS
• THIRD PARTY
LABORATORY
NDT ENGINEERS FOR STRUCTURAL

SUPPROTING STAFF STEEL WORK – R.T. LEVEL- II, UT
LEVEL-II – NDT ENGINEERS
NOTE:
1. The above organization setup is minimum, however their deployment shall be as per the agreed
deployment schedule. The contractor shall prepare a manpower deployment schedule in line
with the finalized L2 network the same shall be submitted to the engineer-in charge for
acceptance/ approval.
2. The contractor shall mobilize the QA& QC manpower in line with the finalized manpower
deployment schedule and shall ensure their availability well in advance (15 days approx.) of the
beginning of the concerned activity/ work.
3. The contractor shall further mobilize required number of skilled & supporting staff and additional
resources, if any to meet the work schedule.
4. All the areas / activities shown above shall headed by experienced and qualified engineers
supported by sufficient numbers of supervisors and supporting staff. The bidder shall indicate
the number of engineers and supervisors in their bid, which shall be discussed and finalized
before award of package.

STAGE-II (2X195 MW)
CLAUSE NO.
QUALITY ASSURANCE
Annexure – III
Indicative List of Bought Out Items for Civil Works
Sr. Bought Out Item Proposed Make Proposed list of

No. Manufacturers
1. Structural steel and

reinforcement steel
2. Cement
3. Doors including fire proof

doors, windows, ventilators,
partitions, louvers, rolling
shutters, etc
4. Finish paints etc
5. Concrete Admixtures,
chemical injection grouting,
waterproofing chemicals etc.
6. Permanently Colour Coated

Sheets
7. PVC Water stops
Note:
The bidder shall furnish the list of manufacturers of each bought out items in their bid,
which shall be reviewed and finalized during the post bid discussions with the
successful bidder.

STAGE-II (2X195 MW)
PART - B
SUB-SECTION-IIIE-17
INDICATIVE FIELD QUALITY PLAN

PART-B
SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN ANNEXURE- IV
ADDRESS: ITEM : CIVIL WORK QP NO. : 1 PROJECT:
Page 1 of 17
LOGO SUB-SYSTEM : GEOTECH INVI, FOUNDATIONS, REV. NO .: 0 PACKAGE:
EXCAVATION & FILL, SITE LEVELLING, CONCRETE, ROAD, DATE : CONTRACT NO.
BUILDING ETC. PAGE : MAIN CONTRACTOR
Sl. No Activity and operation Characteristics / instruments Class# of Type of Check Quantum Of check Reference Document Acceptance Format of Remarks
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
1 GENERAL REQUIREMENTS
A Setting up of Field QA&QC A Physical Once prior to start of work SR √ Functioning of laboratory equipment in
laboratory As agreed / required Tech Specs and Const. Drawings proper working condition to be verified on
monthly basis
B Avialablility of requisite A Physical Once prior to start of SR √
laboratory set up and work and thereof
equipment in good working monthly
As agreed / required Tech Specs and Const. Drawings
condition well before
commencement of concerned
activity
C Submission of QA & QC - A Physical Once prior to start of √
manpower deployment work
Tech Specs and Const. Drawings
schedule based on agreed L-2
network .
D Availability of QA& QC - A Physical Once prior to start of SR √
manpower based on work and thereof Tech Specs and Const. Drawings
deployment schedule . monthly
E Sampling for testing of buliding A Physical Once per each source SR/TR √ Test report along with the
materials, concrete mix design As agreed / required Tech Specs and Const. Drawings recommendations from specialist agency
etc. to be submitted to NTPC.
F Submission of schedule of tests - A Physical Once prior to start of SR √
to be done monthly / quaterly work and thereof
and maintenace of the same on monthly
a computer connected to LAN
of NTPC for monitoring
2 EXCAVATION AND FILLING IN FOUNDATION WORKS

Excavations-
2.1 Nature, type of soil/rock before and B Visual Random in eah shift SR
during excavations
2.2 Initial ground level before start of B Measurement 100% SR
excavations
2.3 Final shape and Dimensions of B Measurement 100% SR
excavations.
2.4 Final excavation lelvels As agreed / required B Measuement 100% Tech Specs and Const. Drawings SR
2.5 Side slope of final excavation As agreed / required B Measurement Random in eah shift Tech Specs and Const. Drawings SR
2.6 Excavation in Hard Rock- If required
i Receipt, Storage, accountability of B Physical Random in each week Indian Explosive Act 1940/all statutory SR √ NTPC approved specialist blasting agency
As agreed / required
Explosive norms, Tech Specs and Const. Drawings such as CMRI, NIRM shall be deployed at
ii Execution of Blasting Operation As agreed / required B Physical Random in eah shift IS:4081, Tech Specs and Const. Drawings SR √ site for trial blasts, design blasts, blast
iii Submission of Blasting report to EIC As agreed / required C Physical Each blast Tech Specs and Const. Drawings √ vibration monitoring etc. Seismographs
2.7 Excavation in Hard Rock (Blasting B Physical 100% As per approved drawing/ scheme, Tech SR √ shall be deployed at site for monitoring of
As agreed / required blast operation vibrations.
Prohibited) Specs and Const. Drawings
Fill/ Backfill -
2.8 A Suitability of borrow fill material - If earth is brought from area within the NTPC acquired area
Suitability B Visual Randon in each shift
As agreed / required As per technical specifications
2.8 B Suitability of borrow fill material- Applicable in case the earth is brought from an area, out of the NTPC aquired land area
i Grain size analysis Set of Seives, B Physical One in every 2000 cum SR/TR √
Hydrometer etc. for each type and source The parameters should not be worse than
IS:2720 (Pt.IV), Tech Specs and Const.
of fill materials subject to the parameter of the existing soil in plant
Drawings
a min. of 2 samples area
SECTION-VI
MUZAFFARPUR THERMAL POWER PROJECT STAGE-II (2X195 MW) PART - B
COAL HANDLING PLANT PACKAGE SUB-SECTION-IIIE-17
BIDDING DOCUMENT NO.: CS-0350-155(R)-2 INDICATIVE FIELD QUALITY PLAN 1 of 17
Page 2 of 17
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
ii Liquid & plastic limit Mechanical liquid limit B Physical One in every 2000 cum SR/TR √
device, grooving tools, for each type and source
The parameters should not be worse than
Evaporating of fill materials subject to IS:2720 (Pt.IV) , Tech Specs and Const.
the parameter of the existing soil in plant
Disc,Spatula, Palette a min. of 2 samples Drawings
area
knives, Balance oven
containers, etc.
iii Shrinkage limit -do- B Physical One in every 5000 cum SR/TR √
for each type and source The parameters should not be worse than
IS:2720 (Pt.IV), Tech Specs and Const.
of fill materials subject to the parameter of the existing soil in plant
Drawings
a min. of 2 samples area
iv Free Swell Index Measuring cylinders, B Physical One in every 5000 cum SR/TR √ The parameters should not be worse than
IS:2720 (Pt.XI), Tech Specs and Const.
etc. for each type and source the parameter of the existing soil in plant
Drawings
of fill materials area
v Chemical Analysis
a Organic Matter Oven chemical B Physical One in every 5000 cum SR/TR √
balance, volumetric for each type and source
flasks, burettes, of fill materials
IS:2720 Pt.XXII, Tech Specs and Const.
pipettes, conical flasks,
Drawings
set of seives,
measuring cylinders
etc.
b Calcium carbonate Reagents and B Physical One in every 5000 cum SR/TR √
Part XXIII of IS-2720, Tech Specs and
indicators,Burette,flask for each type and source
Const. Drawings
s,funnels etc. of fill materials
c pH value B Physical One in every 5000 cum SR/TR √
Part XXVI of IS-2720, Tech Specs and
As agreed / required for each type and source
Const. Drawings
of fill materials
d Total soluble sulphate B Physical One in every 5000 cum SR/TR √
Part XXVII of IS-2720, Tech Specs and
As agreed / required for each type and source
Const. Drawings
of fill materials
2.9 Standard proctor Test Optimum moisture content and max. dry As per IS: 2720, A Physical One in every 2000 cum SR/TR √
IS 2720 (Pt.VII), Tech Specs and Const.
density before fill Proctor needle for each type and source
Drawings
apparatus,etc. of fill materials
2.10 Moisture content Moisture content of fill before compaction As per IS: 2720, A Physical One in every 2000 cum SR/TR √
IS 2720 (Pt.II), Tech Specs and Const.
balance, oven etc. for each type and source
Drawings
of fill materials
2.9 Degree Of Compaction Of Fill if borrowed from outside plant area /
Backfill
i Dry density by core cutter method As per IS: A Physical i) For foundation fill/ SR/TR √
2720/compaction test backfill one for every 10 IS 2720 (Pt. XXIX), Tech Specs and
---- OR---- (core cutter), balance foundations for each Const. Drawings
etc. compacted layer.
Dry density in place by sand ii) For area filling, one SR/TR √
displacement method every 1000 SQM area IS 2720 (Pt. XXVIII), Tech Specs and
for each compacted Const. Drawings
layer.
ii Relative density (Density Index) As per IS: 2720, A Physical ----do----- (i) & (ii) above IS 2720 (Pt. XIV), Tech Specs and Const. SR/TR √
balance oven etc. Drawings
iii Dry Density by proctor needle As per IS-2720, proctor B Physical Random checks to be SR/TR √
penetration nedle apparatus etc. carried out for each Tech Specs and Const. Drawings
compacted layer
3.0 CAST-IN-SITU CONCRETE

MATERIALS
3.1 CEMENT
i Storage in weather tight covered area on as per IS: 4082 B Visual 100% covered storage SR/LB Each consignment of cement shall be duly
raised platform. correlated with Manufacturers TC.
SECTION-VI
Page 3 of 17
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
ii Retesting for compressive Strength & Vicat Apparatus, A Physical At Random Test √ In case the cement is supplied by the
setting time if stored for more than 60 standard sand Report contractor random sample from each lot of
Tech Specs and Const. Drawings delivery shall be tested for Setting time
days in site shed compression testing
machine etc. and Compressive strength. Acceptance
3.2 Coarse Aggregate
i Moisture content . B Physical Once for each stack of SR/LB Accordingly water content of the concrete
100 Cum. or part there of will be adjusted
Except during monsoon
IS:2386 Part-III, IS : 456, IS : 383/Tech
when this has to be done
Spec, Tech Specs and Const. Drawings
every day before start of
concreting
ii Specific gravity, bulk density, voids, Balance, seives B Physical Once for each source & SR/LB/ These tests will be carried out white
IS:2386 Part-III, IS : 456, IS : 383/Tech
water absorption, (conforming to IS:460- for every change of Test establishing design mix and the results to
Spec, Tech Specs and Const. Drawings
1962) etc. source Report be intimated to NTPC.
iii Particle, size & Shape-(Sieve analysis, Seives, balance oven , B Physical One per 100 cum., or SR/LB -do-
determination of material finer than 75 thickness guage ,length part thereof/change of IS:2386 Part-I, IS : 456, IS : 383/Tech
micron, flakiness index, elongation index, gauge metal scoop etc. source whichever is Spec, Tech Specs and Const. Drawings
angularity number) earlier
iv Deleterious materials & organic Balance, seives B Physical Once per source/ on SR/LB/ Experts opinion regarding suitability of the
impurities (determination of clay lumps, (conforming to IS:460- every change of source Test aggregates shall be obtained from the
fine silt, fine dust , light weight pieces , 1962) etc. IS:2386 Part-II, IS : 456, IS : 383/Tech Report specialist agency such as NCB BallbhGarh
soft particle & estimation of organic Spec, Tech Specs and Const. Drawings etc. finalised during preaward. Results will
impurities.) be reported nearest to 0.1% of clay lumps.
v Soundness reagents (sodium B Physical Once per source/ on SR/LB/ Experts opinion regarding suitability of the
sulphate or magnesium every change of source Test aggregates shall be obtained from the
IS: 2386 Part-V, IS:383 , Tech Specs
sulphate )etc Report specialist agency such as NCB BallbhGarh
and Const. Drawings
etc. finalised during preaward.
vi Alkali aggregate reactivity scales, weight, sieves, B Physical Once per source/ on SR/LB/ √ the quantity of dissolved silica , and
glass graduates, mixing every change of source Test reduction in alkalinity to be reported and
bowl, trovel, container, IS: 2386 (Part-VII), IS:383 , Tech Specs Report hence the aggregate type
length comparetor, etc and Const. Drawings (deleterious/innocuous) result should be
supported by petrographic examination
vii Petrographic examination screens , hand lens, B Physical Once per source/ on SR/LB/ √ Reporting of petrographic examination
microscope etc every change of source Test shall be done as illustrated in IS 2386 (
IS: 2386 Part-VIII, IS:383 , Tech Specs Report part-VIII)-1963. petrographic report shall
and Const. Drawings be supported by the analysis and
recommendation by a specialist instute.
viii Crushing value abrasion value and standard apparatus for B Physical Once per source/ on SR/LB/ -do-
IS:383, IS-2386 Part IV/, Tech Specs and
impact value these tests shall be every change of source Test
Const. Drawings
used Report
ix Repeated Temp, Cycle Test of B Physical Once per source/ on Test √ Applicable for Aggregate used in TG,
Aggregate every change of source No residual expansion, , Tech Specs and Report BFP. Fan & Mills Foundations. To be
Const. Drawings carried out at NIRM and their expert
opinion to be sought.
3.3 Fine Aggregate
i Bulkage/ moisture content balance , oven etc B Physical To be done every day SR/LB/ Volume of sand and weight of water shall
IS: 2386 Part-III IS:383 ,
before start of work TR be adjusted as per bulkage & moisture
content.
ii Silt, Clay content and organic impurities B Physical Once per source& for on SR/LB/ Acceptance limit as per relevant IS code
IS: 2386 Part-II, IS:383 , Tech Specs
As agreed / required every change of source TR
and Const. Drawings
iII All other tests similar to coarse B As above Refer S.No. 2.01.02 IS-2386, IS-383, Tech Specs and Const. SR/LB/
aggregates as mentioned above. As agreed / required TR
Drawings
SECTION-VI
Page 4 of 17
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1 2 3 4 5 6 7 8 9 D* 10
3.4 Water
i Test for sulphates and chlorides Buret, conical flask, B Testing Once per each source IS:3025 part 22 and 23 (for test procedure SR/LB/
pipette etc thereof quarterly. ), IS:456(for acceptance criteria ) , Tech TR
ii Tests for ascertaining limit of solids B Physical Once per each source IS:3025 part 18 (organic),IS:456 , Tech SR/LB/
thereof quarterly. Specs and Const. Drawings TR
iii Tests for pH Value pH meter B Testing Once per each source IS:3025, IS:456, Tech Specs and Const. SR/LB/
thereof quarterly. Drawings TR
iv Initial set time for used water and distilled Vicat appratus A Physical See Remarks See √ In case of doubt regarding development of
water Remarks strength,. Initial set time with used
See Remarks, Tech Specs and Const.
water and the distiled watershould meet
Drawings
the requirements of clause 5.4.1.3 of IS
456
v Compressive strength of concrete with Standard sand and A Physical See Remarks See √ In case of doubt regarding development of
used water and distilled water compression testing Remarks strength,. Compressive strength with
See Remarks, Tech Specs and Const.
machine used water and the distiled water should
Drawings
meet the requirements of clause 5.4.1.2 of
IS 456
3.5 CONCRETE
i Proportions of materials for nominal mix B Physical Random in each shift SR/LB/
As per Table-9 of IS 456, Tech Specs and
concrete As agreed / required Test
Const. Drawings
Report
ii Trial mix (Cubes compressive strength) A Physical Min. 4 Trial Mixes with SR/LB/ √ For trial mix min. of 6 cubes for each mix,
as per Mix Design admixtures and Without Test 3 specimen shall be tested at 7 days
admixtures With fly ash. IS: 516 & IS:456, IS:10262, Tech Specs Report remaining 3 shall be for 28 days comp.
and Const. Drawings Strength. Mix design shall carried out at
agency finalised during pre award )
iii Crushing strength (works Tests cubes) A Physical One set of 6 cubes per SR/LB/ √ Min. of 6 cubes for each mix, 3 specimen
50 M3 or part thereof for Test shall be tested at 7 days remaining 3 shall
IS:516, IS:456, Tech Specs and Const.
As agreed / required each grade of concrete Report be for 28 days comp. Strength.
Drawings
per shift whichever is
earlier.
iv Workability - slump test Standard appratus for B Physical One sample every 2 hrs. SR/LB/T Slump test for medium and high
different method used from every mixing plant R workability, Compaction factor test for
IS:456, Tech Specs and Const. Drawings
for measuring medium and low workability, V.B. test for
workability low to Very low workability
v Cement content B Physical At random at the time of IS:1199 , Tech Specs and Const. SR/LB
batching. Drawings
vi Admixtures for Concrete from approved A Review of MTC Random in each shift Test √ Admixture of appd. Brand and tested
As agreed / required IS:456 , Tech Specs and Const. Drawings
sources Report quality shall be used.
vii Water Tightness Test for Water A Physical Each Structure Inspectio
IS:3370 , IS:6494 Tech Specs and Const.
Retaining Structures As agreed / required n Report √
Drawings
viii Dimensions and visual exa-mination of B Physical/ visual 100% As per Tech. Specification./Appd. Drg./IS- SR
finished structure 456
3.6 CONCRETE CONVEYING, PLACING& COMPACTION
i Mixing of concrete mixing of concrete shall be done in a To be calibrated at the time of mixing will be as given in IS 457
approved mixer such as to produce a time of starting and
homogenous mix subsequently once in Review of calibration chart/ Certificate, IS
three months, and shall 457, Tech Specs and Const. Drawings
confirm to IS:4925
ii Calibration of Batching Plant batcher should comply A Physical To be calibrated at the TR Cement consumption at batching plant
with reqirement of IS time of starting and shall also be obtained through comp.
457 subsequently once in Review of calibration chart/ Certificate, Output.Provision of online printer is
three months, and shall Tech Specs and Const. Drawings √ manadatory
confirm to IS:4925
SECTION-VI
Page 5 of 17
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1 2 3 4 5 6 7 8 9 D* 10
iii Handling and Transportation of concrete buckets,chutes,belts,co B Physical Random in each shift SR Free fall or drop shall be limited to 150
nveyer etc cm unless permitted concrete should be
placed within 30 min of its removal from
mixure . Construction methodology to
be approved one week prior to start of
work.
iv Placement of concrete Visual B Physical Random in each shift SR No concrete shall be placed until the place
of deposit has been throughly inspected
and approved, the concrete shall be
deposited in such a manner to maintain,
until completion of unit, a plastic horizontal
surface throughout
v Check for compaction and Curing B Physical Random in each shift SR Exposed concrete surface shall be
Check for period of curing as per IS 456 , protected against heating and drying for
Tech Specs and Const. Drawings atleast 72 hrs after placement, curing
compound may be used
vi Cleanliness, provision of chute and C Visual 100% SR
arrangement for transportation & As agreed / required IS:456, Tech Specs and Const. Drawings
placement of concrete.
x check for segregation As agreed / required C Visual 100% IS:456, Tech Specs and Const. Drawings
3.7 TEST/CHECK ON RCC STRUCTURE IN HARDENDED CONDITIONS
i Core Test A Physical As required by NTPC SR/LB/ Acceptable if average equivalent cube
Engineer. Test strength of the cores is equal to at least
As per IS:456, IS 516, Tech Specs and Report 85% of the cube strength of the grade of
As agreed / required √ concrete specified for the corresponding
Const. Drawings
age and no indivisual conc has result less
than 75%`
ii Dimensional check on finished structures B Measurement Approved Drawing As per IS:456, Tech Specs and Const. SR
& Dimensional tolerances Drawings
iii Rebound Hammer test A physical As required by the NTPC SR
As agreed / required Tech Specs and Const. Drawings √
engineer
iv
3.8 REINFORCEMENT STEEL
i Physical and Chemical Properties for As required/ agreed A Review of MTC Each batch of delivery IS : 1786, IS:432, IS:1566, Tech Specs MTC Applicable if steel is procured by
√
each lot as per relevant IS codes and Const. Drawings Contractor
IS : 1852, IS: 432, IS:1786, Tech Specs
ii Cutting tolerance As agreed / required B Measurement Random in each shift SR Tolerance as per specifications
and Const Drawings
iii Freedom form cracks surface flaws, B Visual Random in each shift SR To be checked at site. Steel collected from
Lamination. IS: 1852, IS:432, IS:1786, Tech Specs source should be free from excessive rust.
and Const. Drawings To be stored as per Technical Specs.
3.9 PLACEMENT OF REINFORCEMENT STEEL

I Check for bar bending schedule with B Visual & Random in each shift Approved Drawings, Tech Specs and SR
necessary laps. Spacers & Chairs Measurement Const. Drawings
ii Check for cover, spacing of bars B Visual & Random in each shift Approved Drawings, Tech Specs and SR
Measurement Const. Drawings
iii Check for bending of bars B Visual & Random in each shift Approved Drawings, Tech Specs and SR
Measurement Const. Drawings
iv Check for spacers and chairs after the B Visual & Random in each shift SR
Approved Drawings, Tech Specs and
reinforcement cage is put inside the As agreed / required Measurement
Const. Drawings
formwork
v Acceptance of placement od B Visual & beofre start of each IS : 456/ Drawings & approved bar SR
reinforcement before start of concreting As agreed / required Measurement concreting bending, Tech Specs and Const.
Drawings schedule
3.10 STAGING AND FORMS
i Materials and accessories B Visual Once before start of SR Proper care should be taken in order to
work As per relevant IS, Tech Specs and combat corrosion. Proper care should
Const. Drawings be taken while cleaning, moving and
stacking the scaffolds
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1 2 3 4 5 6 7 8 9 D* 10
ii Soundness of staging, shuttering and B Visual Once before start of As per manufacturer's spec.and as per SR
scaffolding work 3696,4014, 4990, Tech Specs and Const.
iii Acceptance of formwork before start B Physical / visual beofre start of each As per provisions and tolerances, Tech SR
concreting concreting Specs and Const. Drawings
3.11 EMBEDDED PART(INCLUDING LAYING OF RAILS & ANCHOR
i Position and levels of embedded parts B Physical/ 100% SR Exposed surfsce of the embeded parts
measurement As per drawing, Tech Specs and Const. other than holding down bolts are to be
Drawings painted with primer ,chlorinated , rubber
baed zinc phosphate
ii Position depth and size of bolt hole B Physical/ Random in each shift As per drawing, Tech Specs and Const. SR
measurement Drawings
iii Location verticality of pipe B Physical/ Random in each shift As per drawing, Tech Specs and Const. SR
sleeve/opening of bolt hold measurement Drawings
iv Laying of rails under supervision of B Physical/ Random in each shift As per drawing, Tech Specs and Const. SR
NTPCs specilised agency. measurement Drawings
v Welding / tieing of embeddment to B Physical/ Random in each shift As per drawing, Tech Specs and Const. SR
reinforce-ment measurement Drawings
3.12 PRE-CAST CONCRETE
i Crushing strength compression strength A Physical one sample of six cubes SR/LB a minimum of three specimen shall be
IS:516&IS; 456, Tech Specs and Const.
testing machine per 50 cum or part √ tested for 28 days comp. strength
Drawings
thereof
ii Workmanship free from visual defects B Physical 100% SR The precast units shall be free from
defects like honeycombing, reinforcement
exposure and should have good finish. All
Visual Tech Specs and Const. Drawings relevant tests like workability, cube test
shall be carried out as per IS 456-2000
Same as applicable to cast in situ
concrete.
iii Dimension of finish structure B Measurement 100% SR If the material already tested of the cast-in-
situ concrete and part of the same is used
As per IS:456, Tech Specs and Const. for precast concrete, further testing is not
Drawings required, otherwise testing is required for
every 50 Cum. Of Concrete.
iv Workability B Physical one sample every two IS:1199 &IS:456, Tech Specs and Const. SR/LB According to the mix design
slump test apparatus
hrs from mixing plant Drawings
v B Physical At random at the time of IS:1199 , Tech Specs and Const. SR/LB According to the mix design
Water cement ratio batching Drawings
vi Cement content B Physical At random at the time of IS:1199 /tech spec, Tech Specs and SR According to the mix design
batching Const. Drawings
vii Load Test A Physical 5% or as desired by EIC IS:456/ As decided by NTPC Site Engr. SR These tests shall also be carried out, in
As agreed / required Incharge., Tech Specs and Const. √ case of doubt regarding grade of concrete
Drawings and poor quality.
3.13 JOINTS IN CONCRETE
i Check for the joint material - bitumen As per manufacturer A Review of MTC Each batch of delivery Tech Specs and Const. Drawings, IS MTC
impregnated fibre board, PVC water Standards 1838, IS 1834, IS12200
stops, Sealing compound, Expanded √
polystyrene board, Hydrophillic strip,
Acrylic polymer etc.
ii Acceptance of installation of materials for B Acceptance Each installation
Joints in concrete randomly
3.14 DAMP PROOF COURSE Tech Specs and Const. Drawings
Check for the material - Hot bitumen and Each batch of delivery at
i As agreed / required A Review of MTC Tech Specs and Const. Drawings, IS 702 SR √
water proffing materials etc site
ii Acceptance of damp proof course As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
3.15 GROUTING
i Check for the material A Review of MTC Each batch of delivery Check for chemical, epoxy, resin grouts
As agreed / required Tech Specs and Const. Drawings SR √
etc
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1 2 3 4 5 6 7 8 9 D* 10
Check for the type of mix - fluid mix, B Physical Prior to start of work
plastic mix, stiff mix etc.
ii Check for the mixing, placement, B Physical Random in each shift
As agreed / required Tech Specs and Const. Drawings SR
application and grout pressure
iii Check for the compressive strength As agreed / required A Physical Each batch of delivery Tech Specs and Const. Drawings SR √
iv Acceptance of the grouts As agreed / required B Physical Each grout section Tech Specs and Const. Drawings SR
4.00 BRICK MASONARY

4.1 Test on Bricks
i Check for Dimensions , shape A Measurement/ As per relevant IS Code/ Inspectio Efflorescence shall be checked at each
Physical Test One Sample for 30,000 IS: 1077, Tech Specs and Const. n Report source.
Nos. or part thereof √
Drawings
ii compressive strength, water absorption, Balance Oven B Measurement/ As per relevant IS Code/ IS: 1077, IS:3495 part I ( Compressive Preconditioning of brick shall be done as
warpage efflorescence. compression testing Physical Test One Sample for 30,000 Strength) Part II ( Water Absorbtion) Part per IS. For comperssive strength,
machine etc. Nos. or part thereof √ warpage and water absorbtion
III( Efflorescence) Part IV ( War page),
Test on Bricks(Fly Ash Based) IF FLYASH BRICKS ARE USED
i Dimensions As agreed / required B Physical One sample from each NTPC Tech. Specifn. and SR/LB
lot received at site. relevant IS :3812
ii Compressive Strength As agreed / required A Physical One sample from each NTPC Tech. Specifn. and SR/LB
lot received at site relevant IS:3812
iii Water Absorption As agreed / required B Physical A set of 20 bricks (min.) SR/LB
NTPC Tech. Specifn. and
for each lot of 50000
relevant IS:3812
bricks or part thereof.
4.2 Test on Mortar Compressive strength, consistency for B Test At random LB Cement used in mortar shall confirm to
IS 2250-1981, Tech Specs and Const.
each portion of walls, plasters and As agreed / required either IS 269: 1976 or IS 455- 1976 sand
Drawings
ceilings. shall confirm to IS 2116 -1980
4.3 Masonry construction Acceptance of Workmanship, verticality B Visual/ Physical 100% IS 2212, IS 1905 , Tech Specs and Const. SR/LB
and alignment Drawings
5.00 FINISHING AND ALLIED WORKS .
5.1 MATERIALS- FINE SAND,
SAND FOR PLASTERING
i Deleterious Material As agreed / required B Physical Once per source Specs and Const. Drawings SR
ii Grading As agreed / required B Physical 50 Cum./or part thereof and Const. Drawings SR Table –I of IS:2116
iii Galvanized hexagonal wire netting for B Review of MTC Each batch of delivery SR
As agreed / required , Tech Specs and Const. Drawings
lath plastering
iv Check for the thickness and finishing of B Visual/ Random in each shift As per IS 1661 , Tech Specs and Const. SR/LB
plaster Measurement Drawings
5.2 PLASTERING
i Check for defects and the remedial B Visual/ Physical Random in each shift SR
measure for bond filler , blistering , Tech Specs and Const. Drawings, IS:
cracking and crazing , efflorescence and 1661
irregularity of surface texture
ii Truness of plastering system B Visual/ Physical Random in each shift Tech Specs and Const. Drawings SR finished plaster surface shall not show any
deviation more than 4 mm when checked
with straight edge of 2 m length
iii Acceptance of Grooves and finishing As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
5.3 STONE GRIT PLASTER/ GRANULAR TEXTURED COAT FINISH
i Check for Preparation of surface As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings SR
ii Check for material - Size of chips As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings SR
iii Acceptance of Grooves and finishing As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
5.4
WATER PROOFING SYSTEM
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1 2 3 4 5 6 7 8 9 D* 10
i Physical and SR/
Check for the material As agreed / required A Each lot of delivery Tech Specs and Const. Drawings, √
Review of MTC MTC
Acceptance of water proofing system - Water pounding test shall be done
As agreed / required B Physical 100% Tech Specs and Const. Drawings SR
ii Application, fixing, laying
5.5 FALSE CEILING
i) Check for the Materials - Glass A Physical and MTC Each batch of delivery -do-
Reinforced Gypsum (GRG), Pre-painted Review As per relevant IS and Tech. Specs /
coil coated steel false ceiling system etc.
As agreed / required √
Manufacturer's TC
ii) Acceptance of installation B Physical / Each installation -do- All supports , hangers , accessories shall
measurements be as per Tech. Specifications/ approved
As agreed / required -do-
manufacturer's recommendations
6.00 PAINTING SYSTEM - All surfaces

6.1 Check for the Materials and A Review of MTC Each batch of delivery SR/MTC Mfr.’s T.C. shall be correlated with the
White wash, Distemper and all types of
accessories consignment received.
Primer and Paints - Check for Shade,
type from brand and manufacturer as
approved by NTPC EIC
6.2 Check for Surface prepration As agreed / required B Physical /visual Random in each shift Tech Specs and Const. Drawings SR
6.3 Check for DFT of painted B Physical Each surface at random SR
surfaces
6.4 Acceptance of painted surfaces B Physical Each surface at random SR
7.00 DOORS , WINDOWS VENTILATORS & GRILL

7.1
Check for the material/ items
for all type of timber, flush
doors, Particle doors, wire
guage, Aluminium doors, Review of MTC / make or/and Physical
Review of MTC/ for each batch of
Fire proof doors, windows checks, tests report ( if MTC is not As agreed / required A Tech Specs and Const. Drawings SR √
Physical delivery
fittings, Anodized aluminium available)
works, Mortice locks,
Automatic operating system
etc received at site
7.2 Wood work in frames - Check for

Random for each
Wood work in frames dimensions, surface finish and rebating As agreed / required B Physical Tech Specs and Const. Drawings SR
installation
etc.
7.3 Wardrobe shutter and show
cases
i one sample for each
Check for material as per IS 3087 and Tech Specs and Const. Drawings, IS 3087
As agreed / required B Physical section for each lot of SR
3097 - from NTPC approved source and 3097
delivery
Tech Specs and Const. Drawings, IS 3087
ii Acceptance of fixing after completion As agreed / required B Acceptance 100% SR
and 3098
7.4 Pelmets
Check for material as per IS 3087/ 3097 - Tech Specs and Const. Drawings, IS
As agreed / required B Physical section for each lot of SR
from NTPC approved source 3087/ 3097
delivery
Tech Specs and Const. Drawings, IS
ii Acceptance of fixing after completion As agreed / required B Acceptance 100% SR
3087/ 3098
7.5 MS Grills
Check for the material for section and
As agreed / required A Physical section for each lot of Tech Specs and Const. Drawings SR √
weight from NTPC approved source
delivery
ii Check for fabrication done at approved
As agreed / required B Physical Random Tech Specs and Const. Drawings SR
workshop
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1 2 3 4 5 6 7 8 9 D* 10
Acceptance of fixing of MS Grills As agreed / required B Acceptance Random Tech Specs and Const. Drawings SR
7.6 Fitting and fixtures - MS
sliding door bolts, tower
bolts, pull bolt lock, MS Check for fitting items as per relavent IS Five samples for each
Physical and
handles, Safety Chains, codes, tech specifications and BOQ- As agreed / required B item for each lot of Tech Specs and Const. Drawings SR
acceptance
brass locks, brass latch, from NTPC approved source delivery
hydraulic floor springs &
door closers, etc
7.7 Fitting and fixtures -
Aluminium sliding door Check for fitting items as per relavent IS Five samples for each
Physical and
bolts, tower bolts, pull bolt codes, tech specifications and BOQ- As agreed / required B item for each lot of Tech Specs and Const. Drawings SR
acceptance
locks, handles, door from NTPC approved source delivery
stoppers etc.
7.8 Fire proof doors
As per Technical Specifications and √
i a) Check for the Fire Proof Doors As required/ agreed A Review of MTC Each lot MTC
approved drawings IS 3614 Part (I &II)
ii b) Check for DFT and Fire Retardency of As per Technical Specifications and
As required/ agreed B Physical Each Door SR/LB
Paint approved drawings, IS 3614 Part (I &II)
7.9 Acceptance of all type Physical and Random for each type of
Acceptance of fittings after completion As agreed / required B Tech Specs and Const. Drawings SR
fittings after fixing acceptance fitting
8.00 GENERAL STEEL WORK

8.1
Check for Material - Rolled Review of MTC/ make / Physical checks, Review of MTC For each batch of
As agreed / required A Tech Specs and Const. Drawings SR √
Steel, Z Sections, Plates etc. tests ( if MTC is not available) for each delivery delivery
8.2 Rolling shutters
i Check for surface finish and thickness of
Random for each batch
plate of rolling shutters of approved As agreed / required B Physical Tech Specs and Const. Drawings SR
of delivery
make and DFT
ii Physical and
Acceptance of rolling shutters after fixing As agreed / required B Random Tech Specs and Const. Drawings SR
acceptance
8.3 Steel Glazed doors and T-
iron frames sections
i
Check for shape, tolerances, thickness,
Review of MTC Random for each
welding and finishing of sections (Check As agreed / required A Tech Specs and Const. Drawings SR √
for each delivery delivery
MTC whereever applicable)
ii Acceptance of Steel Glazed doors and T- Physical and Random for each
As agreed / required B Tech Specs and Const. Drawings SR
iron frames sections after fixing acceptance installation
8.4 Pressed steel pressed
frames/ doors
i Check for shape, tolerances, thickness,
Review of MTC Random for each Tech Specs and Const. Drawings, IS4351,
welding and finishing (Check MTC As agreed / required A SR √
for each delivery delivery IS2202
whereever applicable)
ii Acceptance of Pressed steel pressed Physical and Random for each
As agreed / required B Tech Specs and Const. Drawings SR
doors after fixing acceptance installation
8.5 Fencing and Gates
i) PVC coated chain link fencing (IS 2720), A Review of MTC Each batch of delivery SR/MTC Mfr.’s T.C. shall be correlated with the
Check for Materials for fencing Welded wire mesh (IS 1566), Reinforced consignment received.
and gates barbed tape galvanised (IS 2629) etc.
ii) Check for alignments, erection B Physical / Each installation Erection shall be as per NTPC Tech.
painting, DFT etc. measurements SR Specs.
ii) Acceptance of the installation B Physical / Each installation Erection shall be as per NTPC Tech.
and working measurements SR Specs.
8.6 Galvanised Chicken Wire Check for Guage and Dimensions from Random for each
As agreed / required B Acceptance Tech Specs and Const. Drawings SR
Mesh NTPC approved Source delivery
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1 2 3 4 5 6 7 8 9 D* 10
FLOOR FINISHES AND ALIED
9.00
WORKS
9.1 Cement Concrete Flooring
i Check for execution of concreting As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings SR
Check for providing and fixing glass/
ii As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings SR
PVC strips in joints
Check for laying, polishing, curing,
iii finishing for terrazzo, marble chip As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings SR
flooring
iv Acceptance of lines, levels and finishing As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
Acid and or alkali resistance
9.2
tiles
Check for tiles and alkali resistance Review of MTC
i As agreed / required A each batch of delivery Tech Specs and Const. Drawings SR √
cement as per IS for each delivery
ii Acceptance of lines, levels and finishing As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
Kota Stone, Granite and
9.3
Marble
Check for quality, texture, thickness,
i colour for each lot of delivery from As agreed / required A Physical each batch of delivery Tech Specs and Const. Drawings SR √
approved source
Check for the preparation of surface,
laying, joints
Acceptance for curing, polishing and
iii As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
finishing
Ceramic Glazed Tiles,
Vitrified / glass mosaic tiles
9.4
other tiles as per
specification
Check for tiles from NTPC approved
Physical / review
i sources as per specification (Check MTC As agreed / required A each batch of delivery Tech Specs and Const. Drawings SR √
of MTC
Check for the preparation of surface,
laying, joints
Acceptance for curing, polishing and
iii As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
finishing
10.00 SANITORY INSTALLATIONS

