NTPC Limited - BHEL - Industrial Systems Group

NTPC Limited 

(A Government of India Enterprise) 

VINDHYACHAL SUPER THERMAL POWER PROJECT 

STAGE-III (2X500 MW) 

SECTION – VI 

TECHNICAL SPECIFICATIONS 

FOR 

WAGON TIPPLER, CONVEYING & 

CRUSHING PLANT PACKAGE 

(BOOK 1 OF 2) 

(MECHANICAL AND ELECTRICAL) 

BIDDING DOCUMENT NO. : CS-2240-155C-2







FOR 



(BOOK 1 OF 2) 

(MECHANICAL AND ELECTRICAL) 

BIDDING DOCUMENT NO. : CS-2240-155C-2 

(This document is meant for the exclusive purpose of bidding against this Bid 

Document No. / Specification and shall not be transferred, reproduced or 

otherwise used for purposes other than that for which it is specifically issued).

VINDHYACHAL SUPER THERMAL POWER 

PROJECT, STAGE-III (2X500 MW) 

WAGON TIPPLER, CONVEYING & CRUSHING 

PLANT PACKAGE 

TABLE OF CONTENTS 


PART SECTION NO TITLE 

BOOK 1 OF 2 : MECHANICAL & ELECTRICAL 

PART-A Sub Section- I Project Synopsis 

PART-A 

Sub Section – II : Scope of Supply & Services 

IIA-01 

Intent of Specification 

Scope 

Terminal Points & Exclusions 

IIB-01 PG Test Procedure 

IIC-01 Spares 

PART-B Sub Section III : Technical Parameters 

PART-B 

III-A MECHANICAL 

IIIA-01 System Parameters and Operation & Control 

Philosophy 

IIIA-02 Wagon Tippler 

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 


SECTION-VI 

MAIN CONTENTS 

PAGE 1 OF 3




PLANT PACKAGE 



IIIA-14 Inline Magnetic Separator and Suspended 

Magnet 

IIIA-15 Metal Detector 

IIIA-16 Coal Sampling Unit 

IIIA-17 Elevator 

IIIA-18 Apron Feeder 

IIIA-19 Side Arm Charger 

PART-B III-B ELECTRICAL 

PART-B 

IIIB-01 Motors 

IIIB-02 LT Switchgear & Bus Duct 

IIIB-03 HT Cables 

IIIB-04 LT Power Cables 

IIIB-05 Control Cables 

IIIB-06 Instrumentation cables 

IIIB-07 Illumination System 

IIIB-08 Cabling, Earthing & Lightning Protection 

IIIB-09 Transformers 

IIIB-10 HT Switchgear 

IIIB-11 Battery 

IIIB-12 Battery Charger 

IIIB-13 Control Panel 

IIIB-14 Closed Circuit Television System (CCTV) 

BOOK 2 OF 2 : CIVIL / QA&I / GTR / ECC / SPARES 

PART-B III-D CIVIL 

PART-B IIID-01 CHP System - Civil & Structural Works 


SECTION-VI 

MAIN CONTENTS 

PAGE 2 OF 3




PLANT PACKAGE 



IIID-02 Foundation System and Geotechnical Data 

(Turnkey) 

PART-B III-E QA & I SECTION 

PART-B 

IIIE-01 Coal Handling Plant 

IIIE-02 Motors 

IIIE-03 LT Switchgear & Busduct 

IIIE-04 LT Power Cables 

IIIE-05 LT Control Cables 

IIIE-06 Instrumentation Cables 

IIIE-07 Station Lighting 

IIIE-08 Cabling, Earthing & Lightning Protection 

IIIE-09 Control Panels 

IIIE-10 Programmable Logic Controller (PLC) 

IIIE-11 Battery Charger 

IIIE-12 HT Cables 

IIIE-13 HT Switchgear 

IIIE-14 Actuators 

IIIE-15 Auxiliary Transformer 

IIIE-16 Battery & Battery System 

IIIE-17 Measuring & Instrumentation 

IIIE-18 Closed Circuit Television System (CCTV) 

IIIE-19 CHP System - Civil & Structural Works 

PART-C General Technical Requirements 

PART-D Erection Conditions of Contract 

PART-E List of Tender Drawings 

PART-F List of Mandatory Spares 


SECTION-VI 

MAIN CONTENTS 

PAGE 3 OF 3

VINDHYACHAL SUPER THERMAL POWER PROJECT, 



PLANT PACKAGE 

PART - A 


SECTION-VI 

PART-A




PLANT PACKAGE 

PART - A 

SUB-SECTION-I 

PROJECT SYNOPSIS 


SECTION-VI 

PART-A

CLAUSE NO. 

1.00.00 BACKGROUND 




PLANT PACKAGE 



Details of proposed Stage / Units 

Project name Vindhyachal STPP 

Project Stage Wagon Tippler, Conveying & Crushing System 

No. of Units x capacity Applicable for Stage-I (6x210 MW), Stage-II 

Project setting up by NTPC Ltd. 

Details of Existing Units : 

Stage-1: 

Stage-2: 

Stage-3: 

2.00.00 LOCATION AND APPROACH 

(2X500 MW) and for Stage-III (2X500 MW) 

No. of units. : 6 Capacity : 210 MW 

Present Status : Units Commissioned 





Project Location (i.) Place :Vindhyachal 

Latitude and Longitude 

of project location 

(ii) District :Sidhi 


SECTION-VI 

PART-A 

(iii.) State :Madhya Pradesh 

North : 24 Deg 06' N 

East : 82 Deg 40' E 

Nearest Railway station Shakti Nagar 

Distance of project location from 

the Railway station 

2 KM (Approx.) 

SUB-SECTION-I 


PAGE 

1 OF 17

CLAUSE NO. 

3.00.00 WATER 




PLANT PACKAGE 


Nearest Major Town Renukoot 

Distance of the town from the 

Project site 

50 KM 

Nearest Commercial Airport Varanasi 

Distance of airport from the 

project site 

220 KM 

Nearest Highway State Highway 

Distance from nearest highway 

point to the site 

2KM (aprox.) 

Vicinity plan Vicinity plan of the project 

Any other information: Further to the information given in this subsection 

, Bidders are advised to visit the 

project site and collect data on local site 

conditions 

Nearest Water Source Hot water discharge channel of Singrauli 

Water requirement for the 

ultimate Stage (all the three 

stages) 

Proposed source/ 

arrangement to meet the 

water requirement : 

230Cusec 

Hot water discharge channel of Singrauli 

4.00.00 COAL LINKAGE/AVAILABILITY AND TRANSPORTATION 

(a.) Coal Linkage/Availability 

Proposed source/ 

arrangement to meet the 

coal requirement : 

Coal Commitment/ Coal 

Link 


SECTION-VI 

PART-A 

MCL, CCL and Import tie-ups 

The SLC granted linkage of 3.00 million tons 

per annum from MCL, CCL and Import tie-ups 

through Indian Railway System. 

SUB-SECTION-I 


PAGE 

2 OF 17

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-A 

The SLC granted linkage of 9.9 million tons 

per annum from NCL through MGR System. 

Any other information: Coal Requirement for Vindhyachal STPP 

Stage I, II & III is also being met from same 

coal source. 

(b.) Coal Transportation 

Existing coal transportation 

arrangement 

Proposed Coal 

transportation arrangement 

Captive MGR system 

: Through Indian Railway System by laying 

additional track. 

(c.) Coal Quality Parameters and Fuel Oil Characteristics 

The Coal quality Parameters and Fuel Oil Characteristics are enclosed as 

Annexures to this subsection. 

5.00.00 METEOROLOGICAL DATA 

Data of Sidhi station is enclosed as Annexure to this subsection. 

6.00.00 PLANT WATER SCHEME 

6.01.00 Condenser Cooling (CW) Water System 

It is proposed to provide recirculating type CW system with induced draft type cooling 

towers. Raw water for Stage - III of this project shall be pumped from the hot water 

(CW system) discharge channel of Singrauli Project of NTPC to Water Pretreatment 

Plant. The treated clarified water shall be pumped to the CW channels of Stage - III 

Circulating Water (CW) system at the upstream of cooling towers as make up to the 

system. It is proposed to operate the CW system at a C.O.C. of about 2.5 and CW 

side stream filtration and chemical treatment programme (using acid dosing and 

scale cum corrosion inhibitors dosing) shall be employed in addition to blow down of 

CW water to control the CW system water chemistry. The expected circulating water 

analysis is given in Annexure A-III of this sub-section. The CW blow water shall be 

tapped off from the discharge of CW pumps and led to a Service Water Tank. 

6.02.00 Equipment Cooling Water (ECW) System (Unit & Station Auxiliaries) 

The plant auxiliaries of Steam Generator and Turbine Generator shall be cooled by 

Demineralised water (DM) in a closed circuit. The primary circuit DM water shall be 

cooled through plate type heat exchangers by Circulating Water tapped from CW 

SUB-SECTION-I 


PAGE 

3 OF 17

CLAUSE NO. 




PLANT PACKAGE 


system in a closed secondary circuit The hot secondary circuit cooling water shall be 

cooled in the cooling towers and shall be returned back to the system. 

7.00.00 ASH WATER SYSTEM 

It is proposed to operate the ash water system in a closed circuit at a C.O.C. of about 

2.5. The ash water from the ash dyke shall be re-used after treating a part of the 

same in a side stream lime softening plant. During re-circulation mode, the make up 

to the ash water system (to compensate for the ash water blow down and 

evaporation loss) shall be supplied from the CW system blow down water. 

During initial operating stage of the project, when decanted ash water is not available 

from the dyke, the ash water system shall be operated in once through mode. The 

make-up water to ash water system shall be pumped from the raw water (from the 

discharge channel of Singrauli station) source, CW blow down water from the Service 

water tank and as well as from treated water from Central Monitoring Basin of liquid 

Effluent Treatment Plant. 

Considering total ash handling plant water requirement of 2500 Cu.M/hr for slurry 

formation during re-circulation mode operation, it is expected that about 2000 M3/hr 

of decanted ash water shall return to the ash handling system after accounting for 

evaporation loss. Considering a system blow down of about 350 Cu.M/hr from the 

system, raw water make up of 850 M3/hr shall be pumped from the service water 

tank which shall be CW blow down quality. About 30% of decanted ash water shall 

be treated in a side stream lime softening plant bay and treated water be led to ash 

water system. 

During once through mode operation, about 1000 M3/hr shall be pumped from the 

service water tank (CW system blow down quality) and balance 1500 M3/hr water 

shall be pumped from the raw water source (hot water discharge channel). 

8.00.00 OTHER MISCELLANEOUS WATER SYSTEMS 

(a.) CW system blow down water shall be used for the plant service water 

requirement, Wash water for Air-preheaters and ESPs, dust suppression 

system of coal handling plant, make-up to fire water storage tanks and 

cooling water requirement of hydrogen generation plant. CW blow down water 

is estimated to be of the order of 1500 Cu.M/hr. 

(b.) The drinking water requirement shall be provided from the above mentioned 

Water pretreatment plant. 

(c.) It is proposed to provide two numbers of DM water storage tanks for Stage-III 

and these new sets of tanks shall be filled by extension of existing DM water 

pipelines of Stage-II. From the proposed DM water Storage tanks, DM water 

shall be pumped to meet the Steam Cycle make-up water requirement, 

makeup the hydrogen generation plant and makeup to the primary circuit of 


SECTION-VI 

PART-A 

SUB-SECTION-I 


PAGE 

4 OF 17

CLAUSE NO. 




PLANT PACKAGE 


ECW system of unit auxiliaries by means of DM water make up pumps. In 

addition, separate set of boiler fill pumps shall be provided to fill the boiler 

from these DM water storage tank. DM Water required for regeneration of 

Condensate polishing Plant and resin transfer operation shall also be 

provided by these tanks. 

(d.) The service (wash water) collected from various areas shall be treated using 

oil water separators, tube settlers, coal settling pits etc. as per requirement 

and treated water from liquid effluent treatment plant shall be recycled back to 

the service water system for re-use. The excess service water from the 

service water tank/CW blow down pipe line shall be led to central monitoring 

basin for disposal. 

(e.) The quality of Clarified water, filtered (potable) water and DM water is given in 

the enclosed Annexure to this sub-section. 

9.00.00 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 

Specification on Civil Works. 

10.00.00 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 

Specification on Civil Works. 


SECTION-VI 

PART-A 

SUB-SECTION-I 


PAGE 

5 OF 17

CLAUSE NO. 

Sl. 

No. 




PLANT PACKAGE 


COAL QUALITY PARAMETERS ANNEXURE –A- II -1 

Description Unit Design 

Coal 


SECTION-VI 

PART-A 

Range of 95% 

coal Supplies 

Worst 

Coal 

Best 

Coal 

1 2 3 4 5 6 7 

A. PROXIMATE ANALYSIS (As received basis) 

SUB-SECTION-I 


Range of 

Adequacy 

1. Total Moisture % 20.00 22.00 17.00 23 - 16 

2. Ash % 30.00 35.00 24.00 36 - 23 

3. Volatile matter % 21.00 19.00 23.00 18 - 24 

4. Fixed carbon % 29.00 24.00 36.00 23 - 37 

B. ULTIMATE ANALYSIS (As received basis) 

1. Carbon C% 37.56 32.30 45.00 30.4 - 46.90 

2. Hydrogen H2% 3.2 2.9 3.5 2.8 - 3.6 

3. Nitrogen N2% 0.95 0.55 1.6 0.55 - 1.6 

4. Oxygen O2% 6.94 6.25 7.06 6.25 - 7.06 

5. Sulphur S% 0.3 0.3 0.5 0.3 - 0.5 

6. Carbonates CO3% 0.75 0.6 0.92 0.6 - 0.92 

7. Phosphorous P2% 0.3 0.1 0.42 0.1 - 0.42 

8. Total Moisture H2O% 20 22 17 23 - 16 

9. Ash % 30 35 24 36 - 23 

10. Total % 100 100 100 

11. Gross Calorific 

Value 

KCal/Kg 3700 3200 4400 3000 - 4500 

12. Hard grove index 52 48 60 48 – 62 

13. YGP index 

(minimum) 

mg/kg 80 80 80 80 

PAGE 

6 OF 17

CLAUSE NO. 

Sl. 

No. 




PLANT PACKAGE 




Coal 


SECTION-VI 

PART-A 

Range of 95% 

coal Supplies 

Worst 

Coal 

Best 

Coal 

1 2 3 4 5 6 7 

C. ASH ANALYSIS 

SUB-SECTION-I 


Range of 

Adequacy 

1. Silica (SiO2)% 59.6 58.6 62.5 58.1 – 63.0 

2. Alumina (Al2O3)% 24.6 25.6 22.7 26.1 - 22.2 

3. Iron Oxide (Fe2O3)% 10.2 11.2 8.62 11.5-8.32 

4. Titania (TiO2)% 1.07 1.17 0.80 1.2 – 0.82 

5. Phosphoric 

Anhydride 

(P2O5)% 0.18 0.1 0.48 0.1 - 0.5 

6. Lime (CaO)% 3.2 2.08 3.3 1.78 – 3.5 

7. Magnesia (MgO)% 0.6 0.9 0.5 0.9 – 0.5 

8. Sulphuric 

Anhydride 

9. Alkalies 

(By diff.) 

(SO3)% 0.25 0.15 0.4 0.12 - 0.43 

Na2O + 

K2O% 

D. ASH FUSION RANGE (Under reducing atmosphere) 

a) Initial 

Deformation 

Temperature 

b) Hemispherical 

temperature 

c) Fusion 

temperature 

0.3 0.2 0.7 0.2 – 0.73 

(IDT) °C 1110 1050 1150 1000 - 1150 

°C 1300 1250 1350 1200 - 1400 

°C 1400 1400 1400 1400-1450 

PAGE 

7 OF 17

CLAUSE NO. 

Sl. 

No. 




PLANT PACKAGE 




Coal 


SECTION-VI 

PART-A 

Range of 95% 

coal Supplies 

Worst 

Coal 

Best 

Coal 

1 2 3 4 5 6 7 

E. ASH FUSION RANGE (Under oxidising atmosphere) 

a) Initial 

Deformation 

Temperature 

b) Hemispherical 

temperature 

c) Fusion 

temperature 

SUB-SECTION-I 


Range of 

Adequacy 

(IDT) °C 1200 1100 1250 1050 - 1250 

°C 1350 1300 1400 1250 - 1400 

°C 1400 1400 1400 1400-1450 

PAGE 

8 OF 17

CLAUSE NO. 

FUEL OIL CHARACTERISTICS 

Sl. 

No. 