Check for size and surface finish of all
sanitory items and fixtures from NTPC Physical / review Each lot of delivery as To be procured from NTPC approved
10.1 As agreed / required A Tech Specs and Const. Drawings SR √
approved sources, (Check MTC of MTC per Specifications source
Acceptance of installations of all sanitory
10.2 As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
items and fixtures
SCI, CI, S&S Pipes & Fittings
10.3
etc
i Check for Work man ship and finish As agreed / required B Visual Random Tech Specs and Const. Drawings SR
ii Check for Unit weight and Dimensions As agreed / required B Physical Random Tech Specs and Const. Drawings SR
Review of MTC Each lot of delivery as
iii Hydrostatic test As agreed / required A Tech Specs and Const. Drawings SR √
for each delivery per Specifications
11.00 WATER SUPPLY AND ALL TYPES OF FITTINGS

Check for size and surface finish of all
water supply, GI/ MS pipes and fittings,
Physical / review each delivery as per To be procured from NTPC approved
11.1 Photo Voltaic Control System etc from As agreed / required A Tech Specs and Const. Drawings SR √
of MTC Specifications source
NTPC approved sources (Check MTC
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1 2 3 4 5 6 7 8 9 D* 10
Acceptance of installations of all water
11.2 As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
supply, GI pipes and fittings
11.3 CI, S&S Pipes & Fittings
Random as per
i Check for Work man ship and finish As agreed / required B Visual Tech Specs and Const. Drawings SR
Specifications
ii Check for Unit weight and Dimensions As agreed / required B Physical Random Tech Specs and Const. Drawings SR
Physical / review Each lot of delivery as
iii Hydrostatic test As agreed / required A Tech Specs and Const. Drawings SR √
of MTC per Specifications
Polyethylene Water Storage
11.4
Tanks
Check for material of tanks from NTPC Physical / review Each lot of delivery as
i As agreed / required A Tech Specs and Const. Drawings SR √
approved sources of MTC per Specifications
Aceptance for instllation and fitting (IS
ii As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
12701)
12.00 DRAINAGE AND SANITATION

12.1 Sanitary appliances
Check for Viterous China, Glazed,
Physical / review each delivery as per To be procured from NTPC approved
i ceramic sanitary appliances (Water As agreed / required A Tech Specs and Const. Drawings SR √
of MTC Specifications source
closets, Wash basins, urinals) etc.
Acceptance of installation of Viterous
China, Glazed, ceramic sanitary
appliances (Water closets, Wash basins,
urinals) etc.
12.2 SW Pipes and RCC Pipes
Check for size and surface finish of Tech Specs and Const. Drawings, IS458,
i As agreed / required A Physical 100% after delivery SR √
Pipes from NTPC approved sources IS 1536
ii Testing of Joints As agreed / required B Physical 100% Tech Specs and Const. Drawings SR
Acceptance tests shall be done as per
i Acceptance of installations of Pipes As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
specifications
12.3 CI Pipes, Covers and Frames
Check for CI and SFRC covers and

frames as per IS 1726 and IS 12592 from Physical / review Tech Specs and Const. Drawings, IS
i As agreed / required A Each lot of delivery SR √
NTPC approved sources (Check MTC of MTC 1536, IS 12592
Acceptance of installations of CI Pipes,
Covers and Frames
Acceptance of RCC manholes after Tech Specs and Const. Drawings , IS
12.4 RCC manholes As agreed / required B Acceptance 100% SR
completion 4111
13.00 ALUMINIUM WORK

Check for section/ fixtures dimensions Physical and one sample for each
Tech Specs and Const. Drawings, IS 733,
13.1 and anodising from NTPC approved As agreed / required A Review of MTC section for each lot of SR √
IS 1285
sources for each delivery delivery
Tech Specs and Const. Drawings, IS 733,
13.2 Acceptance of fixing after completion As agreed / required B Physical 100% SR
IS 1285
14.00 WATER PROOFING

Check for water proofing compoud,
Blown/ residual bitumen, PVC sheet, Physical and one sample for each
14.1 PVC water stops, Geotextiles, Poly-scrim As agreed / required A Review of MTC section for each lot of Tech Specs and Const. Drawings SR
cloth, elastomeric membrane, from for each delivery delivery
NTPC approved sources
14.2 Acceptance of water proofing work As agreed / required B Physical 100% Tech Specs and Const. Drawings
15.00 GLASS AND GLAZING
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1 2 3 4 5 6 7 8 9 D* 10
For structural glazing the technical
Check for the material - check for MTC Physical and SR/
15.1 As agreed / required A Each lot of delivery Tech Specs and Const. Drawings √ parameters shall be as per the technical
and thickness of glass. Review of MTC MTC
specifications
Check for structural glazing cleaning Physical and SR/
15.2 As agreed / required A Each lot of delivery Tech Specs and Const. Drawings √
system Review of MTC MTC
Acceptance of glass and glazing
15.3 installation work including cleaning As agreed / required B Physical 100% Tech Specs and Const. Drawings SR
system
16.00 FOUNDATION SYSTEM

16.1 SHALLOW FOUNDATIONS
Check for the foundation excavation - As per technical specifications and
i As required / agreed B Physical Each location SR √ lines and levels to be checked
Location, Layout, size, depth etc construction drawings
Check for the foundation casting -
As per technical specifications and lines and levels to be checked. Concrete
ii Layout, Shape, dimensitions, As required / agreed B Physical Each foundation SR
construction drawings Grade to be checked as per Mix Design
Reinforcement, concreting, curing etc
17.00 SHEETING AND OTHER

WORKS
17.1 Check for Material like modular areated As per manufacturer A Review of MTC Each batch of delivery MTC 1)FQP for structural steel shall also be
panel, permanently colour coated sheets Standards applicable.2) For aluminium
, metal decking , pre-engineered door/windows, check for anodisation as
buildings, AC sheeting, Fire proof doors per Tech. Spec. 3) Fire proof doors shall
and insulations (all tests as per tehcnical
Tech Specs and Const. Drawings √ be procured from TAC Approved parties
Specifications) as per relevant IS/Tech. 4) For aluminium
cladding grade of alminium to be checked.
17.2 Check for Storage at Site As agreed / required B Visual Random in each shift Tech Specs and Const. Drawings SR
17.3 Installation, lap alignment & B Visual/ Physical Random in each shift SR No gas cutting of sheets acceptable .
workmanship. Profile sheets will be kept covered in
17.4 Installation of lining &insulation &check B Testing 100% SR weather proof storage &stored at accurate
thermal insulationfor wall clading for height to avoid any exposure of actual
thickness , density , thermal As agreed / required Tech Specs and Const. Drawings √ water. Principle of first in and first out shall
conductivityn at 50 deg c and all other be apply for erecting the sheets.
tests as per IS:8183
17.5 Check for the installation, alignments, B Visual/ Physical Random in each shift SR/LB
finishing etc
17.6 Fasteners for sheeting work B Review of TC SR/LB
including 1000 hrs
As agreed / required 100% Tech Specs and Const. Drawings
salt spray test
17.7 Acceptance of each type of installation As agreed / required B Visual/ Physical Each installation Tech Specs and Const. Drawings SR/LB
18.00 SPECIAL ITEMS
18.1 Bitumastic flooring / layering Check for the Bitumen grade and B Review of MTC Each batch of delivery Tech Specs and Const. Drawings, IS 73, SR/MTC
suitability of filler material
IS 383
18.2 Earthing Mat (Grounding
System)
i Check for the earthing mat material A Physical and MTC Each batch of delivery As per relevant IS and Tech. Specs / SR/MTC
Review Manufacturer's TC, IS 3043
ii Weld sizes & length Visual/Tape B Visual/ 100% Low hydrogen electrode as per NTPC
Measurement approval shall be used.
Free from defect , Tech Specs and Const.
iii D P test DP test Kit A Physical 10% at random TR √
Drawings
Tech Specs and Const. Drawings,
iv Earth test Earthing test kit A Physical 100% SR √ Earthing required as per IS 3043
Relevant IS 3043
18.3 Insulations
i Check for the insulation material such as A Physical and MTC Each batch of delivery SR/MTC
Mineral Wools, Polysocyanyrate / regid As agreed / required Review √
12436, IS 13204, IS 8183
phenolic foam slabs etc.
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1 2 3 4 5 6 7 8 9 D* 10
ii Acceptance of installation of Insulations B Physical Each installation SR
18.4 Aluminium Composite Panel
Cladding (Also refer FQP
items for sheeting)
Check for the material A Physical and MTC Each batch of delivery SR/MTC
i As agreed / required Tech Specs and Const. Drawings √
Review
Acceptance of installation of Aluminium B Physical Each installation SR Installation shall be done by specialist
ii As agreed / required Tech Specs and Const. Drawings
Composite Panel Cladding agency
18.5 Acid/ Alkali Resistance
Treatment
Check for acid/ alkali resistance A Physical and MTC Each batch of delivery SR/MTC
materials - Bricks, vitreous tiles, mortar, Review Tech Specs and Const. Drawings, IS
i
sealing, paints, coatings, sheets, fillers
4860, IS 4457, IS 4832
etc
ii Check for surface preparation As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings, IS 2395
iii Acceptance of each type of installation As agreed / required B Physical Each installation Tech Specs and Const. Drawings SR DFT shall be checked for paints, coats
19.00 ROAD WORKS

19.1 Construction of Sub-Grade
and earthen/hard soulders
i Standard proctor Test to determine As per IS: 2720, A Physical One in every 2000 cum As per Tech Specs and Const. SR/TR √ In cutting or existing levelled ground -
optimum moisture content and max. dry Proctor needle for each type and source Drawings,Section 900 of MORTH quantum of check shall be one per 1000
density apparatus,etc. of fill materials specification, IS 2720 (Pt.VII) SQM
ii Moisture content of fill before compaction B Physical One in every 2000 cum As per Tech Specs and Const. Drawings, SR/TR In cutting or existing levelled ground -
As per IS: 2720,
for each type and source Section 900 of MORTH specification, IS quantum of check shall be one per 1000
balance, oven etc.
of fill materials 2720 (Pt.II) SQM
iii Dry density by core cutter method As per IS: A Physical One in every 500 SQM SR/TR √
As per Tech Specs and Const. Drawings, Both for embankment and cut formation
---- OR---- 2720/compaction test area for each compacted
Section 900 of MORTH specification, IS quantum of check - One in every 1000
Dry density in place by sand (core cutter), balance layer.
2720 (Pt. XXIX)/ IS 2720 (Pt. XXVIII), SQM area for each compacted layer.
displacement method etc.
19.2
Water Bound Macadam (Non-
Bituminous) for base course
and sub-base course
i Aggregate Impact value Agrregate Impact value A Physical One test per 200 cum of As perTech Specs and Const. Drawings, SR √
Test Apparatus Test aggregate Section 900 of MORTH specification,
ii Grading B Physical One test per 100 cum of As perTech Specs and Const. Drawings, SR
Set of IS Sieves
aggregate Section 900 of MORTH specification,
iii Flakiness index and elongation index B Physical One test per 200cun of As perTech Specs and Const. Drawings, SR
Flakiness test gauge
agregate Section 900 of MORTH specification,
iv Atterberg Limits of binding material Atterberg limits A Physical One test per 25 cum of As perTech Specs and Const. Drawings, SR √
determination binding material Section 900 of MORTH specification,
v Atterberg Limits of portion of agreggate Atterberg limits A Physical One test per 100cum of As perTech Specs and Const. Drawings, SR √
passing 425 micron sieve determination aggregate Section 900 of MORTH specification,
vi Standard proctor Test to determine As per IS: 2720, A Physical One in every 2000 cum IS 2720 (Pt.VII), Tech Specs and Const. SR √
optimum moisture content and max. dry Proctor needle for each type and source Drawings,Section 900 of MORTH
density apparatus,etc. of fill materials specification
vii Moisture content of fill before compaction B Physical One in every 2000 cum IS 2720 (Pt.II), Tech Specs and Const. SR
As per IS: 2720,
for each type and source Drawings, Section 900 of MORTH
balance, oven etc.
of fill materials specification
viii Dry density by core cutter method As per IS: A Physical For area filling, one SR √
IS 2720 (Pt. XXIX)/ IS 2720 (Pt.
---- OR---- 2720/compaction test every 1000 SQM area
XXVIII),Tech Specs and Const. Drawings,
Dry density in place by sand (core cutter), balance for each compacted
Section 900 of MORTH specification
displacement method etc. layer.
19.3 Bituminous Macadam for
base and binder course
SECTION-VI
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i Quality of binder A Physical No. of samples per Lot & SR √
As per Tech Specs and Const. Drawings,
Penetrometre with St. tests as per IS:73,
Section 900 of MORTH specification, IS
needle IS:217, IS:8887 as
73
applicable
ii Aggregate Impact Value / Los angeles A Physical One test per 50 cum of SR √
abrasion value Aggregate Impact aggregate As per Tech Specs and Const. Drawings,
ValueTest apparatus Section 900 of MORTH specification
iii Flakiness Index and elongation index of B Physical One test per 50 cum of SR
aggregates Flakiness test gauge aggregate
iv Stripping value of aggregate (Immersion B Physical Initialy one set of 3 SR

tray test) representative specimen
As required / agreed per source, and on every
change of source.
v Water sensitivity of mix A Physical Initialy one set of 3 SR √

representative specimen
change of source.
vi Grading of aggregates B Physical Two test per day per SR

plant both on individual As per Tech Specs and Const. Drawings,
Set of Sieves
constituents and mixed Section 900 of MORTH specification
aggregate from drier
vii Water absorption of aggregate Initially one set of 3 SR
change of source.
viii Soundness ( Magnesium and Sodium A Physical Once per source by each SR √
Sulphate) As required as per method and on every As per Tech Specs and Const. Drawings,
IS:2386 change of source Section 900 of MORTH specification
ix Percentage of fractured faces B Physical When gravel is used one SR

As required / agreed test per 50cum of
aggregates
x Binder content and aggregate grading A Physical Periodic, subject to a SR √
Bitumen extractor min of two tests per day
per plant
xi Control of Temperature of binder and B Physical At regular close intervals SR
aggregate for mixing and of the mix at Thermometer
the time of laying and rolling
xii Rate of spread of mixed materials B Physical Regular control through SR
As required / agreed checks of layer thickness
xiii Density of compacted Layer A Physical One test per 250 sqm of As per Tech Specs and Const. Drawings, SR √
As required / agreed
area Section 900 of MORTH specification
19.4 Bituminous Surfacing - Open
graded premix carpet and
Seal coat
Penetrometre with St. tests as per IS:73, IS 73,Tech Specs and Const. Drawings,
needle IS:217, IS:8887 as Section 900 of MORTH specification
applicable
ii Aggregate Impact Value / Los angeles Aggregate Impact A Physical One test per 50 cum of As per Tech Specs and Const. Drawings, SR √
abrasion value ValueTest apparatus aggregate Section 900 of MORTH specification
iii Flakiness Index and elongation indexof B Physical One test per 50 cum of As per Tech Specs and Const. Drawings, SR
Flakiness test gauge
aggregates aggregate Section 900 of MORTH specification
SECTION-VI
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iv Stripping value of aggregate (Immersion B Physical Initialy one set of 3 SR
tray test) representative specimen
change of source.
v Water absorption test A Physical Initialy one set of 3 SR √

per source, and on every
change of source.
vi Water sensitivity of mix A Physical Initialy one set of 3 SR √

change of source.
vii Grading of aggregates B Physical One test per 25 cum of As per Tech Specs and Const. Drawings, SR
Set of Sieves
aggregates Section 900 of MORTH specification
viii Soundness ( Magnesium and Sodium A Physical Once per source by each SR √
Sulphate) As required as per method and on every As per Tech Specs and Const. Drawings,
IS:2386 change of source Section 900 of MORTH specification
ix Polished stone value As required as per B Physical As required As per Tech Specs and Const. Drawings, SR
BS:812(Part 114) Section 900 of MORTH specification
x Temperature of binder at application B Physical At regular close intervals As per Tech Specs and Const. Drawings, SR
Thermometer
xi Binder content A Physical One test per 500 cum& SR √
Bitumen extractor not less than two tests
per day
xii Rate of spread of materials B Physical One test per 500 cum SR
As required / agreed and not less than 2 tests
per day
xiii Percentage of fractured faces A Physical When gravel is used one SR √
Bitumen extractor test per 50cum of
aggregates
19.5 Tack Coat/ Prime coat/ fog
coat
Penetrometre with tests as per IS:73, IS 73,Tech Specs and Const. Drawings,
Standard needle IS:217, IS:8887 as Section 900 of MORTH specification
applicable
ii Temperature of binder at application B Physical At regular close intervals As per Tech Specs and Const. Drawings, SR
Thermometer
iii Rate of spread of binder B Physical One test per 500 cum SR
As required / agreed and not less than 2 tests
per day
19.6 RCC Pavements Concrete - Material, Mix design, Trial - - Refer FQP for concrete - − FQP for Concrete Works shall be
Mixes, Production, Transportation, Works application for all concrete works
Refer FQP for concrete Works, , Tech
Placement, Compaction, Curing, Test on As required / agreed
Specs and Const. Drawings, IRC & MOST
green concrete, Test on hardened
concrete etc.
19.7 Alignment, Level, Surface
regularity and rectification
i Horizontal alignment, Surface levels and B Physical As per section 900 of As per Tech Specs and Const. Drawings, SR
Surface regularity MORTH specification Section 900 of MORTH specification
ii Rectification B Physical Each rectification As per Tech Specs and Const. Drawings, SR √
20.00 GEOTECHNICAL INVESTIGATION WORK( IF APPLICABLE)
SECTION-VI
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20.1 Deployment of approved Geotechnical A Physical Once before SR √
As per technical specifications and
Investigation Agency - Check for As required / agreed commencement of work
relevant IS Codes
Equipments, Manpower etc
20.2 Execution of Geotechnical Investigation - B Physical Each Location SR √
Check for locations, type etc as per As required / agreed
relevant IS Codes
scheme
20.3 Collection of disturbed and undisturbed B Physical each sampling SR
samples , their packing and storage As required / agreed
relevant IS Codes
20.4 Conducting filed tests as per B Physical each field test SR
investigation scheme- such as, As required / agreed
relevant IS Codes
SPT/ERT/SCPT/PLT/PMT etc
20.5 Submittion of Field Borelogs in approved B Review Within 24 hours after As per technical specifications and SR √
format completion of each BH relevant IS Codes
20.6 Submittion of laboratory test schedule A Review and as per consultation with SR √
and selection of samples for laboratory acceptance engineer during dispatch As per technical specifications and
testing of samples to approved relevant IS Codes
laboratory
20.7 Submission of Final Geotechnical B Physical After completion of - √
investigation report along with As required / agreed investigation work and
relevant IS Codes
recommendations review of draft reports
21.00 ANTI WEED TREATMENT

21.1 Check for the Anti-weed treatment A Physical and MTC Each batch of delivery SR
materials Review
21.2 Execution of treatment B Physical Random check for each SR
treatment
22.00 Piling Works
22.01.01 100 mm Dia borehole As required A Physical 100% NTPC Tech. Specs SR/LB
2201.02 Pile layout Total station B Measurement 100% As per appd. Drawings SR/LB
22.01.03 Recording ground level As required B Measurement Random As per approved drawings SR/LB
22.01.04 Cleaning/Flushing of pile bore at 3 stage As required B Visual Random As per IS:2911 (relevant part) SR/LB
after completion of bore, after lowering
reinforcement cage and just before
placing concrete.
22.01.05 Size of bore and During boring of pile As required B Measurement 100% As per approved drawing SR/LB
record commencement of SPT/ core
recovery to ensure socketing length
equivalent in terms of the Diameter of
the pile below the socketing horizon.
22.01.06 Pouring of sound concrete of required As required B Measurement 100% As per approved drawing SR/LB
grade to project above cutoff level.
22.01.07 Pile termination level SPT & core recovery A Soil data As per NTPC As per NTPC specifications SR
specifications
22.02 Testing
22.02.01 Bentonite As required B Physical Once per source As per IS:2720 / tech. Specs. SR/LB
22.02.02 Density check on sample of mud Sample collection A Physical As per Tech. Spec. As per NTPC Tech Spec. SR/LB Tests to be done before placing concrete.
collected from pile bore bottom Samples to be collected from pile bore
bottom.
22.02.03 Slump test of concrete, Cube Test Slump test cone. B Physical 100% As per Tech. Specs./IS 2911 SR/LB
(Works Test Cubes)
SECTION-VI
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22.02.04 Initial pile load test, Vertical Calibrated dial gauges etc. as A Testing 100% for 3 nos. for each IS:2911 & Tech. Specs. SR/LB & In case of compression test method the
required.
(Compression), Lateral (horizontal) and type/Tech. Spec. interpret loading shall be cyclic.
pullout (tension). ation as
per
IS:2911
(Part 4)
22.02.05 Routine pile tests, compression and Calibrated dial gauges A Testing 100% for 0.5% of the IS: 2911 & Tech. Specs. SR/LB & Routine Test shall be conducted by direct
horizontal etc. as required. total number of piles interpret loading method.
provided for each type of ation as
test/Tech. Spec. per
IS:2911
(Part 4)
22.02.06 Integrity Tests NDT A Testing 100% As per Technical spec. & suppliers Test CHP
manual Report
LEGEND: D * Records, indentified with “Tick” (√) shall be essentially included by supplier in QA documentation. DOC. NO.: CS - Project Code - XXX-X-QVC-G-001 REV: 0
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB
Manufact Main-supplier Categorization Witnessing & Accepting (As per NTPC QA&I System) For NTPC USE
urer/ Sub- Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category ‘C’ Executing
supplier Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate
Signature This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings REVIEWED BY APPROVED BY APPROVAL SEAL
SECTION-VI
SUPPLIERS NAME AND INDICATIVE FIELD QUALITY PLAN 1 of 5 ANNEXURE- IV
ADDRESS: QP NO. : 2 PROJECT:
ITEM : STRUCTURAL STEEL WORK
LOGO REV. NO .: 0 PACKAGE:
CONTRACT NO.
SUB-SYSTEM : FABRICATION & ERECTION DATE :
PAGE : MAIN CONTRACTOR
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1 2 3 4 5 6 7 8 9 D* 10
1.00 STRUCTURAL STEEL MATERIAL

1.00.01 Material- Visual Examination, B Visual Each plate/ Section MS steel conforming to IS 2062
Identification and marking for and IS 8500 to be clearly
grade/ type of steel demarcated by application of
Issed by NTPC Tech Specs and Const. Drawings
distinct coloured paint strips on
each piece/ off-cuts of respective
grades/ type of steel.
1.00.03 Structural steel procured from A Review For each batch of SR
Correlated MTC shall be verified.
NTPC approved sources- each section delivered Technical Specification and In the event of non submission of
Procured by contractor Mechanical (YS, UTS, Elg, UT if at site √
Construction Drawings, IS 2062, 8500 MTC , sample shall be selected by
specified),,and Chemical
FQA for testing
properties (CE as per IS)
1.01 PRE-WELDING REQUIREMENTS
1.01.01 Welding Procedure - A Review Each Welding Technical Specification and WPS *To be approved by CQA
Specification * (WPS *) Process Construction Drawings, ASME-IX/ AWS √
D 1.1
1.01.02 PQR and Welder's Qualification Physical Each welder PQR/ WQR, AWS-D1.1/ASME-IX, Test
- A √
Technical Specifi- cation and Report
1.01.03 Welding consumables - B Physical Random in each shift Approved WPS, Latest NTPC SR √
1.02 FIT-UP
1.02.01 Marking and Cutting B Visual & Each plate/ Section Technical Specification and SR
Tape, ruler etc
Measurement Construction Drawings/ Approved
1.02.02 Match markings for trial B Physical Each fit-up Technical Specification and SR
-
assembled components Construction Drawings
1.02.03 Weld Fit Up- Edge Preparation/ B Physical Each fit-up SR If required suitable stiffners shall
Technical Specification and
Gap/ Alignment Tape, ruler etc √ be provided to prevent deflection.
Construction Drawings, IS 7215
1.03 PRE HEATING (wherever applicable)

1.03.01 Pre-Heating Temperature B Measurement Each pre-heating SR
Thermal chalk √
Construction Drawings, Approved WPS
1.03.02 Post Weld Heat Treatment Thermo couple A Time & Each PWHT SR
(PWHT), if required with time Temperature Technical Specification and
√
temperature Construction Drawings, Approved WPS
recorder
SECTION-VI
PART - B
MUZAFFARPUR THERMAL POWER PROJECT STAGE-II (2X195 MW)
SUB-SECTION-IIIE-17
BIDDING DOCUMENT NO.: CS-0350-155(R)-2
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1.04 WELDING REQUIREMENTS
1.04.01 Sequence of welding B Physical Random in each shift SR

-
Construction Drawings, Agreed scheme
1.04.02 Removal/ grinding of temporary B Measurement All cleats/ attachments Technical Specification and SR
attachments - Construction Drawings, Approved Drg.
1.04.03 Completeness after welding- B Visual Each structure SR

Dimensions/ distortion Weld gauge component
Construction Drawings, IS 822
5.00 NON DESTRUCTIVE AND DESTRUCTIVE TESTING

5.01 Fillet Welds
5.01.01 i). Check for size and visual B Visual/ 100% As per technical specifications and SR As per requirement of NTPC
examination As required/ Measurement Engineer
construction drawings, IS 822, AWS D
agreed
1.1
5.01.02 ii). Microetch Examination on B Physical Main fillet weld with SR
production test coupons As required/ min one joint per built
construction drawings, IS 822, AWS D √
agreed up beam, columns
1.1
and crane girders
5.01.03 iii). Dye Penetration Test - B Physical 25% weld length of As per technical specifications and SR
Crane Girder As required/ tension member of construction drawings, IS 822, AWS D
agreed crane girder 1.2
5.01.04 iv). Dye Penetration Test - B Physical 5% of Weld length As per technical specifications and SR
Except Crane Girder, fo all other As required/ with min. 300mm at construction drawings, IS 822, AWS D
Fillet Welds agreed each loaction 1.3
5.02 Butt Welds

5.02.01 i) Visual examination B Visual Random in each shift As per technical specifications and SR As per requirement of NTPC
As required/ Engineer
construction drawings, IS 822, AWS D
agreed
1.3
5.02.02 ii) DPT B Physical On all butt welds DPT As per technical specifications and IR All butt welds to be back gouged
As required/ after back gouging. construction drawings, IS 822, AWS D before DPT
agreed
1.3
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
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5.02.03 iii) Mechanical testing on B Physical Min. one joint per built As per technical specifications and IR Test on production test coupons
As required/
production test coupons up beams, coloums construction drawings, IS 822, AWS D √
agreed and crane girder. 1.3
5.02.04 iv) Radiography Test A Physical 100% radiography test IR Wherever RT is not feasible UT to
on butt welds of be carried out. In case of failure of
tension flange (bottom any welds in SPOT/RT or UT the
flange) of crane As per technical specifications and % of retesting shall be doubled at
As required/
girder. All other butt construction drawings, IS 822, AWS D √ that particular loaction.
agreed
welds shall be 1.3 Acceptance criteria of NDT on
subjected to 10% weld welds shall be as per AWS D1.1.
length of each welder.
5.03 Full Penetration Welds (Other than butt welds)

5.03.01 i) Ultrasonic Testing A Physical i) 100% UT on the IR In case of failure of any welds in
web to flange joint of SPOT/RT or UT the % of retesting
As required/ crane girder shall be doubled at that particular
construction drawings, IS 822, AWS D √ loaction. Acceptance criteria of
agreed
1.3
NDT on welds shall be as per
AWS D1.1.
5.03.02 ii) Ultrasonic Testing A Physical ii) 10% UT on other As per technical specifications and IR
As required/ full penetration joints construction drawings, IS 822, AWS D √
agreed
1.3
6.00 FOUNDATION CHECKS
6.01 Dimensions and levels- Shape, Theodolite, Tape B Physical/ Each Foundation SR
lines (including diagonal Measurement
Tech Specs and Const. Drawings √
etc
6.02 Foundation Bolts and B Physical/ Each Foundation SR
Theodolite, Tape,
Embedments- Verticality, Measurement Tech Specs and Const. Drawings √
Piano wires etc
Levels, pitch distance
7.00 PRE-ASSEMBLY CHECKS

7.01 Punch Erection marks and B Visual/ Each structural Markings for -
match marks on members Physical member Assembly designation, Part
- Tech Specs and Const. Drawings
number, Weight, Any other
important identifications.
7.02 Pre-assembly as per match B Visual/ Each structural
- Tech Specs and Const. Drawings
mark Physical member
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
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7.03 Camber, sweep and total length Theodolite, Tape, B Visual/ Each structural SR
after trial assembly of structure. plumb, piano Physical member Tech Specs and Const. Drawings √
wires etc
7.04 Control assembly check at shop Theodolite, Tape, B Visual/ Every first and tenth
plumb, piano Physical set of identical Tech Specs and Const. Drawings
wires etc structure
8.00 ERECTION CHECKS

8.01 Alignment, slopes, level, Theodolite, Tape, B Measurement Each structural SR
tolerances of erected member plumb, piano member Tech Specs and Const. Drawings √
wires etc
8.02 Tightening of bolts/ Torque Wrench/ Torque B Visual/ Each structural SR
including foundation bolts with wrench if Physical member Tech Specs and Const. Drawings √
lock nuts specified
8.03 Acceptance of erected structure Theodolite, Tape, B Visual/ Each erected SR
plumb, piano Physical structure √
7215 and IS 12843
wires etc
9.00 PAINTING SYSTEM

9.01 Paining Materials and A Review of Each batch of delivery SR/MTC Mfr.’s T.C. shall be correlated with
- Tech Specs and Const. Drawings √
accessories MTC the consignment received.
9.02 Submission of painting B For Review of Before start of
methodology - painting painting work Tech Specs and Const. Drawings
system
9.03 Surface prepration As agreed / B Physical Each Erection Mark Tech Specs and Const. Drawings, SR
√
required /visual Relevant code/ standards
9.04 Primer Thickness Elcometer B Measurement Each Erection Mark Tech Specs and Const. Drawings SR √
9.05 DFT of paint Elcometer B Measurement Each Erection Mark Tech Specs and Const. Drawings SR √
9.06 Acceptance of painted surfaces B Visual and Each Erection Mark SR
Elcometer Tech Specs and Const. Drawings
measurement
10.00 PERMANENT BOLTS AND NUTS AND WASHERS

10.01 Material- Permanent mild steel A Physical and Once for each lot of SR/MTC
Bolts, mild steel Nuts, High MTC Review delivery
strength structural Bolts, Screw gauge,
Tech Specs and Const. Drawings √
Washers-Dimensions, Vernier, Tape etc.
properties, Class, storage along
with MTC
10.02 Contact surfaces before bolting B Physical Random before Tech Specs and Const. Drawings, IS SR
-
asembly for bolting 4000
10.03 Inspection of the assembled B Physical Randomly in each SR
bolts - shift for assembeled
4000
bolts
10.04 Tensioning B Physical Randomly during snug SR
As agreed / Tech Specs and Const. Drawings, IS
tight test and after full √
required 4000
tensinoning
10.05 Acceptance of installed bolts - B Physical Each bolt Tech Specs and Const. Drawings SR
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
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11.00 ELECTROFORGED GRATINGS
13.1 Check for the Material from As agreed / A Physical and Once for each lot of Tech Specs and Const. Drawings SR/MTC Also refer the approved MQP
√
approved source required MTC Review delivery
13.2 Acceptance of Erection, As agreed / B Physical 100% Tech Specs and Const. Drawings SR
alignment and each Installation required
13.3 Painting system checks - As - - As above painting Tech Specs and Const. Drawings SR As above painting system
-
above painting system system
STAINLESS STEEL HOPPERS
Material and chemical composition A Review of MfrTC Once per Lot SR/LB √
Site fabricationand fit up B Physical Random SR/LB Cutting ,Bending , Welding shall be as per
technical specification, WPS approval,
As agreed /
fabrication of steel and welders
required qualifiction shall be similar to Structural
steel (Fabrication & Erection)
Welding A Physical As per technical SR/LB 10% DPT after back gauging, 5%spot
specifications radiography test on butt welds where
access not available. UT shall be carried
out with prior approval of . Engineer. In
As agreed / case of failure of any welds in SPOT
√ RT/UT , the %age for retesting shall be
required
doubled at that particular location .
Acceptance criteria of Non Destructive
tests ( NDT) on welds shall be as per
AWS D1.1
LEGEND: D * Records, indentified with “Tick” (√) shall be essentially included by supplier in QA DOC. NO.: CS - Project Code - XXXX-XXX-QVC-G-002 REV: 0
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB
Manufac Main-supplier Categorization Witnessing & Accepting (As per owner QA&I System) For NTPC use
turer/ Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category ‘C’
Sub- Executing Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate
supplier
Signature This document shall be read in conjunction with owner Tech. Specifications, BOQ, Drawings REVIEWED BY APPROVED BY APPROVAL SEAL
SECTION-VI
PART - B
SUB-SECTION-IIIE-17
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PART - C
GENERAL TECHNICAL REQUIREMENTS

PART-C
CLAUSE NO. GENERAL TECHNICAL REQUIREMENTS
1.00.00 INTRODUCTION
This part covers technical requirements which will form an integral part of the
Contract. The following provisions shall supplement all the detailed technical
requirements brought out in the Technical Specifications and the Technical Data
Sheets.
2.00.00 BRAND NAME
Whenever a material or article is specified or described by the name of a particular

brand, manufacturer or vendor, the specific item mentioned shall be understood to be
indicative of the function and quality desired, and not restrictive; other manufacturer's
products may be considered provided sufficient information is furnished to enable the
Employer to determine that the products proposed are equivalent to those named.
3.00.00 BASE OFFER & ALTERNATE PROPOSALS
The Contractor's proposal shall be based upon the use of equipment and material
complying fully with the requirements specified herein. It is recognized that the
Contractor may have standardized on the use of certain components, materials,
processes or procedures different than those specified herein. Alternate proposals
offering similar equipment based on the manufacturer's standard practice may also
be considered, provided the base offer is in line with technical specifications and
such proposals meet the specified design standards and performance requirement
and are acceptable to the Employer. Sufficient amount of information for justifying
such proposals shall be furnished to Employer alongwith the bid to enable the
Employer to determine the acceptability of these proposals.
4.00.00 COMPLETENESS OF FACILITIES
4.01.00 Contractors may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and designed in
accordance with the specification requirement. All engineering and associated
services are required to ensure that a completely engineered plant is provided.
4.02.00 All equipments furnished by the Contractor shall be complete in every respect, with
all mountings, fittings, fixtures and standard accessories normally provided with such
equipment and/or those needed for erection, completion and safe operation &
maintenance of the equipment and for the safety of the operating personnel, as
required by applicable codes, though they may not have been specifically detailed in
the respective specifications, unless included in the list of exclusions.
All similar standard components/ parts of similar standard equipment provided, shall
be interchangeable with one another.
5.01.00 In addition to the codes and standards specifically mentioned in the relevant
technical specifications for the equipment / plant / system, all equipment parts,

TECHNICAL SPECIFICATION GENERAL
STAGE-II (2X195 MW)
COAL HANDLING PLANT PACKAGE SECTION-VI TECHNICAL PAGE 1 OF 43
BID DOCUMENT NO. : CS-0350-155(R)-2 PART-C REQUIREMENTS
systems and works covered under this specification shall comply with all currently
applicable statutory regulations and safety codes of the Republic of India as well as
of the locality where they will be installed, including the following:
(a.) Bureau of Indian Standards (BIS)
(b.) Indian electricity act
(c.) Indian electricity rules
(d.) Indian Explosives Act
(e.) Indian Factories Act and State Factories Act
(f.) Indian Boiler Regulations (IBR)
(g.) Regulations of the Central Pollution Control Board, India
(h.) Regulations of the Ministry of Environment & Forest (MoEF), Government of

India
(i.) Pollution Control Regulations of Department of Environment, Government of

India
(j.) State Pollution Control Board.
(k.) Rules for Electrical installation by Tariff Advisory Committee (TAC).
(l.) Any other statutory codes / standards / regulations, as may be applicable.
5.02.00 Unless covered otherwise by Indian codes & standards and in case nothing to the
contrary is specifically mentioned elsewhere in the specifications, the latest editions
(as applicable as on date of bid opening), of the codes and standards given below
shall also apply:
(a.) Japanese Industrial Standards (JIS)
(b.) American National Standards Institute (ANSI)
(c.) American Society of Testing and Materials (ASTM)
(d.) American Society of Mechanical Engineers (ASME)
(e.) American Petroleum Institute (API)
(f.) Standards of the Hydraulic Institute, U.S.A.
(g.) International Organisation for Standardization (ISO)
(h.) Tubular Exchanger Manufacturer's Association (TEMA)
(i.) American Welding Society (AWS)
(j.) National Electrical Manufacturers Association (NEMA)

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(k.) National Fire Protection Association (NFPA)
(l.) International Electro-Technical Commission (IEC)
(m.) Expansion Joint Manufacturers Association (EJMA)
(n.) Heat Exchange Institute (HEI)
5.03.00 Other International/ National standards such as DIN, VDI, BS, etc. shall also be
accepted for only material codes and manufacturing standards, subject to the
Employer's approval, for which the Contractor shall furnish, alongwith the offer,
adequate information to justify that these standards are equivalent or superior to the
standards mentioned above. In all such cases the Contractor shall furnish specifically
the variations and deviations from the standards mentioned else where in the
specification together with the complete word to word translation of the standard that
is normally not published in English.
5.04.00 As regards highly standardized equipments National /International standards such

as JIS, DIN, VDI, ISO, SEL, SEW, VDE, IEC & VGB etc shall also be considered as
far as applicable for Design, Manufacturing and Testing of the respective equipment.
In addition, these standards shall be referred for the design of machine foundations,
wherever specifically mentioned in the specifications. However, for those of the
above equipment not covered by these National / International standards,
established and proven standards of manufacturers shall also be considered.
5.05.00 In the event of any conflict between the codes and standards referred to in the above
clauses and the requirement of this specification, the requirement of Technical
Specification shall govern.
5.06.00 Two (2) English language copies of all-national and international codes and/or
standards used in the design of the plant, equipment, civil and structural works shall
be provided by the Contractor to the Employer within two calendar months from the
date of the Notification of Award.
5.07.00 In case of any change in codes, standards & regulations between the date of bid
opening and the date when vendors proceed with fabrication, the Employer shall
have the option to incorporate the changed requirements or to retain the original
standard. It shall be the responsibility of the Contractor to bring to the notice of the
Employer such changes and advise Employer of the resulting effect.
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE
6.01.00 The functional guarantees of the equipment under the scope of the Contract is given
elsewhere in the technical specification. These guarantees shall supplement the
general functional guarantee provisions covered under General Conditions of
Contract.
6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.

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7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS
7.01.00 Design of Facilities
All the design procedures, systems and components proposed shall have already
been adequately developed and shall have demonstrated good reliability under
similar conditions elsewhere.
The Contractor shall be responsible for the selection and design of appropriate
equipments to provide the best co-ordinated performance of the entire system. The
basic requirements are detailed out in various clauses of the Technical
Specifications. The design of various components, assemblies and subassemblies
shall be done so that it facilitates easy field assembly and dismantling. All the rotating
components shall be so selected that the natural frequency of the complete unit is
not critical or close to the operating range of the unit.
7.02.00 Maintenance and Availability Considerations
Equipment/facilities offered shall be designed for high availability, low maintenance

and ease of maintenance. The Contractor shall specifically state the design features
incorporated to achieve high degree of reliability/ availability and ease of
maintenance. The Contractor shall also furnish details of availability records in the
reference plants stated in his experience list.
Contractor shall state in his offer the various maintenance intervals, spare parts and
man-hour requirement during such operation. The intervals for each type of
maintenance namely inspection of the major equipment in the coal flow path, clearly
defining the spare parts and man-hour requirement for each stage.
Lifting devices i.e. hoists and chain pulley jacks, etc. shall be provided by the
contractor for handling of any equipment during erection and maintenance activities.
Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist /
crane shall be provided by the contractor for lifting the equipment and accessories
covered under the specification.
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY CONTRACTOR
8.01.00 Contractors may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the technical
specification. All engineering and technical services required ensuring a completely
engineered plant shall be provided in respect of mechanical, electrical, control &
instrumentation, civil & structural works as per the scope.
Each main and auxiliary equipment/item of the plant including instruments shall be
assigned a unique tag number. The assignment of tag numbers shall be in
accordance with KKS system. In all drawings/documents/data sheets etc. KKS tag
number of the equipment/item/instrument etc. as applicable shall be indicated.

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The Contractor shall furnish engineering data/drgs. in accordance with the schedule
of information as specified in Technical Specification and data sheet.
8.02.00 The number of copies/prints / CD-ROMs/manuals to be furnished for various types of

documents is given in Annexure-I. Distribution schedule shall be informed to
successful Contractor.
8.03.00 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall include but not be limited
to the following :
8.03.01 INSTRUCTION MANUALS
The Contractor shall make First submission of instruction manuals for all the
equipments covered under the Contract by the end of one year from the date of his
acceptance of the Letter of Award. The Instruction manuals shall contain full details
required for erection, commissioning, operation and maintenance of each equipment.
The manual shall be specifically compiled for this project. After finalization and
approval of the Employer the Instruction Manuals shall be submitted as indicated in
Annexure-I. The Contract shall not be considered to be completed for purposes of
taking over until the final Instructions manuals have been supplied to the Employer.
The Instruction Manuals shall comprise of the following.
(a.) Erection Manuals
The erection manuals shall be submitted atleast three (3) months prior to the
commencement of erection activities of particular equipment/system. The
erection manual should contain the following as a minimum.
a) Erection strategy.
b) Sequence of erection.
c) Erection instructions.
d) Critical checks and permissible deviation/tolerances.
e) List of tool, tackles, heavy equipments like cranes, dozers, etc.
f) Bill of Materials
g) Procedure for erection.
h) General safety procedures to followed during erection/installation.

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i) Procedure for initial checking after erection.
j) Procedure for testing and acceptance norms.
k) Procedure / Check list for pre-commissioning activities.
l) Procedure / Check list for commissioning of the system.
m) Safety precautions to be followed in electrical supply distribution

during erection
(b.) Operation & Maintenance Manuals
The O&M manual shall have the following Chapters:
10 Plant Description
(To contain the following sections specific to the equipment supplied).
1.1 Description of operating principle of equipment/ system with schematic

drawings/layouts.
1.2 Functional description of associated accessories/ controls. Control interlock

protection write-up.
1.3 Integrated operation of the equipment along with the intended system.
(This is to be given by the supplier of the Main equipment by taking into

account the operating instruction given by the associated equipment
suppliers).
1.4 Exploded view of the main equipment, associated accessories and auxiliaries
with description. Schematic drawing of the equipment along with its
accessories and auxiliaries.
1.5 Design data against which the plant performance will be compared.
1.6 Master list of equipments, Technical specification of the equipment/ system

and approved datasheet.
1.7 Identification system adopted for the various components (It will be of a
simple, process linked tagging system).
1.8 Master list of drawings (as built drawings) (Drawings be enclosed in Separate
volume).
2.0 Plant Operations
(To contain the following sections specific to the equipment supplied) :-

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2.1 Protection logic provided for the equipment along with brief philosophy behind
the logic, drawings etc.
2.2 Limiting values of all protection settings.
2.3 Various settings of annunciation/ inleterlocks provided.
2.4 Start up and shut down procedure for equipment along with the associated
systems in step by step mode.
2.5 Do’s & don’t on the equipments.
2.6 Safety precautions to be taken during normal operation. Emergency

instructions on total power failure condition/ lubrication failure/ any other
condition.
2.7 Parameters to be monitored with normal values and limiting values.
2.8 Equipment isolating procedures.
2.9 Trouble shooting with causes and remedial measures.
2.10 Routine testing procedure to ascertain healthiness of the safety devices

alongwith schedule of testing.
2.11 Routing operational checks. Recommended logs and records.
2.12 Changeover schedule if more than one auxiliary for the same purpose is
given.
2.13 Preservation procedure on long shut down.
2.14 System/ plant commissioning procedure.
3.0 Plant Maintenance
(To contain the following sections specific to the equipment supplied).
3.1 Exploded view of each of the equipments. Drawings along with bill of material
including name, code number and population.
3.2 Exploded view of the spare parts and critical components with dimensional
drawings (In case of Electronic cards, the circuit diagrams to be given).
3.3 List of Special Tools and Tackles required for Overhaul/Trouble shooting
including special testing equipment required for calibration etc.
3.4 Stepwise dismantling and assembly procedure clearly specifying the tools to
be used, checks to be made, records to be maintained etc. along with
exploded views, Clearances to be maintained etc.
3.5 Preventive Maintenance schedules linked with running hours/ calendar period
along with checks to be done.

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3.6 Overhaul schedules linked with running hours/ calendar period along with
checks to be done.
3.7 Long term maintenance schedules especially for structural, foundations etc.
3.8 Consumable list along with the estimated quantity required during normal
running and during maintenance like Preventive Maintenance and Overhaul.
3.9 List of lubricants with their Indian equivalent. Lubrication Schedule. Quantity
required for complete replacement.
3.10 Tolerances for fitment of various components.
3.11 Details of sub-vendors with their part no. in case of bought out items.
3.12 List of spare parts with their part no., total population, life expediency & their
interchangeability with already supplied spares to NTPC. Storage &
preservation procedure of spares.
3.13 List of mandatory and recommended spare parts list along with manufacturing
drawings, material specification & quality plan for fast moving consumable
spares.
3.14 Lead time required for ordering of spares from the equipment supplier.
3.14 (a) Instructions for Storage and preservation of spares.
3.15 General information on the equipment.
3.15.1 Modifications carried out in the equipment from its inception.
3.15.2 Equipment population in the country/ foreign country.
3.15.3 List of utilities where similar equipments have been supplied.
8.03.02 Project Completion Report
The Contractor shall submit a Project Completion Report at the time of handing over
the plant.
8.03.03 DRAWINGS
(a.) All documents submitted by the Contractor for Employer's review shall be in
electronic form (soft copies) along with the desired number of hard copies as
per Annexure-I . The soft copies shall be uploaded by the vendors in c-folders,a
web based system of NTPC ERP,for which a username and password will be
allotted to the new vendor by NTPC.
Similarly, the vendor can download the drawings/documents,
approved/commented by NTPC, through above site.
The soft copies of identified drawings/documents shall be in pdf format,
whereas the attachment/reply to the submitted document(s) can be in
.doc,.xls,.pdf,.dwg or.std formats

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(b.) Final copies of the approved drawings alongwith requisite number of hard
copies shall be submitted as per Annexure-I.
(c.) All documents/text information shall be in latest version of MS Office.
(d.) All drawings submitted by the Contractor including those submitted at the time
of bid shall be in sufficient detail indicating the type, size, arrangement, weight
of each component for packing and shipment, the external connection, fixing
arrangement required, the dimensions required for installation and
interconnections with other equipments and materials, clearance and spaces
required between various portions of equipment and any other information
specifically requested in the drawing schedules.
(e.) Each drawing submitted by the Contractor (including those of subvendors) shall
bear a title block at the right hand bottom corner with clear mention of the name
of the Employer, the system designation, the specifications title, the
specification number, the name of the Project, drawing number and revisions. If
standard catalogue pages are submitted the applicable items shall be indicated
therein. All titles, notings, markings and writings on the drawing shall be in
English. All the dimensions should be in metric units.
(f.) The drawings submitted by the Contractor (or their subvendors) shall bear
Employer’s drawing number in addition to contractor’s (their sub-vendor’s) own
drawing number. Employer’s drawing numbering system shall be made
available to the successful Contractor so as to enable him to assign Employer’s
drawing numbers to the drawings to be submitted by him during the course of
execution of the Contract.
(g.) The Contractor shall also furnish a “Master Drawing List” which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged to be
furnished by him during the detailed engineering to the Employer in line with
engineering information flow schedule (to be tied up with successful
Contractor). Such list should clearly indicate the purpose of submission of these
drawings i.e. “FOR APPROVAL” or “FOR INFORMATION ONLY”.
(h.) Similarly, all the drawings/ documents submitted by the Contractor during
detailed engineering stage shall be marked “FOR APPROVAL” or “FOR
INFORMATION” prior to submission. Further, space shall be identified on each
drawing for approval stamp and electronic signature.
(i.) The furnishing of detailed engineering data and drawings by the Contractor
shall be in accordance with the time schedule for the project. The review of
these documents/ data/ drawings by the Employer will cover only general
conformance of the data/ drawings/ documents to the specifications and
contract, interfaces with the equipments provided by others and external
connections & dimensions which might affect plant layout. The review by the
Employer should not be construed to be a thorough review of all dimensions,
quantities and details of the equipments, materials, any devices or items

STAGE-II (2X195 MW)
indicated or the accuracy of the information submitted. The review and/ or

approval by the Employer / Project Manager shall not relieve the Contractor of
any of his responsibilities and liabilities under this contract.
(j.) After the approval of the drawings, further work by the Contractor shall be in
strict accordance with these approved drawings and no deviation shall be
permitted without the written approval of the Employer.
(k.) All manufacturing, fabrication and execution of work in connection with the
equipment / system, prior to the approval of the drawings, shall be at the
Contractor’s risk. The Contractor is expected not to make any changes in the
design of the equipment /system, once they are approved by the Employer.
However, if some changes are necessitated in the design of the
equipment/system at a later date, the Contractor may do so, but such changes
shall promptly be brought to the notice of the Employer indicating the reasons
for the change and get the revised drawing approved again in strict
conformance to the provisions of the Technical Specification.
(l.) Drawings shall include all installations and detailed piping and wiring drawings.
All pipe of 65NB and above shall be routed in detail and smaller pipe shall be
shown schematically or by isometric drawings. All drawings shall be fully
corrected to agree with actual ‘as built’ construction.
(m.) Assessing & anticipating the requirement and supply of all piping and
equipment shall be done by the contractor well in advance so as not to hinder
the progress of piping & equipment erection, subsequent system charging and
its effective draining & venting arrangement as per site suitability.
(n.) Any software used by the contractor shall be given to the project manager and
concerned engineer of employer. The contractor shall make the engineer of the
employer aware of the programme. Any computer aided programme shall be
approved subject to giving entire detail to the project manager.
(o.) Drawings must be checked by the Contractor in terms of its completeness, data
adequacy and relevance with respect to Engineering schedule prior to
submission to the Employer. In case drawings are found to be submitted
without proper endorsement for checking by the Contractor, the same shall not
be reviewed and returned to the Contractor for re-submission. The contractor
shall make a visit to site to see the existing facilities and understand the layout
completely and collect all necessary data / drawings at site which are needed
as an input to the engineering. The contractor shall do the complete
engineering including interfacing and integration of all his equipment, systems &
facilities within his scope of work as well as interface engineering & integration
of systems, facilities, equipment & works under Employer’s scope and submit
all necessary drawings/ documents for the same.
(p.) All drawings shall be reviewed and approved by Engineering coordinator,

including the following drawings / data which require specific approval.

STAGE-II (2X195 MW)
1. Data sheets for various equipments / systems.
2. Field testing procedures for various equipment and piping system.
3. Pre commissioning / commissioning procedures including flushing,

Chemical cleaning, steam blowing and hydro test etc. (Wherever
applicable) O&M manual shall also be reviewed and approved by Employer.
The content of O&M manual shall be as specified elsewhere in the
specification.
4. Guarantee test procedures (including model tests, if any).
5. Any other drawings that may be required by the Engineer from time to time.)
6. Data furnished in the bid shall be binding on the contractor even if superior
to the technical specification requirement and any revision shall be done
with the Employer’s agreement.
(q.) The Contractor shall submit adequate prints of drawing / data / document for
Employer’s review and approval. The Employer shall review the drawings and
return soft copy to the Contractor authorizing either to proceed with
manufacture or fabrication, or marked to show changes desired. When changes
are required, drawings shall be re-submitted promptly, with revisions clearly
marked, for final review. Any delays arising out of the failure of the Contractor to
submit/rectify and resubmit in time shall not be accepted as a reason for delay
in the contract schedule
(r.) Upon review of each drawing, depending on the correctness and completeness
of the drawing, the same will be categorised and approval accorded in one of
the following categories :
CATEGORY I Approved
CATEGORY II Approved subject to incorporation of comments/ modification

as noted. Resubmit revised drawing incorporating the
comments
CATEGORY III Not approved. Resubmit revised drawings for approval after
incorporating comments/modification as noted.
CATEGORY IV For information and records.
(s.) Vendor shall resubmit the drawings approved under Category II and III within
three (3) weeks of receipt of comments on the drawings, incorporating all
comments. Every revision of the drawing shall bear a revision index wherein
such revisions shall be highlighted in the form of description or marked up in the
drawing identifying the same with relevant revision Number enclosed in a
triangle (eg. 1, 2, 3 etc).
In case Vendor does not agree with any specific comment, he shall furnish the
explanation for the same to NTPC ‘EC’ for consideration. In all such cases
STAGE-II (2X195 MW)
vendor shall necessarily enclose explanations along with the revised drawing
(taking care of balance comments) to avoid any delay and/or duplication in
review work.
It is responsibility of the Vendor to get all the drawings approved in the

Category I & IV (as the case may be) and complete engineering activities within
the agreed schedule. Any delay arising out of submission and modification of
drawings shall not alter the contract completion schedule.
Vendor shall not make any changes in the portions of the drawing other than
those commented. If changes are required to be made in the portions already
approved, the vendor shall resubmit the drawing identifying the changes for
Employer’s review and approval.
(t.) If Vendor fails to resubmit the drawings as per the schedule, construction work
at site will not be held up and work will be carried out on the basis of comments
furnished on previous issues of the drawing.
These comments will be taken care by the contractor while submitting the
revised drawing.
(u.) All engineering data submitted by the Contractor after final process including
review and approval by the Project Manager/ Employer shall form part of the
contract documents and the entire works covered under these specification
shall be performed in strict conformity with technical specifications unless
otherwise expressly requested by the Project Manager in writing.
(v.) As Built Drawings
After final acceptance of individual equipment / system by the Employer, the

Contractor will update all original drawings and documents for the equipment /
system to “as built” conditions and submit No. of copies, as per Annexure-1.
8.04.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE
Prior to the award of Contract, a Detailed Engineering Information Submission

Schedule/Master Drawing List shall be tied up with the Employer. For this, the
Contractor shall furnish a detailed list of engineering information alongwith the
proposed submission schedule. This list would be a comprehensive one including all
engineering data / drawings / information for all bought out items and manufactured
items. The information shall be categorised into the following parts.
1. Information that shall be submitted for the approval of the Employer before
proceeding further, and Information that would be submitted for Employer’s
information only.
The Master Drawing List (MDL) shall be updated periodically and submitted to the
Employer, highlighting the changes made in the MDL.
The schedule should allow adequate time for proper review and incorporation of
changes/ modifications, if any, to meet the contract without affecting the equipment

STAGE-II (2X195 MW)
delivery schedule and overall project schedule. The early submission of drawings
and data is as important as the manufacture and delivery of equipment and hardware
and this shall be duly considered while determining the overall performance and
progress.
8.05.00 ENGINEERING COORDINATION PROCEDURE
Identification of Principal Engineering Coordinators
8.05.01 The following principal coordinators will be identified by respective organisations at
time of award of contract
EMPLOYER’S COORDINATORS
NTPC Engineering Coordinators (NTPC EC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
NTPC SITE CO-ORDINATOR (NTPC SC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
VENDOR ENGINEERING CO-ORDINATOR (VENDOR EC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :

STAGE-II (2X195 MW)
8.05.02 All engineering correspondence shall be in the name of above coordinators on behalf
of the respective organisations.
8.05.03 Vendors Drawings
(a) The contractor shall furnish, discuss and finalise with the Employer, the
engineering information flow schedule at the time of award of the contract. The
dates for submission of drawings as finalised in the above engineering
schedule, shall be strictly adhered to. This is essential for the timely
completion of the project.
(b) A detailed drive list shall be furnished along with the tender. Further drive list in
the Employer’s format shall be submitted to the Engineering coordinator within
60 days from the date of award of the contract.
(c) In any case, in order to achieve the project completion dates, the contractor
must strictly comply with engineering schedules.
(d) Final distribution copies of all approved drgs. (in Cat. I & IV) shall be submitted
by the contractor to the Engineer within two (2) weeks of the approval.
(e) Copies of all approved drgs. (in cat. I & IV) shall be submitted incorporating all
site modifications, if any, during construction, erection, commission stages and
performance and guarantee testing (till its continuous operation) as ‘As Built
Drgs’.
(f) The contractor shall use a single transmittal for drgs. Submission. This shall
include transmittal numbers and date, number of copies being sent, names of
the agencies to whom are all the copies being sent drg. numbers and titles,
remarks or special notes if any etc.
(g) All manufacturing and fabrication work in connection with the equipments prior
to the approval of the drg. shall be at contractors risks.
(h) Approval of contractor’s drgs. or work by the Engineer shall not relieve the
contractor of any of his responsibilities or liabilities under the contract.
8.05.04 Erection Drawings
(a) Contractor shall furnish erection drawings for the guidance of his/ Employer’s
site staff at least 4 weeks before scheduled commencement of erection or the
first shipment, whichever is earlier. These shall generally comprise of
fabrication/assembly drawings, various component/part details drawings,
assembly, clearance, data requirements etc. The drawings shall contain
details of components/ equipment with identification numbers, match marks,
bills of materials, assembly procedures etc.
(b) For all major equipment apart from above details, assembly sequence and
instructions with check lists shall be furnished in the form of erection manuals.

STAGE-II (2X195 MW)
8.06.00 ENGINEERING PROGRESS AND EXCEPTION REPORT
8.06.01 Report giving the status of each engineering information including
(a) A list of drawings/engineering information which remains unapproved for

more than four (4) weeks after the date of first submission
(b) Drawings which were not submitted as per agreed schedule.
8.06.02 The draft format for this report shall be furnished to the Employer within four (4)
weeks of the award of the contract, which shall then be discussed and finalised with
the Employer.
8.07.00 TECHNICAL CO-ORDINATION MEETING
8.07.01 The Contractor shall be called upon to organise and attend monthly Design/
Technical Co-ordination Meetings (TCMs) with the Employer/Employer’s
representatives and other Contractors of the Employer during the period of
contract. The Contractor shall attend such meetings at his own cost at NEW DELHI /
NOIDA or at mutually agreed venue as and when required and fully co-operate with
such persons and agencies involved during the discussions.
8.07.02 The Contractor should note that Time is the essence of the contract. In order to
expedite the early completion of engineering activities, the Contractor shall submit all
drawings as per the agreed Engineering Information Submission Schedule. The
drawings submitted by the Contractor will be reviewed by the Employer as far as
practicable within three (3) weeks from the date of receipt of the drawing .The
comments of the Employer shall then be discussed across the table during the above
Technical Co-ordination Meeting (s) wherein best efforts shall be made by both sides
to ensure the approval of the drawing.
8.07.03 The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these meetings.
The Contractor shall be equipped with necessary tools and facilities so that the
drawings/documents can be resubmitted after incorporating necessary changes and
approved during the meeting itself.
8.07.04 Should any drawing remain unapproved for more than six (6) weeks after it’s first
submission, this shall be brought out in the monthly Engineering Progress and
Exception Report with reasons thereof.
8.07.05 Any delays arising out of failure by the Contractor to incorporate Employer’s
comments and resubmit the same during the TCM shall be considered as a default
and in no case shall entitle the Contractor to alter the Contract completion date.
8.08.00 DESIGN IMPROVEMENTS
The Employer or the Contractor may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes the
specification shall be modified accordingly.

STAGE-II (2X195 MW)
If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any changing the
price and/or schedule of completion before the Contractor proceeds with the change.
Following such agreement, the provision thereof, shall be deemed to have been
amended accordingly.
8.09.00 EQUIPMENT BASES
A cast iron or welded steel base plate shall be provided for all rotating equipment
which is to be installed on a concrete base, unless otherwise specifically agreed to by
the Employer. Each base plate which supports the unit and its drive assembly, shall
be of a neat design with pads for anchoring the units, shall have a raised lip all
around, and shall have threaded drain connections.
8.10.00 PROTECTIVE GUARDS
Suitable guards shall be provided for protection of personnel on all exposed rotating
and/or moving machine parts. All such guards shall be designed for easy installation
and removal for maintenance purpose.
8.11.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS
8.11.01 The Contractor’s scope includes all the first fill and one year’s topping, requirements
of consumables such as oils, lubricants including grease, servo fluids, gases and
essential chemicals etc. Consumption of all these consumables during the initial
operation and final filling after the initial operation shall also be included in the scope
of the Contractor. Contractor shall also supply a quantity not less than 10% of the full
charge of each variety of lubricants, servo fluids, gases, chemicals etc. used which is
expected to be utilised during the first year of operation. This additional quantity shall
be supplied in separate Containers.
8.11.02 As far as possible lubricants marketed by the Indian Oil Corporation shall be used.
The variety of lubricants shall be kept to a minimum possible.
Detailed specifications for the lubricating oil, grease, gases, servo fluids, control
fluids, chemicals etc. required for the complete plant covered herein shall be
furnished. On completion of erection, a complete list of bearings/ equipment giving
their location and identification marks shall be furnished to the Employer alongwith
lubrication requirements.
8.12.00 Lubrication
8.12.01 Equipment shall be lubricated by systems designed for continuous operation.

Lubricant level indicators shall be furnished and marked to indicate proper levels
under both standstill and operating conditions.
8.13.00 Material of Construction
8.13.01 All materials used for the construction of the equipment shall be new and shall be in
accordance with the requirements of this specification. Materials utilised for various

STAGE-II (2X195 MW)
components shall be those which have established themselves for use in such
applications.
8.14.00 RATING PLATES, NAME PLATES & LABELS
8.14.01 Each main and auxiliary item of plant including instruments shall have permanently
attached to it in a conspicuous position, a rating plate of non-corrosive material upon
which shall be engraved manufacturer’s name, equipment, type or serial number
together with details of the ratings, service conditions under which the item of plant in
question has been designed to operate, and such diagram plates as may be required
by the Employer.
8.14.02 Each item of plant shall be provided with nameplate or label designating the service
of the particular equipment. The inscriptions shall be approved by the Employer or
as detailed in appropriate section of the technical specifications.
8.14.03 Such nameplates or labels shall be of white nonhygroscopic material with engraved
black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of
transparent plastic material with suitably coloured lettering engraved on the back.
The name plates shall be suitably fixed on both front and rear sides.
8.14.04 Items of plant such as valves, which are subject to handling, shall be provided with
an engraved chromium plated nameplate or label with engraving filled with enamel.
The name plates for valves shall be marked in accordance with MSS standard SP-25
and ANSI B 16.34 as a minimum.
8.14.05 Hanger/ support numbers shall be marked on all pipe supports, anchors, hangers,
snubbers and restraint assemblies. Each constant and variable spring support shall
also have stamped upon it the designed hot and cold load which it is intended to
support. Suitable scale shall also be provided to indicate load on support/hanger.
8.14.06 Valves and strainers shall be identified by tag number of a metal tap permanently
attached to non pressure parts such as the yoke by a stainless steel wire. The
direction of flow shall also be marked on the body.
8.14.07 Safety and relief valves shall be provided with the following :
a). Manufacturer’s identification.
b). Nominal inlet and outlet sizes in mm.
c). Set pressure in Kg/cm2 (abs).
8.14.08 All such plates, instruction plates, etc. shall be bilingual with Hindi inscription first,
followed by English. Alternatively, two separate plates one with Hindi and the other
with English inscriptions may be provided.
8.14.09 All segregated phases of conductors or bus ducts, indoor or outdoor, shall be
provided with coloured phase plates to clearly identify the phase of the system

STAGE-II (2X195 MW)
8.15.00 TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of following special
tools and tackles required for the erection, assembly, disassembly and proper
maintenance of the plant and equipment and systems.
The price of each tool / tackle shall be deemed to have been included in the total bid
price. These tools and tackles shall be separately packed and sent to site. The
Contractor shall also ensure that these tools and tackles are not used by him during
erection, commissioning and initial operation. For this period the Contractor should
bring his own tools and tackles. All the tools and tackles shall be of reputed make
acceptable to the Employer.
Sl. Description Qty.
1 Torque wrench required up to M24 bolts or maximum size in 1 No

package, whichever more
2 Bearing puller set to pull up to maximum bearing size in the 1 No

system
3 Hydraulic jack 50 T 2 No
4 Lifting trolley for LT circuit breakers 2 No
5 Electric powered winch with wire rope (7.5 T, 1500m 1 No

galvanised wire)
6 Bearing grease gun for all applications 2 No
7 Any other special tools as per manufacturer’s manual 1 No
8.16.00 Welding
8.16.01 If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed by others the requirements
shall be submitted to the Employer in advance of commencement of erection work.
8.17.00 COLOUR CODE FOR ALL EQUIPMENTS/ SERVICES
8.17.01 All equipment/ services are to be painted by the Contractor in accordance with
Employer’s standard colour coding scheme, which will be furnished to the Contractor
during detailed engineering stage.

STAGE-II (2X195 MW)
8.18.00 PROTECTION AND PRESERVATIVE SHOP COATING
8.19.00 PROTECTION
All coated surfaces shall be protected against abrasion, impact, discoloration and any
other damages. All exposed threaded portions shall be suitably protected with either
metallic or a nonmetallic protection device. All ends of all valves and pipings and
conduit equipment connections shall be properly sealed with suitable devices to
protect them from damage. The parts which are likely to get rusted, due to exposure
to weather, should also be properly treated and protected in a suitable manner. All
primers/paints/coatings shall take into account the hot humid, corrosive & alkaline,
subsoil or overground environment as the case may be.
8.20.00 Preservative Shop Coating
All exposed metallic surfaces subject to corrosion shall be protected by shop

application of suitable coatings. All surfaces which will not be easily accessible after
the shop assembly, shall be treated beforehand and protected for the life of the
equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides and
other coatings and prepared in the shop. The surfaces that are to be finish-painted
after installation or require corrosion protection until installation, shall be shop painted
with atleast two coats of primer.
Transformers and other electrical equipments if included shall be shop finished with
one or more coats of primer and two coats of high grade resistance enamel. The
finished colors shall be as per manufacturer’s standards, to be selected and specified
by the Employer at a later date.
8.20.01 Shop primer for all steel surfaces which will be exposed to operating temperature
below 95 degrees Celsius shall be selected by the Contractor after obtaining specific
approval of the Employer regarding the quality of primer proposed to be applied.
Special high temperature primer shall be used on surfaces exposed to temperature
higher than 95 degrees Celsius and such primer shall also be subject to the approval
of the Employer.
8.20.02 All other steel surfaces which are not to be painted shall be coated with suitable rust
preventive compound subject to the approval of the Employer.
8.20.03 All piping shall be cleaned after shop assembly.
8.20.04 Painting for Civil structures shall be done as per relevant part of technical
specification
9.00.00 QUALITY ASSURANCE PROGRAMME
9.01.00 The Contractor shall adopt suitable quality assurance programme to ensure that the
equipment and services under the scope of contract whether manufactured or
performed within the Contractor’s works or at his sub-contractor’s premises or at the
Employer’s site or at any other place of work are in accordance with the
specifications. Such programmes shall be outlined by the Contractor and shall be

STAGE-II (2X195 MW)
finally accepted by the Employer/authorised representative after discussions before

the award of the contract. The QA programme shall be generally in line with IS/ISO-
9001.A quality assurance programme of the contractor shall generally cover the
following:
a). His organisation structure for the management and implementation of the
proposed quality assurance programme
b). Quality System Manual
c). Design Control System
d). Documentation and Data Control System
e). Qualification data for Contractor’s key personnel.
f). The procedure for purchase of materials, parts, components and selection of
sub-contractor’s services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.
g). System for shop manufacturing and site erection controls including process,
fabrication and assembly.
h). Control of non-conforming items and system for corrective actions and
resolution of deviations.
i). Inspection and test procedure both for manufacture and field activities.
j). Control of calibration and testing of measuring testing equipment.
k). System for Quality Audits.
l). System for identification and appraisal of inspection status.
m). System for authorising release of manufactured product to the Employer.
n). System for handling, storage and delivery.
o). System for maintenance of records, and
(p) Quality plans for manufacturing and field activities detailing out the specific
quality control procedure adopted for controlling the quality characteristics
relevant to each item of equipment/component.
9.02.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE
9.02.01 All materials, components and equipment covered under this specification shall be
procured, manufactured, erected, commissioned and tested at all the stages, as per
a comprehensive Quality Assurance Programme. An indicative programme of
inspection/tests to be carried out by the contractor for some of the major items is
given in the respective technical specification. This is, however, not intended to form
a comprehensive programme as it is the contractor’s responsibility to draw up and

STAGE-II (2X195 MW)
implement such programme duly approved by the Employer. The detailed Quality
Plans for manufacturing and field activities shall be drawn up by the Contractor and
will be submitted to Employer for approval. Schedule of finalisation of such quality
plans will be finalised before award. Monthly progress reports on MQP/FQP
submission/approval shall be furnished on enclosed format No. QS-01-QAI-P-02/F1
9.02.02 Manufacturing Quality Plan will detail out for all the components and equipment,
various tests/inspection, to be carried out as per the requirements of this specification
and standards mentioned therein and quality practices and procedures followed by
Contractor’s/ Sub-contractor’s/ sub-supplier's Quality Control Organisation, the
relevant reference documents and standards, acceptance norms, inspection
documents raised etc., during all stages of materials procurement, manufacture,
assembly and final testing/performance testing. The Quality Plan shall be submitted
on electronic media through c-folders,a Web based system of NTPC-ERP in addition
to hard copy, for review and approval. After approval the same shall be submitted in
compiled form on CD-ROM.
9.02.03 Field Quality Plans will detail out for all the equipment, the quality practices and
procedures etc. to be followed by the Contractor’s "Site Quality Control
Organisation", during various stages of site activities starting from receipt of
materials/equipment at site.
9.02.04 The Contractor shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., as referred in
Quality Plans along with Quality Plans. These Quality Plans and reference
documents/standards etc. will be subject to Employer’s approval without which
manufacturer shall not proceed. These approved documents shall form a part of the
contract. In these approved Quality Plans, Employer shall identify customer hold
points (CHP), i.e. test/checks which shall be carried out in presence of the
Employer’s Project Manager or his authorised representative and beyond which the
work will not proceed without consent of Employer in writing. All deviations to this
specification, approved quality plans and applicable standards must be documented
and referred to Employer along with technical justification for approval and
dispositioning.
9.02.05 No material shall be despatched from the manufacturer’s works before the same is
accepted, subsequent to predespatch final inspection including verification of records
of all previous tests/inspections by Employer’s Project Manager/Authorised
representative and duly authorised for despatch by issuance of Material Despatch
Clearance Certificate (MDCC).
9.02.06 All material used for equipment manufacture including casting and forging etc. shall
be of tested quality as per relevant codes/standards. Details of results of the tests
conducted to determine the mechanical properties; chemical analysis and details of
heat treatment procedure recommended and actually followed shall be recorded on
certificates and time temperature chart. Tests shall be carried out as per applicable
material standards and/or agreed details.

STAGE-II (2X195 MW)
9.02.07 The contractor shall submit to the Employer Field Welding Schedule for field welding
activities in the enclosed format No.: QS-01-QAI-P-02/F3. The field welding
schedule shall be submitted to the Employer along with all supporting documents,
like welding procedures, heat treatment procedures, NDT procedures etc. at least
ninety days before schedule start of erection work at site.
9.02.08 All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870 or other International
equivalent standard acceptable to the Employer.
All welding/brazing procedures shall be submitted to the Employer or its authorised

representative for approval prior to carrying out the welding/brazing.
9.02.09 All brazers, welders and welding operators employed on any part of the contract
either in Contractor’s/sub-contractor’s works or at site or elsewhere shall be qualified
as per ASME Section-IX or BS-4871 or other equivalent International Standards
9.02.10 Welding procedure qualification & Welder qualification test results shall be furnished
to the Employer for approval. However, where required by the Employer, tests shall
be conducted in presence of Employer/authorised representative.
9.02.11 For all pressure parts and high pressure piping welding, the latest applicable
requirements of the IBR (Indian Boiler Regulations) shall also be essentially complied
with. Similarly, any other statutory requirements for the equipment/systems shall
also be complied with. On all back-gauged welds MPI/LPI shall be carried before seal
welding.
9.02.12 Unless otherwise proven and specifically agreed with the Employer, welding of
dissimilar materials and high alloy materials shall be carried out at shop only.
9.02.13 No welding shall be carried out on cast iron components for repair.
9.02.14 All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
9.02.15 All non-destructive examination shall be performed in accordance with written

procedures as per International Standards, The NDT operator shall be qualified as
per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall
be recorded in a report, which includes details of methods and equipment used,
result/evaluation, job data and identification of personnel employed and details of co-
relation of the test report with the job.
All Bar stock / forgings of diameter equal to or greater than 50mm shall be
ultrasonically tested. In general all plates of thickness equal to or greater than 40mm
and for pressure parts, pates of thickness equal to or greater than 25mm shall be
ultrasonically tested unless as specified otherwise in respective equipment
specification.