PLANT PACKAGE 


Characteristics Heavy 

Furnace Oil 

IS-1593 1971 

Grade HV 


SECTION-VI 

PART-A 

Low Sulphur 

Oil Heavy 

Stock (LSHS) 

SUB-SECTION-I 


ANNEXURE A – II- 2 

(Sheet 1 of 2) 

Heavy 

Petroleum 

Stock (HPS) 

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

2. Gross calorific 

alue(KCal/kg) 

3. Flash Point (Min) 

(PMCC) 

4. Water content by 

volume (Max) 

5. Sediment by weight 

(Max) 

6. Asphaltene content by 

weight (Max.) 

7. Kinematic viscosity in 

Centistokes 50deg C 

(Max) 

8. Ash Content by weight 

(Max.) 

10280 

(Typical) 

Of the 

orderof11,000 

Of the orderof 

10,000 

66 deg C 76 deg C 66-76 deg C 

1.0% 1.0% 1.0% 

0.25% 0.25% 0.25% 

- - - 

370 - - 

0.1% 0.05% 0.1% 

9. Acidity (inorganic) Nil Nil Nil 

10. Pour Point (Max.) 

72Deg.C 

- - 72 deg C 

11. Sodium content - - - 

12. Vanadium content - - - 

13. Specific heat below 

pour point (KCal/Kg °C) 

- - - 

PAGE 

9 OF 17

CLAUSE NO. 




PLANT PACKAGE 


LIGHT OIL CHARACTERISTICS 

(AS PER IS 1460-1974 WITH AMENDMENTS UPTO OCT.85) 

S.No. Characteristics LDO 


SECTION-VI 

PART-A 

SUB-SECTION-I 


ANNEXURE-A-II-2 

(Sheet 2 of 2) 

1. Pour Point (max) 12 deg. C & 21 deg C for 

Winter and summer 

respectively. 

2. Kinematic viscosity in centistokes at 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) percent by 

pass (max.) 

8. Acidity in organic Nil 

9. Flash point (Min.) 

a) Abel ° C, min 

b) PMCC O C, min. 

10. Acidity, total, mg of KOH/g (max.) - 

2.5 to 15.7 

1.50 

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

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

- 

66 

PAGE 

10 OF 17

CLAUSE NO. 




PLANT PACKAGE 


WATER ANALYSIS 

Sl. No. Constituent as mg per litre 

a) COOLING WATER ANALYSIS 

1. Calcium CaCO 3 148.0 

2. Magnesium CaCO 3 37.5 

3. Sodium & Potassium CaCO 3 47.5 

4. Bicarbonates CaCO 3 104.5 

5. Chloride CaCO 3 47.5 

6. Sulphate CaCO 3 81.0 

7. Carbonate CaCO 3 0 

8. Silica SiO2 25.0 

9. Iron Fe 0.75 

10. pH Value - 7.6 - 7.9 

11. Turbidity NTU 50 


SECTION-VI 

PART-A 

SUB-SECTION-I 


ANNEXURE- A-IV 

Note : The C.W system is expected to operate at about 2.5 Cycles of 

Concentration. 

b) RAW WATER (MAKEUP TO ASH WATER SYSTEM) ANALYSIS 






PAGE 

11 OF 17

CLAUSE NO. 




PLANT PACKAGE 







9. Iron Fe 2.0 

10. pH Value - 7.6 - 8.2 

11. Turbidity NTU 50 -500 

12. 

Temperature ( o C) 

Note : Raw water from hot water channel of Singrauli STPP. 

c) CLARIFIED WATER ANALYSIS (PT-CW) 







7. . Carbonate CaCO 3 0 


9. Iron Fe 2.0 

10. pH Value - 7.6 – 8.2 

11. Turbidity NTU 50 - 500 

12. 

Temperature ( o C) 

Note : At the outlet of clarifier of PT plant 


SECTION-VI 

PART-A 

43 

43 

SUB-SECTION-I 



PAGE 

12 OF 17

CLAUSE NO. 




PLANT PACKAGE 




d) FILTERED WATER ANALYSIS (Drinking Water) 









9. Iron Fe 0.30 

10. pH Value - 7.5 – 7.7 

11. Turbidity NTU 2 


SECTION-VI 

PART-A 

SUB-SECTION-I 



PAGE 

13 OF 17

CLAUSE NO. 




PLANT PACKAGE 


ANALYSIS OF DM WATER TO BE USED FOR 

MAKE-UP WATER TO CONDENSER 

Sl. No. Characteristics Value 

1. Silica (Max.) 0.02 ppm as SiO2 

2. Iron as Fe Nil 

3. Total hardness Nil 

4. pH value 6.8 to 7.2 


SECTION-VI 

PART-A 

SUB-SECTION-I 


ANNEXURE-A-IV 

5. Conductivity Not more than 0.1 excluding 

the effects of free CO 2 

PAGE 

14 OF 17

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-A 

SUB-SECTION-I 


VICINITY PLAN 

PAGE 

15 OF 17

CLAUSE NO. 




PLANT PACKAGE 


METEOROLOGICAL DATA 


SECTION-VI 

PART-A 

SUB-SECTION-I 


PAGE 1 OF 2 

PAGE 

16 OF 17

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-A 

SUB-SECTION-I 


PAGE 2 OF 2 

PAGE 

17 OF 17




PLANT PACKAGE 

PART - A 

SUB-SECTION-IIA-01 

SCOPE OF SUPPLY & SERVICES 


SECTION-VI 

PART-A

CLAUSE NO. 




PLANT PACKAGE 


COAL HANDLING PLANT : 

WAGON TIPPLER, CONVEYING & CRUSHING PLANT 

1.00.00 INTENT OF SPECIFICATION 

1.01.00 This specification is intended to cover the following activities and services in respect 

of all the equipment of CHP - Wagon Tippler, Conveying & Crushing Plant to be 

installed for Vindhyachal Super Thermal Power Project of the National Thermal 

Power Corporation Ltd.), 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 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. 

(ix) Furnishing of spares on FOR site basis and handing over to NTPC 

stores. 

(x) Reconciliation with custom authorities, if applicable. 

(xi) Satisfactory conclusion of the contract. 


SECTION-VI 

PART-A 


SCOPE OF SUPPLY & 

SERVICES 

PAGE 

1 OF 21

CLAUSE NO. 




PLANT PACKAGE 


(b.) The equipment and services to be furnished and erected as required in this 

Technical Specification shall also meet all the requirements as stated 

“General Conditions of Contract” (GCC), “ Special Conditions of Contract” 

(SCC) and “Bid Form & Procedures” which shall be considered as a part of 

this technical specification as bound herewith. 

(c.) The Contractor shall be responsible for providing all materials, equipment and 

services, specified or otherwise (unless specifically excluded) which are 

required to fulfill the intent of ensuring operability and the reliability of the 

complete system covered under this specification. 

(d.) It is not the intent to specify completely herein, all aspects of design and 

construction of equipment. Nevertheless, the equipment shall conform in all 

respects to high standards of engineering, design and workmanship and shall 

be capable of performing in continuous commercial operation. 

(e.) Whenever a material or article is specified or described by the name of a 

particular brand, manufacturer or trade mark, the specific item shall be 

understood as establishing type, function and quality desired. Other 

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.) Contractor 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 bid documents. 

The Contractor’s offer should not carry any sections like clarifications, 

interpretations and/or assumptions. 

(g.) If the Contractor 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 Contractor 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. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

2 OF 21

CLAUSE NO. 




PLANT PACKAGE 


(h.) Any deviation or variation from the scope, requirement and/or intent of this 

specification shall be clearly defined under “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 Contractor. Except for those deviations/ variations 

covered under Attachment-6 Schedules which are accepted by the Employer 

before the award of the Contract, it will be the responsibility of the Contractor 

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 Contractor 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 Contractor shall be binding unless specifically 

clarified otherwise by the Employer in writing before the Award of the 

Contract. 

(i.) Before submitting his bid, the Contractor 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 Contractor, the Contractor 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 tunnels indicated in the 

tender drawings and the parameters of equipment’s indicated in various 

sections of technical specifications are the minimum requirements of the 

employer. Any increase in these sizes or the parameters, if required to meet 

the system/maintenance/operational requirement shall be supplied by the 

Contractor without any extra cost implication to the employer. 

(l.) The works under the scope of this contract are to be executed in an operating 

power station. The contractor shall take all necessary precautions to protect 

all the existing equipment, structures, facilities and buildings etc. from 

damage. In case any damage occurs due to the activities of the contractor on 

account of negligence, ignorance, accidental or any other reason whatsoever, 

the damage shall be immediately made good by the contractor at his own 

cost to the satisfaction of the Employer. The contractor shall also take all 

necessary safety measures with specific reference to excavation in rock, at 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

3 OF 21

CLAUSE NO. 




PLANT PACKAGE 


his own cost, to avoid any harm or injury to his workers and staff from the 

equipment and facilities of the power plant. 

(m.) Contractor should note that the existing rail lines within the plant area are 

operational with rail traffic of coal and liquid fuel rakes. Contractor 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 Contractor 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, Contractor 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 contractor shall carry 

out a site survey to identify the location & details of existing facilities that may 

interfere with his proposed facilities. The contractor 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. Contractor 

shall also be responsible to determine and obtain the necessary details at site 

as required for interfacing and interconnection with the existing system / 

facilities. 

If during the execution of works it is found that there is interference with the 

existing facilities / structures, the contractor shall revise his design / detailed 

drawings to clear the interference and shall provide all necessary measures 

for the safety of existing structures. No claim in terms of cost or relaxation in 

time shall be entertained for any redesign, rework and for safety measures 

provided. If at any stage of work, any dismantling or modification or relocation 

of any existing facility is required to be done to complete the work in 

Contractor’s scope and which has been agreed by the Employer, the same 

shall be done by the Contractor 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) Contractor’s Office & Store Buildings 

For his site office and covered store buildings, the contractor shall adopt preengineered 

/ 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, contractor can adopt 

readymade ‘Portacabin’ or similar construction. Contractor shall ensure that 

all such constructions are well engineered, neatly constructed and overall 

present a pleasing look. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

4 OF 21

CLAUSE NO. 




PLANT PACKAGE 


(p) Use of ash and ash based products 

In line with Gazette Notification on Ash Utilisation issued by MOEF and its 

amendment thereafter, contractor 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 Contractor 

Contractor 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. 

Contractor 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 Wagon Tippler, Conveying & Crushing 

Plant Package are described in the following sub-sections : 

MECHANICAL 

III-A-01 : System parameters and Operation & Control Philosophy 

III-A-02 : Wagon Tippler 

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 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

5 OF 21

CLAUSE NO. 

III-A-10 : Ventilation System 

III-A-11 : CHP Buildings 




PLANT PACKAGE 


III-A-12 : Vibrating Screening Feeders. 

III-A-13 : Crusher and VMS 

III-A-14 : Inline Magnetic Separator and Suspended Magnet 

III-A-15 : Metal Detector 

III-A-16 : Coal Sampling Unit 

III-A-17 : Elevator 

III-A-18 : Apron Feeder 

III-A-19 : Side Arm Charger 

ELECTRICAL 

IIIB-01: Motors 

IIIB-02 : LT Switchgear & Bus Duct 

IIIB-03 : HT Cables 

IIIB-04 : LT Power Cables 

IIIB-05 : Control Cables 

IIIB-06 : Instrumentation cables 

IIIB-07 : Illumination System 

IIIB-08 : Cabling, Earthing & Lightning Protection 

IIIB-09 : Transformers 

IIIB-10 : HT Switchgear 

IIIB-11 : Battery 

IIIIB-12 : Battery Charger 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

6 OF 21

CLAUSE NO. 

IIIB-13 : Control Panel 




PLANT PACKAGE 


IIIB-14 : Closed Circuit Television System (CCTV) 

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-19 : 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 forming part of the specification 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) Wagon Tippler, Conveying & Crushing Plant 

Package to be furnished, erected and commissioned under this specification shall be 

as detailed hereinafter. The Contractor shall be fully responsible for system and 

detailed design, engineering, manufacture, shop fabrication, assembly, testing and 

inspection at 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, complete services of construction, 

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. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

7 OF 21

CLAUSE NO. 




PLANT PACKAGE 


1.06.02 The scope of the contractor shall be deemed to include all such items which although 

are not specifically mentioned in the bid documents and/or in Contractor’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 Vindhyachal Super Thermal Power Project consists of three Stages. Under Stage-I, 

six (6) generating units each of 210 MW capacity have already been provided and 

are under operation. Under Stage-II, two (2) generating units each of 500 MW 

capacity have already been provided and are under operation. Under Stage-III, two 

(2) generating units each of 500 MW capacity have already been provided and are 

under operation along with their auxiliaries and other facilities. 

2.01.02 Under Stage-I (6 x 210 MW units) of the project one (1) coal handling plant consisting 

of one (1) track hopper, 2000 MTPH coal conveyor system (with 100 % standby 

parallel stream) along with paddle feeders, crusher house, trippers etc. and one (1) 

no. 2000 MTPH capacity stacker cum reclaimer with associated reclaim conveyors 

have been provided. 

2.01.03 Under Stage-II (2 x 500 MW units) of the project one (1) coal handling plant 

consisting of one (1) track hopper, 1500 MTPH direct stream coal conveyor system 

(with 100 % standby parallel stream) along with paddle feeders, crusher house, 

trippers etc. and one (1) no. 1500/2000 MTPH Stacking / Reclaiming capacity stacker 

cum reclaimer with associated 2000 MTPH reclaim conveyors have been provided. 

2.01.04 An interconnection has been provided between Stage-I and Stage-II for stacking the 

crushed coal from Stage-I to Stage-II stockyard through TP-5, Conveyor 21. 

Similarly, the reclaim conveyors taking feed from both the stockyards of Stage-I and 

Stage-II can drop on to Stage-I or Stage-II conveying stream for onward transfer of 

coal to Boiler Bunkers. 

2.01.05 Under Stage-III (2 x 500 MW units) of the project one (1) coal handling plant 

consisting of one (1) track hopper, 1500 MTPH direct stream coal conveyor system 

(with 100 % standby parallel stream) along with paddle feeders, crusher house, 

trippers etc. and one (1) no. 1500/1500 MTPH Stacking / Reclaiming capacity stacker 

cum reclaimer with associated 1500 MTPH reclaim conveyors have been provided. 

2.01.06 An independent CHP - Wagon Tippler, Conveying & Crushing Plant of 1400 TPH 

rated (guaranteed) capacity is proposed for feeding existing conveyor stream of 

Stage-I and feeding stockyard of Stage-II. Coal handling plant consisting of two (2) 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

8 OF 21

CLAUSE NO. 




PLANT PACKAGE 


nos. wagon tipplers, 1400 TPH coal conveying system (with 100 % standby parallel 

stream) along with crusher house are proposed to be installed along with their 

auxiliaries and other facilities. 

2.01.07 Brief description of proposed Coal handling Plant 

This shall be read in conjunction with Coal Flow Diagram and the General Layout 

Plan enclosed else where in this specification. 

(i) Indian Railway (IR) rakes consisting of Box-N wagons shall transport coal to 

the power plant. The coal received form 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) 

wagon load of coal i.e. 180 Te. Two (2) such Rota side wagon tipplers (WT-1 

& WT-2) 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 feed onto underground reclaim conveyors. 

(ii) Two (2) No. wagon tipplers (WT-1 & 2) alongwith Two (2) Nos. Apron feeder- 

AF-1 & 2 shall be provided to unload coal from Box-N wagons. Apron feeder 

AF-1, receiving coal from WT-1 shall drop coal on to either conveyor 37A or 

37B at Junction Tower JT-1 and Apron feeder-AF-2 receiving coal from WT-2 

shall also drop coal on to either conveyor 37A or 37B at Junction Tower JT-1. 

The rated capacity of Apron Feeder shall be 1200 MTPH and Conveyors shall 

be 1400 MTPH. However rated capacity of existing / extended conveyor 21 is 

2000 MTPH. 

(iii) Conveyor 37A/37B receiving coal from Apron Feeder AF-1 or AF-2 at JT-1 

shall feed coal to conveyor 38A or 38B at Junction Tower JT-2. Suspended 

magnets (SM-1 and SM-2) shall be provided on Conveyor 37A/37B at JT-2 

for removal of tramp Iron pieces. Further at Junction Tower, JT-2 provision 

shall be kept for Conveyor 37A/37B dropping coal on to future conveyor of 

Stage-IV. 

(iv) Conveyor 38A/38B shall feed coal to crusher house CH-WT via Pent House 

(PH). Metal detectors MD-1 and MD-2 shall be provided on Conveyors 

38A/38B to detect metallic tramps present in the “as received” coal. Two 

numbers Belt Scale (BS-1 & BS-2) shall also be provided, one each on 

Conveyor 38A and 38B for measurement of coal flow rate. Further Conveyor 

38A/38B shall have facility for manual stone picking, at a suitable location 

after PH. In line magnetic separators (ILMS-1 & 2) shall be provided on 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

9 OF 21

CLAUSE NO. 




PLANT PACKAGE 


Conveyor 38A/38B head end at crusher house for removal of metallic ferrous 

tramp from “as-received” coal. 

(v) Coal from each incoming Conveyor 38A/38B to Crusher House (CH-WT) will 

pass through a set of dedicated crushers i.e. Crushers (CR-1 & CR-2) 

respectively. There shall be a combination of Rod Gate and Rack & Pinion 

Gate provided in the inlet chute of each vibrating grizzly screen. In Crusher 

house (CH-WT), coal from incoming Conveyor 38A will pass through one (1) 

number (dedicated) Vibrating Screening Feeder (VSF-1) and one (1) number 

(dedicated) crusher (CR-1) respectively. Similarly coal from incoming 

conveyor-38B will pass through one (1) number (dedicated) vibrating 

screening feeders (VSF-2) and one (1) number (dedicated) crushers (CR-2) 

respectively. This shall permit maintenance of equipment, hopper and chutes 

in one stream without effecting the operation of other stream. The crusher 

shall be of ring granulator type. Coal sampling unit (CSU-1) shall be provided 

to sample the coal of (-)250mm size. Further, a passenger cum goods 

elevator (EL-1) as specified elsewhere shall also be provided in Crusher 

House (CH-WT). 

(vi) Each of the two (2) Vibrating Screening Feeder shall be of 1400 TPH 

capacity. Each of the two (2) ring granulator shall be of 1400 MTPH capacity 

which shall crush coal to (-) 20mm size. Both the screened coal below 20mm 

size and crushed coal shall be discharged on to Movable Belt Feeders (BF-1 

& BF2) placed below the crusher floor for discharging crushed coal on to 

either Conveyor 39A or 39B. 

(vii) At Junction Tower JT-3, Conveyor 39A/39B shall drop coal onto either 

existing Conveyor 3A or 3B of Stage-I for bunkering of coal or shall drop coal 

on to Conveyor 39A/39B itself. 

(viii) At Junction Tower JT-4, Conveyor 39A/39B shall drop coal onto extended 

Conveyor 21 of Stage-II for stocking coal at Stage-II Stockyard through 

existing Transfer Point TP-8. 

(ix) Existing Transfer Tower TP-5, of stage-II, shall be modified for extension of 

conveyor-21 to Junction Tower JT-4 to receive coal from conveyor 39A/39B. 

(x) Existing Conveyor gallery of Conveyor 3A/3B, of Stage-I, shall be suitably 

modified for incorporation of new Junction Tower JT-3 and for receiving coal 

from new conveyor 39A/39B. 

(xi) Provisions shall be made on conveyor 39A/39B to receive coal from future 

conveyor 60A/60B through future TP-49. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

10 OF 21

CLAUSE NO. 

2.02.00 DETAILED SCOPE 




PLANT PACKAGE 


2.02.01 Underground wagon tippler hoppers, underground Junction Tower, JT-1, JT-2 

underground tunnels and pent house (PH), complete with civil, structural, 

architectural and electrical works including machinery hatches, steel grating (over 

hopper portion), removable chequered plate covers over openings in machinery 

hatches for handling underground equipment in wagon tipplers and for all other 

buildings, structure over machinery hatches equipment handling facilities for feeders 

below wagon tippler and below machinery hatches, hand rails 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 wagon tipplers are excluded from Contractor’s scope but fixation of 

rails near wagon tippler table is in Contractor’s scope. 

2.02.02 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. 

2.02.03 Two (2) nos. Apron Feeders alongwith dribble Conveyor complete with drives 

including all accessories, electricals, supporting structures, approach/ maintenance 

platform and associated civil & structural works etc. 

2.02.04 Conveyors 37A/37B complete with tunnel alongwith its supporting structures, short 

supports, stringers, deck plates, Conveyor foundations, drive motors drive units, 

Pulleys, Idlers, take-ups, take-up structures, internal and external belt cleaners, pull 

chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes 

all electrical etc. including all civil structural and architectural works and their 

associated foundations. 

2.02.05 Conveyor 38A/38B 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 38A/38B shall have facilities for manual stone picking arrangement at 

an appropriate location after the pent house (PH). 

2.02.06 Belt Conveyors 39A/39B complete with conveyor galleries, conveyor supporting 

structures, fixed trippers, short supports, stringers, deck plate, seal plate, conveyor 

foundations, drive motors, drive units, pulleys, idlers, gravity take ups take up 

structures 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 etc. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

11 OF 21

CLAUSE NO. 




PLANT PACKAGE 


2.02.07 Provisions shall be made on conveyor 39A/39B to receive coal from future conveyor 

60A/60B through future TP-49 

2.02.08 Extension of existing Conveyor 21 of Stage-II, from existing transfer point TP-5 to 

Junction Tower JT-4 complete with ground conveyor gallery, conveyor supporting 

structures, short supports, stringers, deck plates, conveyor foundations, idlers 

pullchord switches, belt sway and zero speed switches etc. for extended length of 

conveyor, electro-hydraulic thruster brakes modification of take-ups and take-up 

structure as required check for adequacy of Belt and Drive Unit and all electrical, 

civil, structural and architectural works and their associated foundations for extended 

conveyor as required. 

2.02.09 Modification of existing conveyor gallery of conveyor 3A/3B, of Stage-I, for 

incorporation of junction tower JT-3 including accessories as described elsewhere. 

Modification of Conveyor 3A/3B and its gallery shall also include provision of chute 

work, skirt board over existing Conveyor 3A/3B for receipt of Coal from Conveyor 

39A/39B etc. 

2.02.10 One (1) number Crusher House (CH-WT) complete with all civil, structural, 

architectural and electrical works etc accommodating two (2) nos. Ring Granulators 

and associated Vibrating Screening Feeders, R&P and Rod Gates etc., passenger 

cum goods elevator, conveyors, chute work alongwith movable belt feeder, 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. 

2.02.11 Two (2) nos. Vibrating screening feeders (in crusher house CH-WT) to feed the coal 

to crushers complete with drives, dust hood, all mechanical, electrical accessories 

and supporting structures etc. 

2.02.12 Two (2) 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. 

2.02.13 Two (2) sets of Gates each comprising of one rod gate and one actuator operated 

rack & pinion gate at inlet to each of the vibrating screening feeder feeding coal to 

crushers complete with drives, all mechanical, electrical, structural works etc. 

2.02.14 Junction Tower JT-1 & JT-2 (along with under ground RCC structures), JT-3 and JT 

-4, tunnel complete with all civil, structural, architectural and electrical works including 

chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, 

external/internal staircases as required., etc. Junction Towers (JT-3 and JT-4) shall 

have debris disposal chute up to the ground floor. Underground Junction Tower JT- 

1& JT-2, shall be provided with machinery hatch with removable chequered plates for 

handling under ground equipment, internal stair case alongwith monorails, 

hoists/chain pulley blocks. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

12 OF 21

CLAUSE NO. 




PLANT PACKAGE 


2.02.15 At Junction Tower JT-2, provision shall be kept for dropping coal from conveyor 

37A/37B to either of Conveyor 38A/38B or to future Stage-IV conveyors. Moving 

head alongwith take-up arrangement of conveyor 37A/37B shall be accordingly 

designed. 

2.02.16 All mechanical and electrical equipment, to be housed in Junction Tower JT-1, JT-2, 

JT-3 and JT-4 including coal feeding chutes, monorails, hoists, maintenance/ 

operating platforms inside the JT’s & maintenance platforms at various levels for 

take-up including support beams. 

2.02.17 Existing Transfer Point TP-5 alongwith conveyor-21 & its gallery, of Stage-II, to be 

modified for extension of conveyor-21 to take coal feed from JT-4. 

2.02.18 Complete chute work along with chute block switches and actuator operated flap 

gates, mobile discharge pulleys and belt feeders as applicable in all Junction Towers 

and crusher house between various conveyors. 

2.02.19 One (1) No. passenger – cum – goods elevator with drives, all electrical, mechanical, 

civil, structural & associated foundation works, accessories and electrical to serve 

various floors of the Crusher House (CH-WT). 

2.02.20 One (1) coal sampling unit to sample the coal of (-) 250mm size with all drives, 

equipment, electrical, mechanical, civil, structural and associated foundation works, 

accessories etc. to be in crusher house (CH-WT) 

2.02.21 Adequate number of ventilation equipment for ventilating the under ground portion of 

wagon tippler complex, underground tunnel of Conveyor 37A/37B, Conveyor 

38A/38B, underground Junction Towers JT-1 & JT-2 complete with all mechanical, 

electrical, civil and structural works and associated foundations. 

2.02.22 Pressurised Ventilation system for all Switchgear rooms, MCC rooms complete with 

all mechanical, electrical, accessories, civil and structural works. 

2.02.23 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/Junction Towers. 

2.02.24 Air conditioning of Main control room and office room in control building, MCC room, 

wagon tippler control rooms, office room in wagon tippler control building, complete 

with all electrical, civil & structural works etc. 

2.02.25 Minimum two (2) Nos. sump Pump for JT-2 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. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

13 OF 21

CLAUSE NO. 




PLANT PACKAGE 


2.02.26 Two (2) Nos. In-line Magnetic Separators on Conveyor 38A/38B & two (2) nos. 

suspended magnets on Conveyor 37A/37B complete with reject chutes & reject 

trolleys for ILMS, supporting arrangement, and all mechanical, electrical, civil, 

structural works and accessories. 

2.02.27 Four (4) Nos. Electronic Belt weighers complete with all mechanical, supporting 

arrangement, electrical, and accessories on conveyors 38A/38B & 39A/39B. 

2.02.28 Four (4) Nos. Metal Detectors complete with all mechanical, electrical, civil, structural 

works and accessories on Conveyor 38A/38B & 39A/39B. 

2.02.29 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. 

2.02.30 Complete dust suppression system for control of fugitive dust in wagon tippler 

hoppers, junction towers, crusher house complete with pump house, 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 wagon tippler top through spray 

nozzles. 

b. Complete dry fog type dust suppression system at all Junction Towers, 

Crusher House both at conveyor discharge and loading points including all 

electrical and accessories. 

c. Water Pump house & water tanks for dust suppression/ extraction, service 

water, cooling water and potable water system. 

2.02.31 Service water, potable water system and cooling water system for complete coal 

handling plant. 

2.02.32 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. 

2.02.33 Cooling water system for scoop couplings, as specified elsewhere in the 

specification. 

2.02.34 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. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

14 OF 21

CLAUSE NO. 




PLANT PACKAGE 


2.02.35 All buildings in contractor’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. 

2.02.36 Drainage of all CHP buildings, wagon tippler hoppers, tunnels, conveyor galleries 

including all civil & structural works as detailed out elsewhere in the specification. 

2.02.37 All equipment/fittings, supporting structure, along with insert plates, bolts, 

accessories, MS sleeves, base plates, grouting as may be required and proper 

alignment etc. 

2.02.38 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. 

2.02.39 First fill of all consumables e.g.; oils and lubricants for one year toppings 

requirements. 

2.02.40 Preservative shop coating, final painting of all structures and equipment under the 

scope. 

2.02.41 All inserts, anchor bolts, foundation bolts for Contractor’s equipment, platforms etc. 

2.02.42 All necessary grouting & finishing of the floor after welding at all such pockets & else 

where is in Contractor’s scope. 

2.02.43 Electrical System / Equipment 

Unless specifically excluded in clause no. 2.04.00 contractor’s scope of work shall 

include all electrical works as required for putting into successful operation of the 

Wagon Tippler Crushing & Conveying Plant covered under this specification. The 

sizing of the various equipments shall be as defined in the specification. 

2.02.43.01 SWITCHGEAR 

6.6KV and 415V Switchgear/motor control centers (as shown in electrical single line 

diagram), busduct (as applicable), distribution boards, One (1) AC fuse board in each 

MCC room, local motor starters as required for plant and equipment. 

In addition, 2 nos. of 125A switch fuse feeders (total load 50 KVA) shall be provided 

on each LT MCC-IA & MCC-IB, for employer’s use. 

Outgoing feeders shall be segregated stream wise and equally distributed on each 

bus section of the MCC. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

15 OF 21

CLAUSE NO. 

2.02.43.02 TRANSFORMERS 

2.02.43.03 MOTORS 

2.02.43.04 CABLES 




PLANT PACKAGE 


Transformers as indicated in electrical single line diagram. 

Motors along with couplings and coupling guards for all rotating auxiliaries covered 

under this package. All motors shall be with cable glands & lugs. 

HT & LT Power, Control & Instrumentation cables, HT & LT trailing cables and any 

special cables required for connection between equipment/devices in Contractor’s 

scope. 

2.02.43.05 CABLING, EARTHING AND LIGHTNING PROTECTION 

(a) i) Cable trays with supporting structure, trenches, duct banks etc. as 

required for the cables to be supplied by the Contractor for the 

complete coal handling system. 

ii) Cabling viz., cable laying along with cable accessories for cables 

supplied by the contractor. 

iii) Cable trestle in Contractor’s scope is as marked in the General Plant 

Layout drawing, however, exact coordinates shall be finalized during 

detail engineering. 

(b) Grounding and lightning protection for the plant and equipment under 

Contractor’s scope along with its interconnection to the nearest employer’s 

earth grid at two points. 

2.02.43.06 ILLUMINATION SYSTEM 

Illumination system for complete internal and external lighting of associated plant, 

equipment, buildings and roads under Contractor’s scope. 

2.02.43.07 220V DC System for the complete WT Crushing & Conveying plant shall be provided 

by the contractor 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. 

2.02.43.08 Emergency stop Push Button for all HT and LT motors. 

2.02.43.09 Closed Circuit TV system as specified elsewhere. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

16 OF 21

CLAUSE NO. 

2.02.43.10 CONTROL SYSTEM 




PLANT PACKAGE 


Contractor shall provide independent PLC based control system consisting of control 

Desk, PLC Panels, I/O racks along with its power supply arrangement etc. for the 

control of entire Coal handling plant except for wagon tipplers. 

2.02.44 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 Contractor 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 contractor. 

2.02.45 ELECTRICAL BUILDINGS 

i) One (1) No. switchgear building near wagon tippler to house Contractor’s 

MCC-IA, 220V DC battery charger panel, MLDBs & Welding DBs as required, 

etc. in the ground floor. Also a separate room to accommodate Contractor’s 

220V DC battery shall be provided in the ground floor. An independent Air 

conditioned room for accommodating Contractor’s PLC panels, I/O panels. 

UPS and programming OWS as per the PLC configuration diagram in the first 

floor shall be provided. Two (2) nos. 6.6/0.433 KV Transformers are to be 

located by the side of the building. An Air conditioned office room (5m x 5m) 

shall be provided at first floor and a control room with view balcony to house 

operator work station. 

ii) One (1) No. Switchgear building near crusher house to accommodate 

Contractor’s 6.6KV switchgear, MCC-IB, MLDBs, Welding DB as required, TR 

panels for ILMS/SM, 24V DC battery and chargers etc. Further, the ground 

floor shall have a separate air conditioned 6mx5m room to accommodate R 

I/O panels. Two (2) Nos. of 6.6/0.433KV, transformers are to be located by 

the side of this building. 

iii) Main CHP Control desk, processor panels, LVS, I/O panels, UPS etc. shall be 

provided I the existing HP control room of Stage-II by suitably extending the 

building by 6x8m. The extended portion should be air control. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

17 OF 21

CLAUSE NO. 

2.02.46 CIVIL 




PLANT PACKAGE 


iv) One (1) No. control room building for Wagon tippler-2 controls to house UPS 

etc. and an office room (5m x 5m) at the ground floor and a control room with 

view balcony to house Operator work station with control desk, R I/O panel 

etc at the first floor. Office rooms and control room shall be air conditioned. 

The rooms shall be suitably located to have good view of the Wagon tippler 

operation. 

2.02.46.01 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 Contractor’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. 

2.02.46.02 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, 

penthouse, wagon tippler, underground tunnels, crusher house, junction 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. 

2.02.46.03 Scope of the Contractor shall also include supply and laying earthing mat all around 

the periphery of buildings, structures, and outdoor equipments, as per the approved 

drawings. 

2.02.46.04 The analysis design and detailed drawing for the structures like wagon tipplers, 

tunnels, etc. coming below the railway track shall be got approved by the Contractor 

from the Concerned railway authority before taking up construction. All necessary 

payment for above work shall be made by the contractor to the Railway authority. 

2.02.46.05 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. 

2.02.46.06 Access roads (concrete, 4m wide) to all buildings/facilities (in Contractor Scope) will 

be in the Contractor’s Scope. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

18 OF 21

CLAUSE NO. 

2.03.00 TERMINAL POINTS 




PLANT PACKAGE 


Broad terminal points for WT crushing & conveying 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 the plant will be furnished and erected by the contractor unless 

specifically excluded as follows: 

2.03.01 Water supply connections for dust suppression, dust extraction, service water 

system, potable water shall be provided at suitable location near proposed CHP 

Package by the employer, details of which shall be given to the successful bidder. 