STAGE-II (2X195 MW)
9.02.16 The Contractor shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-contractors (BOI). All the sub-
contractor proposed by the Contractor for procurement of major bought out items
including castings, forging, semi-finished and finished components/equipment etc.,
list of which shall be drawn up by the Contractor and finalised with the Employer,
shall be subject to Employer's approval. The contractor’s proposal shall include
vendor’s facilities established at the respective works, the process capability, process
stabilization, QC systems followed, experience list, etc. along with his own technical
evaluation for identified sub-contractors enclosed and shall be submitted to the
Employer for approval within the period agreed at the time of pre-awards discussion
and identified in "DR" category prior to any procurement. Monthly progress reports
on sub-contractor detail submission / approval shall be furnished on enclosed on
format no. QS-01-QAI-P-02/F2. Such vendor approval shall not relieve the contractor
from any obligation, duty or responsibility under the contract.
9.02.17 For components/equipment procured by the contractors for the purpose of the
contract, after obtaining the written approval of the Employer, the contractor’s
purchase specifications and inquiries shall call for quality plans to be submitted by
the suppliers. The quality plans called for from the sub-contractor shall set out,
during the various stages of manufacture and installation, the quality practices and
procedures followed by the vendor’s quality control organisation, the relevant
reference documents/standards used, acceptance level, inspection of documentation
raised, etc. Such quality plans of the successful vendors shall be finalised with the
Employer and such approved Quality Plans shall form a part of the purchase
order/contract between the Contractor and sub-contractor. With in three weeks of the
release of the purchase orders /contracts for such bought out items /components, a
copy of the same without price details but together with the detailed purchase
specifications, quality plans and delivery conditions shall be furnished to the
Employer on the monthly basis by the Contractor along with a report of the Purchase
Order placed so far for the contract. **
9.02.18 Employer reserves the right to carry out quality audit and quality surveillance of the
systems and procedures of the Contractor’s or their sub-contractor’s quality
management and control activities. The contractor shall provide all necessary
assistance to enable the Employer carry out such audit and surveillance.
9.02.19 The contractor shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-contractor’s and at site to ensure the
mechanical accuracy of components, compliance with drawings, conformance to
functional and performance requirements, identity and acceptability of all materials
parts and equipment. Contractor shall carry out all tests/inspection required to
establish that the items/equipment conform to requirements of the specification and
the relevant codes/standards specified in the specification, in addition to carrying out
tests as per the approved quality plan.
9.02.20 Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Employer to reject the equipment if it does not

STAGE-II (2X195 MW)
comply with the specification when erected or does not give complete satisfaction in
service and the above shall in no way limit the liabilities and responsibilities of the
Contractor in ensuring complete conformance of the materials/equipment supplied to
relevant specification, standard, data sheets, drawings, etc.
9.02.21 For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.
9.02.22 Repair/rectification procedures to be adopted to make the job acceptable shall be

subject to the approval of the Employer/ authorised representative.
9.02.23 Environmental Stress Screening
All solid state electronic system / equipment / sub assembly shall be free from infant
mortile components. For establishing the compliance to this requirement, the
contractor / sub – contractor should meet the following.
1) The Contractor / Sub – contractor shall furnish the established procedure

being followed for eliminating infant mortile components. The procedure
followed by the Contractor / Sub – contractor should be substantiated along
with the statistical figures to validate the procedure being followed. The
necessary details as required under this clause shall be furnished at the stage
of QP finalization.
Or
In case the Contractor / Sub – contractor do not have any established

procedure to eliminate infant mortile components then two or 10% which ever
is less, most densely populated Panels shall be tested for Elevated
Temperature Cycle Test as per the following procedure.
Elevated Temperature Test Cycle
During the elevated temperature test which shall be for 48 hours, the ambient
temperature shall be maintained at 50° C. The equipment shall be
interconnected with devices and kept under energized conditions so as to
repeatedly perform all operations it is expected to perform in actual service
with load on various components being equal to those which will be
experienced in actual service.
During the elevated temperature test the cubicle doors shall be closed (or
shall be in the position same as they are supposed to be in the field) and
inside temperature in the zone of highest heat dissipating components /
modules shall be monitored. The temperature rise inside the cubicle should
not exceed 10° C above the ambient temperature at 50° C.
In case of any failure during the test cycle, the further course of action should
be mutually discussed for demonstrating the intent of the above requirement.

STAGE-II (2X195 MW)
2) Burn in Test Cycle
The test shall be conducted on all the panels fully assembled and wired
including the panels having undergone the above mentioned elevated
temperature test.
The period of Burn in Test Cycle shall be 120 hrs and process shall be similar
to the elevated temperature test as above except that the temperature shall
be reduced to the ambient temperature prevalent at that time.
During the above tests, the process I/O and other load on the system shall be
simulated by simulated inputs and in the case of control systems; the process
which is to be controlled shall also be simulated. Testing of individual
components or modules shall not be acceptable.
During the Burn in Test the cubicle doors shall be closed (or shall be in the
position same as they are supposed to be in the field) and inside temperature
in the zone of highest heat dissipating components / modules shall be
monitored. The temperature rise inside the cubicle should not exceed 10° C
above the ambient temperature.
The Contractor / Sub-contractor shall carry out routine test on 100% item at
contractor / sub-contractor's works. The quantum of check / test for routine &
acceptance test by employer shall be generally as per criteria / sampling plan
defined in referred standards. Wherever standards have not been mentioned
quantum of check / test for routine / acceptance test shall be as agreed during
detailed engineering stage.
9.02.24 The Contractor shall have suitable Field Quality Organisation with edquate
manpower at Employer’s site to effectively implement the field quality plan (FQP)
requirement for site activities. The contractor shall submit the details of proposed
FQA set-up (Organisation set up & manpower) depending upon the scope of work
involved for Employer’s approval. The FQA set up shall be in place at least one
month before the start of site activities.
9.03.00 QA DOCUMENTATION PACKAGE
The Contractor shall be required to submit the QA Documentation in two hard copies
and two CD ROMs, as identified in respective quality plan with tick (?) mark.
9.03.01 Each QA Documentation shall have a project specific Cover Sheet bearing name &
identification number of equipment and including an index of its contents with page
control on each document.
The QA Documentation file shall be progressively completed by the Supplier’s sub-
supplier to allow regular reviews by all parties during the manufacturing.

STAGE-II (2X195 MW)
The final quality document will be compiled and issued at the final assembly place of
equipment before despatch. However CD-Rom may be issued not later than three
weeks.
9.03.02 Typical contents of QA Documentation is as below:-
a). Quality Plan
b). Material mill test reports on components as specified by the specification and
approved Quality Plans.
c). Manufacturer / works test reports/results for testing required as per applicable
codes and standard referred in the specification and approved Quality Plans.
d). Non-destructive examination results /reports including radiography
interpretation reports. Sketches/drawings used for indicating the method of
traceability of the radiographs to the location on the equipment.
e). Heat Treatment Certificate/Record (Time- temperature Chart)
f). All the accepted Non-conformance Reports (Major/Minor) / deviation, including
complete technical details / repair procedure).
g). CHP / Inspection reports duly signed by the Inspector of the Employer and
Contractor for the agreed Customer Hold Points.
h). Certificate of Conformance (COC) wherever applicable.
i). MDCC
9.03.03 Similarly, the contractor shall be required to submit two sets (two hard copies and
two CD ROMs), containing QA Documentation pertaining to field activities as per
Approved Field Quality Plans and other agreed manuals/ procedures, prior to
commissioning of individual system.
9.03.04 Before despatch / commissioning of any equipment, the Supplier shall make sure
that the corresponding quality document or in the case of protracted phased
deliveries, the applicable section of the quality document file is completed. The
supplier will then notify the Inspector regarding the readiness of the quality document
(or applicable section) for review.
If the result of the review carried out by the Inspector is satisfactory, the Inspector
shall stamp the quality document (or applicable section) for release.
If the quality document is unsatisfactory, the Supplier shall endeavor to correct the
incompleteness, thus allowing to finalize the quality document (or applicable section)
by time compatible with the requirements as per contract documents. When it is
done, the quality document (or applicable section) is stamped by the Inspector.
If a decision is made despatch, whereas all outstanding actions cannot be readily

cleared for the release of the quality document by that time. The supplier shall
immediately, upon shipment of the equipment, send a copy of the quality document
Review Status signed by the Supplier Representative to the Inspector and notify of

STAGE-II (2X195 MW)
the committed date for the completion of all outstanding actions & submission. The
Inspector shall stamp the quality document for applicable section when it is
effectively completed. The submission of QA documentation package shall not be
later than 3 weeks after the despatch of equipment.
9.03.05 TRANSMISSION OF QA DOCUMENTATION
On release of QA Documentation by Inspector, one set of quality document shall be

forwarded to Corporate Quality Assurance Department and other set to respective
Project Site of Employer.
For the particular case of phased deliveries, the complete quality document to the
Employer shall be issued not later than 3 weeks after the date of the last delivery of
equipment.
9.04.00 Project Manager’s Supervision
9.04.01 To eliminate delays and avoid disputes and litigation, it is agreed between the parties
to the Contract that all matters and questions shall be referred to the Project
Manager and without prejudice to the provisions of ‘Arbitration’ clause in Section
GCC of Vol.I, the Contractor shall proceed to comply with the Project Manager's
decision.
9.04.02 The work shall be performed under the supervision of the Project Manager. The
scope of the duties of the Project Manager pursuant to the Contract, will include but
not be limited to the following:
a). Interpretation of all the terms and conditions of these documents and
specifications:
b). Review and interpretation of all the Contractor’s drawing, engineering data,
etc:
c). Witness or his authorised representative to witness tests and trials either at
the manufacturer’s works or at site, or at any place where work is performed
under the contract :
d). Inspect, accept or reject any equipment, material and work under the
contract:
e). Issue certificate of acceptance and/or progressive payment and final payment
certificates
f). Review and suggest modifications and improvement in completion schedules

from time to time, and
g). Supervise Quality Assurance Programme implementation at all stages of the

works.

STAGE-II (2X195 MW)
9.05.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
9.05.01 The word ‘Inspector’ shall mean the Project Manager and/or his authorised
representative and/or an outside inspection agency acting on behalf of the Employer
to inspect and examine the materials and workmanship of the works during its
manufacture or erection.
9.05.02 The Project Manager or his duly authorised representative and/or an outside
inspection agency acting on behalf of the Employer shall have access at all
reasonable times to inspect and examine the materials and workmanship of the
works during its manufacture or erection and if part of the works is being
manufactured or assembled on other premises or works, the Contractor shall obtain
for the Project Manager and for his duly authorised representative permission to
inspect as if the works were manufactured or assembled on the Contractor’s own
premises or works.
9.05.03 The Contractor shall give the Project Manager/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the Contractor’s
account except for the expenses of the Inspector’s. The Project Manager/Inspector,
unless the witnessing of the tests is virtually waived and confirmed in writing, will
attend such tests within fifteen (15) days of the date on which the equipment is
noticed as being ready for test/inspection failing which the contractor may proceed
with test which shall be deemed to have been made in the inspector’s presence and
he shall forthwith forward to the inspector duly certified copies of test reports in two
(2) copies.
9.05.04 The Project Manager or Inspector shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the Contractor, or any objection
to any drawings and all or any equipment and workmanship which is in his opinion
not in accordance with the contract. The Contractor shall give due consideration to
such objections and shall either make modifications that may be necessary to meet
the said objections or shall inform in writing to the Project Manager/Inspector giving
reasons therein, that no modifications are necessary to comply with the contract.
9.05.05 When the factory tests have been completed at the Contractor’s or sub-contractor’s
works, the Project Manager /Inspector shall issue a certificate to this effect fifteen
(15) days after completion of tests but if the tests are not witnessed by the Project
Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the
receipt of the Contractor’s test certificate by the Project Manager /Inspector. Project
Manager /Inspector to issue such a certificate shall not prevent the Contractor from
proceeding with the works. The completion of these tests or the issue of the
certificates shall not bind the Employer to accept the equipment should it, on further
tests after erection be found not to comply with the contract.
9.05.06 In all cases where the contract provides for tests whether at the premises or works of
the Contractor or any sub-contractor, the Contractor, except where otherwise
specified shall provide free of charge such items as labour, material, electricity, fuel,
water, stores, apparatus and instruments as may be reasonably demanded by the

STAGE-II (2X195 MW)
Project Manager /Inspector or his authorised representatives to carry out effectively

such tests on the equipment in accordance with the Contractor and shall give
facilities to the Project Manager/Inspector or to his authorised representative to
accomplish testing.
9.05.07 The inspection by Project Manager / Inspector and issue of Inspection Certificate
thereon shall in no way limit the liabilities and responsibilities of the Contractor in
respect of the agreed Quality Assurance Programme forming a part of the contract.
9.05.08 To facilitate advance planning of inspection in addition to giving inspection notice as

specified at clause no 9.05.03- of this chapter, the Contractor shall furnish quarterly
inspection programme indicating schedule dates of inspection at Customer Hold
Point and final inspection stages. Updated quarterly inspection plans will be made for
each three consecutive months and shall be furnished before beginning of each
calendar month.
9.05.09 All inspection, measuring and test equipment used by contractor shall be calibrated
periodically depending on its use and criticality of the test/measurement to be done.
The Contractor shall maintain all the relevant records of periodic calibration and
instrument identification, and shall produce the same for inspection by NTPC.
Wherever asked specifically, the contractor shall re-calibrate the measuring/test
equipment in the presence of Project Manager / Inspector.
9.06.00 ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE PROGRAMME:
9.06.01 Subcontractor approval Schedule Status / Exception Format No.:QS-01-QAI-

P-02/F1-R2
9.06.02 Quality Plan Schedule Status/ Exception Format No.: QS-01-QAI-P-02/F2-R2
9.06.03 Field Welding Schedule Format No.: QS-01-QAI-P-02/F3-R1
9.06.04 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R1
9.06.05 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1

The above formats are enclosed as Annexures-III to VII.
10.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES
a). As soon as the facilities or part thereof has been completed operationally and
structurally and before start-up, each item of the equipment and systems
forming part of facilities shall be thoroughly cleaned and then inspected jointly
by the Employer and the Contractor for correctness of and completeness of
facility or part thereof and acceptability for initial pre-commissioning tests,
commissioning and start-up at Site. The list of pre-commissioning tests to be
performed shall be as mutually agreed and included in the Contractor’s quality
assurance programme as well as those included elsewhere in the Technical
Specifications.

STAGE-II (2X195 MW)
b). The Contractor’s pre-commissioning/ commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying out all
the pre-commissioning tests at Site. On completion of inspection, checking and
after the pre-commissioning tests are satisfactorily over, the commissioning of
the complete facilities shall be commenced during which period the complete
facilities, equipments shall be operated integral with sub-systems and
supporting equipment as a complete plant.
c). The time consumed in the inspection and checking of the units shall be
considered as a part of the erection and installation period.
d). The check outs during the pre - commissioning period should be programmed
to follow the construction completion schedule. Each equipment/system, as it is
completed in construction and turned over to Employer's commissioning (start-
up) Engineer(s), should be checked out and cleaned. The checking and
inspection of individual systems should then follow a prescribed commissioning
documentation [SLs (Standard Check List) / TS (Testing Schedule) / CS
(Commissioning Schedule)] approved by the Employer.
e). On completion of all precommissioning activities / tests and as a part of

commissioning the complete facilities shall be put on 'Trial Operation' during
which period all necessary adjustments shall be made while operating over the
full load range enabling the facilities to be made ready for the Guarantee Tests
(f.) The duration of 'Trial Operation' of the complete facility as an integral unit shall
be fourteen (14) days. The Trial Operation shall be considered successful,
provided that each item/part of the facility can operate continuously at the
specified operating characteristics, for the period of Trial Operation with all
operating parameters within the specified limits and at or near the predicted
performance of facility/equipment.
(g.) For the period of 'Trial Operation', the time of operation with any load shall be
counted. Minor interruptions not exceeding four (4) hours at a time caused
during the 14 days trial operation period shall not effect the total duration of
Initial Operation. If in the opinion of the Employer the interruption is long, the
Trial Operation shall be prolonged for the period of interruption
(h.) A Trial Operation report comprising of observations and recordings of various

parameters to be measured in respect of the above Trial Operation shall be
prepared by the Contractor. This report, besides recording the details of the
various observations during trial operation shall also include the dates of start
and finish of the Trial Operation and shall be signed by the representatives of
both the parties. The report shall have sheets, recording all the details of
interruptions occurred, adjustments made and any minor repairs done during
the Trial Operation. Based on the observations, necessary modifications/repairs
to the plant shall be carried out by the Contractor to the full satisfaction of the
Project Manager to enable the latter to accord permission to carry out the
Guarantee tests on the facilities. However, minor defects which do not

STAGE-II (2X195 MW)
endanger the safe operation of the equipment, shall not be considered as

reasons for with- holding the aforesaid permission
(i.) Contractor shall furnish the commissioning organization chart for review &
acceptance of employer at least eighteen months prior to the schedule date of
synchronization of 1st unit. The chart should contain
(1.) Experience of the Commissioning Engineers.
(2.) Role and responsibilities of the Commissioning Organisation members.
(3.) Expected duration of posting of the above Commissioning Engineers at

site.
10.01.00 Guarantee Tests
(a) The final tests as to the guarantees shall be conducted at Site, by the
Contractor. The Contractor's Commissioning and start-up Engineers shall
make the unit ready for such tests. Such test will be commenced, within a
period of three (3) months after the successful completion of Trial Operation.
Any extension of time beyond the above three months shall be subject to
Employer's approval.
(b) These tests shall be binding on both the parties of the Contract to determine
compliance of the equipment with the performance guarantee.
(c) Any special equipment, tools and tackles required for the successful
completion of the Guarantee Tests shall be provided by the Contractor, free
of cost.
(d) The guarantee figures and design/performance parameters of the equipment

shall be proved by the Contractor during theswe Guarantee Tests/ and or
during the 'Trial operation' as detailed out elsewhere. Should the results of
these tests show any deterioration from the guaranteed values, the
Contractor shall modify the equipment as required to enable it to meet the
guarantees. In such case, the Guarantee Tests shall be repeated and all cost
for modifications including labour, materials and the cost of additional testing
to prove that the equipment meets the guarantees, shall be borne by the
Contractor.
(e) The specific tests to be conducted on equipment have been brought out in the
technical specification.
10.02.00 Test Codes
The provisions outlined in the ASME Performance Test Codes shall be used as a
guide for all the above test procedures unless otherwise specified in the technical
specifications.

STAGE-II (2X195 MW)
11.00.00 TAKING OVER
Upon successful completion of Initial Operations and all the tests conducted to the
Employer's satisfaction, the Employer shall issue to the Contractor a Taking over
Certificate as a proof of the final acceptance of the equipment. Such certificate shall
not unreasonably be with held nor will the Employer delay the issuance thereof, on
account of minor omissions or defects which do not affect the commercial operation
and/or cause any serious risk to the equipment. Such certificate shall not relieve the
Contractor of any of his obligations which otherwise survive, by the terms and
conditions of the Contract after issuance of such certificate.
12.00.00 TRAINING OF EMPLOYER'S PERSONNEL
12.01.00 The scope of service under training of Employer’s engineers (min. 12 nos.) shall
include a training module in the areas of Operation & Maintenance.
Such training should cover the following areas as a minimum in order to enable these
personnel to individually take the responsibility of operating and maintaining the
power station in a manner acceptable to the Employer:
12.02.00 The scope of services under training shall also necessarily include training of
Employer's Engineering personnel covering a training module of upto 52 man
months. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & QA etc.
and shall include all the related areas like Design familiarization, training on product
design features and product design softwares of major equipment and systems,
engineering, manufacturing, erection, commissioning, training on operating features
of equipment, quality assurance and testing, plant visits and visits to manufacturer's
works, exposure to various kinds of problems which may be encountered in
fabrication, manufacturing, erection, welding etc.
12.03.00 Contractor shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Employer's approval. Consolidated training
period included above (i.e. 35 and 52 man months respectively for O&M and
Engineering) is indicative only. Employer reserves the right to reappropriate the
training period between O&M and engineering depending upon the details of training
module proposed by the Contractor.
12.04.00 Exact details, extent of training and the training schedule shall be finalised based on
the Contractor's proposal within two (2) months from placement of award.
12.05.00 In all the above cases, wherever the training of Employer's personnel is arranged at
the works of the manufacturer's it shall be noted that the lodging and boarding of the
Employer's personnel shall be at the cost of Contractor.
13.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION
In addition to the requirements given in Erection Conditions of Contract (ECC) the

following shall also cover:
a). Working platforms should be fenced and shall have means of access.

STAGE-II (2X195 MW)
b). Ladders in accordance with Employer’s safety rules for construction and erection
shall be used. Rungs shall not be welded on columns. All the stairs shall be
provided with handrails immediately after its erection.
14.00.00 NOISE LEVEL
The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m
above floor level in elevation and at a distance of one (1) metre horizontally from the
nearest surface of any equipment / machine, furnished and installed under these
specifications, expressed in decibels to a reference of 0.0002 microbar, shall not
exceed 85 dBA.
15.00.00 PACKAGING AND TRANSPORTATION
All the equipments shall be suitably protected, coated, covered or boxed and crated
to prevent damage or deterioration during transit, handling and storage at Site till the
time of erection. While packing all the materials, the limitation from the point of view
of the sizes of railway wagons available in India should be taken account of. The
Contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing. The Contractor shall ascertain the
availability of Railway wagon sizes from the Indian Railways or any other agency
concerned in India well before effecting despatch of equipment. Before despatch it
shall be ensured that complete processing and manufacturing of the components is
carried out at shop, only restricted by transport limitation, in order to ensure that site
works like grinding, welding, cutting & pre-assembly to bare minimum. The
Employer's Inspector shall have right to insist for completion of works in shops before
despatch of materials for transportation.
16.00.00 ELECTRICAL ENCLOSURE
All electrical equipments and devices, including insulation, heating and ventilation
devices shall be designed for ambient temperature and a maximum relative humidity
as specified elsewhere in the specification,
17.00.00 INSTRUMENTATION AND CONTROL
All instrumentation and control systems/ equipment/ devices/ components, furnished

under this contract shall be in accordance with the requirements stated herein,
unless otherwise specified in the detailed specifications.
17.01.00 All instrument scales and charts shall be calibrated and printed in metric units and
shall have linear graduation. The ranges shall be selected to have the normal reading
at 75% of full scale.
All scales and charts shall be calibrated and printed in Metric Units as follows:
a) Temperature - Degree centigrade (deg C)
b) Pressure - Kilograms per square centimetre (Kg/cm2).

STAGE-II (2X195 MW)
Pressure instrument shall have the unit suffixed

with 'a' to indicate absolute pressure. If nothing is
there, that will mean that the indicated pressure is
gauge pressure.
c) Draught - Millimetres of water column (mm wc).
d) Vacuum - Millimeters of mercury column (mm Hg) or water

column (mm Wcl).
e) Flow - Tonnes/ hour
f) Flow (Liquid) - Tonnes / hour
g) Flow base - 760 mm Hg. 15 deg.C
h) Density Grams per cubic centimetre.
17.02.00 All instruments and control devices provided on panels shall be of miniaturized
design, suitable for modular flush mounting on panels with front draw out facility and
flexible plug-in connection at rear.
17.03.00 All electronic modules shall have gold plated connector fingers and further all input
and output modules shall be short circuit proof. These shall also be tropicalised &
components shall be of industrial grade or better.
18.00.00 ELECTRICAL NOISE CONTROL
The equipment furnished by the Contractor shall incorporate necessary techniques to

eliminate measurement and control problems caused by electrical noise. Areas in
Contractor’s equipment which are vulnerable to electrical noise shall be hardened to
eliminate possible problems. Any additional equipment, services required for
effectively eliminating the noise problems shall be included in the proposal. The
equipment shall be protected against ESD as per IEC-801- 2. Radio Frequency
interference (RFI) and Electro Magnetic Interference (EMI) protection against
hardware damage and control system mal-operations/errors shall be provided for all
systems.
19.00.00 INSTRUMENT AIR SYSTEM (AS APPLICABLE)
The instrument air supply system as supplied by the Contractor for various
pneumatic control & instrumentation devices like pneumatic actuators, power
cylinders, E/P converters, piping / tubing etc. shall be as per the details furnished
elsewhere.
Each pneumatic instrument shall have an individual air shut - off valve. The pressure
regulating valve shall be equipped with an internal filter, a 50 mm pressure gauge
and a built-in filter housing blow down valve.

STAGE-II (2X195 MW)
20.00.00 TAPPING POINTS FOR MEASUREMENTS
Tapping points shall include probes, wherever applicable, for analytical

measurements and sampling.
For direct temperature measurement of all working media, one stub with internal
threading of approved pattern shall be provided along with suitable plug and washer.
The Contractor will be intimated about thread standard to be adopted.
The following shall be provided on equipment by the Contractor. The standard which
is to be adopted, will be intimated to the Contractor.
Temperature test pockets with stub and thermowell
Pressure test pockets
21.00.00 ELECTRONIC MODULE/COMPONENT DETAILS
The Contractor shall have to furnish all technical details including circuit diagrams,
specifications of components, etc., in respect of each and every electronic
card/module as employed on the various solid state as well as microprocessor based
systems and equipment including conventional instruments, peripherals etc.
It is mandatory for the Contractor to identify clearly the custom built ICs used in the
package. The Contractor shall also furnish the details of any equivalents of the same.
22.00.00 JUNCTION BOXES
The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates
shall be removable type and made of 3 mm thick sheet steel. The boxes shall be
provided with detachable cover or hinged door with captive screws. Top of the box
shall be arranged to slope towards the rear of the box. The box shall be hot dip
galvanized and shall be provided with suitable neoprene gaskets to achieve degree
of protection of IP-55 as per IS: 2147. Adequate spacing shall be provided to
terminate the external cables. The boxes shall be suitable for mounting on various
types of steel structures. The terminal blocks provided shall be of 650 V grade, rated
for 10 A for control cables. Suitable numbering for terminal blocks shall be done. In
case of junction box for power cable, the box shall be rated for maximum current
carrying capacity. Terminal blocks shall be of one piece, klippon RSF-1 or ELMEX
CSLT-1 type with insulating barriers.
23.00.00 SPECIFIC REQUIREMENT FOR DC PANELS
23.01.00 DC starter shall essentially consists of following:–
a) One (1) - Double pole 220 V D.C. air break switch and HRC fuses.
b) One (1) - Double pole 220 V D.C. contactor with 2 NO and 2 NC contacts.
c) Contactors and timers as required for the control scheme.
d) Overload relay (for alarm only).

STAGE-II (2X195 MW)
e) Shunt and ammeter for motors rated 15 KW an above.
f) One (1) - Red indicating lamp to give motor 'ON' indication.
g) One (1) - Green indicating lamp to give motor 'OFF' indication.
h) Starting resistor.
The resistance shall be air cooled, stainless steel grid type, suitable for 220 V DC
and continuously rated. The resistance shall be provided with sheet steel covers with
louvers and canopy type top cover.
24.00.00 A comprehensive Engineering and Quality Coordination Procedure Shall be Finalised

with successful bidder during pre award discussion covering salient features as
described in this section of the specification.

STAGE-II (2X195 MW)
ANNEXURE-I
S. NO. DESCRIPTION OF DOCUMENTS NO OF NO. OF CD-

PRINTS ROMs
1. Drawings, Data sheets, Design calculations, Purchase specifications and

other documents
a) First submission and

submission with major
changes
i) Layout (A0&A1 4
--
sizes)
ii) Other 2
Drawings/Documents --
(A0&A1 sizes)
iii) P&ID (All sizes) 4 --
b) Final drawings/documents 6 2 CD-ROMs

(Directly to site)
c) “As Built” Drawing/Documents 6 2 CD-ROMs

(Directly to site)
d) Analysis reports of equipments/piping 2 2 CD-ROMs

/structures components/system
employing software packages as
detailed in the specifications.
2. Erection Manual (Directly to site) 4 Sets 2 CD-ROMs
3. Operation & Maintenance manual
i) First Submission 1 Set --

ii) Final Submission (Directly to site) 4 Sets 2 CD-ROMs
4. Plant Hand Book 1 1 CD-ROMs
i) First Submission
ii) Final Submission (Directly to site) 4 2 CD-ROMs

STAGE-II (2X195 MW)
5.. Commissioning and Performance Test

Procedure manual
i) First Submission
1 Sets --
ii) Final Submission (Directly to site) 4 Sets 2 CD-ROMs
6. Performance and Functional Guarantee Test

Report
2 Sets --
i) First Submission
ii) Approved Copies (Directly to site) 4 Sets 2 CD-ROMs
7. Project Completion Report (Directly to site) 6 2 CD-ROMs
8. QA programme including Organisation for 1 --

implementation and QA system manual(with
revisions)
9. Vendor details in respect of proposed 1 --

vendors including contractor’s evaluation
report.
10. Manufacturing QPs, Field QPs, Field welding 1 --

schedules and their reference document like
test procedures, WPS, POR etc
i) For review/comment
ii) For final approval -- 2 CD-ROMs
11. Welding Manual, Heat Treatment Manuals,

Storage & preservation manuals
i) For review/comment 1 --
ii) Approved copies (Direct to Site) 4 2 CD-ROMs
12. QA Documentation Package for items / 2 Sets 2 CD-ROMs

equipment manufactured and despatched to
site
13. QA Documentation Package for field 2 Sets 2 CD-ROMs

activities on equipment/systems at site

STAGE-II (2X195 MW)
ANNEXURE-II
Project : Stage : LIST OF ITEMS REQUIRING QUALITY PLAN DOC. NO.:

Package : AND SUB-SUPPLIER APPROVAL REV. NO.:
Supplier : DATE :
Contractor No. : SUB-SYSTEM : PAGE : OF
S. Item QP/ QP No. QP QP Proposed sub- Place Sub- Sub- Remar
N. Insp. Sub. approv supplier supplier supplier ks
Cat. Schedu al s Details
le schedul approval submissi
e status / on
category schedule
LEGENDS
1. SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY NTPC)
A – For these items proposed vendor is acceptable to NTPC. To be indicated with letter “A” in the list alongwith the condition of approval, if any.
DR – For these items “Detailed required” for NTPC review. To be identified with letter “DR” in the list.
NOTED – For these items vendors are approved by Main Supplier and accepted by NTPC without specific vendor approval from NTPC. To be identified with “NOTED.’
2. QP/INSPN CATEGORY:
CAT-I : For these items the Quality Plans are approved by NTPC and the final acceptance will be on physical inspection witness by NTPC.
CAT-II : For these items the Quality Plans approved by NTPC. However no physical inspection shall be done by NTPC. The final acceptance by NTPC shall be on the basis
review of documents as per approved QP.
CAT-III : For these items Main Supplier approves the Quality Plans. The final acceptance by NTPC shall be on the basis certificate of conformance by the main supplier.
UNITS/WORKS : Place of manufacturing Place of Main Supplier of multi units/works.
FORMAT NO.: QS-01-QAI-P-1/F3-R0 1/1 Engg. Div. / QA&I

STAGE-II (2X195 MW) GENERAL TECHNICAL
REQUIREMENTS
BID DOCUMENT NO. : CS-0350-155(R)-2 PART-C
ANNEXURE-III
Project : Stage : STATUS OF ITEM REQUIRING QP& DOC. NO.:
Package : SUB-SUPPLIER APPROVAL REV. NO.:
Contractor : DATE :
Contractor No. : PAGE : OF
S. N. Item / Service QP/ QP Sub. Date Date Statu Proposed Sub-suppliers Place of Appro Sub- Remarks
Insp. Schedul of of s manufacturing val supplier
Cat. e sub- com Code works Status detail
Approva missi mt C/II/I submissio
l on Appl. n schedule
schedul
e

REQUIREMENTS
ANNEXURE-IV
Project : Stage : FIELD WELDING SCHEDULE DOC. NO.:
Contractor : (To be raised by the contractor) REV. NO.:
Contractor No. : Welding Code: ……………………………………… DATE :
System : PAGE : OF
Sl. DRG No. for Weld Descript Matl. Dimensio Process Type of Electrode WPS. Min. Heat treatment NDT REF Remarks
No. Location and ion of Spec. ns of Weld filler No. pre- method/
Identification mark parts to welding spec. heat Temp. Holdin Quantum Spec. ACC Norm
welded g time No. Ref.
NOTES:
SIGNATURE

REQUIREMENTS
ANNEXURE-V
MANUFACTURER’S NAME AND MANUFACTURING QUALITY PLAN PROJECT :
ADDRESS ITEM : QP NO.: PACKAGE :
REV.NO.: CONTRACT NO. :
MFGR.’s SUB-SYSTEM: DATE: MAIN-SUPPLIER:
LOGO PAGE: …. OF….
QUANTUM
OF
TYPE CHECK REMARKS
SL. COMPONENT & CHARACTERISTICS CLASS REFERENCE ACCEPTANCE Format of
OF
NO OPERATIONS DOCUMENT Norms Record
CHECK
M C/
M C N
N
1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” ( √ ) SHALL BE DOC. NO.: REV…… CAT…..
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, N: NTPC
P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE,
CHP: NTPC SHALL IDENTIFIED IN COLUM “N” AS ‘ W”
MANUFACTURER/ MAIN-SUPPLIER FOR
SUB-SUPPLIER NTPC
SIGNATURE USE REVIEWED BY APPROVED BY APPROVAL
SEAL
FORMAT NO.: QS-01-QAI-P-09/F1-R1 1/1 ENGG. DIV./QA&I

REQUIREMENTS
ANNEXURE-VI
SUPPLIER’S NAME AND FIELD QUALITY PLAN PROJECT :
ADDRESS ITEM : QP NO.: PACKAGE :
REV.NO.: CONTRACT NO. :
MFGR.’s SUB-SYSTEM : DATE: MAIN-SUPPLIER:
LOGO PAGE: …. OF….
QUANTU
CHARACTERISTICS / CLASS# TYPE REFERENC
SL. ACTIVITY AND M ACCEPTANCE FORMAT OF REMARKS
INSTRUMENTS OF OF E
NO OPERATION OF NORMS RECORD
CHECK CHECK DOCUMENT
CHECK
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (√) DOC. NO.:

SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA REV……
DOCUMENTATION.
LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR,
C=MINOR;
‘A’ SHALL BE WITNESSED BY NTPC FQA, ‘B’ SHALL BE
WITNESSED BY NTPC ERECTION / CONSTRUCTION
MANUFACTURER/ MAIN- DEPTT. AND ‘C’ SHALL BE WITNESSED BY ERECTION FOR
SUB-SUPPLIER SUPPLIER SUPPLIER (A & B CHECK SHALL BE NTPC CHP STAGE) NTPC
SIGNATURE USE REVIEWED BY APPROVED APPROVAL
BY SEAL
Format No.: QS-01-QAI-P-09/F2-r0 1/1 Engg. Div./QA&I

REQUIREMENTS
PART - D
ERECTION CONDITIONS OF CONTRACT

COAL HANDLING PLANT PACKAGE PART-D
CLAUSE NO. ERECTION CONDITIONS OF CONTRACT
ERECTION CONDITIONS OF CONTRACT
1.00.00 GENERAL
1.01.00 The following provisions shall supplement the conditions already contained in the
other parts of these specifications and documents and shall govern that portion of the
work of this contract which is to be performed at site. The erection requirements and
procedures not specified in these documents shall be in accordance with the
recommendations of the equipment manufacturer, or as mutually agreed to between
the Employer and the Contractor prior to commencement of erection work.
1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project Co-
ordinator, nominate another responsible officer as his representative at Site suitably
designated for the purpose of overall responsibility and co-ordination of the Works to
be performed at Site. Such a person shall function from the Site office of the
Contractor during the pendency of Contract.
2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES
2.01.00 In addition to the local laws and regulations, the Contractor shall also comply with the
Minimum Wages Act and the Payment of Wages Act (both of the Government of
India) and the rules made there under in respect of its labour and the labour of its
sub-contractors currently employed on or connected with the contract.
2.02.00 All registration and statutory inspection fees, if any, in respect of his work pursuant to
this Contract shall be to the account of the Contractor. However, any registration,
statutory inspection fees lawfully payable under the provisions of the Indian Boiler
Regulations and any other statutory laws and its amendments from time to time
during erection in respect of the plant equipment ultimately to be owned by the
Employer, shall be to the account of the Employer. Should any such inspection or
registration need to be re-arranged due to the fault of the Contractor or his Sub-
Contractor, the additional fees for such inspection and/or registration shall be borne
by the Contractor.
3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING
The welding of all pressure parts and high pressure piping shall be in accordance
with the following requirements :
3.01.00 Qualification of Weld Procedures
Only qualified welding procedures as per ASME Section IX shall be used by

contractor at site. Procedure qualification records along with WPS shall be submitted
to NTPC for review. Welding procedure shall indicate all essential and non-essential
parameters as per ASME Section IX. Makes of welding consumables shall be subject
to employer’s approval.
3.02.00 Welder's Qualification
Only welders, who are qualified in accordance with the latest applicable requirements
of the Indian Boiler Regulations, shall be permitted to perform any welding work on

TECHNICAL SPECIFICATION ERECTION
STAGE-II (2X195 MW)
COAL HANDLING PLANT PACKAGE SECTION-VI CONDITIONS OF PAGE 1 OF 41
BID DOCUMENT NO. : CS-0350-155(R)-2 PART-D CONTRACT
the pressure parts and its attachment welding. In addition to such statutory
qualification requirements, the welders shall also undergo a satisfactory pre-
production qualification test to be conducted by the Contractor at site as per ASME
Sec IX in presence of employer’s representative(s), prior to performing work under
these specifications. The services of an independent testing laboratory shall be
retained by the Contractor to perform welder qualification tests for welders.
All the welders carrying out welding at site shall carry an identification badge, which
shall indicate the category and the grade of welding for which they have been tested
and authorised to carry out welding. All such badges shall be countersigned by the
Employer.
3.03.00 Records
Welders performance shall be monitored regularly and record of their performance

shall be maintained by contractor in a manner acceptable to the employer.
Contractor shall maintain such records including record of procedure qualification &
welder qualification and hand-over to the employer at the end of work.
3.04.00 MARKING
On completion of each welded joint, the welder shall mark his regularly assigned
identification mark near the joint. The welder's identification numbers, inspection
stamps or code symbol stamps and any other information shall not be directly
stamped on any alloy steel piping. In alloy steel piping, all such information shall be
stamped on separate marking plate which shall be tack welded on pipe near the
weld.
4.00.00 HEAT TREATMENT
4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds, shall be
performed in accordance with the requirements of applicable code. Local post weld
stress relieving heat - treatments shall be adopted only in cases where it is normally
impracticable to subject the entire assembly as such for stress relieving operations.
Heating may be by means of electric induction coils or electric resistance coils. Oxy-
acetylene flame heating or exothermic chemical heating methods will not be
permitted. Complete recording of the temperatures through out the stress relieving
cycle of the material and the weld subjected to heat treatment shall be made by
means of a potentiometric recorder. Recorders other than those of potentiometric
type shall not be used for such temperature recording during stress relieving
operations.
The contractor & employer’s representative, at start and at the end of HT Cycle shall
sign the time and temperature charts for heat-treatment.
4.02.00 After setting up the weld joint for heat treatment operation, the Employer's signature
shall be obtained on the strips chart of the recorder prior to starting of heat treatment
cycle. The right hand corner of the strip chart at the starting point of the heat
treatment cycle shall contain details like the weld number, material, diameter and
thickness, method of heating adopted, prescribed ranges of heat treatment