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 JT’s, crusher house, control rooms, MCC rooms, 

toilets, wagon tipplers etc. shall be under the scope of the contractor. 

2.03.02 Electrical Terminal Points 

2.03.03 Civil 

Employer’s CHP 6.6KV Switchgear. 

The trunk sewer lines are proposed to be installed by the employer. The sewerage 

from all the facilities planned under the contract shall be connected by the Contractor 

to this trunk sewer network. 

2.04.00 EXCLUSIONS 

2.04.01 Supply, laying and fixing of rail over wagon tippler is excluded from the scope of this 

Contract. However, necessary pockets for fixation of rails on wagon tippler shall be in 

the scope of Contractor. 

2.04.02 Site leveling is excluded from the scope of this Contract. However site clearance i.e. 

removal of vegetation including bushes and trees etc. shall be the responsibility of 

the Contractor. 

3.00.00 SYSTEM DESIGN BASIS 

3.01.00 The rated capacity of the CHP shall be 1400 TPH. The mechanical and structural / 

civil system shall be designed for 1540 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. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

19 OF 21

CLAUSE NO. 




PLANT PACKAGE 


b) HGI of the Coal shall be between 44 to 65. Normally moisture content in coal 

will vary between 12% to 15%. However for design purposes, moisture content 

of 20% shall be considered. 

c) 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, feeders etc. covered under the system shall be based on the 

above characteristic of coal and operating conditions. Contractor shall ensure 

that equipment/ system efficiency shall not be affected particularly during 

monsoon when surface moisture is at its maximum value. 

3.03.00 For the purpose of volumetric computation, the bulk density of the coal shall be taken 

as 800 kg/m 3 . Therefore for calculation of belt conveyor capacity, for their drives & 

drive motors kW requirement, and sizing (volume calculations) of chute, hoppers etc. 

the above bulk density shall be considered. For all other purposes viz. for stresses/ 

load on structures, 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/ m 3 . 

3.04.00 All mechanical, and structural / civil system design shall consider simultaneous 

running of both the streams at rated load starting of one stream with the other stream 

in standstill condition as well as starting of one stream with the other stream in 

operation. 

3.05.00 Coal Flow paths 

3.05.01 For the purpose of conducting guarantee test coal, flow is divided into following coal 

flow paths. 

(i) Flow Path IA (Direct Stream): 

Apron feeder AF-1 taking feed of incoming coal from Wagon Tippler-WT-1 

and discharging crushed coal into existing conveyor 3A/3B of Stage-I 

including all intermediate Conveyors and equipment. 

(ii) Flow Path IB (Direct Stream) : 


and discharging crushed coal into conveyor-21 of stage-II including all 

intermediate Conveyors and equipment. 

(iii) Further for the purpose of Guarantee tests Conveyor 21 alongwith all 

associated equipment shall also be considered. 


SECTION-VI 

PART-A 



SERVICES 

PAGE 

20 OF 21

CLAUSE NO. 




PLANT PACKAGE 


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 Contractor. 

3.05.03 Contractor shall also demonstrate that all intermediate equipments can perform as 

per specification and design requirement. Simultaneous operation of both the paths 

in conveyor streams shall also be demonstrated during PG Test. 

3.05.04 Performance and Guarantee tests have been elaborated elsewhere in the 



SECTION-VI 

PART-A 



SERVICES 

PAGE 

21 OF 21




PLANT PACKAGE 

PART - A 

SUB-SECTION-IIB-01 

PG TEST PROCEDURE 


SECTION-VI 

PART-A

CLAUSE NO. 




PLANT PACKAGE 

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 


1.01.05 GUARANTEES 

The Contractor shall furnish a declaration in the manner prescribed and included in 

the relevant Attachment of Section-VII for the following guaranteed parameters which 

shall attract levy of liquidated damages for shortfall in Performance. 

Capacity in T/Hr (equivalent to 100% of rated) of conveyor system including the 

intermediate equipments for each of the two parallel conveyor streams separately or 

any combination thereof to be tested in the following flow path operations. 

(i) Flow Path IA (Direct Stream): 


and discharging crushed coal into existing conveyor 3A/3B of Stage-I 

including all intermediate Conveyors and equipment. 

(ii) Flow Path IB (Direct Stream) : 


and discharging crushed coal into conveyor-21 of stage-II including all 

intermediate Conveyors and equipment. 

(iii) Any Combination of the above paths for the purpose of checking the control 

system. 

(iv) Further for the purpose of Guarantee tests Conveyor 21 along with all 

associated equipment shall also be considered. 


SECTION-VI 

PART-A 



PAGE 

1 OF 43

CLAUSE NO. 

1.01.06 Major Equipment Capacity 




PLANT PACKAGE 


Guaranteed capacity in T/Hr of the following : 

Apron Feeders 

Crushers 

Vibrating Screen Feeders 

Wagon tippler with side arm charger 

Note : Guaranteed (rated ) capacities of above equipments are indicated in section 

IIIA-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. 

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. 


SECTION-VI 

PART-A 



PAGE 

2 OF 43

CLAUSE NO. 




PLANT PACKAGE 


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.) While operating the guaranteed capacity of the flow paths, non-spillage of 

coal and non-choking of chutes/ equipments shall be demonstrated as 

indication of smooth continuous flow through the conveyor system. 

2.02.02 Major Equipment Capacity Tests 

(a.) Guaranteed capacity of all the major equipments as identified shall be 

established separately by operating only one equipment out of the two of a 

set at a time. Following equipments shall be considered: 

Equipment Capacity Requirement 

(1.) Vibrating Screen Feeders 

(2.) Crusher (after blanking the screen of VGS) 

(3.) Apron feeders 

(3.) Wagon Tippler with side arm charger 


SECTION-VI 

PART-A 



PAGE 

3 OF 43

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 

(c.) Time Duration 

Power Consumption measurement shall be done only for 30 minutes after the 

conveyor flow rate stabilizes at the guaranteed capacity. 


SECTION-VI 

PART-A 



PAGE 

4 OF 43

CLAUSE NO. 

(d.) Meters 

2.02.04 GENERAL 




PLANT PACKAGE 


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. Energy meters shall be used for measurement of power by side 

arm chargers. 

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. 

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-incharge. Zero error shall be checked before conducting the PG 

Test. 

(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 repreparation 

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. 


SECTION-VI 

PART-A 



PAGE 

5 OF 43

CLAUSE NO. 




PLANT PACKAGE 


(2.) Readings for flow rate capacity test shall be taken at intervals of every 

3 minutes. 

(3.) 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 X and Performa 7 to 16. 

2.03.00 Testing for Demonstration Requirements 

2.03.01 Conveyors 

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. 

(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 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. 


SECTION-VI 

PART-A 



PAGE 

6 OF 43

CLAUSE NO. 




PLANT PACKAGE 


(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. 

(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. 


SECTION-VI 

PART-A 



PAGE 

7 OF 43

CLAUSE NO. 

(j.) GEAR BOXES 




PLANT PACKAGE 


Temperature rise not to exceed design values. 

No leakages 

No abnormal sound. 

Satisfactory performance of hold back devices in preventing running back of 

conveyor belts in case of conveyor being stopped in fully loaded (at design 

load) condition to be demonstrated. 

(k.) Fluid Coupling. 

No excessive rise of temperature. 

Satisfactory and quick operation of scoop in manual/remote modes with no oil 

leakages. 

(l.) Brakes 

Satisfactory and non jerky operation to avoid hold up of Coal in chutes. 

(m.) Skirt board and skirt sealing, inspection door, chute joints 

2.03.02 Metal Detector 

Perfect sealing with no spillage/no dust from sealing areas. 

(a.) Tests for detection of specified smallest size pieces (25 mm sphere) of 

different metals including aluminium. 

(b.) Operation of liquid spray marker/ multiple markers. 

(c.) Demonstration of coast count, total count for multiple tramp metal pieces. 

2.03.03 In-Line Magnetic Separators/Suspended Magnets 

(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 


SECTION-VI 

PART-A 



PAGE 

8 OF 43

CLAUSE NO. 

2.03.04 Flap Gates 




PLANT PACKAGE 


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 

(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 

2.03.05 Dust Suppression System 

(a.) Measurement of head of pumps compressor. 

(b.) Pressure available at nozzle manifolds (on random basis) in running condition 

not to be less than of 0.5 kg / cm 2 for water and 5.0 kg / cm 2 . 

Proper functioning of pressure regulating stations in case of fogging type dust 

suppression system 

(c.) Satisfactory spray atomization and dust suppression effectiveness of all the 

DS systems as per Appendix-VIII. 

(d.) Measurement of SPM before and after DS system operation as per Appendix 

- VIII. 

(e.) Complete coverage of yard by spray units in stockyard. 

(f.) Measurement of noise level and vibration (velocity and amplitude) at the 

bearing of motors and pumps. 

2.03.06 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) 


SECTION-VI 

PART-A 



PAGE 

9 OF 43

CLAUSE NO. 




PLANT PACKAGE 


2.03.07 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. 

2.03.08 Belt Weighers 

(a.) Demonstration of specified weighing accuracy of + 0.25% between 20% and 

120% of rated capacity 

(b.) Satisfactory operation of flow rate indicator and totaliser etc. 

2.03.09 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 

2.03.10 Coal Sampling Unit 

2.03.11 Crushers 

(1) Demonstration of bias testing on random basis 

(2) Demonstration of satisfactory of operation of CSU which shall necessary 

include ability to collect samples automatically and continuously for a 

minimum period of 7 days of conveyor operation without requiring manual 

intervention 

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. 


SECTION-VI 

PART-A 



PAGE 

10 OF 43

CLAUSE NO. 

2.03.12 Belt Scrappers 

2.03.13 Noise Levels 




PLANT PACKAGE 


Satisfactory operation of belt scrappers shall be demonstrated even with wet coal as 

specified. Scrapping efficiency of belt scrapper shall be minimum 95%. 

2.03.13.01 Noise level measurement, for conformance to specified levels, to be done around the 

following equipments/ areas: 

(a) Conveyor Discharge Terminal (including discharge chute, gearbox, coupling 

& motor). 

(b) Coal discharge chutes on intermediate floors in possible impact zones. 

(c) Ventilation fans 

(d) Water Supply & Dust Suppression Pumps. 

(e) Coal crushers 

(f) Vibrating Screening Feeders 

2.03.13.02 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. 


SECTION-VI 

PART-A 



PAGE 

11 OF 43

CLAUSE NO. 

2.03.14 Elevators 




PLANT PACKAGE 


a) Check for average speed and load capacity 

b) Leveling accuracy 

c) Trouble free smooth operation 

d) Satisfactory operation of controls and limit switches 

e) Unmanned tests of safety devices like brakes etc. 

f) Testing as per manufacturer’s PG Test Procedure given in Annexure-I 

2.03.15 Movable belt feeder 

a) Demonstration of remote, local and manual actuation. 

b) Check for travel, brake and operation of limit switches. 

2.03.16 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 2.03.05. 

Apron Feeders 

Satisfactory operation even with wet coal containing stones and moisture upto 20% 

Guaranteed capacity coal flowing capability 

Vibrations of drive within permissible level 

No spillage of coal 


SECTION-VI 

PART-A 



PAGE 

12 OF 43

CLAUSE NO. 

Elevator 

Sl. No. NAME OF THE 

TEST 




PLANT PACKAGE 


PROCEDURE EXPECTED 

RESULTS 

1.0 Trial Run Test each landing (5 

times) 

a) Push the “UP”, 

“STOP” and “DOWN” 

buttons at every 

landing 

b) Try to operate the 

hoist with the “UP” 

and “DOWN” button 

leaving the landing 

door open (cage door 

closed) 

c) Close the landing 

door and also the 

cage door, keep the 

stop button pressed 

while trying to 

operate the Elevator 

with the "UP” & 

“DOWN” buttons five 

times. 

d) At each landing floor, 

the level deviation 

should be within 

specified limits. 


SECTION-VI 

PART-A 

Cage should 

respond 

correctly to 

each button 

Hoist must not 

start. 

-do- 



REMARKS 

/RESULT 

OBTAINED 

ANNEXURE -I 

Results of Test 

1 2 3 4 5 

PAGE 

13 OF 43

CLAUSE NO. 


TEST 

2.0 Check for 

operation from 

inside cage 

3.0 Check for 

interlocking 




PLANT PACKAGE 



RESULTS 

Operate the elevator with 

the “UP” “STOP” & 

“DOWN” button five 

times 

a) Try to operate the 

elevator “UP” & 

“DOWN” leaving the 

cage door open 

(landing door closed). 

(All the doors are to 

be tried separately) 

b) Try to operate the 


“DOWN” leaving the 

trap door open (cage 

and landing door 

closed). 

c) Try to operate the 


“DOWN” keeping the 

emergency stop 

button pressed after 

the test. 

d) Check the other 

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” 


SECTION-VI 

PART-A 

Cage should 

respond 

correctly to 

each button 

The elevator 

must not start 

when testing 

according to 

a,b,c and d. 

-do- 

-do- 

-do- 



ANNEXURE -I 

REMARKS 

/RESULT 

OBTAINED 

Results of Test 

1 2 3 4 5 

PAGE 

14 OF 43

CLAUSE NO. 


TEST 

4.0 Check for 

Automatic 

System “Stop 

Next Landing” 

5.0 Check for travel 

speed 




PLANT PACKAGE 



RESULTS 

a) Start at the ground 

landing and operate 

from the push button 

box in the Cage, 

Push the 0-button as 

soon as the elevator 

has started. 

b) Continue upwards 

and test all landings 

in the same way. 

c) Make the test 

according to a) & b) 

but now in the 

opposite direction 

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. 

Before start of test, 

check and record voltage 

and frequency of 

incoming power supply 

a) Start from ground 

landing and operate 

the “UP” button 

b) Start a “Stop Watch” 

when cage is in line 

with first landing 


SECTION-VI 

PART-A 

Cage must 

stop at the 

next landing in 

the direction of 

travel. 

Cage must 

stop at the 

next landing in 


travel. 



ANNEXURE -I 

REMARKS 

/RESULT 

OBTAINED 

PAGE 

15 OF 43

CLAUSE NO. 

Sl. No. NAME OF 

THE TEST 




PLANT PACKAGE 



RESULTS 

c) Stop the “Stop Watch” 


with second landing 

and note the timing. 

Press “Emergency 

Stop” button 

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) 


SECTION-VI 

PART-A 

The rated travel 

speed should 

be checked at 

415 V, 50 Hz 

and should be 

as specified 

N.B. The test may be repeated for longer travel distances 

6.0 Checking of 

Safety Devices 

a) Electro-magnetic 

brake and manual 

brake release 

operation during 

power failure. 

The Electromagnetic 

brake 

and Manual 

brake release 

shall function as 

per their design 

and the brake 

shall hold 

without creep at 

all levels. 



REMARKS 

/RESULT 

OBTAINED 

ANNEXURE-I 

PAGE 

16 OF 43

CLAUSE NO. 

Sl. No. NAME OF 

THE TEST 




PLANT PACKAGE 



RESULTS 

b) Over travel switch Cage must stop 

automatically at 

Ground and 

Top landings. 

c) Reverse phase relay 

operation 


SECTION-VI 

PART-A 

Lift will not start 

in case of 

reversal of 

phase 

d) Alarm at the basement Should operate 

when button is 

pressed in cage 

e) Remote control for 

testing the safety 

devices as per 

Technical 

Specifications 

7.0 Drop Test Make the test according 

to supplier’s procedure 

8.0 Measurement 

of Power 

Note : 

Note : Remember to reset 

the safety device after the 

test has been carried out. 

Current and power 

measurement by will be 

carried out during elevator 

movement upwards and 

downwards in loaded 

condition 

Safety Device 

should stop 

cage in less 

than 7 m. of 

travel 

Measured 

current & power 

will be within 

the limits as 

specified in the 

Technical 

Specifications. 



REMARKS 

/RESULT 

OBTAINED 

ANNEXURE-I 

Ensure that no 

person is present 

inside the cage 

during the test. 

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 

-------------------------- 

Signature : 

Name : 

Designation : 

Contractor 

----------------- 

Signature : 

Name : 

Designation : 

PAGE 

17 OF 43

CLAUSE NO. 




PLANT PACKAGE 


GENERAL 

PREREQUISITES TO GUARANTEE TESTS TO BE ENSURED BY NTPC 

1. Availability of adequate and uninterrupted supply of coal. 


SECTION-VI 

PART-A 



APPENDIX-I 

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 and sufficient space in coal stockyard. 

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 

PAGE 

18 OF 43

CLAUSE NO. 

Project : 

Package : 

Date : 

1. Size 

2. HGI 

3. Moisture 




PLANT PACKAGE 


4. Shale and sand-stone content 

COAL PARAMETERS 

As specified, As observed 


SECTION-VI 

PART-A 

during the test 

NTPC Contractor 



APPENDIX-IA 

PAGE 

19 OF 43

CLAUSE NO. 




PLANT PACKAGE 




SECTION-VI 

PART-A 



APPENDIX –IB 

JOINT DECLARATION BY NTPC AND VENDOR ON READINESS OF PLANT FOR 

PG TEST 

Project : VINDHYACHAL SUPER THERMAL POWER PROJECT 

Package: WAGON TIPPLER, CONVEYING AND CRUSHING PLANT PACKAGE 

Date : 

The above system consisting of wagon tippler, conveyors and crushing plant was 

jointly inspected by NTPC and VENDOR on _________________. The present state 

of the plant is generally conducive to conducting the PG test. (Any observations to 

be enclosed as annexure) 

It has been jointly agreed that PG test of the said package shall be conducted with 

effect from date_______________. 

NTPC VENDOR 

Sd/- Sd/- 

PAGE 

20 OF 43

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-A 



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. 

PAGE 

21 OF 43

CLAUSE NO. 




PLANT PACKAGE 


FORMAT FOR SUBMISSION OF GUARANTEE TEST PROCEDURE 

Clause No. as per 

LOA/ Tech. Specs. 

Provision of 

LOA / Tech. 

Specs. 


SECTION-VI 

PART-A 

Name and 

Methodology of 

Test proposed 

by Vendor 



ANNEXURE – IIA 

NTPC 

comments on 

the tests 

proposed by 

vendor 

PAGE 

22 OF 43

CLAUSE NO. 

Project : 

Package : 

Date : 

1. Composition of Stream 




PLANT PACKAGE 


i) Conveyor Nos. 

GUARANTEE TEST PROFORMA 

FLOW PATH CAPACITY TEST 


SECTION-VI 

PART-A 



APPENDIX-III 

ii) Dust suppression pumps, service water pumps, Ventilation fan drives. 

iii) .......................... 

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 : 

PAGE 

23 OF 43

CLAUSE NO. 




PLANT PACKAGE 


Sl.No Time Flow Rate Totaliser 

Total plant run time : 

Average Flow Rate : 



SECTION-VI 

PART-A 



PAGE 

24 OF 43

CLAUSE NO. 

Project : 

Package : 

Date : 




PLANT PACKAGE 



POWER MEASUREMENT 

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. 

No. 

Measurement 

Terminal 

Location 

Time Voltage 

(Volts) 

Current 

(amps) 


SECTION-VI 

PART-A 

kw Reading 

M.F. 

W1 W2 

Total 

(W1+W2) 

MF kw 



APPENDIX-IV 

Remarks 

PAGE 

25 OF 43

CLAUSE NO. 

7. Energymeter Readings 

Sl. 

No. 




PLANT PACKAGE 


Equipment Time 

Duration 


SECTION-VI 

PART-A 

Energymeter 

Readings 

kwHr 

Initial Final Initial Final 

Equipment 

kw (R2- 

R1)/(t2-t1) 



APPENDIX-IV 

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


Remark 

PAGE 

26 OF 43

CLAUSE NO. 





PLANT PACKAGE 


VIBRATION LEVEL MEASUREMENTS 

Project : 

Package : 

Date : 

Time : 

Details of vibration Level Meter 

1. Make 

2. Model & Sl.No. 

3. Date of calibration with name of Test House 

Sl.No Equipme Pick 

*Point 


SECTION-VI 

PART-A 

Vibration level Amplitude/Velocity 

Horizontal 

Micron/ 

mm/ sec. 

Vertical 

micron/ 

mm/sec. 



APPENDIX-V 

Axial Micron / 

mm/sec. 

• Reading shall be taken at all the bearings of motor, gear box and driven 

equipment. In case of conveyor galleries, vibrations shall be measured at min. 

three locations, at midpoint of stringer between two short supports. 


PAGE 

27 OF 43

CLAUSE NO. 

Project : 

Package : 

Date : 

Details of Sound Level Meter 

1. Make 

2. Model 




PLANT PACKAGE 



NOISE LEVEL MEASUREMENT 

3. Date of calibration with name of Test House 

Sl.No Equipment 

with 

location 

Equipment 

load/capacity 


SECTION-VI 

PART-A 

Measurement* 

point no. 


Sound 

level dBA. 



APPENDIX-VI 

Remarks 

* For each equipment location, a Projected Plan Diagram shall be made and the 

location of measurement points shall be identified. 

PAGE 

28 OF 43

CLAUSE NO. 




PLANT PACKAGE 


WAGON TIPPLER 

1. Nos of Wagon Tippled : 58 

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 


SECTION-VI 

PART-A 



APPENDIX - VII 

7. Over all performance : Satisfactory / Not satisfactory 

8. Date of testing : 

For NTPC For Vendor 

PAGE 

29 OF 43

CLAUSE NO. 




PLANT PACKAGE 


DUST SUPPRESSION SYSTEM 

Fixing of acceptance criteria of ambient air quality 


SECTION-VI 

PART-A 



APPENDIX - VIII 

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 Vokane. 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 perwe size analysis by sieve 

Analysis method as a standard test laboratory. 

The quantity respirabte dust shall thus be determined from patbcie size Analyser. 

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

Acceptable Norms : 

i) If the respirable dust fraction contain less than 5% quartz. The permissible 

concentration of respirabie dust shall be less than 2 Mg/M 3 . 

ii) In case, respirable dust has more than 5% quartz, the permissible concentration 

of respirable dust shall be computed as per following formula. 

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

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 Metre radius of 

application point) with chemjet 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. 

PAGE 

30 OF 43

CLAUSE NO. 




PLANT PACKAGE 


SIDE ARM CHARGER 

1. Capacity : Haulage limit of -----MT. 

(--- Nos loaded wagons) 


SECTION-VI 

PART-A 



APPENDIX - IX 

2. It can/cannot pull ---Nos wagons : Satisfactory / Not satisfactory 

3. If not, mention the reasons : 

4. Time of test : 

5. Date of test : 


PAGE 

31 OF 43

CLAUSE NO. 




PLANT PACKAGE 


WEIGH BRIDGE 

A. Wagon Tippler No : 

B. Date of Test : 


SECTION-VI 

PART-A 



APPENDIX - X 

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. 


PAGE 

32 OF 43

CLAUSE NO. 




PLANT PACKAGE 


PROFORMA – 7 

CONTROL AND SEQUENTIAL INTERLOCKS 

1.0 Date and time of starting test : 

2.0 Date and time of completion of test : 

3.0 Path and streams being tested : 

4.0 Document No. of approved control write up : 

5.0 Observations 

- Control / sequential interlocks are checked: Working Not working 

On no load and found Satisfactorily satisfactorily 

- If found not working satisfactorily, list the : ____________________________ 

Defects observed ____________________________ 

- Performance of PLC ____________________________ 

- Communication failures of PLC ____________________________ 

- Display of operated pullcord / belt ____________________________ 

Sway No on CRT 

6.0 Workmanship of control-cum-mimic 

Panel is satisfactory : Yes / No 

7.0 There are spurious trippings : Yes / No 

8.0 Other tests (as given elsewhere in this 

Procedure and technical specifications) 



SECTION-VI 

PART-A 



PAGE 

33 OF 43

CLAUSE NO. 




PLANT PACKAGE 



CONDITION OF CHUTE & CHUTE CONNECTIONS 

1.0 Location : 

2.0 Date and time of starting of test : 


4.0 Path and stream being tested : 

5.0 Observations on chutes 

___________________________________________________________________ 

Sl.No. Transfer point Choking Dust leakage Remarks 

___________________________________________________________________ 

i) Transfer chute 

from ………… 

to……………. 

ii) Transfer chute 

from …………. 

To …………… 

iii) Transfer chute 

from ………….. 

to …………….. 

6.0 Inspection doors are provided at an : Yes / No 

Intervals of 3M and at convenient 

Locations with proper platforms and 

No interference with floors, structures etc. 

Inspection doors, chute flange joints : Perfectly sealed / Not properly 

Etc. are & no leakages sealed 




SECTION-VI 

PART-A 



PAGE 

34 OF 43

CLAUSE NO. 




PLANT PACKAGE 



MAGNETIC SEPARATOR 


2.0 Type of magnetic separator : SM / ILMS 


4.0 Date and time of completion test : 

5.0 Performance on full load : Remarks 

5.1 Start/Stop (Whether Lifting) : 

5.2 Is separation of Tramp iron pieces of requisite: Yes / No 

Weight and size burried under coal effective 

5.3 Discharge of tramp iron is satisfactory : Yes / No 

(Applicable for ILMS) 

(All pieces need to be discharged into 

The tramp iron chute) ( No coal pieces 

Discharged in tramp iron chute) 

5.4 Slippage of belt over the pulley : Normal / Abnormal 

(Applicable for ILMS) 

5.5 Other observations : _____________________ 

(Bearing temperature,) _____________________ 

Magnet body temperature _____________________ 

5.6 Current drawn at the time of energizing : Amps 

5.7 Current drawn after 4 hours of energizing : Amps 

5.8 Gauss value at the face of the magnet & at : 

The belt surface at the time of energizing & 

After four hours of energizing 

5.9 There is no sway of belt throughout : Yes / No 

The trial operation 





SECTION-VI 

PART-A 



PAGE 

35 OF 43

CLAUSE NO. 




PLANT PACKAGE 



METAL DETECTOR 




4.0 Performance Remarks 

4.1 Start / Stop : 

4.2 Is metal (25mm spheres of different : Yes / No 

Metals including aluminium) detected / 

Identified properly 

4.3 Sounding of buzzer and tripping of belt : Yes / No 

On detection of metal is satisfactory? 

4.4 General observation 

(Search coil & hooter) 

4.5 Performance of coal counter/total counter : Satisfactory / Not 

satisfactory 

4.6 Performance of INK marker : Satisfactory / Not satisfactory 





SECTION-VI 

PART-A 



PAGE 

36 OF 43

CLAUSE NO. 




PLANT PACKAGE 



SUMP PUMP 


2.0 Date and time of starting the test : 


4.0 Performance observation Remarks 


Whether pumping Required : Yes / No 

4.2 Vibration at motor bearing level : Horizontal Vertical 

4.3 Noise level at 1.0m from pump : 

4.4 Is Functional Test : Yes / No 

Satisfactory (Whether pump is able 

To handle slurry) 

4.5 General (Performance satisfactory) : Yes / No 

4.6 Performance of auto level switch : Satisfactory / Not satisfactory 





SECTION-VI 

PART-A 



PAGE 

37 OF 43

CLAUSE NO. 




PLANT PACKAGE 



RACK AND PINION GATE OPERATION 

1.0 Designation : 






5.2 Remote, local, manual : 

Observation on operation for no coal flow 


Observation on operation for full coal flow 

5.4 Coal leakage / spillage in the blocked path, : 

If any 

5.5 Provision for the operation of manually : Yes / No 

Provided with suitable safety switch 

5.6 General Observations 

a) Whether operation of gate is smooth : Yes / No 

b) Any other : 

5.7 Stroke and operation of limit switches, : Satisfactory / Not satisfactory 

Torque switches 





SECTION-VI 

PART-A 



PAGE 

38 OF 43

CLAUSE NO. 




PLANT PACKAGE 



VIBRATING SCREEN FEEDERs 

1.0 Capacity of Grizzly feeder : 


3.0 Date and time of stopping the test : 

4.0 Performance on full load Remarks 

4.1 Equipment start / stop : 

4.2 Vibrations in microns : Horizontal Vertical 

a) At screen bearings : 

b) At screen motor bearings : 

c) At floor at various locations : 

4.3 Noise 

a) At 1.0m from screen : ______________db 

4.4 General observation of (a) screen and its drive unit : 

4.5 Out put size from screen 

a) +20 mm % age presenting undersize material (-20mm) 

b) -20 mm % age presenting oversize material (+20 mm) 

Choking of screen observed : Yes / No 

4.6 Input feed rate of coal as per conveyor scale : ________________TPH 

4.7 

Note : Minimum three samples shall be taken with adequate time gap. 

General observation 

(Material flow choking of chute, dust leakage 

From feeder / crusher cage, Temperature of bearings, 

Motors, gear boxes, etc. current in accordance with 

Motor rating) 

4.8 Whether vibrations are transmitted to 

To building structure 

: Yes / No 

4.9 Choking tendency, if any : 

4.10 Loosening of screens : 





SECTION-VI 

PART-A 



PAGE 

39 OF 43

CLAUSE NO. 




PLANT PACKAGE 



FLAP GATE OPERATION 

1.0 Designation : 







Observation on operation for no coal flow 


Observation on operation for full coal flow 

5.4 Coal leakage / spillage in the blocked path, : 

If any 

5.5 Provision for the operation of manually : Yes / No 

Provided with proper safety switch 

5.6 General Observations 

a) Whether operation of gate is smooth : Yes / No 

b) Any other : 

5.7 Stroke and operation of limit switches, : Satisfactory / Not satisfactory 

Torque switches 





SECTION-VI 

PART-A 



PAGE 

40 OF 43

CLAUSE NO. 




PLANT PACKAGE 



RING - GRANULATOR 

1.0 Capacity of crusher : 


3.0 Date and time of stopping the test : 

4.0 Performance on full load Remarks 

4.1 Equipment start / stop : 

4.2 Vibrations in microns (microns,mm/sec) : Horizontal Vertical 

a) At crusher bearings : 

b) At crusher motor bearings : 

c) At fluid coupling bearing : 

d) Crusher floor at various locations : 

4.3 Noise 

a) At 1.0m from crusher : ______________db 

4.5 General observation of (a) crusher, and its drive unit : 

4.5 Out put size from crusher sieve analysis 

a) +20 mm 

b) -20 mm 

c) -1 mm 

4.6 Input feed rate of coal as per conveyor scale : ________________TPH 

Note : Minimum three samples shall be taken with adequate time gap. 

4.7 Operation of scoop tube : 

4.8 

Coupling along with actuator for crushers 

General observation 

(Material flow choking of chute, dust leakage 

From screen / crusher cage, Temperature of bearings, 

Motors, gear boxes, etc. current in accordance with 

Motor rating) 

4.9 Temperature of bearings : 





SECTION-VI 

PART-A 



PAGE 

41 OF 43

CLAUSE NO. 




PLANT PACKAGE 



BELT WEIGHER 




4.0 Performance on full load, half load : Remarks 

4.1 Counter (panel) : 

4.2 Counter (remote) : 

4.3 TPH indicator : 

4.4 Percentage meter : 

4.5 Chart recorder : 

4.6 Reading with test chain : 

4.7 Accuracy +/-0.25 % : 

4.8 General deviations : 





SECTION-VI 

PART-A 



PAGE 

42 OF 43

CLAUSE NO. 




PLANT PACKAGE 



PLANT STOPPAGE RECORD 


2.0 Path and stream being tested : 

3.0 Date and time of trip : 

4.0 Designation of equipment responsible : 

For plant stoppage 

5.0 Reason for equipment trip / stop : 

Prior to completion of test 

6.0 Date and time of restarting the plant : 

7.0 Plant stoppage shall be considered as : Yes / No 

Equipment / system fault 

8.0 Break down time for this plant stoppage : Hrs 

(Item 6.0 – Item 3.0) 

9.0 Date and time of stopping the system. : 

Time period of operation of the 

System 

(Item 9.0 – Item 2.0) 

10.0 Cumulative time period of operation during : 

The test considering earlier time period operated 



SECTION-VI 

PART-A 



Remarks 

PAGE 

43 OF 43




PLANT PACKAGE 

PART - A 

SUB-SECTION-IIC-01 

SPARES 


SECTION-VI 

PART-A

CLAUSE NO. 





PLANT PACKAGE 

SPARES 

SPARES 

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. 


SECTION-VI 

PART-A 


SPARES 

PAGE 

1 OF 4

CLAUSE NO. 




PLANT PACKAGE 

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 


SECTION-VI 

PART-A 


SPARES 

PAGE 

2 OF 4

CLAUSE NO. 




PLANT PACKAGE 

SPARES 

these in the relevant schedules of the Bid Form and Price Schedules. The general 

requirements pertaining to the supply of these spares is given below. 

5.02.00 The Contractor shall indicate the service expectancy period for the spares parts (both 

mandatory and recommended) under normal operating conditions before 

replacement is necessary. 

5.03.00 All spares supplied under this contract shall be strictly 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. 


SECTION-VI 

PART-A 


SPARES 

PAGE 

3 OF 4

CLAUSE NO. 




PLANT PACKAGE 

SPARES 

5.11.00 The Contractor shall guarantee the long term availability of spares to the Employer 

for the full life of the equipment covered under the contract. The Contractor shall 

guarantee that before going out of production of spares parts of the equipment 

covered under the Contract, he shall give the Employer atleast 2 years advance 

notice so that the latter may order his bulk requirement of spares, if he so desires. 