STAGE-II (2X195 MW)
temperatures, date of heat treatment, reference to item number of the Field welding
Schedule (as specified at clause no 7.00.00- of this chapter) etc.
5.00.00 WELD EDGE PREPARATION
Preparation at site of weld joint shall be in accordance with details acceptable to the
Employer. Wherever possible, machining or automatic flame cutting shall be used for
edge preparation. Hand flame cutting will be permitted only where edge preparation
otherwise is impractical. All slag shall be removed from cuts and all the hand cuts
shall be ground smooth to the satisfaction of the Employer. Flame cutting of alloy
steel pipe shall be avoided. Wherever such cutting is done, a 200mm length at the
cut face shall be removed by machining. Pneumatic hand tools such as edge
preparation, tube cutting machine can be used.
6.00.00 CLEANING AND SERVICING
6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose
scales before being erected. All the pipelines shall be thoroughly blown and/or
flushed. Each steam and water tubes shall be blown with compressed air and shall
be subjected to 'ball test' before erection to ensure that no obstructions exist. A
system for recording of all such operations shall be developed and maintained in a
manner to ensure that no obstructions are left inside the tubes and no tubes are left
uncleaned and untested.
6.02.00 All valves and valve actuators, and dampers and damper actuators, if any, shall be
thoroughly cleaned and serviced prior to pre-commissioning tests and/or Initial
Operations of the plant. A system for recording of such servicing operation shall be
developed and maintained in a manner acceptable to the Employer and to ensure
that no valves or dampers including their actuators are left unserviced.
6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing - up to
remove all traces of oil preservations.
7.00.00 FIELD WELDING SCHEDULE
The Contractor shall submit to the Employer, a certified and complete field welding
schedule for all the field welding activities to be carried out in respect of the pressure
parts involved in the equipment furnished and erected by him, at least 90 days prior
to the scheduled start of erection work at site. Such schedule will be strictly followed
by the Contractor during the process of erection. The above field-welding schedule to
be issued by the Contractor shall contain the following:
(a.) Drawing No (s)
(b.) Location of the weld
(c.) Size of the weld (outside diameter and thickness)
(d.) Type of joints
(e.) Material specifications

STAGE-II (2X195 MW)
(f.) Size of fillet on backing ring, when the type of joint is with backing ring
(g.) Electrode/ filler metal specifications
(h.) Number of welds per unit
(i.) Quantity of filler metal per weld
(j.) Indication of required Non-destructive Examination (NDE) for each weld
(k.) Pre-heat temperatures for welding
(l.) Process of welding
(m.) Post-welding heat treatment temperature ranges, duration, under as specified

at clause no 4.00.00- of this chapter entitled "Heat Treatment".
(n.) Qualification details of weld procedures to be adopted as specified under as

specified at clause no 3.01.00- of this chapter entitled 'Qualification of Weld
Procedures'.
8.00.00 SITE RUN MISCELLANEOUS PIPING
Sketches or diagrams of the proposed routings of all piping, not already indicated
and routed on the shop drawings which were reviewed by the Employer, shall be
submitted to the Employer for review, Employer's acceptance of such site routings
shall be obtained before the piping is erected. All these site run piping shall be
installed in such a manner as to present an orderly and neat installation. They shall
be located as to avoid obstruction of access and passages. Valves, instruments or
any other special items shall be located convenient for operation by the operating
personnel. Pipe runs shall be plumb or level except where pitch for drainage is
required. Pipe runs that are not parallel to the building structure, walls or column
rows shall be avoided so that deflection of pipes between hangers does not exceed 6
mm. No miscellaneous pipe shall be routed and installed above or adjacent to
electrical equipment.
9.00.00 THERMAL EXPANSIONS
All piping installation shall be such that no excessive or destructive expansion forces
exist either in the cold condition or under condition of maximum temperature. All
bends, expansion joints and any other special fittings, necessary to provide proper
expansion, shall be incorporated. During installation of expansion joints and anchors,
care must be taken to make sure that full design movement is available at all times
for maximum to minimum temperature and vice-versa.
10.00.00 PIPING SUPPORTS
10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,
reliable and complete pipe installation. All supports shall be properly leveled and
anchored when installed. The anchors shall be so placed that thermal expansion will

STAGE-II (2X195 MW)
be absorbed by bends without subjecting the valves or equipment to excessive

strains.
10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the
pipe into place. Other means shall be used to securely hold the pipe in place till the
pipe support is completely assembled and attached to the pipe and building
structures and spring support is set to accommodate the pipe way. All temporary
rigging shall be removed in such a way that the pipe support is not subjected to any
sudden load. All piping, having variable spring type supports, shall be held securely
in place by temporary means during the hydraulic test of pipe system. Constant
support type spring hangers used during hydraulic test shall be pinned or blocked
solid during the test. After complete installation and insulation of the piping and filling
of the piping with its normal operating medium, the pipe support springs shall be
adjusted to the cold positions. If necessary, the spring support shall be re-adjusted to
the hot positions after the line has been placed for service at its normal maximum
operating temperature conditions. Electric arc welding only shall be used to weld all
pipe supports to structural steel members that form part of the building supporting
structure. The structural beams shall not be heated more than necessary during
welding of supports and such welds shall run parallel to the axis of the span. All lugs
or any other attachments welded to the piping shall be of the same material as the
pipe.
11.00.00 PRESSURE TESTING
11.01.00 On completion of erection of pressure parts, a hydraulic test in accordance with the
requirements of the Indian Boiler Regulations shall be performed by the Contractor.
11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the
pressure parts shall be tested along with pressure parts. All blank flanges or any
removable plugs required for openings not closed by the valves, and piping provided,
shall be furnished by the Contractor. The pressurization equipment including water
piping from the supply, needed for the above test shall also be furnished by the
Contractor. Any defects noticed during the testing are to be rectified and the unit re-
tested. If any welding is done on the pressure parts after the Hydraulic test, the
Hydraulic test for that portion of pressure parts shall be repeated.
11.03.00 Thy hydraulic test shall be considered successful only on certification to that effect by
the concerned inspecting Authority as per the provisions of the Indian Boiler
Regulations and the Employer.
12.00.00 THERMOWELLS AND FLOW NOZZLES
12.01.00 All the thermowells and flow nozzles in the equipment furnished under the technical
specifications shall be installed as a part of this work.
12.02.00 All thermowell connections incorporated in the steam service shall be plugged during
the pressure testing and the blow out of steam piping systems. Upon completion of
the blow out operation, all thermowells shall be installed and seam welded. Similarly,
all flow nozzles in the steam lines shall also be installed only on completion of steam
blowing operations unless otherwise agreed to by the Employer, depending upon the

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sequence of cleaning and purging operations to be adopted by the Contractor at the

field.
13.00.00 INSULATION, LAGGING AND CLADDING
The provision of insulation, lagging and cladding of the various equipments and
portion of the equipment covered under the Contract, shall be furnished by the
Contractor as specified elsewhere or agree to separately in writing. Welds required
for holding insulation on pressure parts shall be carried out by IBR qualified welder.
13.01.00 Protection of Equipment during Insulation Applications
All equipment and structures shall be suitably protected from damage while applying
insulation after completion of insulation. All equipment and structures shall be
thoroughly cleaned and remove insulating materials which might have fallen on them.
14.00.00 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation of

the equipment shall be in accordance with the relevant Indian Electricity Rules &
Codes, Indian Boiler Regulations, ASME codes and accepted good practices, the
Employer's Drawings and other applicable Indian recognised codes and laws and
regulations of the Government of India.
15.00.00 ELECTRICAL SAFETY REGULATIONS
15.01.00 In no circumstances will the Contractor interfere with fuses and electrical equipment
belonging to the other Contractor or Employer.
15.02.00 Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other Contractor or Employer, he shall:
(a.) Satisfy the Employer that the appliance is in good working condition;
(b.) Inform the Employer of the maximum current rating, voltage and phases of the
appliances;
(c.) Obtain permission of the Employer detailing the socket to which the appliances
may be connected.
The Employer will not grant permission to connect until he is satisfied that
(a) The appliance is in good condition and is fitted with a suitable plug.
(b) The appliance is fitted with a suitable cable having two earth conductors, one of
which shall be an earthed metal sheath surrounding the cores.
15.03.00 No electric cable in use by the other Contractor/ Employer will be disturbed without
permission. No weight of any description will be imposed on any such cable and
ladder or similar equipment will rest against or be attached to it.

STAGE-II (2X195 MW)
15.04.00 No repair work shall be carried out on any live equipment. The equipment must be
declared safe by the Employer and a permit to work issued before any work is carried
out.
15.05.00 The Contractor shall employ the necessary number of qualified, full time electricians
to maintain his temporary electrical installation.
16.00.00 REMOVAL OF MATERIAL
No material brought to the Site shall be removed from the Site by the Contractor
and/or his Sub-Contractors without the prior written approval of the Employer.
17.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
The provisions of the clause entitled Inspection, Testing and Inspection Certificates
given in Part - C of the Technical Specification, shall also be applicable to the
erection portion of the Works. The Employer shall have the right to re-inspect any
equipment though previously inspected and approved by him at the Contractor’s
works, before and after the same are erected at Site. If by the above inspection, the
Employer rejects any equipment, the Contractor shall make good for such rejections
either by replacement or modification/ repairs as may be necessary to the
satisfaction of the Employer. Such replacements will also include the replacements or
re-execution of such of those works of other Contractors and/or agencies, which
might have got damaged or affected by the replacements or re-work done to the
Contractor’s work.
18.00.00 ACCESS TO SITE AND WORKS ON SITE
18.01.00 Suitable access to site and permission to work at the Site shall be accorded to the
Contractor by the Employer in reasonable time.
18.02.00 In the execution of the Works, no person other than the Contractor or his duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do work
on the Site, except by the special permission, in writing by the Employer or his
representative.
19.00.00 CONTRACTOR’S SITE OFFICE ESTABLISHMENT
The Contractor shall establish a Office at the Site and keep posted an authorised
representative for the purpose of the Contract. Any written order or instruction of the
Employer or his duly authorised representative shall be communicated to the said
authorised resident representative of the Contractor and the same shall be deemed
to have been communicated to the Contractor at his legal address.
20.00.00 CO-OPERATION WITH OTHER CONTRACTORS
20.01.00 The Contractor shall co-operate with all other Contractors or tradesmen of the
Employer, who may be performing other works on behalf of the Employer and the
workmen who may be employed by the Employer and doing work in the vicinity of the
works under the Contract. The Contractor shall also arrange to perform his work as
to minimise, to the maximum extent possible, interference with the work of other

STAGE-II (2X195 MW)
Contracts and their workmen. Any injury or damage that may be sustained by the
employees of the other Contractors and the Employer, due to the Contractor’s work
shall promptly be made good at his own expense. The Employer shall determine the
resolution of any difference or conflict that may arise between the Contractor and
other Contractors or between the Contractor and the workmen of the Employer in
regard to their work. If the work of the Contractor is delayed because of the any acts
of omission of another Contractor, the Contractor shall have no claim against the
Employer on that account other than an extension of time for completing his works.
Employer shall have full access to visit the contractor’s site at any time for inspection
and surveillance checks.
20.02.00 The Employer shall be notified promptly by the Contractor of any defects in the other
Contractor’s works that could affect the Contractor’s Works. The Employer shall
determine the corrective measures if any, required to rectify this situation after
inspection of the works and such decisions by the Employer shall be binding on the
Contractor.
21.00.00 DISCIPLINE OF WORKMEN
The Contractor shall adhere to the disciplinary procedure set by the Employer in
respect of his employees and workmen at Site. The Employer shall be at liberty to
object to the presence of any representative or employee of the Contractor at the
Site, if in the opinion of the Employer such employee has mis-conducted himself or is
incompetent, negligent or otherwise undesirable then the Contractor shall remove
such a person objected to and provide in his place a competent replacement.
22.00.00 CONTRACTOR’S FIELD OPERATION
22.01.00 The Contractor shall keep the Employer informed in advance regarding his field
activity plans and schedules for carrying out each part of the works. Any review of
such plan or schedule or method of work by the Employer shall not relieve the
Contractor of any of his responsibilities towards the field activities. Such reviews
shall also not be considered as an assumption of any risk or liability by the Employer
or any of his representatives and no claim of the Contractor will be entertained
because of the failure or inefficiency of any such plan or schedule or method of work
reviewed. The Contractor shall be solely responsible for the safety, adequacy and
efficiency of plant and equipment and his erection methods.
22.02.00 The Contractor shall have the complete responsibility for the conditions of the Work-
Site including the safety of all persons employed by him or his Sub-Contractor and all
the properties under his custody during the performance of the work. This
requirement shall apply continuously till the completion of the Contract and shall not
be limited to normal working hours. The construction review by the Employer is not
intended to include review of Contractor’s safety measures in, on or near the Work-
Site, and their adequacy or otherwise.
23.00.00 PHOTOGRAPHS AND PROGRESS REPORT
23.01.00 The Contractor shall furnish three (3) prints each to the Employer of progress
photographs of the work done at Site. Photographs shall be taken as and when indi-
cated by the Employer or his representative. Photographs shall be adequate in size

STAGE-II (2X195 MW)
and number to indicate various stages of erection. Each photograph shall contain
the date, the name of the Contractor and the title of the photograph.
23.02.00 The above photographs shall accompany the monthly progress report detailing out
the progress achieved on all erection activities as compared to the schedules. The
report shall also indicate the reasons for the variance between the scheduled and
actual progress and the action proposed for corrective measures, wherever
necessary.
23.03.00 The Contractor shall submit the progress of work in video cassettes (2 copies)
quarterly highlighting the progress and constraints at site.
24.00.00 MAN-POWER REPORT
24.01.00 The Contractor shall submit to the Employer, on the first day of every month, a man
hour schedule for the month, detailing the man hours scheduled for the month, skill-
wise and area-wise.
24.02.00 The Contractor shall also submit to the Employer on the first day of every month, a
man power report of the previous month detailing the number of persons scheduled
to have been employed and actually employed, skill- wise and the areas of
employment of such labour.
25.00.00 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it is finally
taken over by the Employer. No claim will be entertained by the Employer or the
representative of the Employer for any damage or loss to the Contractor’s works and
the Contractor shall be responsible for complete restoration of the damaged works to
original conditions to comply with the specification and drawings. Should any such
damage to the Contractor’s Works occur because of other party not being under his
supervision or control, the Contractor shall make his claim directly with the party
concerned. If disagreement or conflict or dispute develops between the Contractor
and the other party or parties concerned regarding the responsibility for damage to
the Contractor’s Works the same shall be resolved as per the provisions of the as
specified at clause no 20.00.00- of this chapter entitled “Co-operation with other
Contractors.” The Contractor shall not cause any delay in the repair of such
damaged Works because of any delay in the resolution of such disputes. The
Contractor shall proceed to repair the Work immediately and no cause thereof will be
assigned pending resolution of such disputes.
26.00.00 EMPLOYMENT OF LABOUR
26.01.00 In addition to all local laws and regulations pertaining to the employment of labour to
be complied with by the Contractor pursuant to GCC, the Contractor will be expected
to employ on the work only his regular skilled employees with experience of the
particular work. No female labour shall be employed after darkness. No person below
the age of eighteen years shall be employed.

STAGE-II (2X195 MW)
26.02.00 All travelling expenses including provisions of all necessary transport to and from
Site, lodging allowances and other payments to the Contractor’s employees shall be
the sole responsibility of the Contractor.
26.03.00 The hours of work on the Site shall be decided by the Employer and the Contractor
shall adhere to it. Working hours will normally be eight (8) hours per day - Monday
through Saturday.
26.04.00 Contractor’s employees shall wear identification badges while on work at Site.
26.05.00 In case the Employer becomes liable to pay any wages or dues to the labour or any
Government agency under any of the provisions of the Minimum Wages Act,
Workmen Compensation Act, Contact Labour Regulation Abolition Act or any other
law due to act of omission of the Contractor, the Employer may make such payments
and shall recover the same from the Contractor’s Bills.
27.00.00 FACILITIES TO BE PROVIDED BY THE EMPLOYER
27.01.00 Space
The Contractor shall advise the Employer within thirty (30) days from the date of
acceptance of the Notification of Award about his exact requirement of space for his
office, storage area, pre-assembly and fabrication areas, labour and staff colony
area, toilets, etc. The above requirement shall be reviewed by the Employer and
space as decided by Employer will be allotted to the Contractor for construction of
his temporary structures/ facilities like office, storage sheds, pre-assembly and
fabrication areas, toilets, etc. for Contractor's as well as his Sub-Contractor’s use.
Land for staff and labour colony shall not be provided by the owner and bidder has to
make his own arrangement for the same at his own cost.
27.02.00 Electricity
The Contractor shall submit to the Employer within thirty (30) days from the date of
acceptance of the Notification of Award, his electrical power requirements, if any, to
allow the planning of the same by the Employer. The Contractor shall be provided
with free supply of electricity for the purposes of the Contract, only at two locations in
the Employer's Site and at 415V voltage level. The Contractor shall make his own
further distribution arrangement. All temporary wiring must comply with local
regulations and will be subject to Employer's inspection and approval before
connection to supply. The free supply of power will not be provided for the use in the
labour and staff colony. Power supply for labour and staff colony shall be provided at
one point and the Contractor shall be charged at rates prevalent at the site.
27.03.00 Water
Contractor shall make all arrangements himself for the supply of construction water
as well as potable water for labour and other personnel at the worksite/colony.

STAGE-II (2X195 MW)
27.04.00 Communication
The Employer will extend the telephone facilities, if available at Site, for purposes of
Contract. The Contractor shall be charged at actuals for such facilities.
28.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
28.01.00 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an authorized
representative for the purpose of the contract, pursuant to GCC.
28.02.00 Tools, tackles and scaffoldings
The Contractor shall provide all the construction equipments, tools, tackles and
scaffoldings required for pre-assembly, installation, testing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He shall
submit a list of all such materials to the Employer before the commencement of pre-
assembly at Site. These tools and tackles shall not be removed from the Site without
the written permission of the Employer. The Contractor shall arrange Dozer, Hydra,
Cranes, Trailer, etc. for the purpose of fabrication, erection and commissioning.
28.03.00 Testing Equipment and Facilities:
The contractor shall provide the necessary testing, equipment and facilities.
28.04.00 Site laboratory for civil works:
Contractor shall provide and maintain a site laboratory for the testing of construction
material under the direction and general supervision of employer.
28.05.00 First-aid
28.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. Enough number of Contractor’s
personnel shall be trained in administering first-aid.
28.05.02 The Employer will provide the Contractor, in case of any emergency, the services of
an ambulance for transportation to the nearest hospital.
28.06.00 Cleanliness
28.06.01 The Contractor shall be responsible for keeping the entire area allotted to him clean
and free from rubbish, debris etc. during the period of Contract. The Contractor shall
employ enough number of special personnel to thoroughly clean his work-area at
least once in a day. All such rubbish and scrap material shall be stacked or disposed
in a place to be identified by the Employer. Materials and stores shall be so arranged
to permit easy cleaning of the area. In areas where equipment might drip oil and
cause damage to the floor surface, a suitable protective cover of a flame resistant, oil
proof sheet shall be provided to protect the floor from such damage.
28.06.02 Similarly the labour colony, the offices and the residential areas of the Contractor’s
employees and workmen shall be kept clean and neat to the entire satisfaction of the

STAGE-II (2X195 MW)
Employer. Proper sanitary arrangements shall be provided by the Contractor, in the

work-areas, office and residential areas of the Contractor.
29.00.00 LINES AND GRADES
All the Works shall be performed to the lines, grades and elevations indicated on the
drawings. The Contractor shall be responsible to locate and layout the Works.
Basic horizontal and vertical control points will be established and marked by the
Employer at Site at suitable points. These points shall be used as datum for the
works under the Contract. The Contractor shall inform the Employer well in advance
of the times and places at which he wishes to do work in the area allotted to him so
that suitable datum points may be established and checked by the Employer to
enable the Contractor to proceed with his works. Any work done without being
properly located may be removed and/or dismantled by the Employer at Contractor’s
expense.
30.00.00 FIRE PROTECTION
30.01.00 The work procedures that are to be used during the erection shall be those which
minimise fire hazards to the extent practicable. Combustible materials, combustible
waste and rubbish shall be collected and removed from the Site at least once each
day. Fuels, oils and volatile or flammable materials shall be stored away from the
construction and equipment and materials storage areas in safe containers.
Untreated canvas, paper, plastic or other flammable flexible materials shall not at all
be used at Site for any other purpose unless otherwise specified. If any such
materials are received with the equipment at the Site, the same shall be removed
and replaced with acceptable material before moving into the construction or storage
area.
30.02.00 Similarly corrugated paper fabricated cartons etc. will not be permitted in the
construction area either for storage or for handling of materials. All such materials
used shall be of water proof and flame resistant type. All the other materials such as
working drawings, plans etc. which are combustible but are essential for the works to
be executed shall be protected against combustion resulting from welding sparks,
cutting flames and other similar fire sources.
30.03.00 All the Contractor’s supervisory personnel and sufficient number of workers shall be
trained for fire-fighting and shall be assigned specific fire protection duties. Enough of
such trained personnel must be available at the Site during the entire period of the
Contract.
30.04.00 The Contractor shall provide enough fire protection equipment of the types and
number for the warehouses, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all time.
31.00.00 SECURITY
The Contractor shall have total responsibility for all equipment and materials in his
custody stores, loose, semi-assembled and/or erected by him at Site. The Contractor
shall make suitable security arrangements including employment of security
personnel to ensure the protection of all materials, equipment and works from theft,

STAGE-II (2X195 MW)
fire, pilferage and any other damages and loss. All materials of the Contractor shall
enter and leave the Employer Site only with the written permission of the Employer in
the prescribed manner.
32.00.00 CONTRACTOR’S AREA LIMITS
The Employer will mark-out the boundary limits of access roads, parking spaces,
storage and construction areas for the Contractor and the Contractor shall not
trespass the areas not so marked out for him. The Contractor shall be responsible to
ensure that none of his personnel move out of the areas marked out for his
operations. In case of such a need for the Contactor’s personnel to work out of the
areas marked out for him the same shall be done only with the written permission of
the Employer.
33.00.00 CONTRACTOR’S CO-OPERATION WITH THE EMPLOYER
In case where the performance of the erection work by the Contractor affects the
operation of the system facilities of the Employer, such erection work of the
Contractor shall be scheduled to be performed only in the manner stipulated by the
Employer and the same shall be acceptable at all times to the Contractor. The
Employer may impose such restrictions on the facilities provided to the Contractor
such as electricity, etc. as he may think fit in the interest of the Employer and the
Contractor shall strictly adhere to such restrictions and co-operate with the Employer.
It will be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and operation
of the equipment systems which are erected by him. The Contractor shall also be
responsible for flushing and initial filling of all the oil and lubricants required for the
equipment furnished and installed by him, so as to make such equipment ready for
operation. The Contractor shall be responsible for supplying such flushing oil and
other lubricants unless otherwise specified elsewhere in documents and
specifications.
34.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES
34.01.00 GENERAL
34.01.01 The Contractor upon completion of installation of equipments and systems shall
conduct pre-commissioning and commissioning activities, to make the
equipment/systems ready for safe, reliable and efficient operation on sustained basis.
All pre-commissioning/commissioning activities considered essential for such
readiness of the equipment/systems including those mutually agreed and included in
the Contractor’s quality assurance programme as well as those indicated in clauses
elsewhere in the technical specifications shall be performed by the contractor.
34.01.02 The pre-commissioning and commissioning activities including Guarantee tests,

checks and trial operations of the equipment/systems furnished and installed by the
contractor shall be the responsibility of the Contractor as detailed in relevant clauses
in Technical Specification. The Contractor shall provide, in addition, test instruments,
calibrating devices etc. and labour required for successful performance of these
operations. If it is anticipated that the above test may prolong for a long time, the

STAGE-II (2X195 MW)
Contractor’s workmen required for the above test shall always be present at site
during such operations.
34.01.03 The following activities shall be carried out by the contractor, 18 month prior to
schedule date of commissioning of the equipment/systems installed by him.
(a.) The contractor shall furnish the organization chart of his operation and
commissioning engineers for the acceptance of employer. Adequate number of
operation and commissioning engineers shall be deployed by the contractor to
effectively meet the requirement of round the clock operation in shifts also, till
the plant is taken over by the employer.
(b.) The contractor shall submit the bio-data containing the details of experience of
his operation and commissioning engineers for the acceptance of employer.
(c.) The contractor shall furnish the deployment schedule of his operation and
commissioning engineers for the acceptance of the employer.
(1.) Apart from above, contractor shall ensure deployment of sufficient

skilled/semi-skilled/unskilled manpower during pre-commissioning and
commissioning activities.
34.01.04 It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial
operation of the equipment/systems which are installed by him.
34.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils and
lubricants required for the equipment furnished and installed by him so as to make
such equipment ready for operation. The Contractor shall be responsible for
supplying such flushing oil and other lubricants unless otherwise specified elsewhere
in these specifications and documents.
34.02.00 COMMISSIONING DOCUMENTATION
34.02.01 The contractor shall submit the commissioning documentation, comprising of

Standard checklists, pre-commissioning procedures, testing schedules,
commissioning schedules and commissioning networks for various
equipment/systems covered under the contract, for the approval of employer.
34.02.02 Standard checklist, as the name suggests, shall be a fairly general documents,
containing the list of all checks required to be carried out for similar and repetitive
type of equipment to ensure consistent and thorough checking. An indicative list of
such equipment is enclosed as Annexure I.
34.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system Commissioning schedule is a
document envisaged for commissioning of a system The testing/Commissioning
schedule shall have a standard format in order to maintain consistency of
presentation, content and reporting. A brief write up on the contents of the Testing
Schedule/Commissioning Schedule is enclosed as Annexure-II.

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34.02.04 The contractor shall submit the list of commissioning documentation to be submitted
by him, alongwith their submission schedule for various equipment/systems covered
under the contract, with in 6(six) month from the date of award of contract, for the
acceptance of employer.
34.02.05 The Contractor shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of employer, at least 18
months before the scheduled date of commissioning of the equipment/systems.
34.03.00 COMMISSIONING ACTIVITIES
34.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall initiate

commissioning of facilities. During commissioning the Contractor shall carry out
system checking and reliability trials on various parts of the facilities.
34.03.02 Contractor shall carry out the checks/tests at site to prove to the Employer that each
equipment of the supply complies with requirements stipulated and is installed in
accordance with requirements specified.
34.03.03 Before the plant is put into initial operation the Contractor shall be required to
conduct test to demonstrate to the Employer that each item of the plant is capable of
correctly performing the functions for which it was specified and its performance,
parameters etc. are as per the specified/approved values. These tests may be
conducted concurrently with those required under commissioning sequence.
34.03.04 Other tests shall be conducted, if required by the Employer, to establish that the plant
equipment are in accordance with requirements of the specifications.
34.03.05 The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including
all electrical equipment/systems not specifically brought out above but are within the
scope of work and facilities being supplied and installed by the Contractor and follow
the guidelines indicated above or elsewhere in these technical specifications
(Section-VI)
34.04.00 Initial Operation
Upon completion of system checking/Tests as above and as a part of commissioning

of facilities, complete plant/facilities shall be put on initial operation as stipulated in
General Technical Requirements.
35.00.00 MATERIALS HANDLING AND STORAGE
35.01.00 All the equipments furnished under the Contract and arriving at Site shall be promptly
received, unloaded and transported and stored in the storage spaces by the
Contractor.
35.02.00 Contractor shall be responsible for examining all the shipment and notify the
Employer immediately of any damage, shortage, discrepancy etc. for the purpose of
Employer's information only. The Contractor shall submit to the Employer every
week a report detailing all the receipts during the week. However, the Contractor

STAGE-II (2X195 MW)
shall be solely responsible for any shortages or damage in transit, handling and / or
in storage and erection of the equipment at Site. Any demurrage, wharfage and other
such charges claimed by the transporters, railways etc. shall be to the account of the
Contractor.
35.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the list
of all equipment received by him for the purpose of erection and keep such record
open for the inspection of the Employer.
35.04.00 All equipment shall be handled very carefully to prevent any damage or loss. No bare
wire ropes, slings, etc. shall be used for unloading and/or handling of the equipment
without the specific written permission of the Employer. The equipment stored shall
be properly protected to prevent damage either to the equipment or to the floor where
they are stored. The equipment from the store shall be moved to the actual location
at the appropriate time so as to avoid damage of such equipment at Site.
35.05.00 All electrical panels, controls gear, motors and such other devices shall be properly
dried by heating before they are installed and energised. Motor bearings, slip rings,
commutators and other exposed parts shall be protected against moisture ingress
and corrosion during storage and periodically inspected. Heavy rotating parts in
assembled conditions shall be periodically rotated to prevent corrosion due to
prolonged storage.
35.06.00 All the electrical equipment such as motors, etc. shall be tested for insulation
resistance at least once in three months from the date of receipt till the date of
commissioning and a record of such measured insulation values maintained by the
Contractor. Such records shall be open for inspection by the Employer.
35.07.00 The Contractor shall ensure that all the packing materials and protection devices
used for the various equipments during transit and storage are removed before the
equipment are installed.
35.08.00 The consumables and other supplies likely to deteriorate due to storage must be
thoroughly protected and stored in a suitable manner to prevent damage or dete-
rioration in quality by storage.
35.09.00 All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flameproof covering material wherever applicable.
35.10.00 If the materials belonging to the Contractor are stored in areas other than those
earmarked for him, the Employer will have the right to get it moved to the area
earmarked for the Contractor at the Contractor’s cost.
35.11.00 The Contractor shall be responsible for making suitable indoor storage facilities to
store all equipment which require indoor storage. Normally, all the electrical
equipments such as motors, control gear, exciters and consumables like electrodes,
lubricants etc. shall be stored in the closed storage space. The Employer, in addition,
may direct the Contractor to move certain other materials, which in his opinion will
require indoor storage, to indoor storage areas which the Contractor shall strictly
comply with.

STAGE-II (2X195 MW)
36.00.00 CONSTRUCTION MANAGEMENT
36.01.00 The field activities of the Contractors working at Site, will be coordinated by the
Employer and the Employer decision shall be final in resolving any disputes or
conflicts between the Contractor and other Contractors and tradesmen of the
Employer regarding scheduling and coordination of work. Such decision by the
Employer shall not be a cause for extra compensation or extension of time for the
Contractor.
36.02.00 The Employer shall hold weekly meetings of all the Contractors working at Site, at a
time and place to be designated by the Employer. The Contractor shall attend such
meetings and take notes of discussions during the meeting and the decisions of the
Employer and shall strictly adhere to those decisions in performing his Works. In
addition to the above weekly meeting, the Employer may call for other meeting either
with individual Contractors or with selected number of Contractors and in such a case
the Contractor if called, will also attend such meetings.
36.03.00 Time is the essence of the Contract and the Contractor shall be responsible for
performance of his works in accordance with the specified construction schedule. If
at any time, the Contractor is falling behind the schedule, he shall take necessary
action to make good for such delays by increasing his work force or by working
overtime or otherwise accelerate the progress of the work to comply with the
schedule and shall communicate such actions in writing to the Employer, satisfying
that his action will compensate for the delay. The Contractor shall not be allowed any
extra compensation for such action.
36.04.00 The Employer shall however not be responsible for provision of additional labour
and/or materials or supply or any other services to the Contractor except for the co-
ordination work between various Contractors as set out earlier.
37.00.00 FIELD OFFICE RECORDS
The Contractor shall maintain at his Site Office up-to- date copies of all drawings,
specifications and other Contract Documents and any other supplementary data
complete with all the latest revisions thereto. The Contractor shall also maintain in
addition the continuous record of all changes to the above Contract Documents,
drawings, specifications, supplementary data, etc. effected at the field and on
completion of his total assignment under the Contract shall incorporate all such
changes on the drawings and other Engineering data to indicate as installed
conditions of the equipment furnished and erected under the Contract. Such
drawings and Engineering data shall be submitted to the Employer in required
number of copies.
38.00.00 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE
38.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,
including construction equipment, tools and tackles for the purpose of the Works
under intimation to the Employer. All such goods shall, from the time of their being
brought vest in the Employer, but may be used for the purpose of the Works only and
shall not on any account be removed or taken away by the Contractor without the

STAGE-II (2X195 MW)
written permission of the Employer. The Contractor shall nevertheless be solely

liable and responsible for any loss or destruction thereof and damage thereto.
38.02.00 The Employer shall have a lien on such goods for any sum or sums which may at
any time be due or owing to him by the Contractor, under, in respect of or by reasons
of the Contract. After giving a fifteen (15) days notice in writing of his intention to do
so, the Employer shall be at liberty to sell and dispose off any such goods, in such
manner as he shall think fit including public auction or private treaty and to apply the
proceeds in or towards the satisfaction of such sum or sums due as aforesaid.
38.03.00 After the completion of the Works, the Contractor shall remove from the Site under
the direction of the Employer the materials such as construction equipment, erection
tools and tackles, scaffolding etc. with the written permission of the Employer. If the
Contractor fails to remove such materials, within fifteen (15) days of issue of a notice
by the Employer to do so then the Employer shall have the liberty to dispose off such
materials as detailed under as specified at clause no 38.02.00- of this chapter and
credit the proceeds thereto to the account of the Contractor.
39.00.00 PROTECTION OF PROPERTY AND CONTRACTOR’S LIABILITY
39.01.00 The Contractor shall be responsible for any damage resulting from his operations. He
shall also be responsible for protection of all persons including members of public
and employees of the Employer and the employees of other Contractors and Sub-
Contractors and all public and private property including structures, building, other
plants and equipments and utilities either above or below the ground.
39.02.00 The Contractor will ensure provision of necessary safety equipment such as barriers,
sign - boards, warning lights and alarms, etc. to provide adequate protection to
persons and property. The Contractor shall be responsible to give reasonable notice
to the Employer and the Employers of public or private property and utilities when
such property and utilities are likely to get damaged or injured during the
performance of his Works and shall make all necessary arrangements with such
Employers, related to removal and/or replacement or protection of such property and
utilities.
40.00.00 PAINTING
All exposed metal parts of the equipment including pipings, structure railings, etc.
wherever applicable, after installation unless otherwise surface protected, shall be
first painted with at least two coats of suitable primer which matches the shop primer
paint used, after thoroughly cleaning all such parts of all dirt, rust, scales, greases,
oils and other foreign materials by wire brushing, scraping or sand blasting and the
same being inspected and approved by the Employer for painting. Afterwards, the
above parts shall be finished painted with three coats of allowed resin machinery
enamel paints. The minimum thickness of paint film shall not be less than 100
microns. The quality of the finish paint shall be as per the standards of Bureau of
Indian Standards (BIS) or equivalent and to be of the colour as approved by the
Employer.

STAGE-II (2X195 MW)
41.00.00 INSURANCE
41.01.00 In addition to the conditions covered under the Clause entitled “Insurance” in Section
General Conditions of Contract (GCC), the following provisions will also apply to the
portion of works to be done beyond the Contractor’s own or his Sub-Contractor’s
manufacturing Works.
41.02.00 Workmen’s Compensation Insurance
This insurance shall protect the Contractor against all claims applicable under the
Workmen’s Compensation Act, 1948 (Government of India). This policy shall also
cover the Contractor against claims for injury, disability disease or death of his or his
Sub-Contractor’s employees, which for any reason are not covered under the
Workmen’s Compensation Act, 1948. The liabilities shall not be less than the
following:
Workmen's Compensation - As per Statutory Provisions
Employee's Liability - As per Statutory Provisions
41.03.00 Comprehensive Automobile Insurance
This insurance shall be in such a form to protect the Contractor against all claims for
injuries, disability, disease and death to members of public including the Employer’s
men and damage to the property of other arising from the use of motor vehicles
during on or off the Site operations, irrespective of the Ownership of such vehicles.
The liability covered shall be as herein indicated :
Fatal Injury : Rs.100,000 each person
: Rs.200,000 each occurrence
Property Damage : Rs.100,000 each occurrence
41.04.00 Comprehensive General Liability Insurance
41.04.01 The insurance shall protect the Contractor against all claims arising from injuries,
disabilities, disease or death of members of public or damage to property of others,
due to any act or omission on the part of the Contractor, his agents, his employees,
his representatives and Sub-Contractors or from riots, strikes and civil commotion.
This insurance shall also cover all the liabilities of the Contractor arising out of the
Clause entitled “Defence of Suits” in Section General Conditions of Contract (GCC).
41.04.02 The hazards to be covered will pertain to all the Works and areas where the
Contractor, his Sub-Contractors, his agents and his employees have to perform work
pursuant to the Contract.
41.05.00 The above are only illustrative list of insurance covers normally required and it will be
the responsibility of the Contractor to maintain all necessary insurance coverage to
the extent both in time and amount to take care of all his liabilities either direct or
indirect, in pursuance of the Contract.