The same provision will also be applicable to sub-contractors. Further, in case of 

discontinuance of manufacture of any spares by the Contractor and/or his sub 

contractors, Contractor will provide the Employer, two years in advance, with full 

manufacturing drawings, material specifications and technical information including 

information on alternative equivalent makes required by the Employer for the purpose 

of manufacture/procurement of such items. 

5.12.00 In case of equipment supplied with grease/lubricants from imported origin, the 

supplier shall clearly indicate the indigenous equivalent of the grease/lubricant and 

source of supply so as to enable the Employer to procure these items from 

indigenous sources. 


SECTION-VI 

PART-A 


SPARES 

PAGE 

4 OF 4

PART - B 

MECHANICAL 



WAGON TIPPLER, CONVEYING & CRUSHING PLANT PACKAGE 


SECTION-VI 

PART-B

PART - B 

SUB-SECTION-IIIA-01 

SYSTEM PARAMETERS AND OPERATION 

& CONTROL 





SECTION-VI 

PART-B

CLAUSE NO. 




PLANT PACKAGE 

TECHNICAL REQUIREMENTS 

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 (a) Conveyor System (37A/37B, 38A/38B, 39A/39B, AF-1, AF-2, and MBF-1, 

MBF-2) 

i. Rated Capacity (Guaranteed) : 1400 TPH 

ii. Design capacity : 1540 TPH 

iii. Belt width : Minimum 1400 mm 

iv. Maximum Belt speed : 3.2 M/sec. 

(b) Existing / Extended Conveyor System (Conveyor-21) 

2.01.01 Belting and Pulleys 

i. Rated Capacity (Guaranteed) : 2000 TPH 

ii. Belt width : Minimum 1600 mm 

iii. Maximum Belt speed : 3.2 M/sec. 

(a.) Belt ratings shall be selected in such a way that there are only three (3) 

ratings of belting. This however excludes belting of belt feeders. Belting shall 

be completely interchangeable among same rating of belt. 

(b) Minimum number of plies for belting shall be four (4). Other details of belting 

shall be as specified else where in the specification. 

(c) 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 


SECTION-VI 

PART-B 


SYSTEM PARAMETERS 

AND OPERATION & 

CONTROL PHILOSOPHY 

PAGE 

1 OF 22

CLAUSE NO. 

(4.) Diameter : 




PLANT PACKAGE 


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

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

Further approval from belt manufacturers shall be obtained by the contractor 

regarding the adequacy of the pulley diameters. 

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 exclusive of Pulleys for 

Belt Feeder & SS pulleys. 

2.01.02 Coal Crushers & Vibrating Screen Feeders 

2.01.03 Apron Feeder 

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

(b) Guaranteed (rated) capacity 

(considering 100% feed coal 

above (+)20 mm size) : 1400 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 

(a) Nos. required : Two (2) 

(b) Guaranteed (rated) capacity : 1200 MTPH 

(c) Design capacity : 1320 MTPH 

2.01.04 Wagon Tippler (Rota side) 


(b) (i) Guaranteed (Rated) capacity : 20 tips/hr (min) 

2.01.05 Side Arm Charger 

(ii) Design capacity : 24 tips/hr (min) 


(b) Guaranteed (rated) haulage capacity : 58 wagons 


SECTION-VI 

PART-B 





PAGE 

2 OF 22

CLAUSE NO. 

2.01.06 Dust Control System 




PLANT PACKAGE 


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) 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 : Two (2) zones, One (1) no. on each 

side 

(4) No. of nozzles operating : All 

Simultaneously 

b) 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/cm 2 for water (min.) 

at inlet of spray lead 5.0 Kg/cm 2 for air (min.) 

c) Dust extraction system 

2.01.07 Service Water System 

Type : Venturi scrubber type 

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 


SECTION-VI 

PART-B 





PAGE 

3 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(b.) Minimum discharge 

Pressure at tap point : 2 kg/sq.cm 

(c) No. of valves operated : 6 nos. 

simultaneously 

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

2.01.09 Ventilation System 

2.01.10 Chutes 

2.01.11 Hoists 

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. 

Minimum clear cross section of chute : 1000 mm x 1200 mm (inside both ways). 

Minimum clear cross section of : 750mm X 1000mm (inside both ways) 

discharge chute for stone picking 

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, 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 etc. 

2.01.12 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. 


SECTION-VI 

PART-B 





PAGE 

4 OF 22

CLAUSE NO. 

3.02.00 General Requirements 




PLANT PACKAGE 


The instruments and controls to be furnished and erected under this specification 

are as required for safe and satisfactory operation of the Coal Handling System, as 

outlined under mechanical section and as specified elsewhere in the specification. 

For the equipment and materials procured by the Contractor from his sub-vendors, 

the Contractor shall study the specification, safety requirements, interface drawings 

for such equipment and material in detail and shall coordinate his work with his sub 

vendors and supply instrumentation and control to suit the actual Wagon Tippler, 

Conveying and Crushing Plant 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 





PAGE 

5 OF 22

CLAUSE NO. 

3.03.02 Design 




PLANT PACKAGE 


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 

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 Wagon Tippler, Crushing and 

Conveying Plant shall be controlled from the main control room. 

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

couplings. 

(b.) Complete Dust Suppression system, service water system, cooling water 

system & potable water system. 

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

(d.) In line Magnetic separators and Suspended Magnet (ON/OFF control with 

indication). 

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

(f.) Coal Sampling Units. 

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

(h) Apron feeders & dribble conveyor (indication only). 


SECTION-VI 

PART-B 





PAGE 

6 OF 22

CLAUSE NO. 

4.02.00 Local Control Panels 




PLANT PACKAGE 


Local control stations for following equipment’s shall be provided 

(a) Belt Weighers 

(b) Metal detectors 

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

(d) In line magnetic separators 

(e) Suspended Magnet 

(f) Sump Pump 

(g) Coal Sampling Units 

(h) Dust suppression system for wagon unloading at wagon tippler. 

(i) Dust Extraction System 

(j) 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 (g.) to (k) controls shall be through main PLC 

& MCC as applicable. Further, necessary controls, indications and annunciations for 

all the above equipment shall also be provided at main Control Room as described 

under relevant clause. 

4.03.00 Wagon Tippler control Room 

The entire control & operation of wagon tipplers, apron feeders alongwith dribble 

conveyor’s and side arm chargers shall be from the wagon tippler control room. 

4.04.00 In addition to the remote control of various equipment, local stop push button 

stations shall be provided for all equipment. 

4.05.00 System Operation 

4.05.01 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. 


SECTION-VI 

PART-B 





PAGE 

7 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(1) Wagon Tippler to Stage – I conveyors (con. 3A/3B) 

(2) Wagon Tippler to Stage – II conveyors (con. 21) 

(3) Combination of above 

(b) 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. 

(c) The Control system will be designed for “Auto” & “Manual” operation of the 

conveyors in the selected path. Auto/Manual Selection shall be done from 

keyboard. 

Auto Mode : In the “Auto” mode, the conveyors and related equipment will 

start sequentially when the “System Start” is activated. During stopping, 

when the “System Stop” is activated, all conveyors will also stop sequentially 

(in the reverse sequence) allowing time delays for clearing the belts. 

Manual Mode : In Manual Mode, the operator will start the conveyor system, 

in the same sequence as in Auto mode from keyboard. The operator will also 

stop the conveyor system, by pressing "System stop" or individual “Stop” 

push buttons/command from keyboard in the reverse sequence. 

(d) 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. 


SECTION-VI 

PART-B 





PAGE 

8 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(e) 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. 

(f) Graphic display status indicators associated with a particular 

motor/equipment shall flicker fast in case of fault / trip. 

(g) In addition, emergency stop push button on the control desk for immediate 

shut down of complete plant shall be provided. 

(h) Lamp test facility will be provided for the annunciation and mimic lamps. 

4.06.00 Conveyor System 

(a) Approach of a Railway wagon rake to the plant shall be signaled (visual and 

audible) in the 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. 

(b) 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. 

(c) All the conveyors shall be protected from reverse running due to power 

failure by providing mechanical or electrical locking system. 

(d) 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 Stage-I or II conveyors, start 

from Stage-I or II conveyor and end up with reclaim conveyors below 

Wagon Tippler 

(2.) The starting of apron feeders and wagon tipplers shall be interlocked 

with operation of the reclaim conveyors below wagon tippler hopper 


SECTION-VI 

PART-B 





PAGE 

9 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(e) Any individual equipment (belt conveyor etc.) should not be allowed to start 

unless the equipment immediately following the same in the direction of flow 

of material is already in operation. 

(f) Stop/tripping of any equipment from running condition shall trip all preceding 

equipment in the system, except crushers but shall not effect succeeding 

ones which shall continue to operate. 

(g) Adequate number of pull-cord switches shall be provided at suitable intervals 

along the length of each belt conveyor, which shall enable the respective 

conveyor to be stopped immediately. Each pull chord switch shall be 

identified by a specific number on HMI in the main control room. Each belt 

sway switch shall also be identified by a specific number on HMI in control 

room. 

(h) Means shall be provided to pre-warn personnel working nearby when starting 

any conveyor, Wagon Tippler. 

(i) Interlocking of various conveyors shall be achieved with Flap Gate, discharge 

pulleys, Rack & Pinion gate, limit switches and zero speed switches. 

(j) Motors shall start only when the brake/rail clamp if-provided, is in “not applied’‘ 

condition. This signal shall be obtained from limit switch provided for that 

purpose. 

(k) Ring granulators shall be provided with speed and vibration monitoring 

instruments. Ring granulators shall trip in case speed/ vibration is going 

beyond tolerable limits of design. Temperature sensing devices shall be 

installed on all bearings of each of the ring granulator to trip the ring 

granulator in case of temperature goes beyond limit. Audio-visual 

annunciation shall be provided in main control room and locally also. 

(l) Once a conveyor trips, flap gate directing coal from this conveyor shall change 

over its position with a time delay and shall come back to the original position 

again. This is to prevent jamming of gate. 

(m) 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. 

(n) 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. 


SECTION-VI 

PART-B 





PAGE 

10 OF 22

CLAUSE NO. 

4.07.00 Interlocking 




PLANT PACKAGE 


(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 

(7) Crushers 

(8) Belt scale 

(9) Suspended Magnet 

(10) Wagon tipplers 

(11) 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. 


SECTION-VI 

PART-B 





PAGE 

11 OF 22

CLAUSE NO. 

(g.) Interlock for H.T. Motor : 




PLANT PACKAGE 


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 

(f) Chute Block switch - not operated. 

(g) Brakes for conveyor – not operated. 

(h) Trip circuits healthy. 

(i) Temp. of fluid coupling oil - not high 

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. 


SECTION-VI 

PART-B 





PAGE 

12 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(b) Torque limit switches - reset. 

(c) Local stop - reset. 

Ring Granulator 

(a) Zero speed - not operated 

(b) Temp. of fluid coupling oil - not high. 

(c) Local stop push button reset. 

(d) Temperature of bearings – not high. 

(e) Cooling water flow switch – reset 

Wagon tippler 

(a) Motor O/L – not tripped 

(b) Local E-Shop PB-reset 

(c) Shop 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. 

4.07.01 The lists of indications and audio-visual annunciation given in subsequent clauses 

are indicative only and the same shall be finalised during detail engineering. 

4.07.02 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' 


SECTION-VI 

PART-B 





PAGE 

13 OF 22

CLAUSE NO. 

(b.) Flap Gate/Rack and Pinion. 




PLANT PACKAGE 


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

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

CRT). 

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

CRT). 

(f.) Zero speed switch operated for each conveyor 

(g.) Crusher ON 

(h.) MD/ ILMS/ SM/ CSU ON 

(i.) DS/ SW/PW/CW/DE/ Vent ON (System wise) 

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

(k.) Wagon Tippler – ON 

(l.) Apron feeder - ON 

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

4.08.00 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 


SECTION-VI 

PART-B 





PAGE 

14 OF 22

CLAUSE NO. 

(4.) Buchholz trip 




PLANT PACKAGE 


(5.) Winding/oil temperature high trip 

(e) A.C Control Supply failure. 

(f) D.C. Control Supply failure. 

(g) Annunciation supply failure. 

(h) Both CPU fail 

(i) Stand by CPU in service 

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

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

(l) HT motor trip on electrical fault (Group) 

(m) LT motor overload tripped (Group). 

(n) Crusher vibration monitor alarm (Group). 

(o) Belt sway switch operated (Group) 

(p) Pull cord switch operated (Group) 

(q) Zero speed switch operated. (Group) 

(r) Chute plugged (Group) 

(s) Wagon rake arrived. 

(t) Magnetic separator fault and cleaning belt trip. 

(u) (i) Metal Detector fault (Group) 

(ii) Metal detected / MD not reset (Group) 

(v) Belt Scale fault (Group) 

(w) Sampling system faults and trips (Group) 

(ab) Dust suppression/service water / dust extraction system faults and trips 

(system wise) 


SECTION-VI 

PART-B 





PAGE 

15 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(ac) Water level low in tanks (group) 

(ad) Oil temperature of fluid coupling high 

(ae) Crusher low speed & crusher bearing temperature – high. 

(af) Wagon tippler tripped (group) 

(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. 


SECTION-VI 

PART-B 





PAGE 

16 OF 22

CLAUSE NO. 




PLANT PACKAGE 


Fault : Ann. Window : Blinking. 

Press 

Accept. PB. 

Press Reset 

PB (When 

fault is 

cleared): 


Status indication : Fast blinking 

Buzzer : Sounding. 

Ann. Window : Steady glow. 

Status indication : Fast blinking 

Buzzer : Off. 

Ann. Window : Off. 

Status indication : i) Steady blinking (if on 

selected path) 

Buzzer. : Off. 

(a.) Conveyors / Equipment 


SECTION-VI 

PART-B 

ii) Off (if not on selected path) 

(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. 





PAGE 

17 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(7.) Pumps shall be started manually or from PLC. 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 

(iii) Water level high in tank. 

(b.) Wagon unloading (Wagon Tippler Hopper) 

(1.) System shall be operated from local control panel. However, the controls 

shall be through PLC. 

(2.) Dust suppression system shall be provided to cover the Wagon Tippler 

Hopper in maximum one sections. Push button for section shall be 

located on side of wagon tippler hopper at convenient location. 

(3.) Pumps shall be started manually or from PLC 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. 

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

(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 


SECTION-VI 

PART-B 





PAGE 

18 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(ii) Discharge pressure healthy 

(iii) Water level high in tank. 

(c) Following individual inputs shall be provided to PLC system from all the 

above dust suppression systems for alarms/indications. 

4.10.00 Metal detectors 

4.11.00 Sump Pumps 

(i.) Motor ON/OFF/TRIP 

(ii.) Water level low in tank 

(iii.) Water level high in tank 

(iv.) Discharge pressure low 

(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. 

(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. 

(b) Any of the pumps can be selected as auto-standby. 


SECTION-VI 

PART-B 





PAGE 

19 OF 22

CLAUSE NO. 




PLANT PACKAGE 


(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. 

4.12.00 Coal Sampling system 

(a) Coal Sampling Unit shall be controlled through main coal handling plant PLC. 

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. 

4.15.00 Flap Gates/ R&P Gates 

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

control room. 

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. 


SECTION-VI 

PART-B 





PAGE 

20 OF 22

CLAUSE NO. 

4.16.00 Belt Weighers 




PLANT PACKAGE 


Each belt scale shall give output to PLC 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. 

4.17.00 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 deenergised 

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. 

(b.) Incoming supply ON 

(c.) ‘Under current relay’ operated 

(d.) Cleated belt motor ON/OFF/TRIP 

(e.) Oil temperature high 

4.18.00 Service water, Cooling Water Dust Extraction 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 PLC 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 


SECTION-VI 

PART-B 





PAGE 

21 OF 22

CLAUSE NO. 

4.19.00 Wagon Tippler 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-B 





PAGE 

22 OF 22

PART - B 


WAGON TIPPLER 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


WAGON TIPPLER 

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. 

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) an 

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 The rake comprising of specified maximum 58 numbers 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 whose travel length shall suit the requirement of 

wagon tippler hopper dimensions approved by RDSO/railway authorities. 

1.01.04 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. 

1.01.05 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 including civil and 

structural drawing only after getting the same approved from the concerned Railway 

authorities. Bidder shall take case of the observations of RDSO/Railway authorities 

in their designed & drawings for wagon tippler and its accessories. 

1.01.06 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. 

1.01.07 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 


SECTION-VI 

PART-B 


WAGON TIPPLER 

PAGE 

1 OF 7

CLAUSE NO. 




PLANT PACKAGE 


account. It is the responsibility of the Contractor to carry out any modifications as 

required by the RDSO/Railway authorities, at no extra cost to the Owner. 

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 for atleast three (3) nos. 8 wheeled 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 350 mm x 350 mm 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 about 35T. 

2.00.00 CODES AND STANDRDS 

The design, manufacture, inspection and testing of Wagon Tippler shall comply with 

all the currently applicable statutes, regulations and safety codes in the locality 

where the equipment is to be installed. The Wagon Tippler shall conform to the 

latest edition of the 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 constructed to relieve 

the contractor of the required statutory responsibility. In case of any conflict in the 

standard and this specification, the decision so the Employer shall be final and 

binding. 

3.00.00 DESIGN REQUIREMENT 

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 at least 150° 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 movement (WDG3A) over tippler table 

at creep speed. 

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 or the wagon or the track. 

3.03.00 The tippler shall be suitable for continuous operation, 24 hours a day, round the 

clock. Although the tippling rate shall be 20 Tips per hour all drive components, by 


SECTION-VI 

PART-B 


WAGON TIPPLER 

PAGE 

2 OF 7

CLAUSE NO. 




PLANT PACKAGE 


hydraulic, electrical structures shall be designed for 24 tips per hour continuous 

operation. 

3.04.00 The wagon tippler structure shall be designed to conform to the requirements of 

Indian Railway’s “Research, Design and Standards Organisation, (RDSO), Lucknow 

226011” 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 standard broad gauge (1676 mm) Indian Railways diesel locomotives 

over tippler table at restricted speed. 

3.05.00 The wagon tippler shall be suitably counter balanced at each stage of operation so 

as to require minimum driving power. 

3.06.00 Wagon Tippler weighing System 

3.06.01 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 no. 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 

tipping 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 with the facility for 

computerized printed output of data gross weight, tare weight, wagon no., 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. 

4.00.00 CONSTRUCTION REQUIREMENT 

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 


SECTION-VI 

PART-B 


WAGON TIPPLER 

PAGE 

3 OF 7

CLAUSE NO. 

4.02.00 Rail Table 




PLANT PACKAGE 


failure of one of the drive pinions and / or gear racks shall be provided and the same 

shall be clearly indicated in the bid. 

4.02.01 The rail table shall be constructed of rolled steel joints with standard steel rails (52 

kg/metre) 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 tipping 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 

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 drive with each pinion drive through slow speed high torque 

hydraulic motors using gear boxes or fully hydraulic drive (without gear box) 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 overtip limit switch operated by a 

striker on the tippler trunnion shaft shall be furnished. 

4.08.00 Ballast 

4.08.01 Ballast necessary for counter weight and balancing the tippler shall be provided as 

per the requirement. 


SECTION-VI 

PART-B 


WAGON TIPPLER 

PAGE 

4 OF 7

CLAUSE NO. 

4.09.00 Lubrication 




PLANT PACKAGE 


4.09.01 All bearings shall be properly lubricated. Grease nipples and reservoirs shall be 

furnished where necessary. 

4.10.00 Guards 

4.10.01 All gears inside machinery pits and other moving parts shall be securely guarded. 

4.10.02 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. 


SECTION-VI 

PART-B 


WAGON TIPPLER 

PAGE 

5 OF 7

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET 

1.1.0 Wagon Type : Standard broad gauge, 8 wheeler 

wagons of RDSO 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. 

2.0.0 DESIGN & CONSTRUCTION 

2.1.0 Wagon Tippler Hopper 

2.1.1 Construction : RCC Construction. 

2.1.2 Size : To accommodate atleast (three) 3 nos. 

8 wheeled wagons (min.180 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 350 mm 

(ii) Grating Section : 200 mm x 30 mm thick flats. 


2.2.1 Type : Rotaside type 

2.2.2 Tipping angle : Atleast 150° 

2.2.3 Duty Requirement : Continuous operation 

2.2.4 Counter balancing : Suitable to keep power requirement at 

minimum. 


SECTION-VI 

PART-B 


WAGON TIPPLER 

PAGE 

6 OF 7

CLAUSE NO. 




PLANT PACKAGE 


2.2.5 Cradle : Heavy welded steel plate construction 

trunion mounted. 

2.2.6 Driving Gear 

(i) Racks : Cast steel rack sections bolted to end 

sectors. 

(ii) Pinion : Multiple pinions meshing with rack. 

2.2.7 Rail Table : Rolled steel joints with steel rails 

mounted on it. 

2.2.8 Drive : Hydraulic motors integral with 

Gear Box or direct hydraulic drive. 

2.2.9 Brake : Electro hydraulic thruster operated. 

2.2.10 Clamping : Hydraulically operated 

2.2.11 Top & side stops : Self aligning type made of resilient 

material. 


SECTION-VI 

PART-B 


WAGON TIPPLER 

PAGE 

7 OF 7

PART - B 


BRAKES & CLAMPS 





SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 BRAKES AND CLAMPS 





PLANT PACKAGE 


BRAKES AND CLAMPS 

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

requirement. 

1.01.01 STANDARDS 

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

The design, manufacture, inspection and testing of Brakes & Clamps shall comply 

with all the currently applicable statutes, regulations and safety codes in the locality 

where the equipment is to be installed. The Brakes & Clamps shall conform to the 


standards/codes, which ensure equal or higher performance, shall also be accepted. 

Nothing in this specification shall be construed to relieve the contractor of the 

required statutory responsibility. In case of any conflict in the standard and this 

specification, the decision of the Employer shall be final and binding. 


1.02.01 Electro Hydraulic Thruster Brakes/Disc Brakes 

1.02.02 Clamps 

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. 

Electro-hydraulic thruster and manual rail clamp shall be designed for holding the 

machine stationary. Electro-hydraulic thruster and manual rail clamp shall be 

actuated by compression springs, the spring shall apply the clamping force directly 

on the Rail clamp mechanism once power supply is cut-off. The force transmission 

mechanism from spring to rail clamp faces shall be very simple with minimum 

linkages. 


1.03.01 Thruster Brakes 

1.03.02 The electro hydraulic thruster shall be fitted with the brake. Limit switches shall be 

provided for brake applied/released positions. The windings shall be provided with 

class-B insulation suitable for 415V ± 10% at 50 Hz ± 5% and combined variation of 

± 10%. Brake lining shall be asbestos with inter woven brass wires capable of 

withstanding 200°C temperature. 


SECTION-VI 

PART-B 



PAGE 

1 OF 3

CLAUSE NO. 

1.03.03 Clamps 




PLANT PACKAGE 


1.03.04 Electro Hydraulic thruster shall be fitted directly above spring. 

1.03.05 Rail clamp shall be provided between the two travel wheels. Further, limit switches 

shall be provided for Rail clamp ‘ENGAGED’ and ‘DISENGAGED’ signals. 

1.03.06 Minimum clearance between the Rail clamp face and rail surface shall be 50mm. 

However, this clearance may not be uniform for both the faces of Rail clamp 

throughout the length of rails. Rail clamp shall operate satisfactorily under this 

condition without the need for any adjustments. 


SECTION-VI 

PART-B 



PAGE 

2 OF 3

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET: BRAKES AND CLAMPS 

1.1.0 Brakes (i) For decelerating of conveyors 

& rotating equipment’s. 


SECTION-VI 

PART-B 

(ii) Brakes are mandatory for H.T. 

drives involving scoop type 

coupling. 

1.2.0 Rail Clamps For various mobile equipment 

travelling on rails (as applicable). 

2.0.0 DESIGN & CONSTRUCTION REQUIREMENT 

2.1.0 Brakes 

2.1.1 Type Electro Hydraulic Thruster brakes A.C. 

operated or Disc brakes. 

2.1.2 Braking Torque Adjustable from 0 to 100% of rated 

braking torque. 

2.1.3 Brake Shoes Operated directly by spring 

2.1.4 Shoe lining Asbestos with interwoven brass wires. 

2.1.5 Max. Temperature for shoe lining 200 degree C. 

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

2.2.0 Clamps 

2.2.1 Rail Clamp support Independent from the rails. 

2.2.2 Limit Switches “ENGAGED” & "DISENGAGED” 

signals. 

2.2.3 Clearance between Rail clamp face 

& Rail surface 

Minimum 50 mm 

2.2.4 Material for Rail clamp Mechanism Forged steel 

2.2.5 Thruster Class-B insulation, IP-65 Protection 

2.2.6 Type Electro hydraulic thruster, manual 



PAGE 

3 OF 3

PART - B 


MONORAILS AND HOISTS 





SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 MONORAILS AND HOISTS 





PLANT PACKAGE 


MONORAILS AND HOISTS 

Suitable handling arrangements shall be provided for all equipment’s included in 

Contractor’s scope to transfer the equipment to maintenance area within the building 

and/or to transfer the equipment outside the building upto ground level for further 

transportation by the Employer. For this purpose Contractor shall provide monorails 

and hoist blocks with cross travel facility. 

1.01.01 CODES AND STANDARDS 

The design, manufacture, inspection and testing of Monorails and Hoists shall 

comply with all the currently applicable statutes, regulations and safety codes in the 

locality where the equipment is to be installed. The Monorails & Hoists shall 

conform to the latest edition of the following standards & codes. Other 

internationally acceptable standards/codes, which ensure equal or higher 

performance than those specified, shall also be accepted. Nothing in this 

specification shall be construed to relieve the contractor of the required statutory 

responsibility. In case of any conflict in the standard and this specification, the 

decision of the Employer shall be final and binding. 

IS:3938 : Specification for Electric Wire Rope Hoist 

IS:3832 : Chain pulley blocks 

IS:2429 : Round steel short link chain 

IS:6216 :Short link chain grade 80 

IS:8610 :Points hooks with shank for general engineering purposes 

IS:210 : Cast Iron Castings 

1.02.00 DESIGN REQUIREMENTS 

1.02.01 For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with 

the exception of hoists for GTU and bend pulleys motor operated hoist blocks for 

both long travel and lift shall be provided. Other hoist blocks shall be of hand 

operated type for both travel and lift. All monorails coming out of the buildings shall 

be provided with electric hoist blocks, irrespective of load and lift. Minimum 3 meter 

length of Cantilever from edge of building/cladding, shall be provided in monorails 

coming out of the building to lower the equipment to ground level clearing the 


SECTION-VI 

PART-B 


MONORAILS AND 

HOISTS 

PAGE 

1 OF 7

CLAUSE NO. 




PLANT PACKAGE 


building sidewalls / cladding and any other facilities beneath the floor upto ground 

level. 

1.02.02 The exact lift/travel and the number of the hoisting mechanisms and the mode of 

lifting equipment’s to various floors of the buildings shall be as decided by the 

employer at the time of detailed engineering. Clear height shall be maintained when 

handling one equipment over other, in such case dismantling of any equipment shall 

not be permitted. The center line of monorail shall not deviate by more than 500 mm 

from the center of gravity of any equipment that is to be lifted. Contractor shall take 

clear note of the fact that the number and monorail hoisting systems shall also be 

decided considering the movement of the equipment being lifted over/by the side of 

other equipment’s without removing the later. The necessary levels of floors in 

various buildings shall be decided considering the above requirement. 

1.02.03 Monorails shall be extended outside the building to handle the equipment to ground 

level. For monorail/hoist routed inside the buildings, suitable machinery well and 

removable handrailing and grating shall be provided on various floors of buildings, 

as necessary, to handle the equipment. 

1.02.04 Electrically operated monogirder type hoists shall consist of following major 

components. 

(a.) Electrically operated trolley complete with drive motor (Trolley travel speed 

maximum 15 m/min.). 

(b.) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting 

speed maximum 6m/min.). 

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

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

(e.) Erection hardware. 

(f.) Pendent control station suspended from hoist. 

(g.) Control panel mounted on wall. 

1.02.05 The electric hoist shall be designed and constructed in accordance with the latest 

revision of IS:3938 and shall be suitable for duty class 2. 

1.02.06 For electric hoists, trolley movement and hoisting shall be effected by using two 

separate motors. Motors shall be as per technical requirements discussed 

elsewhere. However the motors shall be suitable for 150 starts per hour at 40% 

CDF. 


SECTION-VI 

PART-B 


MONORAILS AND 

HOISTS 

PAGE 

2 OF 7

CLAUSE NO. 




PLANT PACKAGE 


1.02.07 Trolley for motorized / manual cross travel shall be designed to accommodate a 

wide range of I beams and shall be capable of travelling on straight as well as 

curved monorails with the design being such to maintain uniform distribution of 

pressure on the flanges. 

1.02.08 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which 

shall be driven through motor. 

1.02.09 Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36 construction 

with a breaking strength of 160 -175 kgf/ sq. mm. Reverse bend of ropes is not 

acceptable. Minimum number of falls of rope shall be four (4). 

1.02.10 All gears and pinions shall be of hardened and tempered steel with machine cut 

teeth in metric modules. Surface hardening of steel is not acceptable. 

1.02.11 All running shafts and wheels shall be fitted with ball / roller bearings with a rated life 

not less than 20 years based on equivalent running time as per IS:3938. 

1.02.12 An electromechanical brake shall be provided for hoisting as well as cross travel. 

Brake lining shall be of asbestos. 

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

1.02.14 All chain pulley blocks shall be designed to IS:3832, the operating hand chain shall 

conform to IS:2429 grade 30 pitched and polished and the load chain to IS:6216 

grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be 

as per IS: 8610 & with antifriction bearing. 

1.02.15 All hoists/chain pulley blocks shall be selected to have minimum headroom and shall 

be selected to lift heaviest piece of equipment. Further, it shall be possible to handle 

any equipment without disturbing other equipment. 

1.02.16 The hand chain wheels shall be of cast steel, the wheels shall be with flanges and 

designed to ensure effective operation of hand chain. Further, suitable local brake 

shall be provided as per IS:3832 to arrest and sustain loads in all working positions. 

1.02.17 The velocity rates, effort on chain required to raise the safe working load and travel 

and speed shall be within the limit specified in IS:3832. Proof load test shall be 

carried out as per IS:3832. Balance requirements shall be as discussed in earlier 

clauses pertaining to electric hoists. 

1.02.18 Hoist for Gravity Take up arrangement and bend pulley. 

For handling bend pulley, take-up pulley and counter weights following hoisting 

arrangement shall be provided: 


SECTION-VI 

PART-B 


MONORAILS AND 

HOISTS 

PAGE 

3 OF 7

CLAUSE NO. 




PLANT PACKAGE 


(1) For handling bend pulleys, hooks of adequate capacity shall be provided at 

the top of gallery. Further minimum four (4) nos. manually operated chain 

pulley blocks of adequate capacity shall also be provided for the entire coal 

handling plant for handling bend pulleys. 

(2) For handling take-up pulleys, manual hoist along with mono rail beam of 

adequate capacity having cross travel, arrangement shall be provided at 

bottom of gallery to handle take-up pulley only of conveyors. 

(3) For handling take-up weight, a separate manual hoist with mono rail beam of 

adequate capacity shall be provided to hold complete counter weight 

(inclusive of all counter weight blocks). This hoist shall be provided for 

holding the counter weight and shall be located in the zone of counter weight 

travel. 


1.03.01 The hoist mechanism shall consist of a grooved rope drum driven by electric motor 

through gears. Each end of the rope shall be anchored to the drum in such a way as 

the anchorage is readily available for maintenance. Each rope shall have two (2) full 

turns of the drum when the hook is at its lowest position and one (1) spare groove 

when the hook is at its highest position. The leading rope taken by the drum should 

not slope sideways when slack and it should not be caught between the gear wheel. 

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

1.03.03 Trolley wheels shall be of single flange type in the taper treads. The wheels shall be 

mounted on antifriction bearings and shall be easily removable for repair/ 

replacement. 

1.03.04 The load hook shall be swiveling type forged circular shank section and shall confirm 

to IS:8610. 

1.03.05 All gears and bearings shall be lubricated by grease. All lubricating points shall be 

grouped together in easily accessible position. 

1.03.06 The bottom block shall be of enclosed type and shall have guard against rope 

jamming in normal use. It shall have standard forged swivel shank hook fitted on 

antifriction thrust bearing. Lock to prevent hook from rotation and locking 

arrangement to prevent accidental unlocking shall be provided. Pulley of the bottom 

block shall be provided with antifriction bearings. 

1.03.07 All parts requiring replacement/inspection/lubrication shall be accessible without 

need for dismantling of other parts/structures. 

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


SECTION-VI 

PART-B 


MONORAILS AND 

HOISTS 

PAGE 

4 OF 7

CLAUSE NO. 




PLANT PACKAGE 


1.03.09 Hoists shall have permanent inscription in English on each side readily recognizable 

from floor level stating safe working load. 

1.03.10 Pendant shall be provided with flourscent up/down/forward/reverse travel push 

buttons and indicating lamps. Its power supply shall be limited to 24V AC. 

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

a standing man. 

1.03.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 

1.5m) with ladder shall be provided for each electrical hoist. 