STAGE-II (2X195 MW)
42.00.00 UNFAVOURABLE WORKING CONDITIONS
The Contractor shall confine all his field operations to those works which can be
performed without subjecting the equipment and materials to adverse effects during
inclement weather conditions, like monsoon, storms, etc. and during other
unfavourable construction conditions. No field activities shall be performed by the
Contractor under conditions which might adversely affect the quality and efficiency
thereof, unless special precautions or measures are taken by the Contractor in a
proper and satisfactory manner in the performance of such Works and with the
concurrence of the Employer. Such unfavourable construction conditions will in no
way relieve the Contractor of his responsibility to perform the Works as per the
schedule.
43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS
The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc.
which he may come across during the course of performance of his Works either
during excavation or elsewhere, are properly protected and handed over to the
Employer. Similarly the Contractor shall ensure that the bench marks, reference
points, etc., which are marked either with the help of Employer or by the Employer
shall not be disturbed in any way during the performance of his Works. If, any work is
to be preformed which disturb such reference, the same shall be done only after
these are transferred to other suitable locations under the direction of the Employer.
The Contractor shall provide all necessary materials and assistance for such
relocation of reference points etc.
44.00.00 WORK & SAFETY REGULATIONS
44.01.00 The Contractor shall ensure proper safety of all the workmen, materials, plant and
equipments belonging to him or to Employer or to others, working at the Site. The
Contractor shall also be responsible for provision of all safety notices and safety
equipment required both by the relevant legislation and the Employer as he may
deem necessary.
44.02.00 The Contractor will notify well in advance to the Employer of his intention to bring to
the Site any container filled with liquid or gaseous fuel or explosive or petroleum
substance or such chemicals which may involve hazards. The Employer shall have
the right to prescribe the conditions, under which such container is to be stored,
handled and used during the performance of the works and the Contractor shall
strictly adhere to and comply with such instructions. The Employer shall have the
right at his sole discretion to inspect any such container or such construction
plant/equipment for which material in the container is required to be used and if in his
opinion, its use is not safe, he may forbid its use. No claim due to such prohibition
shall be entertained by the Employer and the Employer shall not entertain any claim
of the Contractor towards additional safety provisions/conditions to be provided
for/constructed as per the Employer's instructions.
Further, any such decision of the Employer shall not, in any way, absolve the
Contractor of his responsibilities and in case, use of such a container or entry thereof
into the Site area is forbidden by the Employer, the Contractor shall use alternative

STAGE-II (2X195 MW)
methods with the approval of the Employer without any cost implication to the
Employer or extension of work schedule.
44.03.00 Where it is necessary to provide and/or store petroleum products or petroleum

mixtures and explosives, the Contractor shall be responsible for carrying-out such
provision and/or storage in accordance with the rules and regulations laid down in
Petroleum Act 1934, Explosives Act, 1948, and Petroleum and Carbide of Calcium
Manual published by the Chief Inspector of Explosives of India. All such storage shall
have prior approval of the Employer. In case, any approvals are necessary from the
Chief Inspector (Explosives) or any statutory authorities, the Contractor shall be
responsible for obtaining the same.
44.04.00 All equipment used in construction and erection by Contractor shall meet
Indian/International Standards and where such standards do not exist, the Contractor
shall ensure these to be absolutely safe. All equipments shall be strictly operated and
maintained by the Contractor in accordance with manufacturer’s operation Manual
and safety instructions and as per Guidelines/Rules of Employer in this regard.
44.05.00 Periodical Examinations and all tests for all lifting/ hoisting equipment & tackles shall
be carried-out in accordance with the relevant provisions of Factories Act 1948,
Indian Electricity Act 1910 and associated Laws/Rules in force from time to time. A
register of such examinations and tests shall be properly maintained by the
Contractor and will be promptly produced as and when desired by Employer or by the
person authorised by him.
44.06.00 The Contractor shall be fully responsible for the safe storage of his and his Sub-
Contractor’s radioactive sources in accordance with BARC/DAE (Bhabha Atomic
Research Centre/ Department of Atomic Energy, Govt. of India) Rules and other
applicable provisions. All precautionary measures stipulated by BARC/DAE in
connection with use, storage and handling of such material will be taken by
Contractor.
44.07.00 The Contractor shall provide suitable safety equipment of prescribed standard to all
employees and workmen according to the need, as may be directed by Employer
who will also have right to examine these safety equipments to determine their
suitability, reliability, acceptability and adaptability.
44.08.00 Where explosives are to be used, the same shall be used under the direct control
and supervision of an expert, experienced, qualified and competent person strictly in
accordance with the Code of Practices/Rules framed under Indian Explosives Act
pertaining to handling, storage and use of explosives.
44.09.00 The Contractor shall provide safe working conditions to all workmen and employees
at the Site including safe means of access, railings, stairs, ladders, scaffoldings etc.
The scaffoldings shall be erected under the control and supervision of an
experienced and competent person. For erection, good and standard quality of
material only shall be used by the Contractor.
44.10.00 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to the Employer or other Contractors under any circumstances,

STAGE-II (2X195 MW)
whatsoever, unless expressly permitted in writing by the Employer to handle such

fuses, wiring or electrical equipment.
44.11.00 Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other Contactor or Employer, he shall:
(a.) Satisfy the Employer that the appliance is in good working condition:
(b.) Inform the Employer of the maximum current rating, voltage and phases of the
appliances;
(c.) Obtain permission of the Employer detailing the sockets to which the
appliances may be connected.
44.12.00 The Employer will not grant permission to connect until he is satisfied that;
(a.) The appliance is in good condition and is fitted with suitable plug;
(b.) The appliance is fitted with a suitable cable having two earth conductors, one of
which shall be an earthed metal sheath surrounding the cores.
44.13.00 No electric cable in use by the Contractor/Employer will be disturbed without prior
permission. No weight of any description will be imposed on any cable and no ladder
or similar equipment will rest against or attached to it.
44.14.00 No repair work shall be carried out on any live equipment. The equipment must be
declared safe by the Employer and a permit to work shall be issued by the Employer
before any repair work is carried out by the Contractor. While working on electric
lines/equipments whether live or dead, suitable type and sufficient quantity of tools
will have to be provided by Contractor to electricians/workmen/officers.
44.15.00 The Contractors shall employ necessary number of qualified, full time Electricians/
Electrical Supervisors to maintain his temporary electrical installations.
44.16.00 The Contractor employing more than 250 workmen whether temporary, casual,
probationer, regular or permanent or on contract, shall employ atleast one full time
officer exclusively as Safety Officer to supervise safety aspects of the equipments
and workmen, who will coordinate with the Employer Safety Officer. In case of work
being carried out through sub-Contractors, the Sub- Contractor’s
workmen/employees will also be considered as the Contractor’s employees/workmen
for the above purpose.
The name and address of such Safety Officer of Contractor will be promptly informed
in writing to Employer with a copy to Safety Officer-Incharge before he starts work or
immediately after any change of the incumbent is made during currency of the
Contract.
44.17.00 In case any accident occurs during the construction/ erection or other associated
activities undertaken by the Contractor thereby causing any minor or major or fatal
injury to his employees due to any reason, whatsoever, it shall be the responsibility of

STAGE-II (2X195 MW)
the Contractor to promptly inform the same to the Employer in prescribed form and
also to all the authorities envisaged under the applicable laws.
44.18.00 The Employer shall have the right at his sole discretion to stop the work, if in his
opinion the work is being carried out in such a way that it may cause accidents and
endanger the safety of the persons and/or property, and/or equipments. In such
cases, the Contractor shall be informed in writing about the nature of hazards and
possible injury/accident and he shall comply to remove shortcomings promptly. The
Contractor after stopping the specific work can, if felt necessary appeal against the
order of stoppage of work to the Employer within 3 days of such stoppage of work
and decision of the Employer in this respect shall be conclusive and binding on the
Contractor.
44.19.00 The Contractor shall not be entitled for any damages/ compensation for stoppage of
work due to safety reasons as provided in para 44.18.00 and the period of such
stoppage of work will not be taken as an extension of time for completion of the
facilities and will not be the ground for waiver of levy of liquidated damages.
44.20.00 The Contractor shall follow and comply with all Safety Rules of the Employer,
relevant provisions of applicable laws pertaining to the safety of workmen, employees
plant and equipment as may be prescribed from time to time without any demur,
protest or contest or reservation. In case of any inconformity between statutory
requirement and Safety Rules of the Employer referred above, the later shall be
binding on the Contractor unless the statutory provisions are more stringent.
44.21.00 If the Contractor fails in providing safe working environment as per the Employer's
Safety Rules or continues the work even after being instructed to stop work by the
Employer Manager as provided 44.18.00, the Contractor shall promptly pay to the
Employer, on demand by the Employer compensation at the rate of Rs. 5,000/- per
day or part thereof till the instructions are complied with and so certified by the
Employer. However, in case of accident taking place causing injury, to any individual,
the provisions contained in paragraph 44.22.00 shall also apply in addition to
compensation mentioned in this paragraph.
44.22.00 If the Contractor does not take all safety precautions and/or fails to comply with the
Safety Rules as prescribed by the Employer or under the applicable law for the safety
of the equipment and plant and for the safety of personnel and the Contractor does
not prevent hazardous conditions which cause injury to his own employees or
employees of other Contractors, or the Employer's employees or any other person
who are at Site or adjacent thereto, the Contractor shall be responsible for payment
of compensation to Employer as per the following schedule:-
1 Fatal injury or accident These Rs. 1,00,000/- These are

are causing death applicable applicable for
death/ injury to any
2 Major injuries or accident Rs. 20,000/- person
causing 25% or more whomsoever.
permanent disablement to
workmen or employee

STAGE-II (2X195 MW)
Permanent disablement shall have same meaning as indicated in Workmen’s

Compensation Act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the relevant provisions of
the Workmen’s Compensation Act and rules framed thereunder or any other
applicable laws as applicable from time to time. In case the Employer is made to pay
such Compensation then the Contractor is liable to reimburse the Employer such
amount in addition to the compensation indicated above.
44.23.00 If the Contractor observes all the Safety Rules and Codes, Statutory Laws and Rules
during the currency of Contract awarded by the Employer and no accident occurs
then the Employer may consider the performance of the Contractor and award
suitable “ACCIDENT FREE SAFETY MERITORIOUS AWARD” as per scheme as
may be announced separately from time to time.
45.00.00 FOREIGN PERSONNEL
45.01.00 The Contractor shall submit to the Employer data on all personnel he proposes to
bring into India from abroad for the performance of the Works under the Contract, at
least sixty (60) days prior to their departure to India. Such data will include for each
person the name, his present address, his assignment and responsibility in
connection with the works, and a short resume of his qualification, experience etc. in
relation to the work to be performed by him.
45.02.00 Any person unsuitable and unacceptable to the Employer shall not be brought to
India. Any person brought to India, if found unsuitable or unacceptable by the
Employer, the Contractor shall within a reasonable time make alternate
arrangements for providing a suitable replacement and repatriation of such
unsuitable personnel.
45.03.00 No person brought to India for the purposes of the works shall be repatriated without
the consent of the Employer in writing, based on a written request from the
Contractor for such repatriation giving reasons for such an action to the Employer.
The Employer may give permission for such repatriation provided he is satisfied that
the progress of work will not suffer due to such repatriation.
45.04.00 The cost of passports, visas and all other travel expenses to and from India, incurred
by the Contractor shall be to his account. The Employer will not provide any
residential accommodation and/or furniture for any of the Contractor’s personnel
including foreign personnel and Contractor shall make his own arrangements for
such facilities in the area allotted at Site, to him by the Employer for that purpose.
45.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws, rules
and regulations and shall not in any way interfere with Indian political and religious
affairs and shall conform to any other rules and regulations which the Government of
India and the Employer may establish from time to time, on them. The Contractor’s
expatriate personnel shall work and live in close co-operation and coordination with
their co-workers and the community and shall not engage themselves in any other
employment neither part-time or full-time nor shall they take part in any local politics.

STAGE-II (2X195 MW)
45.06.00 The Employer shall assist the Contractor, to the extent possible, in obtaining
necessary permits to travel to India and back, by issue of necessary certificates and
other information needed by the Government agencies.
46.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES
46.01.00 The surfaces of foundations shall be dressed to bring the top surface of the
foundations to the required level, prior to placement of equipment/equipment bases
on the foundations.
46.02.00 All the equipment/ equipment bases, shall be grouted and finished as per these
specifications unless otherwise recommended by the equipment manufacturer.
46.03.00 The concrete foundation surfaces shall be properly prepared by chipping, grinding as
required to bring the top of such foundation to the required level, to provide the
necessary roughness for bondage and to assure enough bearing strength.
46.04.00 Grout
The grout shall be high strength grout with crushing strength one grade higher then
the foundation concrete. Minimum crushing strength shall be 30N/mm2 unless higher
strength requirements is specified by the equipment supplier or the grout
manufacturers . The grout shall be chloride - free, cement based, free flowing, non-
metallic grout.
The Grout shall have good flowability even at very low water/ grout powder ratio.
The Grout shall have characteristics of controlled expansion to be able to occupy its
original volume to fill the voids and to compensate for shrinkage. Grout shall be of
pre-mix variety so that only water needs to be added before use.
The mixing of the Grout shall conform to the recommendations of the manufacturer of
the Grout.
46.05.00 Placing of Grout
46.05.01 After the base has been prepared, its alignment and level has been checked and
approved and before actually placing the grout, a low dam shall be set around the
base at a distance that will permit pouring and manipulation of the grout. The height
of such dam shall be at least 25mm above the bottom of the base. Suitable size and
number of chains shall be introduced under the base before placing the grout, so that
such chains can be moved back & forth to push the grout into every part of the space
under the base.
46.05.02 The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides to make the grout move in a solid mass under the
base and out in the opposite side. Pouring shall be continued until the entire space
below the base is thoroughly filled and the grout stands at least 25 mm higher all
around than the bottom of the base. Enough care should be taken to avoid any air or
water pockets beneath the bases.

STAGE-II (2X195 MW)
46.05.03 In addition to the above, recommendations of Grout manufacturer shall also be

followed.
46.06.00 Finishing of the Edges of the Grout
The poured grout should be allowed to stand undisturbed until it is well set.
Immediately thereafter, the dam shall be removed and grout which extends beyond
the edges of the structural or equipment base plates shall be cut off, flushed and
removed. The edges of the grout shall then be pointed and finished with 1:2 cement
mortar pressed firmly to bond with the body of the grout and smoothened with a tool
to present a smooth vertical surface. The work shall be done in a clean and scientific
manner and the adjacent floor spaces, exposed edges of the foundations, and
structural steel and equipment base plates shall be thoroughly cleaned of any
spillage of the grout.
46.07.00 Checking of Equipment After Grouting
After the grout is set and cured, the Contractor shall check and verify the alignment
of equipments, alignment of shafts of rotating machinery, the slopes of all bearing
pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as
applicable and the like items to ensure that no displacement had taken place
during grouting. The values recorded prior to grouting shall be used during such post
grouting check- up and verifications. Such pre and post grout records of alignment
details shall be maintained by the Contractor in a manner acceptable to the
Employer.
47.00.00 SHAFT ALIGNMENTS
All the shafts of rotating equipment shall be properly aligned to those of the matching
equipments to as perfect an accuracy as practicable. The equipment shall be free
from excessive vibration so as to avoid overheating of bearings or other conditions
which may tend to shorten the life of the equipment. The vibration level of rotating
equipments measured at bearing housing shall not exceed forty (40) microns and
shall conform to VDI 2056.All bearings, shafts and other rotating parts shall be thor-
oughly cleaned and suitably lubricated before starting.
48.00.00 DOWELLING
All the motors and other equipment shall be suitably doweled after alignment of
shafts with tapered machined dowels as per the direction of the Employer.
49.00.00 CHECK OUT OF CONTROL SYSTEMS
After completion of wiring, cabling furnished under separate specification and laid
and terminated by the Employer, the Contractor shall check out the operation of all
control systems for the equipment furnished and installed under these specifications
and documents.

STAGE-II (2X195 MW)
50.00.00 COMMISSIONING SPARES
50.01.00 It will be the responsibility of the Contractor to provide all commissioning spares
including consumable spares required for initial operation till the Completion of
Facilities. The Contractor shall furnish a list of all commissioning spares within 60
days from the date of Notification of Award and such list shall be reviewed by the
Employer and mutually agreed to. However. such review and agreement will not
absolve the Contractor of his responsibilities to supply all commissioning spares so
that initial operation do not suffer for want of commissioning spares. All
commissioning spares shall be deemed to be included in the scope of the Contract at
no extra cost to the Employer.
50.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to
the schedule date of commencement of initial operation of the respective equipment
and utilised as and when required. The unutilised spares and replaced parts, if any,
at the end of successful completion of guarantee tests shall be the property of the
Contractor and he will be allowed to take these parts back at his own cost with the
permission of Employer.
51.00.00 CABLING
51.01.00 All cables shall be supported by conduits or cable tray run in air or in cable channels.
These shall be installed in exposed runs parallel or perpendicular to dominant
surfaces with right angle turn made of symmetrical bends or fittings. When cables
are run on cable trays, they shall be clamped at a minimum intervals of 2000mm or
otherwise as directed by the Employer.
51.02.00 Each cable, whether power or control, shall be provided with a metallic or plastic tag
of an approved type, bearing a cable reference number indicated in the cable and
conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at
both ends of the cable adjacent to the terminations. Cable routing is to be done in
such a way that cables are accessible for any maintenance and for easy
identification.
51.03.00 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC
insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the
cable. Installation of other cables like high voltage, coaxial, screened, compensating,
mineral insulated shall be in accordance with the cable manufacturer’s
recommendations. Wherever cables cross roads and water, oil, sewage or gaslines,
special care should be taken for the protection of the cables in designing the cable
channels.
51.04.00 In each cable run some extra length shall be kept at a suitable point to enable one or
two straight through joints to be made, should the cable develop fault at a later date.
51.05.00 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to the Employer’s approval. Multicore control cable jackets
shall be removed as required to train and terminate the conductors. The cable jacket
shall be left on the cable, as far as possible, to the point of the first conductor branch.
The insulated conductors from which the jacket is removed shall be neatly twined in
bundles and terminated. The bundles shall be firmly but not tightly tied utilising

STAGE-II (2X195 MW)
plastic or nylon ties or specifically treated fungus protected cord made for this
purpose. Control cable conductor insulation shall be securely and evenly cut.
51.06.00 The connectors for control cables shall be covered with a transparent insulating
sleeve so as to prevent accidental contact with ground or adjacent terminals and
shall preferably terminate in Elmex terminals and washers. The insulating sleeve
shall be fire resistant and shall be long enough to over pass the conductor insulation.
All control cables shall be fanned out and connection made to terminal blocks and
test equipment for proper operation before cables are corded together.
52.00.00 EQUIPMENT DELIVERY AND ERECTION
(a.) This part covers Contractor's responsibilities for packing, shipping, ware-
housing and the installation of all equipment and materials furnished and
installed under this specification.
(b.) The Contractor shall submit for Employer's approval draft manual for
Equipment Delivery and Erection (EDE Manual) covering detailed instructions,
write up, technical data, drawings, check-lists, documentation formats for all
activities after equipment manufacture upto installation of equipment. This
manual shall cover general instructions for all equipment and specific
instructions for individual equipment wherever required and shall include at
least the following :
(1.) Instructions for packing, shipping, receiving handling, ware-housing and

storage.
(2.) Instructions for location and installation of equipment furnished by this

specification.
(3.) Installation drawings for field mounted equipment, panels, cubicles and
other equipment covered under this specification.
(4.) Instruction relating installation of piping/ tubing, support and routing

drawings of impulse pipes/signal tubes and tube/cable trays.
(5.) Check lists and quality assurance hold points.
(6.) Format for all related documentation.
(c.) The EDE Manual shall conform to the requirements of this specification, all
applicable codes and standards, recommendations of equipment manufacturers
and accepted good engineering practices and shall be subject to Employer
approval during detailed engineering.
(d.) The Contractor shall ensure that all work under this part shall be performed as
per the requirements of this specification, Employer approved EDE Manual and
drawing/documents approved by the Employer during detailed engg.

STAGE-II (2X195 MW)
52.02.00 Crating
(a.) All equipment and materials shall be suitably coated, wrapped, or covered and
boxed or crated for moist humid tropical shipment and to prevent damage or
deterioration during handling and storage at the site.
(b.) Equipment shall be packed with suitable desiccants, sealed in water proof
vapour-proof wrapping and packed in lumber of plywood enclosures, suitably
braced, tied and skidded. Lumber enclosures shall be solid, not slatted.
(c.) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to
provide the required surface area and activated prior to placing in the
packaging. Calcium sulphate desiccants shall be of a chemical nature to absorb
moisture. In any case, the desiccant shall not be of a type that will absorb
enough moisture to go into solution. Desiccants shall be packed in porous
containers, strong enough to withstand handling encountered during normal
shipment. Enough desiccant shall be used for the volumes enclosed in
wrapping.
(d.) Review by the Employer of the Contractor's proposed packaging methods shall
not relieve the Contractor of responsibility for damage or deterioration to the
equipment and materials specified.
(e.) All accessory items shall be shipped with the equipment. ; Boxes and crates
containing accessory items shall be marked so that they are identified with the
main equipment. The contents of each box and crates shall be indicated by
markings on the exterior.
(f.) All boxes, crates, cases bundles, loose pieces, etc. shall be marked
consecutively from No.1 upward throughout all shipments from a given port to
completion of the order without repeating the same number.
(g.) An itemized list of contents shall be enclosed inside each case and one other
copy securely fastened to the outside of the case in a tin or light weight sheet
metal envelope or pocket. The lists shall be plainly marked and placed in
accessible locations to facilitate receipt and inspection. The packing list shall
indicate whether shipment is partial or complete and shall incorporate the
following information on each container, etc., according to its individual shipping
number :
1. Export case markings
2. Case number
3. Gross weight and net weight in Kilograms
4. Dimensions in centimeters
5. Complete description of material

STAGE-II (2X195 MW)
(h.) Packaging or shipping units shall be designed within the limitations of unloading
facilities and the equipment which will be used for transport. Complications
involved with ocean shipment and the limitations of ports, railways and roads
shall be considered. It shall be the Contractor's responsibility to investigate
these limitations and to provide suitable packaging to permit safe handling
during transit and at the job site.
(i.) Electrical equipment, control and instrumentation shall be protected against

moisture and water damage. All external gasket surfaces and flange faces,
couplings, motor pump shafts, bearing and like items shall be thoroughly
cleaned and coated with rust preventive compound as specified above and
protected with suitable wood, metal or other substantial type covering to ensure
their full protection.
(j.) Equipment having antifriction or sleeve bearings shall be protected by weather

tight enclosures.
(k.) Coated surfaces shall be protected against impact, abrasion, discolouration and
other damage. Surfaces which are damaged shall be repaired.
(l.) All exposed threaded parts shall be greased and protected with metallic or
other substantial type protectors. All female threaded openings shall be closed
with forged steel plugs. All pipings, tubing, and conduit equipment and other
equipment openings shall be sealed with metallic or other rough usage covers
and tapped to seal the interior of the equipment piping, tubing, or conduit.
(m.) Provisions shall be made to ensure that water does not enter any equipment
during shipment or in storage at the plant site.
(n.) Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Contractor's expense.
(o.) While packaging the material, care shall be taken for the limitation from the
point of view of availability of railway wagon sizes in India.
52.03.00 Factory Assembly
(a.) Instrument enclosures shall be supplied and erected completely in the factory
with instrument, air supply and blow down piping with necessary valves, fittings,
etc. and also all electrical wiring between the instruments and the enclosure
terminal blocks. Control panel and cubicles shall also be fully wired in the
factory. Control panel mounted equipments are to be dismounted from the
panels before shipment and individually packed for shipment. Electronic control
modules of the plug-in type are to be removed from equipment racks after
factory checkout are individually packed for shipment. Other equipment shall be
fully assembled at the factory, except for necessary shipping splits in panels.
(b.) All separately packaged accessories items and parts shall be shipped with the
equipment. Containers for separately packaged items shall be marked so that
they are identified with the main equipment. An itemized packing slip, indicating

STAGE-II (2X195 MW)
what is in that carton only, shall be attached to the outside and inside of each
container used for packing.
A master packing slip covering all accessories items for a given piece of equipment
which are shipped in separate containers, shall be attached to one container.
52.04.00 Equipment Installation
(a.) General Requirements
The Contractor shall furnish all construction materials, tools and equipment and
shall perform all work required for complete installation of all control and
instrument equipment furnished under this specification.
Contractor shall prepare detailed installation drawings for each equipment

furnished under this specification for Employer’s approval. Installation of all
equipment/systems furnished by this specification shall be as per Employer's
approval.
Erection procedures not specified herein shall be in accordance with the

recommendations of the equipment manufacturers. The procedures shall be
The Contractor shall coordinate his work with other suppliers where their
instruments and devices are to be installed under specifications.
(b.) Installation Materials
All materials required for installation, testing and commissioning of the

equipment shall be furnished by the Contractor.
(c.) Regulatory Requirements
All installation procedures shall confirm with the accepted good engineering
practice and with all applicable governmental laws, regulations and codes.
(d.) Cleaning
All equipment shall be cleaned of all sand, dirt and other foreign materials
immediately after removal from storage and before the equipment is brought
inside the power plant building or to other installation sites. All piping and tubes
shall be air blown.
(e.) Equipment Assembly
Equipment installed under these specifications shall be assembled if shipped

unassembled. The equipment shall be dismantled and reassembled as
required to perform the installation and commissioning work described in these
specifications.

STAGE-II (2X195 MW)
(f.) Equipment Setting
Field mounted instruments and accessories shall be bracket or sub panel

mounted on the nearest suitable firm steel work or masonry. The brackets,
stands, supports and other miscellaneous hardware required for mounting
instruments and accessories such as receiver gauge, air set, valve manifold,
purge-meter etc. shall be furnished and installed. No field mounted instruments
shall be installed such that it depends for support or rigidity on the impulse
piping or on electrical connection to it.
Indicating type field mounted instruments shall be installed in such a way that
centre of indicating dial shall be about 1600-1800mm from operating floor level.
Non-indicating type field instruments shall be installed such that operating
handle of manifold block / isolating cock comes within 1600 mm from operating
floor level.
All free standing instrumentation cabinets and panels shall be located within the
construction tolerances of +/- 3 mm of the location dimensions indicated on the
Employer's plant arrangement drawings.
(g.) Free-Standing Equipment
Free-standing Cabinets shall be attached to the floor, concrete equipment

bases or supporting steel as indicated on the manufacturer's drawings and the
Employer's Plant Arrangement Drawings. The cabinets shall be shimmed for
proper alignment before bolting them to the floor. Adjacent enclosures shall be
shimmed to maintain mutually level appearance before they are attached to
floor. Vibration dampening mounts shall be installed between supporting
structures and panels when specified.
(h.) Non-free Standing Equipment
Non-free standing local enclosures and cabinets shall be mounted in accessible

locations on columns, walls, or stands in locations as indicated on the
Employer's Plant Arrangement Drawings. Bracket and stands shall be
fabricated as required to install the local enclosures and cabinets in a workman
like manner.
Rough edges and welds on all fabricated supports shall be ground smooth.
The supports shall be finished with two coats of primer and two coats of paint
as specified in this part.
(i.) Equipment Location
All individual items of equipment not located in cabinets or on panels and racks
are located approximately according to the floor elevation and the nearest
building column designated by the Employer.
Solenoid valves not located in enclosures or mounted on valves shall be

mounted in easily accessible protected locations near the components with
which they are associated.

STAGE-II (2X195 MW)
All brackets, stands, supports and other miscellaneous hardware required for
mounting devices shall be furnished and installed.
Thermometers shall be installed in the process lines and ducts as required and
adjusted for ease in reading.
Permanent temperature wells on the main steam, hot reheat and cold reheat
piping shall not be installed until steam blowing has been completed.
Temporary temperature wells shall be installed in the main and reheat steam
piping during steam blow and discarded after completion.
Any required adapting hardware such as pipe bushings, nipples, drilled caps
and the like shall be provided for complete installation of control devices into
process connections.
For location of C&I related equipment/devices, the requirement specified

elsewhere in the technical specification may be referred.
(j.) Installation of Field Mounted Instruments and Devices
The Contractor shall submit installation drawings for all field mounted
equipment furnished under this specification for Employer's approval. These
drawings shall meet the requirements of this specification, installation drawings,
applicable codes and standards and recommendations of manufacturers of
instruments/devices. All installation work under this specification shall be
strictly as per installation drawings approved by the Employer during detailed
engineering stage.
In addition to above relevant Portion as specified elsewhere in technical

specification may be referred.
(k.) Piping Connections
All equipment having piping connections shall be levelled, aligned and wedged
in place but shall not be grouted or bolted prior to the initial fitting and alignment
of connecting piping. All equipment shall, however, be grouted or bolted to its
foundation prior to final bolting or welding of the connection piping.
All flanged joints shall be checked and retightened after approximately 10 days
of operation at normal operating temperature.
(l.) Equipment Checkout
All equipment shall be cleaned after installation. Equipment subject to pressure

differentials shall be checked for leakage.
After erection, all equipment having moving parts, having electrical apparatus,
or subject to pressure differentials shall be trial-operated.

STAGE-II (2X195 MW)
(m.) Defects
All defects in erection shall be corrected to the satisfaction of the Employer and
the Project Manager. The dismantling and reassembly of Contractor furnished
equipment to remove defective parts, replace parts, or make adjustments shall
be included as a part of the work under these specifications.
The removal of control and instrument equipment in order to allow bench

calibration, if required, and the re-installation of the said equipment after
calibration shall also be included as a part of the work under these
specifications.
(n.) Equipment Protection
All equipment to be erected under these specifications shall be protected from

damage of any kind from the time of contract award until commissioning of
each unit.
The equipment shall be protected during storage as described herein.
Equipment shall be protected from weld spatter during construction.
Suitable guards shall be provided for protection of personnel on all exposed

rotating or moving machine parts. All such guards with necessary spares and
accessories shall be designed for easy removal and maintenance.
Equipment having glass components such as gauges, or equipment having

other easily breakable components, shall be protected during the construction
period with plywood enclosures or other suitable means. Broken, stolen, or lost
components shall be replaced by the Contractor.
Machine finished surfaces, polished surfaces, or other bare metal surfaces

which are not to be painted, such as machinery shafts and couplings shall be
provided temporary protection during storage and constructional periods by a
coating of a suitable non- drying, oily type, rust preventive compound.
53.00.00 WELDING - SPECIAL REQUIREMENTS
If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed under separate
specifications, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.
54.00.00 DEVIATIONS DISPOSITIONING:
Any deviation to the contract and employer approved documents shall be properly
recorded in the format prescribed by NTPC. Al the deviations shall be bought to the
knowledge of employer’s representative for suitable dispositioning.

STAGE-II (2X195 MW)
55.00.00 NON-DESTRUCTIVE TESTING ( NDT):
The contractor shall record results of NDTs carried out at site in the format
acceptable to employer. All the radiographs & its report duly signed & correlated to
the job shall be handed over to the employer. Sensitivity of all the test equipment
shall be compatible to the job & acceptance norms agreed.
56.00.00 TESTING EQUIPMENT & FACILITIES:
Contractor shall provide the testing equipment and facilities necessary to carry out
tests & inspections.

STAGE-II (2X195 MW)
ANNEXURE-I
STANDARD CHECKLIST (TYPICAL)
Commissioning/Testing Essential pre-requisite
(a.) Mechanical
Sl. No. DESCRIPTION
VALVES
(i.) Manually operated valve
(ii.) Electrically operated valve
(iii.) Pneumatically actuated valve
(iv.) Hydraulically actuated valve
(v.) Safety valve
(vi.) Butterfly valve(electrically operated)
(vii.) Butterfly valve (manually operated)
(viii.) Butterfly valve(four way-electrical)
(ix.) Non-return valve (including hydraulic/pneumatic FCNRVS)
(x.) Relief valve
(xi.) Differential pressure regulating valve
(xii.) Float operated valves
Pumps
(xiii.) Pump Low Pressure Centrifugal (Motor Driven)
(xiv.) Pump up to 350 HP (260 Kw)
(xv.) Pump Sump Installation
(xvi.) Gear Pump/Screw Pump
PIPE WORK SYSTEM
(xvii.) Water services
(xviii.) Oil Resistant Fluid System
(xix.) Air services (compressor)

STAGE-II (2X195 MW)
(xx.) High pressure services
(xxi.) Constant load support
(xxii.) Spring supports
(xxiii.) Hangers and other supports
STRAINER AND FILTER
(xxiv.) Strainer/Filter Basket Type
Heat Exchanger (Scoop Coupling)
(xxv.) Heat exchanger (general)
(xxvi.) Heat Exchanger-Oil/Water
FANS AND COMPRESSORS
(xxvii.) Fans-Non-pressure Lubricated
(xxviii.) Fans-Axial flow pressure Lubricated
(xxix.) Compressors-General
GATES
(xxx.) Manually operated gate
(xxxi.) Electrically operated gate
Duct Work
(xxxii.) Ventilation ducting
(xxxiii.) Expansion Joints
(xxxiv.) Observations & Access Door
HOISTS AND ELEVATORS
(xxxv.) Electric Hoist / Elevator
(xxxvi.) Travel Support Structure For Hoists / Elevator
(xxxvii.) Long travel & cross traverse motion of hoists
(xxxviii.) Main aux. Hoist motion

STAGE-II (2X195 MW)
POWER TRANMISSION
(xxxix.) Power transmission gear box
(xl.) Bearing
(xli.) Fluid Couplings
(b.) Electrical
D.C. Motor
HV squirrel cage induction motor
415 V squirrel cage induction motor
Motor operated actuators
HT Switchgears
LT Switchgears/MCC
Standard Checklists for all types of relays used in Switchgears Protection

System
PT Carriage and Cubicles
Cable/Bus Duct/Bus Bars
Contractor Module
Switch fuse module
Master Panel of Lube Oil Panel
Feeder panel of lube oil panel
Space heater and cable module
HT Circuit Breaker
415 V Circuit Breaker
Power cable
Auxiliary cable
D.C. cable

STAGE-II (2X195 MW)
Explosion Proof Electrical Equipment
Junction box
Control transformer module
Soot blower sequence panel
Brush gear assembly
Aux. Control and relay panel desk
Indicating instrument
Recording instrument
Integrating instrument
Level switch (float actuated)
Level switch (electrode type)
Level Switch Displaced actuated)
Level Indicator (Float/Pulley Type)
Local temperature indicators including test procedure
Resistance Thermometer Element including Test Procedure
Thermocouple element and connecting cable
Thermocouple and Resistance Thermometer Convertor/Transmitter including

Test Procedures.
Temperature Switch/Thermostat including test procedures
Cold Junction Boxes
Pressure and Vacuum Gauge
Pressure And Vacuum Switch Including Test Procedure
Differential Pressure Transmitter including test procedure
Differential Pressure switch including test procedure.

STAGE-II (2X195 MW)
Flow Indicator (variable area)
Orifice plate
Tachometer
Vibration measurement
Digital indicator
Moving coil indicator including test procedure
Recorder including test procedure
Electrical auto manual control station
Push button module
Alarm annunciator equipment including test procedure
Test procedure for electronic Modules of DDCMIS
Note: The items which are not part of this specification may not be considered as not
applicable.

STAGE-II (2X195 MW)
ANNEXURE-II
BRIEF WIRE UP ON THE CONTENTS OF TESTING SCHEDULE /

COMMISSIONING SCHEDULE
Testing Schedules should be designed to ensure that the plant area, equipment or
apparatus are tested and commissioned and will operate as per the employer’s
specifications and good engineering practices.
Testing Schedule/Commissioning Schedule is required to be of a standard format in

order to maintain consistency of presentation, content and reporting.
Testing Schedule/Commissioning Schedule should contain the following sections to

make the document a self contained one:
(a.) Plant Details/Design data
(b.) Testing Objective/Proposals
(c.) STATE OF THE PLANT
Erection Status with respect to Mech. Elect
AVAILABILITY OF THE SERVICES REQUIRED
SAFETY REQUIREMENTS AS PER MANUFACTURER’S
(d.) Test method including completion/acceptance criteria
(e.) RESULTS
(f.) APPENDIX
TESTING PROGRAMME
Mech/Elect–Plant item completing list
List of Drawing/documents required for carrying out the testing.

STAGE-II (2X195 MW)
PART - E
LIST OF TENDER DRAWINGS

COAL HANDLING PLANT PACKAGE PART-E
CLAUSE NO.
----------------------------------------------------------------------------------------------------------------
S.NO. DRG. NO. TITLE
----------------------------------------------------------------------------------------------------------------
A MECHANICAL
1. 0350-155-POM-A-001 General Layout Plan
2. 0350-155-POM-A-002 Coal Flow Diagram
3. 0350-155-POM-A-003 GA of Track Hopper & Conveyor 1A/1B
4. 0350-155-POM-A-004 GA of Wagon Tippler Complex, TP-6 and

Conveyor 8A/8B
5. 0350-155-POM-A-005 GA of Crusher House.
6. 0350-155-POM-A-006 GA of Conveyor 2A/2B, 9A/9B & TP-2
7. 0350-155-POM-A-007 GA of Conveyor 3A/3B, 10A/10B & TP-7.
8. 0350-155-POM-A-008 GA of Conveyor 4A/4B, Yard Conv 11 &

TP-3, TP-8.
9. 0350-155-POM-A-009 GA of Conveyor 12A/12B, 5A/5B, 6A/6B &

TP-4.
10. 0350-155-POM-A-010 GA of Conveyor 7A/7B & Transfer point TP-

5.
11. 0350-155-POM-A-011 Single Line Diagram for DS, SW, CW &

Potable Water System.
12. 0350-155-POM-A-012 General Notes.
13. 0350-155-POM-A-013 GA of Conveyor 13, 14 and TP-4, TP-4A,

TP-2A, TP-9.
B ELECTRICAL
1. 0350-155-POE-A-001 Coal Handling Plant Single Line Diagram

(Two sheets)
2. 0350-155-POE-A-002 Coal Handling Plant Typical PLC

Sh. 1 of 2 configuration for Stacker Reclaimer control
3. 0350-155-POE-A-002 Coal Handling Plant Typical PLC

Sh. 2 of 2 configuration for Wagon Tippler Control

STAGE-II (2X195 MW) SECTION-VI LIST OF TENDER PAGE
PART - E DRAWINGS 1 OF 2
CLAUSE NO.
C CIVIL
1. 0350-155-POC-A-001(2 sheets) GA & Detail of Track Hopper & tunnel
2. 0350-155-POC-A-002 (4 sheets) Typical Architectural Details
3. 0350-155-POC-A-003 Plan showing spot levels of NGL and

Formation level inside plant.

STAGE-II (2X195 MW) SECTION-VI LIST OF TENDER PAGE
PART - E DRAWINGS 2 OF 2
PART - F
LIST OF MANDATORY SPARES

COAL HANDLING PLANT PACKAGE PART-F
CLAUSE NO.
S.N. ITEM QUANTITY Unit
1 Mechanical
A) Paddle Feeder
1 Rotor arm with Liners & Bolts 1 sets of each type
2 Liners of rotor arms 2 sets of each type
3 Gear box (including Paddle wheel,
Travel drive, cable reel drive)
i) Complete assembly 1 set of each type
ii Bearings 1 set of each type
iii) Oil Seals 2 nos. of each size
iv) Input shaft with pinion 2 sets of each type
4 Hydraulic Power Pack
i) Rotor Pump with electric motor, 2 set of each type and rating
coupling, valves & EP control
(mounted on pump)etc.
ii) Solenoid Valves complete with 2 set of each type and size
coils
iii) Filter element (1 No. Pressure 10 sets of each type

Filter + 1 No. Return Filter)
iv) Hydraulic Hoses 4 sets
v) Hydraulic Motor (for Paddle wheel) 2 nos of each type
vi) Hydraulic Motor (for Traverse nos of each type

Drive), if applicable 2
vii) Traverse pump with electric motor, 2 sets of each type

coupling, valves (mounted on
pump) & servo motor (mounted on
pump) etc., if applicable

TECHNICAL SPECIFICATION PART-F
STAGE-II (2X195 MW)
COAL HANDLING PLANT PACKAGE SECTION-VI LIST OF MANDATORY PAGE 1 OF 33
BID DOCUMENT NO. : CS-0350-155(R)-2 SPARES
CLAUSE NO.
viii) Oil cooling fan with motor 2 sets of each type
ix) Oil filling motor 1 nos of each type
x) Servo motor 1 nos of each type
5 Dust Suppression System for Paddle Feeder
i) Dust suppression pump and motor 1 nos of each type

assembly
ii) Spray nozzles of dust suppression 10 nos of each type

system
6 Carriage wheel assembly
i) Bearings 2 nos. of each type & size
ii) Plummer Block 2 nos. of each type & size
iii) Oil seals 2 nos. of each type & size
iv) Carriage wheel with shaft (without 1 sets

plummer blocks)
v) Traverse drive assy including 1 set

electric motor, gear box, coupling
etc. Or Geared Motor, as
applicable
vi) Tension roller of paddle feeder 1 set

trolley
7 i) All type of coupling (including those 2 nos. of each type

between electric motor and pump,
between hydraulic motor and gear
box and between gear box and
paddle wheel & between carriage
wheel and motor), as applicable
ii) Coupling bolt with bushes / spider 2 sets of each size

/inserts
iii) Rubber bush / spider / inserts 8 sets of each size

STAGE-II (2X195 MW)
CLAUSE NO.
8 i) Brakes (if any) 2 sets of each type & size
ii) Brake shoe, if any 4 sets of each type & size
9 Cable reel drive
I) Complete drive unit assembly 1 sets of each type & rating

including motor, gear box, coupling
etc.
ii) Chain 2 nos.
iii) Plummer Block and bearings for 1 sets

cable reel drum
iv) Cable guide assembly 1 set
v) Torque regulator unit 1 set
vi) Friction pads 2 set
vii) Spring stacks 2 set
viii) Oil seals 4 sets
ix) Eddy current/magnetic coupling 1 set of each type & rating
x) Spare Festoon hanger cum roller 10 nos.

assembly(below CRD)
xi) Spare energy chain links (if 5% of population

applicable)
B) IDLERS
1 I) 35o Troughing idlers complete with 200 nos

base frame and mounting brackets
etc.
ii) Rolls for (i) above 300 nos.
2 i) Troughing idlers complete with 20 nos.

base frame & mounting brackets
ctc.(for belt feeder).
ii) Rolls for (i) above 30 nos. of each type

STAGE-II (2X195 MW)
CLAUSE NO.
3 i) 350 impact idlers complete with 100 nos.

mounting brackets and base frame
etc.
ii) Rolls for (i) above 300 nos.
4 350 troughing training idler 20 % of total installed quantity

complete with base frame and
brackets etc. (if used)
5 Transition idler complete as in (1) 5 nos.

above
6 Flat return idlers complete with 100 nos.

mounting brackets etc.
7 Flat return idlers complete with 10 nos.

mounting brackets etc.(for belt
feeders)
8 Flat return trainer complete with 10 nos.

mounting brackets etc.
9 Belt cleaning spiral rubber disc 10 nos.

return idler complete with mounting
brackets etc.
10 i) Two roll 10o troughing return idler 40 nos.

assy
ii) Rolls for (I) above 40 nos.
11 SS idlers 2 sets of each type
C) CONVEYOR GEAR BOXES
(including boom conveyor, belt

feeders
i) Input shafts with pinion 1 set of each type and rating
ii) Oil seals 2 sets of each type and rating
iii) Bearings 1 set of each type and rating
iv) Hold back device 2 nos. of each type and

rating

STAGE-II (2X195 MW)
CLAUSE NO.
v) Cooling fan with cover 2 nos. of each type and

rating
vi) Complete gear box assy with hold 1 set of each type and rating
back device for population upto 10 Nos.
2 sets of each type and rating

(for population more than
10 Nos.)
D) CONVEYOR DRIVE AND

CONVEYOR BELT
a) Gear Coupling
i) Gear Coupling 2 nos. of each type
ii) Bolts for gear coupling 2 sets of each size
iii) Seal kit for gear coupling (o-ring) 2 sets of each type
b) Fluid Coupling
i) Fluid Coupling complete 1 no. of each type and size
ii) Multi Disc assembly (for fluid 4 nos each type and size
coupling), if applicable.
iii) Resilient Drive plate assy., if 1 no. of each type and size
applicable
iv) Bearings 1 no. of each type and size
v) Seal kit for fluid coupling 2 sets of each size
vi) Fusible plug 10 nos. of each size
vii) Complete actuator and engaging 1 set of each type

assembly (including motor, gear
box etc.)
Viii) Oil Cooler assembly (if applicable) 1 set of each type
ix) Oil pump-motor set (if applicable) 1 set of each type
x) Water pump motor 1 set of each type
xi) Oil filters 5 sets of each type

STAGE-II (2X195 MW)
CLAUSE NO.
xii) Oil Cooler valves (if applicable) 2 nos. of each type
c) Belting
Conveyor Belt
i) Main Conveyors one drum length of 250 m of

each type, size and rating
ii) Boom conveyor, belt feeder, one complete length of each

intermediate conveyor & bunker
seal belt
d) Brakes
i) Brakes 1 no of each size & type
ii) Brake shoes 2 sets of each size
E) PULLEYS
i) Pulleys complete with shaft 1 no. of each type and size in

excluding bearing & plummer pulley drum and shaft
blocks (complete with lagging) dia.(for population upto 10
Nos)
2 no. of each type and size in

pulley drum and shaft
dia.(for population more
than 10 Nos)
ii) Plummer Block complete with 2 no. each type and size
bearings & sleeves
iii) SS Pulleys complete with shaft 1 no. of each type and size in
excluding bearing & plummer pulley drum and shaft dia.
blocks (complete with lagging)
BELT CLEANERS AND SKIRT

F) BOARD
i) Modular segments for belt cleaner 5 %of total population of

each type & size
ii) Modular segments for skirt board 5 %of total population of

each type & size
iii) Skirt Rubber 5 %of total population of

each type & size

STAGE-II (2X195 MW)
CLAUSE NO.
iv) Complete belt cleaner (internal / 2 %of total population of

external ) each type & size
IN-LINE MAGNETIC
G) SEPARATORS
i) Cleated conveyor belt 1 set
ii) Motor, gear box drive assy. 1 set

complete
iii) Pulleys with plummer block & 1 set of each size & type
bearings
H) COAL SAMPLER
i) Plummer block 1 No. of each type and size
ii) Hammers 1 Set of each type and size
iii) Liner plate 1 Set
iv) Cutter lip 1 No.
v) Cutter seal 1 No.
vi) V-belts (for crusher) 1 Sets
vii) Hammer pins 1 Sets of each type and size
viii) Pulley 1 No. of each type and size
ix) Conveyor belt 1.2 Times length of each type

and rating
x) Gear box assembly for conveyor 1 No. of each type and rating
xi) Gear box drive assy, for primary 1 Set of each type and rating
and secondary samplers
xii) Solenoid valves with coils, if 2 Set of each type

applicable
xiii) Hydraulic pump with motor and 1 Set of each type

coupling, if applicable

STAGE-II (2X195 MW)
CLAUSE NO.
xiv) Hydraulic motor, if applicable 1 Set of each type
xv) Hydraulic cylinder, if applicable 1 Set of each type
xvi) Cylinder sealing kit, if applicable 2 Set of each type
xvii) Set of hoses, if applicable 2 Set of each type
xviii) Coupling with grid for primary 2 Sets

sampler
xix) Screw conveyor gear box assembly 1 Set
I) COAL CRUSHER
i) Plummer Block assembly complete 2 Set

including bearing, lock nut, lock
washer etc.(DE+NDE)
ii) Shaft seal 4 Sets
iii) Hammer sets 10 Sets or 750 Nos whichever

is more (1 set means
hammers required for one
crusher)
iv) Rotor assembly complete 1 Set

consisting of rotor shaft & keys,
End discs, Centre discs, distance
rings, suspension bars, disc
clamping nuts and shaft extension
etc. but without hammers, bearings
and pillow blocks, as applicable
v) Cags bars, if applicable 4 Set
vi) Breaker plate 4 sets
vii) Liners 2 sets
viii) Suspension bars 4 set
ix) Kick-off plate 4 set
x) Screen plate upper & lower 4 no. each

STAGE-II (2X195 MW)
CLAUSE NO.
xi) Tramp iron pick up plate 2 no. each
xii) Fluid coupling
a) Fluid coupling complete 1 set
b) Bearings 2 set
c) Seal kit (sealing rings) 2 sets
d) Fusible plugs 8 nos.
e) Oil pump motor set (if applicable) 1 set of each type
f) Water pump motor set (if 1 set of each type

applicable)
g) Oil filter 3 sets
h) Complete actuator and engaging 1 set

assembly (including motor, gear
box etc.)
I) Cooler assembly (if applicable) 1 no.
j) Oil Cooler valves 2 nos. of each type
k) Gear Coupling of crusher drive 2 sets

along with bolts and sealing kit.
l) Multi Disc assembly (for fluid 2 sets. of each type and

coupling) , if applicable rating
m) Resilient Drive plate assy., if 2 sets. of each type and

applicable rating
J) VIBRATING SCREENING
FEEDER
i) Bearings 2 no. of each type & size
ii) Seals 2 no. of each size
iii) Liners 1 sets.
iv) Screen plates 10 sets

STAGE-II (2X195 MW)
CLAUSE NO.
v) Complete vibrating assembly 1 set of each type and rating

consisting of all rotating parts and direction
including drive & driven unbalanced
shafts including bearings, casing,
spring, vibrating blocks, main shaft,
sheave & unbalanced weights, (as
applicable).
vi) Hoses (if applicable) 2 set
vii) Drive unit assembly (including 1 set

electric motor, hydraulic pump,
hydraulic motor, flexible shaft, gear
box, (as applicable)
viii) Base springs, rubber pads 2 sets. of each type & size
ix) V belts 4 sets. of each type & size
K) ELECTRIC HOISTS
i) Brake linings 2 sets of each type
ii) Rope guide & rope tightner 1 no. of each type
iii) Limit switch 2 nos. of each type & size
iv) Gear box/gear set 2 sets of each type
v) Motor/geared motor 1 no of each type & rating
vi) Drum bearing 1 set of each type & rating
L) FLAP GATES (INCLUDING THAT

OF TRIPPERS)
i) Limit switch 8 nos. of each type & rating
ii) Actuator (complete with motor, gear 1 nos. of each type & rating
box, limit switches etc.)
iii) Oil seals of Actuator 2 nos. of each type & rating
iv) Flap gate shaft 1 nos. of each type & rating
v) Pressure nut 12 nos. of each type & size

STAGE-II (2X195 MW)
CLAUSE NO.
M) RACK & PINION GATE
i) Limit switch 2 no. of each type & size
ii) Rollers with bearings 2 no. of each size
iii) Motor gear box assembly 1 set of each type
iv) Actuator (complete with motor, gear 1 nos of each type & rating
box, limit switches etc.)
N) SUMP PUMP
i) Complete pump assembly with 1 set

pump, motor, coupling base etc
ii) Impeller with key & nut 2 set of each size & type
iii) Oil seal 2 nos. of each size
iv) Coupling bolt with bushes 2 set of each type
v) Pump shaft 2 no. of each size
vi) Shaft sleeve 2 sets of each size
vii) Bearing bush 2 sets of each size
viii) Set of bearings 2 sets
O) DUST SUPRESSION & SERVICE

WATER SYSTEM
a) Pump impeller with key & nut 1 set of each type & size
b) Pump Shaft 1 no of each type & size
c) Bearings 1 sets each type & size
d) Wearing rings 2 sets of each type & size
e) Shaft sleeve 2 sets of each type & size
f) Bushings 2 sets of each type & size

STAGE-II (2X195 MW)
CLAUSE NO.
g) Coupling bolts & nuts (with bushes) 1 sets each type & size
h) Spray nozzles (for fog type dust 50 nos. of each type & size
suppression)
i) Spray nozzles (for plain water dust 25 nos. of each type & size.
suppression)
j) Solenoid valves 5 % of each type and size
k) Globe valve / plug valves 10 % of each type and size
l) Gate valve 2 nos. of each size
m) Strainers 1 no. of each type
n) Compressor
(i) Air filter element 8 Nos.
(ii) Oil filter 6 Nos.
(iii) Discharge check valve 3 Nos.
(iv) Oil Pump Parts (including 2 Sets

distance ring, eccentric rings,
Pump element, Pin, Key O,
Ring) as applicable)
(v) Inlet valve assembly 2 Nos.
(vi) Electronic regulator 3 Nos.
P) VENTILATION SYSTEM
i) V-Belt 1 set of each type
ii) Pre-filter element of pressurizing 2 sets of each type

fans
iii) Foundation Rubber pads 1 sets of each type & size
iv) Bearings 1 sets of each type & size
v) Plummer Blocks 1 set of each type & size

STAGE-II (2X195 MW)
CLAUSE NO.
Q) TRAVELLING TRIPPER
i) Complete drive assembly including 1 set

gear box, coupling, brake etc.
ii) Complete internals of speed 1 set of each size & type

reducer (including input shaft,
output shaft, gearset)
iii) Bearings for reducer 2 sets
iv) Drive axle with wheels, plummer 1 set

blocks, bearings etc.
v) Oil seals 2 nos. of each size
vi) Non-drive axle with wheels 1 set of each type

plummer blocks, bearings etc.
vii) Chain assembly with sprockets 1 set of each type & size
viii) Festoon Roller assembly for flexible 4 Nos

cable
ix) Pulleys and plummer block 1 no of each type

bearings
x) Plummer block with bearing for 1 set of each type

cable reel drums
R) STACKER/RECLAIMER
(Including boom conveyor)
1 Fluid coupling (complete) 1 no. of each type
2 Fluid coupling spares
I) Fusible plug 4 sets for each type of

coupling
ii) Oil seals 4 sets for each type of

coupling
iii) Bearings 2 set of each type
3 Couplings consisting input and 1 no. of each type

output halves (for travel drive)

STAGE-II (2X195 MW)
CLAUSE NO.
4 Bearings excluding slewing 1 no.of each type

bearings
5 Hydraulic pump with electric motor 1 no. of each type

& valves
6 Hydraulic cylinder 1 no. of each type
7 Repair kit for hydraulic cylinder 2 set for each type of cylinder
including oil seals etc.
8 Grease pump 1 no. of each type
9 Hoses 2 sets of each type and size
10 Solenoid valves with coils 2 nos. of each type
11 Slew gear Box 1 nos of each type and size
12 Gear Box of bucket wheel 1 nos of each type and size
13 i) Carbon brushes for current 2 sets for each drum

collector of cable reeling drum
ii) Plummer blocks and bearings of 1 set of each type

(CRD)
14 Traverse drive assembly consisting 1 no. of each type and

of reducer, couplings, brake assy. direction
etc.
15 Brake shoes 4 sets for each type of brake
16 Complete carriage wheel assembly 1 sets
(Each set comprising of 1 wheel + 1

axle + 2 bearing + 2 locking assly)
17 Complete bucket with liners, etc. 1 Bucket requirement
18 Drive assembly of cable reel drive 1 set of each type

consisting of motor, gear box,
coupling, brake etc., as applicable

STAGE-II (2X195 MW)
CLAUSE NO.
19 Chain & chain sprockets 1 set of each type
20 Cable guide assembly 1 set of each type
21 Various plummer block used in 1 no. of each type & size

Stacker reclaimer
22 Plummer block with bearing for 1 Set of each type

cable reel drums
23 Rail clamp assembly 1 set of each type
24 Seal kit for thrustor assembly 1 set of each type
Thrustor cylinder assembly 1 set of each type
S) ELEVATOR
a. Brake
1. Tool to brake 1 No.
2. Fan 1 No.
3. Magnet coil with housing pads 2 Nos.
4. Brake pads 6 Nos.
5. Adjusting sleeve 2 Nos.
6. Fixed brake disc 2 Nos.
b. Worm Gear
1. Worm gear 1 no.
2. 'O' ring 2 nos. of each type
3. Sealing ring 2 nos. of each type
c. Door Front
1. Bearing 2 Nos.
2. Roller 3 Nos.
3. Bushing 2 Nos.

STAGE-II (2X195 MW)
CLAUSE NO.
d. Limit Cams
1. Sensor 1 No
2. Switch 2 Nos.
3. Switch arm 2 Nos.
e. CAD
1. Guide roller 50 % of the total ones installed

each type or minimum 1 no.
whichever is higher
2. Switch 1 no.
f. Sliding Door
1. Rollers 4 nos. of each type
g. Machinery
1. Guide roller 2 nos.
2. Pinion 1 no.
3. Rubber inserts 6 nos.
4. Grove ring 6 nos.
5. Brake motor 1 no.
h. Cable trolley
1. Ball bearing 2 nos. of each type
T) DUST EXTRACTION SYSTEM
1 Fan Motor 1 nos. of each type & rating
2 Plummer Blocks 2 sets. of each type
3 Bearing of fans & motor 1 sets of each type
4 Pulley 2 nos of each type
5 Belts 2 sets. of each size

STAGE-II (2X195 MW)
CLAUSE NO.
6 Motor terminal blocks with studs for 1 set of each rating and type
all motors of motor
7 Spray nozzle 10 nos of each type
8 Solenoid valve with coil 2 nos of each type
U) SIDE ARM CHARGER
1 Gear box spares
i) Gear Internal 1 set each type
ii) Oil Seal 1 set each type
iii) Bearing 1 set each type
2 Carriage Wheels
(a) Bearings 1 set of each size and type
(b) Oil Seals 2 set of each size and type
(c) Plummer Block 1 set of each type and size
(d) Carriage wheel fitted with shaft 1 Set

(without Plummer Block)
3 Coupling 1 set each type
4 Travel Wheel Assembly 1 no
5 Bearing 1 no. of each type
6 Speed Reduers
(a) Internals complete including input 1 set of each type and rating.
and output shafts and gears etc.
(b) Oil seals 4 sets of each type and rating
(c) Bearings 2 sets of each type and rating
7 Motor
(a) Motor including slip ring motor 1 set of each type and size

STAGE-II (2X195 MW)
CLAUSE NO.
(b) Bearings 1 set of each type and size
(c) Oil Seal 1 set of each type and size
8 Brakes
(a) Complete assembly 1 no. of each type and size
(b) Linings & springs 1 set of each type and size
9 Couplings
(b) Pins, bushes and nuts 1 set of each type and size
i) Hydraulic Pump with electric motor, 1 set of each type and rating
coupling, valves & servo motor
(mounted on pump)etc.
ii) Solenoid Valves complete with 1 set of each type and size
coils
iii) Filter element (1 No. Pressure 4 sets of each type

Filter + 1 No. Return Filter)
iv) Hydraulic Hoses 2 sets
v) Hydraulic Motor 1 nos of each type
vi) Traverse pump with electric motor, 2 sets of each type

pump) & servo motor (mounted on
pump)etc.
vii) Hydraulic cylinder 1 no. of each type
viii) Oil cooling fan with motor 2 sets of each type
ix) Oil filling motor 1 nos of each type
x) Servo motor 1 nos of each type

STAGE-II (2X195 MW)
CLAUSE NO.
V) Wagon Tippler and Accessories
1 Speed Reducers
(a) Internals complete including input 1 set of each type and rating
and output shafts and gears etc.
(b) Oil Seals 4 sets of each type and rating
(c) Bearings 2 sets of each type and rating
2 Motor
(a) Motor including slip ring motor 1 no. of each type
(b) Bearings 1 set of each type and size
(c) Oil Seal 1 set of each type and size
3 Brakes
(b) Linings & springs 1 set of each type and size
4 Couplings
(b) Pins, bushes and nuts 1 set of each type and size
(a) Hydraulic Pump with electric motor, 1 set of each type and size
pump) etc
(b) Hydraulic Motor 1 no. of each type and size
(c) Valves 1 no. of each type and size
(d) O.P. Coolers 1 no.
(e) Filter Elements 10 nos. of each type
(f) Pressure Switch 1 no. of each type
(g) Temperature Switch 1 no. of each type

STAGE-II (2X195 MW)
CLAUSE NO.
6 Bearings (not covered separately) 1 set of each type and size
7 Limit Switches 2 nos. of each type.
8 Cylinder Manifold block with all 1 set

valves mounted on it
9 Hydraulic cylinder with piston 1 set of each type and size
10 Seals of hydraulic cylinder and 2 sets of each type.

pumps etc.
11 Hydraulic hoses 2 sets
12 Gear box total 1 set
13 Gear flexible coupling 1 set
14 Rod end bearings with housing 1 set for all four clamps
15 Pressure Switches 1 no
16 Common manifold block complete 1 no.

with all valves mounted on it.
17 Main Pivot bearing 1 no.
18 Pinion support & bearing 1 no. each type.
19 Pinion 2 no.
20 Latch (Pinion & rack segment 1 no.

locking device)
21 Chain & Sprocket 1 set
22 One set of bush bearing liners for 1 set

all drive group bearings
23 Paul lever assy. 1 set of each type
24 Rack segment two pieces (in case of non machined) and

one complete set in case of machined rack
segment
25 Spur wheel along with key. 1 set of each type
26 Drive shaft fitted with pinion 1 set of each type

STAGE-II (2X195 MW)
CLAUSE NO.
27 Bolts for rack segment (fitted bolts) 2 sets

one complete set
28 Coupling bolts of drive shaft 2 sets

(fitted/machined bolts) one
complete set
W) APRON FEEDER
1 Head Pulley complete with shaft 1 no.
2 Tail pulley complete with shaft 1 no.
3 Drive Motor 1 no. of each type and size
4 Gear Box 1 no. of each type and size &

direction.
5 Complete internals of gear box 1 set of each type & size

including input and output shafts
6 Reduction gears 1 sets of each type and size
7 Fluid coupling, flexible coupling etc. 1 No. of each type and size
8 Traction rollers 20 %of population
9 Carrying idlers 20 %of population
10 Return Rollers 20 %of population
11 Sprocket segments 2 sets of each type and size
12 Link Chain 20 % of each type and size
13 Pans (flights) 10 %
14 Hydraulic Cylinder 1 sets of each type and size
15 Seal kit of hydraulic cylinders 0 sets.
16 Plummer Blocks 1 no. of each type and size
17 Bearings 1 set of each type and size

STAGE-II (2X195 MW)
CLAUSE NO.
II "ELECTRICAL"
A) PADDLE FEEDERS
1 Main paddle wheel drive motor 1 no.

complete
2 Cable reel drive motor complete 1 no. of each type
3 Various limit switches, pressure, 2 nos. of each type

temperature & level switches
4 Flexible Trailing cable (power & 1 length each type

control)
5 Cable tension switches with leads 1 set of each type
6 Traverse drive motor, gear box 1 set of each type

assy
7 Cooling fan with motor for oil cooler 1 no.
8 Oil filling motor 1 no.
9 Slip ring and carbon bushes 1 set
10 Servo motor 1 no.
11 Motor terminal block with studs for 1 set of each rating and type
all motors of motor
12 Carbon brushes for current 2 sets

collector of cable reeling drum
(CRD)
B) CONVEYORS
(including Boom
Conveyor/intermediate conveyor of
stacker reclaimers/belt feeders)
1 Drive Motor 1 no. of each type & rating

(for population upto 10
Nos)
2 no. of each type & rating

(for population more 10
Nos)

STAGE-II (2X195 MW)
CLAUSE NO.
2 Belt Sway Switches 5 % of each type
3 Pull cord switches 15 % of each type
4 Zero speed switches 15 % of each type
5 Chute Block switches 15 % of each type
6 Position switches for trippers, 10 % of each type

paddle feeders
7 Sensor/probe for zero speed switch 20 % (min. 1 no)of each type

and speed range
8 Micro/limit switch of pull cord 20 %(min. 1 no)of each type

switch, belt sway switches, chute
block switches
9 Motor terminal block with studs for 1 set. of each type and rating
all motors of motor
10 Temperature transmitter 10%
C) CRUSHING EQUIPMENT
1 Motor of crusher 1 No.
2 Set of pressure, temperature flow 2 nos. of each type and

switches, zero speed/under speed rating
switches, limit switches etc.)
3 Motor terminal block with studs for 1 set of each rating and type
all motors of motor
4 Temperature transmitter 10%
D) a) MAGNETIC SEPARATORS
1 Rectifier with surge absorber 1 set
2 Rectifier transformer 1 no.
3 Auxiliary and power relays 2 nos. of each type
4 Control transformers 1 no. of each type

STAGE-II (2X195 MW)
CLAUSE NO.
5 Ammeter 2 nos. of each type
6 Under current relay 1 no. of each type
7 Isolating switch 1 no. of each type
8 Motor terminal block with studs for 1 set. of each rating and type
all motors of motor
b) SUSPENDED MAGNEIS
1 Rectifier with surge absorber 1 set
2 Rectifier transformer 1 no
3 Auxiliary and power relays 2 nos. of each type
4 Control transformers 1 nos. of each type
5 Ammeter 2 nos. of each type
6 Under current relay 1 nos. of each type
7 Isolating switch 1 nos. of each type
E) COAL SAMPLER
1 Motors 1 no. of each type
2 Set of various limit switches 2 nos. of each type
3 Zero speed switch 1 no. of each type
4 Solenoid valves with coils 2 nos. of each type and size
all motors of motor
F) TRAVELLING TRIPPER
1 Drive motor 1 no.
2 Brake assembly for traverse drive 2 sets

complete
3 Set of limit switches 2 nos. of each type

STAGE-II (2X195 MW)
CLAUSE NO.
4 Cable tension switches with lead 2 sets of each type
5 Infra red anti-collision device 1 set
6 Any other type of motor (flap gate 1 no of each type and rating
motor)
all motors of motor
8 Festoon roller assembly 2 sets
G) METAL DETECTOR
1 Cards 1 set complete
2 Relays 2 nos. of each type
3 Coils of metal detector 2 sets
4 Cables for search coils 1 set
H) BELT WEIGHER
1 Set of cards 2 nos. of each type
2 Load Cells 2 nos. of each type
3 Display Unit 2 nos. of each type
4 Speed sensor 1 nos. of each type
5 Cables for load cells & speed 2 Sets

sensor
6 Transducer, if applicable 2 nos. of each type
I) STACKER RECLAIMER
1 Motor (other than those covered in 1 no of each type and rating

B)(1) above)
2 Proximity detectors 5 % of total population min 1

no

STAGE-II (2X195 MW)
CLAUSE NO.
3 Level switches 5 % of total population min 1

no
4 Rotation digit emitters (Flashing 5 % of total population min 1

Beacon) no
5 Limit Switch 5 % of total population min 1

no
6 Pressure switch 5 % of total population min 1

no
7 Temperature switch 5 % of total population min 1

no
8 Cable tension switches with loads 2 sets. of each type
9 Flow switches 2 nos. of each type
10 Flexible Trailing cable (power & 1 length of each size & rating
control)
LT drive of Stacker Reclaimer
11 Transducers of VFD panels 2 nos. of each type
12 Complete converter and inverter 1 Set of each type

unit consisting of Thyristors of
thyristor/Main control Transistor
(main current carrying components)
13 Potentiometers of thyristor / 10 Nos. of each type

equivalent panel
14 Set of cards of thyristor/Power 2 Sets complete

Board Gate Drive Board
15 All type of electronics modules 10 % or 1 no (whichever is

more) of each type and
model
16 Input and out put chokes 1 Set
all motors of motor
18 Coupling relays 10 Nos. of each type

STAGE-II (2X195 MW)
CLAUSE NO.
Slew Drive
19 Transducers VFD panel 2 nos. of each type
20 Complete converter and inverter 1 Set of each type

unit consisting of Thyristors of
thyristor/Main control Transistor
(main current carrying components)
21 Potentiometers of thyristor / 10 Nos. each type

equivalent panel
22 Set of cards of thyristor/Power 2 Sets complete

Board Gate Drive Board
23 All type of electronics modules 10 % or 1 no (whichever is

more) of each type and
model
24 Input and output chokes 1 set
25 Coupling relays 10 Nos. of each type
all motors of motor
J) AUXILIARY TRANSFORMERS
(DRY)
i) HT Bushing 3 nos. of each type & rating
ii) LT Bushing 3 nos. of each type & rating
iii) Neutral bushing 1 no. of each type & rating
iv) Neutral CT 1 no. of each type & rating
v) Winding temp. indicator with alarm 1 no. of each type

& trip contacts
K) HT LOAD BREAK SWITCH AND

JUNCTION BOX
i) Trip coil 1 no.
ii) Support Insulators 1 set.
L) BUS DUCT
i) Support insulators 3 no. for each type & rating

STAGE-II (2X195 MW)
CLAUSE NO.
ii) Flexible terminal connectors for 1 set of each rating

switchgear end with fastners.
iii) Flexible terminal contactors for 1 set of each type

transformer end with fasteners.
iv) Enclosure expansion bellows(if 1 set of each type

applicable)
M) L.T. SWITCHGEAR / MCCs,/

DISTRIBUTION BOARDS
a) Circuit Breaker Components
i) Spring charging motor 4 no. of each type
ii) Primary disconnect (power) 1 no. of each type
iii) Auxiliary contact set 2 set of each type / rating of

breaker
iv) Limit switch 5 nos. of each type
v) Arc chutes for each rating 2 sets
vi) Moving contacts of each rating 1 sets
vii) Fixed contact of each rating 2 sets
viii) Arcing contact of each type 2 sets
ix) Closing coils for each type 10 nos.
x) Tripping coils for each type 10 nos.
xi) Closing & tripping springs 5 nos. of each type
xii) Releases 2 nos. of each type
xiii) Carbon brushes for spring charging 5 sets of each type

motor
xiv) Over current devices 1 no of each type and rating
xv) All type of protection/aux/relays, 1 no of each type and rating

timers

STAGE-II (2X195 MW)
CLAUSE NO.
xvi) Coupling relays 10 nos of each type and rating
b) LT panel components
i) Auxiliary contactor 2 nos of each type and rating
ii) Coupling relays without base 10 nos of each type and rating
iii) Bi-metallic overload relay 2 nos of each type and rating
iv) Overload relay reset chord 10 nos of each type

complete
v) Switch fuse unit 5 nos of each type and rating
vi) Control fuse base with carrier 20 Nos
vii) LT module incoming male/female 3 Sets of each type and

power contacts rating
viii) LT module outgoing male/female 3 Sets of each type and

power contacts rating
ix) Moving/detachable control 5 Sets of each type and

disconnects contacts of each rating rating
x) Power fuse base with carrier 3 Sets (9nos) of each type

and rating
c) Instrument Transformer
i) Current Transformer 3 nos of each type & rating
ii) Voltage Transformer 1 nos of each type & rating
d) Control supply transformer 1 nos of each type & rating
e) Meters
i) Ammeters 2 nos of each type & range
ii) Voltmeters 1 nos of each type & range
f) Relays (Protection, aux, coupling 1 Nos of each type

relay and timers)

STAGE-II (2X195 MW)
CLAUSE NO.
g) Contactors
i) Contactors and aux. Contactors 2 Nos of each type & rating

(complete)
ii) Coil for the Contactors and 2 Nos of each type & rating
aux. Contactors
iii) Main Contacts sets for power. 2 Nos of each type & rating
Contactors
h) Control, isolating & selector 1 Nos of each type & rating

switches
i) Push button of Various colours 2 Nos of each type & rating
N) CONTROL PANEL
(Wagon tippler control desk,

Stacker/Reclaimer control desk &
local control panels of paddle
feeders, metal detector, magnetic
separator, coal sampling system,
belt weigher, hoists, dust
suppression system, sump pumps,
fluid couplings etc.)
i) Control supply transformers 1 no. of each type & rating
ii) Relays and timer 1 no. of each type & rating
iii) Contactors 1 no. of each type & rating
iv) Ammeters 1 no. of each type & rating
v) Voltmeters 1 no. of each type & rating
vi) LEDs 5 nos. of each type & rating
vii) Control switches 1 no. of each type
viii) Selector switches 1 no. of each type
ix) Push button (complete with contact 1 no. of each type & colour
elements)

STAGE-II (2X195 MW)
CLAUSE NO.
x) Auxiliary contactors and bimetallic 1 Complete set

overload relay set for panel
xi) Control fuse base with carrier 1 Complete set

complete set for panel
xii) Any special meter 1 no. of each type
xiii) Bi-metallic overload relay 2 Complete sets
Note Spares already covered under

respective equipment spares shall
not be duplicated under control
panel spares.
O) PLC (STACKER / RECLAIMER &

WAGON TIPPLER)
i) PLC cards (Processor, memory and 1 no. of each type

all cards other than I/O cards)
ii) Stabiliser 1 no. of each type
iii) Power pack 1 no. of each type
iv) I/O cards 2 nos. of each type & rating
v) Fuses & Fused terminals 10 Nos. of each type & rating
vi) Set of cards for UPS 1 Set
vii) Modems 1 No. of each type
viii) Optical fibre cable 10 %
P) VIBRATION MONITORING
SYSTEM
i) Vibration pick up 2 Nos
ii) Pick up cable 1 Length
iii) Vibration monitor module and other 1 No. of each type

cards

STAGE-II (2X195 MW)
CLAUSE NO.
iv) Power supply 1 No.
v) Relays 2 Nos. of each type
vi) Indicating lamps / LEDs 5 Nos. of each colour
Q) DUST SUPRESSION & SERVICE

WATER SYSTEM
i) Electric motor 1 Nos. of each type & rating
ii) Flow switches 2 Nos. of each type
iii) Pressure switches 2 Nos. of each type
iv) Level switch 2 Nos. of each type
R) SUMP PUMP
i) Level switch 1 Set. of each type
S) VENTILATION SYSTEM
i) Electric motor 1 Nos. of each type & rating
T) ELEVATORS
i) Contactors 4 Nos. of each type
ii) Auxiliary Transformer, control 1 Nos. of each type & rating

transformer
iii) Relays 4 Nos. of each type & rating
iv) Resistor 6 Nos. of each type & rating
v) Switch 1 no. of each type
vi) Rectifier 10 nos.
vii) Limit switch 4 nos. of each type
viii) Battery Charger 1 no. of each type

STAGE-II (2X195 MW)
CLAUSE NO.
xiii) Tone frequency transmitter 1 set. of each type
xiv) Tone frequency receiver 1 set. of each type
U) VIBRATING SCREENING
FEEDER
i) Motor terminal block with studs for 1 set. of each rating and type
all motors of motor
V) WAGON TIPPLER AND

ACCESSORIES
1 Over Travel Limit Switch (OTLS) 1 No of each type
2 Thruster brake 1 No of each type
3 Aux gear cam switch 1 No of each type
4 Resistance box. 1 No of each type
5 Power contactors. 1 No of each type
6 Actuator for side arm charger travel 1 No of each type

cut off
Note :
1. Unless stated otherwise a ‘set’ means items or sub-items required for each type/size range
of the assembly/ sub-assembly, required for replacement in one main equipment. It is
further intended that the assembly/ sub-assembly which have different orientation( like left
hand or right hand, top or bottom), different direction of rotation or morrior image positioning
or any other reasons which result in maintaining two different sets of the spares to be used
for the subject assembly/ sub-assembly, these shall be considered as different types of
assembly/ sub-assembly.
2. Wherever quantity has been specified as percentage(%), the quantity of mandatory spares
to be provided by contractor shall be the specified percentage(%) of the total population of
the plant. In case the quality so calculated happens to be a fraction, the same shall be
rounded off to next higher whole number.
3. Whenever the quantities have been indicated for each type, size, thickness, material,
radius, range etc., these shall cover all the items supplied and installed and the breakup for
these shall be furnished in the bid.
4. In case spares indicated in the list are not applicable to the particular design offered by the
bidder, the bidder should offer spares applicable to offered design with quantities generally
in line with the approach followed in the above list.
5. Price of each and every item is to be given separately.

STAGE-II (2X195 MW)

STAGE-II (2X195 MW)
ATTACHMENT-12
T0
SECTION-VII
TECHNICAL DATA SHEETS
FOR
COAL HANDLING PLANT PACKGE


STAGE-II (2X195 MW)
ATTACHMENT-12
T0
SECTION-VII
FOR
COAL HANDLING PLANT PACKGE
This document is meant for the exclusive purpose of bidding against this
specification and shall not be transferred, reproduced or otherwise used for
purposes other than that for which it is specifically issued.
ATTACHMENT - 12
TO
SECTION – VII
CONTENTS
SECTION DESCRIPTION TOTAL PAGES
SECTION – A TECHNICAL INFORMATION 1 TO 34

AND DATA TO BE SUMBITTED
WITH THE PROPOSAL.
SECTION – B TECHNICAL INFORMATION 1 TO 3

AND DATA TO BE SUMBITTED
AFTER AWARD OF CONTRACT
SECTION - A
TECHNICAL INFORMATION AND DATA TO BE

SUBMITTED WITH THE PROPOSAL
CLAUSE NO. TECHNICAL INFORMATION DATA TO BE SUBMITTED WITH THE PROPOSAL
BIDDER’S NAME : ………………………………..
SECTION - A
TECHNICAL INFORMATION
TECHNICAL DATA
The information sought out in data sheets enclosed hereafter in this section, shall
be furnished by the Bidder in the format specified, by typing out answers to the
questionnaire at the appropriate places allotted. The Bidder shall enclose these
data sheets for all conveyors/eqpt. of Coal Handling Plant completely filled up with
his proposal. The technical particulars filled up by the bidder in these data sheets
shall be the minimum that the bidder will have to supply during execution of the
contract. Bidder would be allowed to only upgrade the technical particulars during
execution of the contract.
I. COAL HANDLING EQUIPMENT, DUST CONTROL & MISC SYSTEMS,
VENTILATION SYSTEM
(Section III-A-01 to III-A-22) Bidder to fill separate sheets for separate

items/equipment.
Conveyor Nos. Boom Conveyor
of S/R
1.00.00 BELT CONVEYOR SYSTEM
1.01.00 Conveyor Capacity, MTPH
a) Rated (Guaranteed)
b) Design
1.02.00 Belt width, mm
1.03.00 Belt speed, m/sec
1.04.00 Length, centre to centre, meter
1.05.00 Lift, meter

1.06.00 Conveyor belting
1.06.01 Belt Rating
- Nylon - Nylon
- Steel Cord
MUZAFFARPUR THERMAL POWER PROJECT ATTACHMENT-12

STAGE-II (2X195 MW) TO SECTION-A
PAGE 1 OF 34
COAL HANDLING PLANT PACKAGE SECTION-VII
BID DOCUMENT NO. : CS-0350-155(R)-2 TECHNICAL DATA SHEETS
BIDDER’S NAME : ………………………………..
1.06.02 Code/Standard to which the beltings conforms to
1.06.03 Cover thickness, mm,
– face cover
– back cover.
1.06.04 Cover Grade
1.06.05 Code/standard for Fire Resistance

properties of the covers
1.07.00 Drive Pulleys
1.07.01 Diameter (mm),
1.08.00 Tail and Take-up pulleys
1.09.00 Bend and snub pulleys
1.10.00 Discharge Pulley
1.10.01 Diameter
1.11.00 Troughing idlers
1.11.01 Spacing, mm
– Normal
– Over convex curves
1.11.02 Troughing angle, degrees
1.11.03 Shell diameter, mm
1.12.00 Return Idlers
1.12.01 Spacing, mm

PAGE 2 OF 34
BIDDER’S NAME : ………………………………..
1.12.03 Shell diameter, mm
1.13.00 Self aligning return

idlers
1.13.01 Spacing, mm
1.14.00 Conveyor Galleries
1.14.01 Gallery Cross-section
a) Width, mm
b) Clear headroom
inside gallery from
walkway level, mm
1.14.02 Deck plates along entire length of conveyor provided Yes/No
1.14.03 Seal plates along entire length of conveyor provided Yes/No
1.15.00 Drive Equipment for

Belt Conveyor system
1.15.01 Reduction gears
a) Type
1.15.02 Fluid Couplings
a) Type
1.15.03 Brakes provided Yes/No
1.15.04 Flexible couplings
a) Type
i) High Speed Side
ii) Low Speed Side
1.15.05 Drive motors
a) Motor nameplate rating,

KW at 50 deg.C Ambient

PAGE 3 OF 34
BIDDER’S NAME : ………………………………..
2.00.00 CHUTES, HOPPERS
2.01.00 Chutes & hoppers

construction details
2.01.01 Material & Plate thickness
a) Sliding zones
b) Non striking zones
c) ILMS zone
2.02.00 Flap Gates
2.02.01 Type of actuator
3.00.00 COAL CRUSHERS
3.01.00 Type offered
3.02.00 Guaranteed capacity, MTPH
3.03.00 a) Crusher
(i) Rotor dia x Rotor length (mm)
b) Guaranteed output
coal size, mm
3.03.01 Type of hammers
3.03.02 Suspension Bars
a) No. of suspension
bars passing through
each hammer row
3.03.03 Rotor speed, rpm

PAGE 4 OF 34
BIDDER’S NAME : ………………………………..
3.03.04 Drive Arrangement
a) Motor synchronous
speed, rpm
b) Hydraulic scoop fluid

coupling provided Yes/No
3.03.05 Hydraulic Cage Actuating mechanism provided Yes/No
3.03.06 Material of construction
a) Ring Hammers
i) Material
ii) Hardness, BHN
b) Rotor Shaft
c) Suspension bars
d) Cage bars
e) Side screen plates
f) Rotor discs
g) Breaker plate
i) Material
ii) Hardness, BHN
iii) Plate thickness, mm
h) Liners
i) Material
ii) Thickness, mm
3.03.07 Drive motor
a) Motor nameplate rating

at 50 deg.C Ambient KW

PAGE 5 OF 34
BIDDER’S NAME : ………………………………..
3.03.08 Vibration isolation system for

crusher foundation provided as
per Technical Specification Yes/No
4.00.00 VIBRATING SCREENING FEEDERS
4.01.00 Type Offered
4.03.00 Solid Deck (Pan) size

(mm x mm)
4.04.00 Screening Area (mm x mm)
4.05.00 Inclination of deck
4.06.00 Vibrator
a) Type of drive
b) Type of vibrator
4.07.00 Perforated Deck
a) Material
4.08.00 Solid Deck
a) Material of solid plate

of the deck
b) Liners on the solid

plate provided ? Yes/No
c) Material of liners
4.09.00 Supporting Springs provided Yes/No
4.10.00 Drive Motors
a) Motor name plate rating,


PAGE 6 OF 34
BIDDER’S NAME : ………………………………..
5.00.00 PADDLE FEEDER
5.02.00 Capacity, Adjustment Range
5.03.00 Paddle Wheel
a) Diameter of wheel
b) Number of vanes
c) Material of vane
d) Material for vane liner
e) Type of drive arrangement
f) Motor nameplate rating

KW at 50 deg. C Ambient
5.04.00 Feeder Carriage
a) Type of drive
arrangement
b) Motor nameplate rating,

6.00.00 TRAVELLING TRIPPERS
6.01.00 Max conveyor angle

over tripper, deg
6.02.00 Travel Motors
a) Nos. provided
b) Motor rating, KW
at 50 deg.C Ambient
6.03.00 Tripper walkways
a) Provided on both sides of tripper? Yes/No
6.04.00 Brakes
a) Type

PAGE 7 OF 34
BIDDER’S NAME : ………………………………..
6.05.00 Rail clamps
a) Type
6.06.00 Bunker Sealing Arrangement
6.06.01 Sealing Belt
a) Belt width, mm,
b) No. of plies
7.00.00 BELT WEIGHING SCALES Conveyors Boom Conveyor
7.01.00 Measuring capacity
a) Max. MTPH
b) Min. MTPH
7.02.00 Location
7.03.00 Accuracy (%)
a) at maximum load
b) at minimum load
7.04.00 Rate Indicators provided Yes/No
7.05.00 Totaliser
a) Provided
b) Location
8.00.00 IN-LINE MAGNETIC SEPARATORS

& SUSPENDED MAGNETS
8.01.00 Location For crushed coal For uncrushed coal
8.02.00 a) Mounting height, mm
b) Strength in gauss at
mounting height

PAGE 8 OF 34
BIDDER’S NAME : ………………………………..
8.03.00 Magnet
a) Type
b) Material of magnet
core
c) Material of coil
d) Class of insulation
e) KW rating at 50 deg.C
Ambient
8.04.00 Self-Cleaning Belt provided Yes/No

for In Line Magnetic Seperator
9.00.00 COAL HANDLING PLANT BUILDINGS
9.01.00 Transfer points/Crusher house
9.01.01 Cladding
a) Material
b) Thickness
9.01.02 Identify Structures where
piling is envisaged
1) TP
2) Conveyor galleries
3) Control Bldgs.
4) Stacker-reclaimer foundation
5) Any other structure
9.01.03 Piles (if applicable) :
a) Type:
b) Method of boring
c) Dia/ Capacity

PAGE 9 OF 34
BIDDER’S NAME : ………………………………..
9.01.04 No. of staircases provided for the

following buildings as per specification Yes/No
a) For TP
b) For Crusher house
c) For Main Control Room building
d) For Track Hopper Control

Room building
e) For MCC
f) For Wagon Tippler Control

Room Building
10.00.00 COAL SAMPLING UNIT
10.01.00 a) Name of Coal sampler

Supplier/manufacturer
b) Experience & Details Plant 1 Plant 2
(i) Details of Installation

(address & year of
Commissioning)
(ii) Quantity & Capacity

Of Coal samplers
(iii) Application
(power plant /mines etc.)
(iv) Coal sampler parameters
- Lump size of coal
- Suitable for belt width,
- belt capacity (TPH)
(v) Certificate from client Yes/No Yes/No

Enclosed

PAGE 10 OF 34
BIDDER’S NAME : ………………………………..
10.02.00 Standard /Code to which the For uncrushed For Crushed

sampling system conforms Coal Coal
10.03.00 a) Location
b) Make
c) Model No.
d) Catalogue/Technical
literature furnished ? Yes/No
11.00.00 ELEVATORS
11.01.00 Salient Particulars
i) Load Carrying Capacity (kg)
ii) Location
iii) Type of elevator
12.00.00 DUST CONTROL & MISC.

SYSTEMS
12.01.00 Plain Water Dust Coal Track P/F WT

Suppression System stockyard hopper Carriage
provided
12.02.00 Dry Fog System provided for Transfer

Point & Crusher House Yes/No
12.03.00 Sump Pumps provided Yes/No
13.00.00 METAL DETECTORS PROVIDED Yes/No
14.00.00 VENTILATION SYSTEM
14.01.00 Type of Ventilation System provided
a) MCC Room
b) Under Ground Structures
c) Over Ground Structures

PAGE 11 OF 34
BIDDER’S NAME : ………………………………..
14.03.00 Air Conditioning System Main TH SR SR WT

Control Control Machine Machine Control
Room Room Operator MCC Room
Cabin Room
Type of Air Conditioning
System Provided
15.00.00 DUST EXTRACTION SYSTEM IN

CRUSHER HOUSE AT VSF &
BELT FEEDER FLOOR :
a) Type of DE System
16.00.00 STACKER-CUM-RECLAIMER
16.01.00 Type
16.02.00 Stacking capacity, MTPH
a) Guaranteed
b) Design
16.03.00 Reclaiming capacity, MTPH
a) Guaranteed
b) Peak
16.04.00 Boom length, m
16.05.00 Stockpile configuration
a) Height of stock piles,

m
b) Width of stockpile
base on either side
of yard conveyor, m
16.06.00 Maximum safe wind

velocity, KMPH
a) Under operating condition
b) Under non operating

condition

PAGE 12 OF 34
BIDDER’S NAME : ………………………………..
16.07.00 Rail Track
Rail clamps
– Type
16.08.00 Travel Mechanism
16.08.01 Travel speed, m/min
a) Maximum speed
b) Minimum speed
c) Control for continuous

variation in speed provided Yes/No
16.08.02 Travel Carriage
a) Type of Equalizing
Arrangement
b) No. of wheels
– Driven
– Non-driven
c) Type of wheels
(double flanged?) Yes/No
d) Drive arrangement
e) Brakes
– Type
16.09.00 Bucket wheel
16.09.01 Diameter of bucket wheel, mm
16.09.02 Bucket Details
a) Number of buckets
b) Bucket wheel specd, RPM

PAGE 13 OF 34
BIDDER’S NAME : ………………………………..
c) Water fill Capacity of each bucket,

(excluding ring volume), litres
d) Total volume of ring for

complete bucket wheel, litres
e) Peak reclaim capacity

MTPH
(Bucket wheel speed x
Number of Bucket x
Density of Coal x (80%
Bucket Capacity + 50%
Effective ring vol. of each
Bucket) x 60
---------------------------------
1000
f) Bucket replaceable ? Yes/No
16.09.03 Bucket wheel drive
a) Bucket wheel speed, rpm
b) Drive arrangement type
16.09.04 Method of lubrication arrangement

provided for Bucket wheel
16.10.00 Boom Conveyor - Data to be

filled up in conveyor section
at sl. no. 1.00.00
16.10.01 Boom Luffing
a) Angle of inclination, deg.
i) Above horizontal
ii) Below horizontal
b) No. of luffing cylinders
16.11.00 Slewing Mechanism
16.11.01 Maximum slew angle, deg.
Control for continuous

variation in speed provided Yes/No

PAGE 14 OF 34
BIDDER’S NAME : ………………………………..
16.11.02 Slew Drive
a) Type
b) No. of drive pinions
c) Brakes
– Type
16.11.03 Slew bearing type
16.11.04 Type of lubrication arrangement

provided for slew drive
16.12.00 Tripper
16.12.01 Walkways with hand railings
a) Provided on both sides ? Yes/No
16.12.02 Maximum angle of inclination, deg.
16.13.00 Self-lubricating bearings
16.13.01 Whether provided at all

angular movement points
(hinge points)? Yes/No
16.14.00 Cables & Cable Reeling Drums
16.14.01 Location of CRDs with respect

to Rail Tracks (inside/outside)
----------------------------------------------------
16.15.00 Drive Motors Long Slew Bucket Boom Boom
Travel Drive wheel Conv. Hoist
Drive Drive Drive Drive
-----------------------------------------------------
16.15.01 Tentative motor rating,

17.00.00 WAGON TIPPLER
17.01.00 Name of Manufacturer

PAGE 15 OF 34
BIDDER’S NAME : ………………………………..
17.02.00 Type
17.03.00 Hopper Capacity
17.04.00 Type of drive
17.05.00 Drive Rating
17.06.00 Experience & Details Plant 1 Plant 2
(i) Details of Installation

(address & year of
Commissioning)
(ii) Quantity & Capacity
(iii) Parameters
- belt width,
- belt capacity (TPH)
(iv) Certificate from client Yes/No Yes/No

Enclosed
18.00.00 SIDE ARM CHARGER
18.01.00 Range of travel
18.02.00 Type of drive
18.03.00 Haulage capacity
19.00.00 APRON FEEDER
19.01.00 Width of pan
19.02.00 Drive KW
19.03.00 Material of Construction
i) Apron pan
ii) Rollers
20.00.00 MAKES OF EQUIPMENT
20.01.00 Paddle Feeder

PAGE 16 OF 34
BIDDER’S NAME : ………………………………..
20.02.00 Bakes & clamps
20.03.00 EOT & HOT – Hoists
20.04.00 Belting
20.05.00 Couplings
- Fluid Coupling
- Flexible Coupling
- Scoop Coupling
20.06.00 Gear Box
20.07.00 Vibrating Screening Feeder
20.08.00 Crusher
20.09.00 ILMS / Magnets
20.10.00 Metal Detectors
20.11.00 Coal Sampling System
20.12.00 Elevator
20.13.00 Stacker – Reclaimer
20.14.00 Pumps – DS/SW/CW/PW/Sump
20.15.00 Fans
20.16.00 Package Air Conditioner
20.17.00 Wagon Tippler
20.18.00 Travelling Tripper
20.19.00 Side Arm Charger

PAGE 17 OF 34
BIDDER’S NAME : ………………………………..
II. COAL HANDLING ELECTRICAL EQUIPMENTS
MOTORS
(To be filled in for each
type & rating)
1.00.00 Manufacture & country of origin .............................. ............................
2.00.00 Equipment .............................. ............................
3.00.00 (a) Motor type (Squirrel cage/ .............................. ............................

slipring/DC etc.)
(b) Type of duty .............................. ............................
4.00.00 Application standard to which .............................. ............................

motor confirms
5.00.00 Stator winding insulation
(a) Class & Type .............................. ............................
(b) Tropicalized .............................. ............................
(c) Temperature rise .............................. ............................

over specified
ambient of 50oC
6.00.00 Power factor at rated .............................. ............................

load
7.00.00 Starting current at
100% voltage .............................. ............................
85% voltage .............................. ............................
8.00.00 Type of enclosure and .............................. ............................

method of cooling
9.00.00 Degree of protection .............................. ............................
10.00.00 Rated voltage and frequency .............................. ............................
11.00.00 Rated speed .............................. ............................

PAGE 18 OF 34
BIDDER’S NAME : ………………………………..
12.00.00 Efficiency at design .............................. ............................

duty point (without -ve
tolerance) & 100% full
load
13.00.00 Type of mounting .............................. ............................
14.00.00 Type of terminal box for .............................. ............................

stator leads

PAGE 19 OF 34
BIDDER’S NAME : ………………………………..
LT SWITCHGEAR
(Bidder to furnish following data

for each type and class of switch-
gear separately)
1.00.00 SWITCHGEAR & MCC
a) General
i) Manufacturer's Name .............................................
ii) Type designation .............................................
b) Rated voltage .............................................
c) Symmetrical short circuit .............................................

withstand current at rated
voltage of switchgear/
MCC cubicle
d) Peak short circuit withstand .............................................

current
e) Degree of protection
as per IS:13947
i) Breaker/MCC cubicles .............................................
ii) Busbar chamber .............................................
f) Shrouding arrangement in cable Yes/No

alley provided or not
g) Earth busbar size & material .............................................
2.00.00 POWER BUSBARS & INSULATORS
a) Material & applicable standards .............................................
b) Bare/painted/epoxy insulated/sleeved .............................................
c) Continuous current rating
i) Over an Ambient temperature ............................*................

(Amps.)

PAGE 20 OF 34
BIDDER’S NAME : ………………………………..
d) Temperature rise over design .............................................

ambient temperature for con-
tinuous current rating deg.C
e) Material of the support insulators .............................................
f) One Second current rating (kA) .............................................
3.00.00 CONTROL SUPPLY TRANSFORMERS
a) Make .............................................
b) Type .............................................
c) Material & class of insulation .............................................
d) Voltage rating & taps .............................................
4.00.00 CIRCUIT BREAKER
a) Manufacturer's name and country .............................................

of manufacturer
b) Rated Voltage .............................................
c) Rated operating duty .............................................
d) Design ambient temperature .............................................
e) Rated symmetrical breaking .............................................

current
f) Rated peak making current .............................................
g) Rated short time rating .............................................

(for 1 sec.)
h) Power operating mechanism .............................................
i) Spring charging motor details
i) Type .............................................
ii) Rating Watts .............................................
iii) Rated voltage .............................................

PAGE 21 OF 34
BIDDER’S NAME : ………………………………..
iv) Class of insulation .............................................
j) Emergency Manual charging Yes/No

facility provided
k) Manual operating mechanism .............................................
l) Telescopic trolley
i) Make .............................................
ii) Type designation .............................................
iii) Dimensions .............................................
5.00.00 AIR BREAK SWITCHES

(The following details shall be
furnished for each type & rating)
a) Make .............................................
b) Type .............................................
c) Applicable standards .............................................
6.00.00 CONTROL / SELECTOR SWITCH
a) Make .............................................
b) Type Designation .............................................
c) Voltage grade .............................................
7.00.00 CONTACTOR
furnished for each type & rating)
a) Make .............................................
b) Type & applicable standards .............................................
8.00.00 FUSES
a) Make .............................................
b) Type .............................................
c) Category .............................................

PAGE 22 OF 34
BIDDER’S NAME : ………………………………..
9.00.00 CURRENT TRANSFORMER

provided for each type & rating)
a) Make .............................................
b) Applicable standards .............................................
c) Class & Type of insulation .............................................
10.00.00 VOLTAGE TRANSFORMERS
a) Make .............................................
b) Ratio .............................................
c) Class & Type of insulation .............................................
11.00.00 RELAYS
furnished for each type & appli-
cations including coupling relay)
a) Make .............................................
b) Type .............................................
c) Application .............................................
12.00.00 THERMAL OVERLOAD RELAY &

SINGLE PHASING PREVENTER
Make & type designation .............................................
13.00.00 VOLTMETER
a) Make .............................................
b) Type .............................................
14.00.00 AMMETER
a) Make .............................................
b) Type .............................................

PAGE 23 OF 34
BIDDER’S NAME : ………………………………..
15.00.00 LOCAL STARTERS
Make & Type .............................................
16.00.00 415V NON SEGREGATED BUSDUCTS
a) Manufacturer's name & address .............................................
b) Type of busduct .............................................
c) Material of busbars .............................................
d) Rated voltage (volts) .............................................
e) Short circuit current ratings .............................................

& duration (kA/Sec.)
g) Temperature rise over the ambient

temperature
i) Busbars .............................................
ii) Enclosures .............................................
f) Material of support insulator .............................................
g) Clearance (mm)
i) Phase to Phase .............................................
ii) Phase to earth .............................................
17.00.00 LIGHTING AND WELDING TRANSFORMERS
a) Make .............................................
b) Voltage ratio .............................................
c) KVA Rating .............................................

PAGE 24 OF 34
BIDDER’S NAME : ………………………………..
POWER, CONTROL AND TRAILING CABLES

(Use separate sheet for each type and size of cables)
1.01.00 Make & Type .............................................
1.02.00 Country of Manufacturer ..............................................
1.03.00 Type & Designation ..............................................
1.04.00 Applicable standard ..............................................
1.05.00 Rated voltage ..............................................
1.06.00 Conductor ..............................................
a) Material ..............................................
b) Nominal cross section area ..............................................

in sq.mm
1.07.00 Insulation
a) Material ..............................................
b) Nominal thickness (in mm) ..............................................
c) Type of curing (for XLPE) ..............................................
1.08.00 Type of Inner sheath ..............................................
1.09.00 Armour material ..............................................
1.10.00 Outer sheath material ..............................................
1.11.00 Guarantee value of minimum ..............................................

oxygen index of outer sheath
1.12.00 Maximum acid-gas generation ..............................................

by weight (%) of outer sheath
1.13.00 Average light transmission ..............................................

PAGE 25 OF 34
BIDDER’S NAME : ………………………………..
ILLUMINATION SYSTEM
1.00.00 Lighting distribution board
a) Make ..............................................
b) Type of construction ..............................................
2.00.00 Lighting Panel
a) Make ..............................................
b) Applicable standard ..............................................
c) Enclosure Protection ..............................................
3.00.00 Lighting fixtures & Accessories
a) Make of lighting fixture & ..............................................

accessories
b) Applicable standard ..............................................
4.00.00 Receptacles/Sockets
a) Make ..............................................
b) Type ..............................................
a) Make ..............................................
b) Type ..............................................
c) Material ..............................................
6.00.00 Terminal Blocks
a) Make ..............................................
b) Type ..............................................
7.00.00 Rigid Steel Conduits/Fittings

& Accessories
a) Make ..............................................

PAGE 26 OF 34
BIDDER’S NAME : ………………………………..
b) Material ..............................................
c) Applicable Standard ..............................................
8.00.00 Hume Pipes
a) Make ..............................................
b) Applicable Standard ..............................................
9.00.00 Flexible steel conduit
a) Make ..............................................
10.00.00 Lighting Wires
a) Make ..............................................
c) Conductor material ..............................................
d) Insulation ..............................................
11.00.00 Lighting Poles
a) Make ..............................................
c) Type ..............................................
d) Pole height ..............................................
12.00.00 Lighting Masts
a) Make ..............................................
b) type ..............................................
c) Overall height ..............................................

PAGE 27 OF 34
BIDDER’S NAME : ………………………………..
CABLING, EARTHING AND LIGHTNING PROTECTION
CABLE SUPPORT SYSTEM
1.00.00 Cable, Trays, Tray Covers

& Accessories
1.01.00 Make ..............................................
1.02.00 Type of cable tray ..............................................
1.03.00 Type of cable support system ..............................................
2.00.00 Conduit Pipes & Accessories
2.01.00 Make ..............................................
2.02.00 Material ..............................................
2.03.00 Applicable Standard ..............................................
3.01.00 Make ..............................................
3.02.00 Material ..............................................
4.00.00 Cable Glands
4.01.00 Make ..............................................
4.02.00 Material ..............................................
5.00.00 Cable Jointing / Termination Kits
5.01.00 Make ..............................................
5.02.00 Type of system
a) Termination ..............................................
b) Joints ..............................................

PAGE 28 OF 34
BIDDER’S NAME : ………………………………..
6.00.00 Cable Lugs & Terminals
6.01.00 Make ..............................................
7.00.00 Earthing System
a) Buried earthmat
i) Material & size ..............................................
ii) Applicable standard ..............................................

for the system
b) Equipment earthing
i) Material ..............................................
ii) Size ..............................................
iii) Applicable standard ..............................................
8.00.00 Lightning Protection System
i) Applicable standard ..............................................

PAGE 29 OF 34
BIDDER’S NAME : ………………………………..
TRANSFORMER
[Use Different Sheets for
Dry Type transformers
1.00.00 Manufacture ..............................................
2.00.00 Service
Indoor / Outdoor ..............................................
3.00.00 Type / Designation ..............................................
4.00.00 Rated Voltage
a) HV winding (KV) ..............................................
b) LV winding (KV) ..............................................
5.00.00 Type of Cooling ..............................................
6.00.00 Class of insulation ..............................................
7.00.00 Type of insulation ..............................................
8.00.00 Tap changing equipment
A) No. of Steps ..............................................
9.00.00 Guaranteed positive sequence

impedence at 75 deg.C with
100% rating at Principal tap
10.00.00 Temperature rise over an ambient
A) Windings (by resistance measure- ..............................................

mend method) (deg.C)
11.00.00 Withstand time for three phase ..............................................

short circuit at terminals (sec.)
12.00.00 Bushings
a) Manufacturer ..............................................
b) Type ..............................................
c) Minimum creepage distance ..............................................

PAGE 30 OF 34
BIDDER’S NAME : ………………………………..
d) Rating ..............................................
13.00.00 Insulation level
a) Separate source power

frequency voltage withstand
i) HV winding (KV rms) ..............................................
ii) LV winding (rms) ..............................................
b) Induced over voltage withstand
i) HV winding (KV rms) ..............................................
ii) LV winding (rms) ..............................................
c) Full wave lightning impulse

withstand
i) HV winding (KVp) ..............................................
14.00.00 Over excitation withstand time ..............................................

(sec.) and %over excitation
continuous and short time

PAGE 31 OF 34
BIDDER’S NAME : ………………………………..
CONTROL DESK/CONTROL PANELS/PLC
1.00.00 Different Control Panels
a) Application ................................................
2.00.00 Control Switch
a) Manufacturer ................................................
b) Type and designation ................................................
3.00.00 Annunciators
a) Manufacturer ................................................

4.00.00 Meter & Instruements
a) Manufacturer ................................................
5.00.00 Energy Meters
a) Manufacturer ................................................
6.00.00 Indicating Lamps
a) Manufacturer ................................................
7.00.00 Push Buttons
a) Manufacturer ................................................
8.00.00 Panels
a) Manufacturer ................................................

PAGE 32 OF 34
BIDDER’S NAME : ………………………………..
9.00.00 Control Panel Details
a) Make of control panel
b) Manufacturer's type designation
c) Antivibration pad provided (Yes/No)
d) Panel IP protection
10.00.00 PLC System
a) Make of the PLC system
b) Description of list and diagonstic

features of PLC system
c) Field interrogation voltage level
i) For input
ii) For output
d) Hot standby provided Yes/No
11.00.00 Vibration Monitoring System
a) Type .............................................
b) Make .............................................
c) Power supply .............................................

PAGE 33 OF 34
BIDDER’S NAME : ………………………………..
H.T. LOAD BREAK SWTICH AND JUNCTION BOX
1.00.00 H.T. Load Break Switch
a) Make .............................................
b) Type .............................................
c) Whether shunt trip coil provided .............................................
d) Type of insulators .............................................
2.00.00 H.T. Junction Box
a) Make .............................................
b) Type .............................................
d) Type of insulators

PAGE 34 OF 34
SECTION - B

SUBMITTED AFTER AWARD OF CONTRACT
CLAUSE NO. TECHNICAL INFORMATION AND DATA TO BE SUBMITTED
BIDDER’S NAME : ………………………………..
SECTION - B

SUBMITTED AFTER AWARD OF CONTRACT
GENERAL
1.00.00 After award of contract, the contractor shall submit drawings, data sheets, design
calculations/criteria, write up on operation, control interlock protection, type test
procedure, guarantee test procedure and erection/O&M manuals as per agreed
engineering information flow schedule finalised on the basis of standard master list
of drawings/data sheets/documents.
2.00.00 The formats for data sheets of equipments shall be furnished to successful bidder
during preaward discussion which shall be followed while submitting equipment data
sheets for approval during detailed engineering stage.
3.00.00 General arrangement drawings for track hopper, wagon tippler, transfer houses,
tunnel conveyors, overground conveyors, overhead conveyors, control rooms,
crushers house, bunker bays, dust control/ventilation equipment etc. shall be
accompanied by load data details along-with basis and embedded part
details/anchor bolt schedule.
4.00.00 Fabrication drawings of conveyor technological structures, chutes/hoppers, paddle

feeders and trippers shall be submitted for reference.
5.00.00 Bidder shall furnish reports on shop tests, type test alongwith test certificates,
protocols.
6.00.00 Bidder shall furnish GA and cross sectional drawing, bill of material, performance
characteristics and material specification as applicable for all equipment.
7.00.00 Bidder shall furnish selection calculations for all drives, gearboxes, couplings, brakes
etc. for all equipments.
8.00.00 Bidder shall furnish field testing, precommissioning and commissioning procedure
for each equipment and system.
9.00.00 Bidder shall furnish performance and guarantee test procedures.
10.00.00 Bidder shall furnish to the Employer the design calculations selection criteria for
models of all major equipment.
11.00.00 Bidder shall furnish operation and maintenance instruction manual which shall
interalia include :
(a) Instruction for initial operation.
(b) Instruction for operation, maintenance and repair.

STAGE-II (2X195 MW) TO SECTION-B
PAGE 1 OF 3
BIDDER’S NAME : ………………………………..
(c) Recommended inspection points and periods of inspection.
(d) Safety and other warning notices and cautions for operation and
maintenance.
(e) List of spare parts, material specification, ordering information for all
replaceable parts etc.
12.00.00 The following informations shall be submitted for review/approval of Employer after
award of contract with regard to civil and structural works involved in this package.
(a) Design calculations and computations and design drawings for approval.
(b) Loading drawings setting out clearly and concisely the various loads taken
into consideration for design including equipment loads.
(c) Sequence of pile driving, if piles are required.
(d) Civil and structural drawings showing arrangement, reinforcement details,

architectural details, floor details, finishing works, door and windows
including their fixing details, rail fixing arrangement, drainage etc.
(e) With in 30 days of receipt of approval/comments on design drawings from

Employer, the final working drawings including bar bending schedules shall
be submitted to Employer for reference. Inserts and anchorage as required
shall be shown.
(f) The bidder shall also prepare and submit structural steel fabrication drawings
for reference of Employer.
13.00.00 The infomations to be submitted for review/approval of Employer after award of

contract in connection with Electrical/works covered under this package shall
interalia include :
(a) GA drgs of control/MCC/SWGR rooms.
(b) All equipment GAs with cross section, bill of materials, performance
characteristics and material specifications.
(c) General layout/details of cable trenches, trestles risers etc.
(d) Earthing & lighting layouts with earthing & lighting conductor size
calculations.
(e) Detail drawings of cable boxes, cable termination for various motors,
switchgears, MCC etc.
(f) Interlock schematics.

PAGE 2 OF 3
BIDDER’S NAME : ………………………………..
(g) Terminal arrangements and inter connection diagrams for different control
panels, switch-boards, MCC etc.
(h) Cable schedules/selection.
(i) Voltage drop calculations during starting and normal operation.
(j) Fault level calculations on HT/LT (415V) switchgear.
(k) List of drives, kw, frame size, full load current etc.
(l) Transformer size calculations.
(m) Details of 3.3 KV, 415V AC and 220V DC and other loads with single line
diagrams.
(n) Lighting design critieria, lighting layouts with BOQ.
(o) Complete technical literature supported by catalogues for all the equipments
and accessories covered in his scope of supply.
(p) Instrumentation manuals for all the equipments covered in the Bidder’s scope
of supply.
(q) Technical data sheets (Guaranteed technical particulars) of the equipment

offered.
(r) Type test and routine test reports for all the equipments and accessories
covered under Bidder scope of supply.
14.00.00 The informations sought out in the data sheets enclosed hereinafter in this section
shall be furnished by contractor in format specified by typing out answers to the
questionnaire at the appropriate place allotted.
15.00.00 Electrical
15.01.00 The formats of the data sheets of various electrical equipment required to the bidder
after award to contract.

PAGE 3 OF 3

2A NTPC MTPP CHP Tech Spec Datasheet & Tender Drawings

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2A NTPC MTPP CHP Tech Spec Datasheet & Tender Drawings

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KANTI BIJLEE UTPADAN NIGAM LTD.

(A JOINT VENTURE OF NTPC LIMITED AND BSEB)

MUZAFFARPUR THERMAL POWER PROJECT

COAL HANDLING PLANT PACKAGE

BID DOCUMENT NO.: CS-0350-155(R)-2

MUZAFFARPUR THERMAL POWER PROJECT

COAL HANDLING PLANT PACKAGE

BID DOCUMENT NO.: CS-0350-155(R)-2

PART SECTION NO TITLE

PART-A SUB SECTION- I PROJECT SYNOPSIS

IIA-01 INTENT OF SPECIFICATION

IIB-01 GUARANTEE TEST PROCEDURE

IIIA-01 SYSTEM PARAMETERS AND OPERATION &

IIIA-02 PADDLE FEEDER

IIIA-03 BRAKES & CLAMPS

IIIA-04 MONORAILS AND HOISTS

IIIA-05 CHUTES & HOPPERS

IIIA-06 BELT CONVEYOR SYSTEM

IIIA-07 DRIVE EQUIPMENT

IIIA-08 BELT SCALE

IIIA-09 DUST CONTROL & MISCELLANEOUS SYSTEM

IIIA-10 VENTILATION SYSTEM

IIIA-11 CHP BUILDING

IIIA-12 VIBRATING SCREENING FEEDER

IIIA-13 RING GRANULATOR AND VMS

IIIA-14 TRAVELLING TRIPPER & BUNKER SEALING

IIIA-15 INLINE MAGNETIC SEPARATOR AND

IIIA-16 METAL DETECTOR

IIIA-17 COAL SAMPLING UNIT

MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATION

PART SECTION NO TITLE

IIIA-19 STACKER CUM RECLAIMER

IIIA-20 WAGON TIPPLER

IIIA-21 APRON FEEDER

IIIA-22 SIDE ARM CHARGER

IIIB-02 LT SWITCHGEAR & BUS DUCT

IIIB-03 POWER CABLES

IIIB-04 CONTROL CABLES

IIIB-05 INSTRUMENTATION CABLES

IIIB-06 ILLUMINATION SYSTEM

IIIB-07 CABLING, EARTHING & LIGHTNING

IIIB-10 HT LOAD BREAK SWITCH AND JUNCTION BOX

IIIB-12 BATTERY CHARGER

IIIB-13 CONTROL PANEL

IIID-01 CHP SYSTEM - CIVIL & STRUCTURAL WORKS

IIID-02 FOUNDATION SYSTEM AND GEOTECHNICAL

PART-B QA & I SECTION

IIIE-01 TO E-17 QUALITY ASSURANCE AND INSPECTION

MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATION

PART SECTION NO TITLE

PART-C GENERAL TECHNICAL REQUIREMENTS

PART-D ERECTION CONDITIONS OF CONTRACT

PART-E LIST OF TENDER DRAWINGS

PART-F LIST OF MANDATORY SPARES

MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATION

MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATION

MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATION

2.00.00 LOCATION AND APPROACH

The vicinity plan of the project site is placed at Annexure – 1

The project is planned to be accommodated within existing premises of MTPS.

MUZAFFARPUR THERMAL POWER PROJECT TECHNICAL SPECIFICATIONS

Water Requirement and Commitment

Govt. of Bihar has accorded water commitment for availability of 45 Cusecs of