1.03.13 Inline magnetic separator shall have motorised hoist for handling / maintenance 

purpose. Each suspended magnet shall be provided with a dedicated motorised 

trolley. 


SECTION-VI 

PART-B 


MONORAILS AND 

HOISTS 

PAGE 

5 OF 7

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : MONORAILS AND HOISTS 

1.1.0 Functional Requirement : To transfer equipment’s to 

maintenance area or outside the 

building. 


2.1.0 Hoists 

2.1.1 Drive 

(i) More than 2.0 tonne or more than 

10.0 m lift or hoists coming out-side 

the buildings 

(ii) Other hoists including the hoists for 

handling takeup pulley and takeup 

weight 

2.1.2 Maximum trolley travel speed for electric 

hoists 

2.1.3 Maximum Hoisting speed for electric 

hoists 


SECTION-VI 

PART-B 

Motor driven for both travel & lift. 

Manual for both travel & lift. 

15m/min 

6 m/min 

2.1.4 Drive Motors SQIM, Separate for travel & lift 

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

2.1.6 Wire Rope 

2.1.7 Bearing 

(i) Type/Construction Pre-formed type, hemp cored, 

regular lay 6/36 construction 

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

(i) Type Ball/Roller bearing 

(ii) Life 20 years 

2.1.8 Brake Electro Mechanical type with 

asbestos lining. 


MONORAILS AND 

HOISTS 

PAGE 

6 OF 7

CLAUSE NO. 




PLANT PACKAGE 


2.1.9 Load Hook Swiveling type forged circular 

shank section. 

2.1.10 Duty Class –2 

2.2.0 Monorail location/layout 

2.2.1 Cross section I beam 

2.2.2 Distance between C/L of monorail & 

C.G. of equipment to be lifted 


SECTION-VI 

PART-B 

Maximum 500 mm 

2.2.3 Power Cables Support Festoon type arrangement 

2.3.0 Manual Hoists 

2.3.1 Maximum manual effort for operation. 30 Kg 


MONORAILS AND 

HOISTS 

PAGE 

7 OF 7

PART - B 


CHUTES & HOPPERS 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


CHUTES AND HOPPERS 

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 

latest edition of the following standards and codes. Other internationally acceptable 


shall also be accepted. Nothing in this specification shall be construed to relieve the 

contractor of the required statutory responsibility. In case of any conflict in the 

standard and this specification, the decision of the Employer shall be final and 

binding. 

IS:4682 :Code of practice for lining of vessels and equipment for chemical 

processes. 

IS:226 : Structural Steel (Standard Quality) 

IS:11592 : Code of practice for selection and design of Belt Conveyors. 

1.02.00 DESIGN AND CONSTRUCTION 

1.02.01 Chutes, Hoppers 

1.02.02 The minimum valley angle of chutes shall be 60 degrees from horizontal. 

1.02.03 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal 

without any accumulation anywhere. 

1.02.04 Complete chute work above the drive floor for conveyors provided with ‘In-line belt 

magnetic separators’ shall be of 10 mm thick SS - 304 in the zone of magnetic field. 

1.02.05 Direct impact of material on conveyor belt shall be avoided by providing an inclined 

surface at 60 degrees valley angle at the feeding point to guide the material in the 

direction of belt travel. Further, chute construction below flap gate shaft shall be 

such that there will not be any accumulation of coal dust between chute and flap 

gate in that zone. 


SECTION-VI 

PART-B 



PAGE 

1 OF 8

CLAUSE NO. 




PLANT PACKAGE 


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 

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. While fabricating the chute, no welds in between shall be allowed. 

1.02.08 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 

4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors 

with suitable access to them. Further, serrated rubber seal shall also be provided at 

the very inlet of head chute to minimize dust nuisance. 

1.02.09 Separate maintenance sealed door shall be provided for access to belt cleaners in 

head pulley hood, flap gates for maintenance and inspection doors shall be of 

hinged with positive locking facility. 

1.02.10 (a) There should be sufficient clear space to install, remove and maintain 

scrappers without cutting structures. 

(b) Slope of plates below scrappers to direct coal scrapped by these to the main 

stream shall be 60 O min. 


SECTION-VI 

PART-B 



PAGE 

2 OF 8

CLAUSE NO. 

1.03.00 Skirt Boards 




PLANT PACKAGE 


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 3 m ahead of front edge of chute and 500 mm beyond rear edge 

of chute. The width of the Skirt Boards shall be two-third the conveyor belt width. In 

the belts 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. 


1.04.01 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 


SECTION-VI 

PART-B 



PAGE 

3 OF 8

CLAUSE NO. 




PLANT PACKAGE 


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 operation the flap gate shall not exceed 25 kg. 

1.04.08 All the two way chutes, one way of which is leading towards the future conveyor 

shall be provided with blind flange. 

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 & debris chute inside buildings. 

1.04.16 Shaft & flap gate shall be tightly fitted to each other. 

1.05.00 Rack & Pinion Gates 

1.05.01 Rotary actuator operated rack and pinion gates shall be provided at various 

locations as specified. The gate shall be mounted such that coal load does not act 

vertically on gate. 


SECTION-VI 

PART-B 



PAGE 

4 OF 8

CLAUSE NO. 




PLANT PACKAGE 


1.05.02 Suitable manually operated rod gates shall be provided over rack and pinion gates 

for their easy operation and maintenance. 

1.05.03 The rack and pinion gate shall be guided properly and suitable rollers with bearings 

sealed for life and dust proof shall be provided. 

1.05.04 The rack and pinion gates shall be of mild steel construction with liner plate of 10 

mm thick TISCRAL or equivalent material. The gates shall be operated by means of 

double rack and pinion. The material for rack & pinion wheel shall be cast steel and 

shaft shall be EN.-8. 

1.05.05 Provision for alternative manual operation of motorized rack and pinion gates shall 

also be made. Limit switch for safety of person operating the hand wheel shall be 

provided. 

1.05.06 Manual effort required to operate the rack and pinion gate shall not exceed 25 kg. 

1.05.07 Approach/maintenance platforms complete with chequered plate floor, hand railings, 

ladder etc. shall be provided for all gates. 


SECTION-VI 

PART-B 



PAGE 

5 OF 8

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : CHUTES AND HOPPERS 

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 above 

In the zone of magnetic field of 

ILMS (chute above floor over 

which ILMS is suspended) 


SECTION-VI 

PART-B 

All four sides of 20 mm thk. 

TISCRAL/equivalent material 

SS-304 10 mm thk. 

In the zone of flap gates 20 thk TISCRAL/ equivalent material 

Discharge Hoods over head 

pulleys 

4 mm thk M.S. with rubber curtain 

2.1.3 Inspection Doors Hinged & leak proof construction 

(min. size 350 x 450 mm) 

2.1.4 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 



PAGE 

6 OF 8

CLAUSE NO. 

2.2.0 Skirt Boards 




PLANT PACKAGE 


2.2.1 Length Entire feeding chute and shall be 

extended min. 3 m ahead of front 

edge of chute and 500 mm beyond 

rear edge of chute. 

2.2.2 Height Not less than 750 mm 

2.2.3 Width 2/3 of belt width 

2.3.0 Flap Gate 

Side plate Min. 10 thk TISCRAL/equivalent 

Top cover 6 mm thk M.S. 

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) 

(iv) Protection Travel and Thrust dependent limit 

Switches. 

2.4.4 Manual Operation 

(a) Maximum effort Convenient for single operator by 

declutchable hand wheel regardless 

of electrical power. 

(b) Minimum Handwheel 

Diameter 

2.4.5 Flap gate shaft 


SECTION-VI 

PART-B 

500 mm 

(i) Diameter minimum 130 mm 

(ii) Material EN-8 



PAGE 

7 OF 8

CLAUSE NO. 




PLANT PACKAGE 


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 

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 130 mm 

2.5.9 No. of Operations /hr. 15 (with 10 consecutive) 


SECTION-VI 

PART-B 



PAGE 

8 OF 8

PART - B 


BELT CONVEYOR SYSTEM 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


BELT CONVEYOR SYSTEM 

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:226 : Structural Steel (Standard Quality) 

IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical 

Processes. 

IS:11592 :Code of practice for selection and design of Belt Conveyors. 

CAN / CASA - M422 M87 : Canadian standard association. 


1.02.01 Design of belt conveyor system shall be suitable for coal parameters specified 

elsewhere. 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

1 OF 16

CLAUSE NO. 




PLANT PACKAGE 


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 shall be designed for 110% 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 Remote operated Movable discharge pulleys and movable belt feeders shall be 

provided as per the tender drgs alongwith the complete electrically driven moving 

mechanism with rails, trolleys, guide roller etc. The complete discharge pulley 

movement area shall be covered with proper sealing arrangement. Proper brakes 

and mechanical locks shall be provided to avoid the rushing of the discharge pulley 

due to load and the design shall prevent over travel of pulley / belt feeder. The 

discharge chute opening shall be provided with proper handrails for the safety 

purpose. Suitable rotating strobe lights and siren shall be provided to warn 

personnel at the time of operation. Suitable arrangement for sensing correct 

positioning of movable pulley / belt feeder shall be provided which shall be used in 

protective interlock. 

1.02.08 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. 


1.04.00 Belting 

1.04.01 The belting shall be of either synthetic fabric such as Nylon-Nylon, Steel Cord. etc. 

with rubber covers of adequate flexibility to give a troughing angle of 35 deg. For all 

the conveyors the number of plies, cover thickness, factor of safety etc. shall be as 

per the recommendation of belt manufacturer, but not inferior to the figures as 

tabulated in data sheet. 

1.05.00 Idlers 

1.05.01 Carrying idlers shall be provided with three equal rolls with troughing angle of 35 

deg. and 2 deg. forward tilt (except in case of reversible conveyors). 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

2 OF 16

CLAUSE NO. 




PLANT PACKAGE 


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 

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 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

3 OF 16

CLAUSE NO. 




PLANT PACKAGE 


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 

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 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 or 0.5% for steel cord belting) whichever is larger. Suitable guides 

shall be provided both for take up pulley and take up weight. 

1.07.03 Two (2) meter safety fencing along with suitable gate and locking arrangement shall 

be provided around gravity take-up at the base level / ground level. 

1.07.04 Irrespective of take-up location, the travel zone of take-up weight shall start from a 

suitable height above ground level. 

1.07.05 Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley in 

order to avoid damage of the pulley assembly in case of belt snapping. Similar 

buffer arrangement shall be provided for take-up weight also, in case of, take-up 

weight travel zone terminating above a building floor. Sandpits of 600 mm deep 

shall be provided at ground below the take-up weights. 

1.07.06 In case of double stream conveyors, a partition of 3 mm steel plate shall be provided 

between the two take-up pulleys along entire travel zone of take-up pulleys. 

Intermediate platforms shall be provided in the take-up zone for maintenance of take 

- up pulleys / counter weight. 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

4 OF 16

CLAUSE NO. 




PLANT PACKAGE 


1.07.07 Take-up weight shall consist of multi-blocks and not of single block to facilitate 

adjustment in weight if required during operation. Single heaviest piece shall be 

suitable for easy handling. Take-up weight block shall be provided with edge 

protection angle to take care of any damage. Take up weights shall be kept inside a 

take up weight box and shall be properly anchored / bolted with the main frame, so 

that the none of the weight shall be loose/free inside the box. The box shall be 

painted with counter weight and conveyor number and shall have good aesthetic 

look. 

1.08.00 Hold Back Devices 

1.08.01 Suitable hold back devices for preventing running back of the conveyor belt in case 

of conveyor being stopped in loaded conditions due to power failure or during normal 

operational delays shall be provided to give positive protection. The hold back shall 

instantaneously engage without shock and be capable of protecting equipment and 

personnel. It shall be released instantly when ‘power’ resumes or the ‘delay’ is 

removed. The holdback devices shall be integral with gearbox. 

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 

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. 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

5 OF 16

CLAUSE NO. 




PLANT PACKAGE 


1.09.09 Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall be 

provided for all tail pulleys and bend pulleys for safety of operating personnel. 

1.09.10 Suitable stiffening arrangements shall be provided in all pulleys. For selection of 

pulley shaft dia of all the pulleys, a margin of atleast 20% shall be considered on the 

maximum tension at designed Conveyor capacity. Selection of pulley diameter, 

shell thickness, stiffening and shaft diameter shall be subject to approval of 

Employer during detailed engineering. 

1.10.00 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 / 

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 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

6 OF 16

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 

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 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

7 OF 16

CLAUSE NO. 




PLANT PACKAGE 


plates, walkways of chequered plates with anti-skid arrangement(s), hand rails (on 

both sides of each conveyor belt. 

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 

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. 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

8 OF 16

CLAUSE NO. 

1.13.00 Stone Picking 




PLANT PACKAGE 


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. Four (4) nos. manual pickers 

shall be positioned for stone picking. Two (2) 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 Wagon Tippler, Conveying & Crushing 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. 

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. 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

9 OF 16

CLAUSE NO. 

1.16.00 Belt Jointing Facilities 




PLANT PACKAGE 


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 JT’s, Conv. Gallery to pull the old belt while replacing the 

same with new belt. 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

10 OF 16

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : BELT CONVEYOR 

1.1.0 Design Capacity 110% of rated (guaranteed) capacity for all 

conveyors. 

1.2.0 Maximum slope 16 deg 

1.3.0 Max. belt Sag between idlers 2% 

1.4.0 Minimum Radius 

(i) Concave curve 250 m (In case of travelling trippers, the 

requirement of minimum radius shall be 

decided based on the space availability) 

(ii) Convex Curve 50 m 

1.5.0 Coal Parameters As specified elsewhere 


2.1.0 Belting 

2.1.1 Type Synthetic Fabric of Nylon / Nylon, Steel 

Cord. etc. 

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

2.1.3 Cover Thickness (without –ve 

tolerances). 


SECTION-VI 

PART-B 

b) Drum Friction and Electrical Surface 

Resistance Test: Conforming to 

Canadian standard association CAN / 

CSA M-422- M87 Grade - C. 

Synthetic belting Steel Cord 

(a) Face 5.0 mm (min.) 8.0 mm (min.) 

(b) Bottom 2.0 mm (min.) 5.0 mm (min.) 

2.1.4 No. of plies Minimum 4 

2.1.5 Drive Arrangement Snub drive 

2.1.6 Factor of Safety - 10 (Minimum) for N-N/EP belt. 

- 7 (minimum) for Steel Cord Belt. 


BELT CONVEYOR 

SYSTEM 

PAGE 

11 OF 16

CLAUSE NO. 




PLANT PACKAGE 


2.1.7 Normal Working tension at design 

capacity 

2.2.0 Idlers 

2.2.1 Type 

2.2.2 

2.2.3 

2.2.4 


SECTION-VI 

PART-B 

Less than 80% of max. allowable working 

tension 

(a) Carrying Three roll, 35 degree troughing, 

2 degree forward tilt 

(b) Return 

(c) Loading point Impact type 

Spacing 

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 

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

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

m.) 

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

(d) Self-aligning troughing 

idlers 

At 10 m distance from head & Tail pulleys 

with intermediate spacing 15m 

(e) Self - aligning return idlers At 10 m distance from Head & Tail pulleys 

with intermediate spacing 20m. (Not 

required for conveyors more than 400m c/c 

long where 2 roll return idlers are provided). 

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. 

Material 

(a) Roller ERW Steel tube min. wall thickness 

4.0 mm 

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


BELT CONVEYOR 

SYSTEM 

PAGE 

12 OF 16

CLAUSE NO. 

2.3.0 

2.3.1 

2.3.2 

2.4.0 

2.4.1 

2.4.2 

2.4.3 

2.5.0 

2.6.0 

2.6.1 

2.6.2 

Belt Cleaners 




PLANT PACKAGE 


External Spring loaded scraper type cleaner with 

modular, segmented and replaceable PU 

blades with separate main-cleaner & precleaner 

etc. 

Internal V-Plough type, mild steel flats with hard 

rubber strips. 

Belt Take up 

Type Automatic Gravity Type. 

Location In relation to the drive to keep belt tension 

at minimum. 

Take-up travel To suit all operating conditions or (2.5% for 

synthetic belt and 0.5% for steel/cord belt) 

of conveyor center to center length 

whichever is larger. Further the initial 

location of take-up shall be decided in such 

a way that it is possible to carryout min. two 

(2) nos. Vulcanizing Joints without adding 

any external belt. 

Hold Back Device 

Pulleys 

General (for all types of Pulleys) 


SECTION-VI 

PART-B 

Integral with gear Box 

(i) Pulley shaft diameter Margin of minimum 20% shall be 

Considered on maximum tension at design 

capacity for arriving at the shaft dia. 

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 

(3) Minimum angle of wrap 210° degrees 

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


BELT CONVEYOR 

SYSTEM 

PAGE 

13 OF 16

CLAUSE NO. 

2.6.3 

2.6.4 

2.6.5 

2.6.6 

2.6.7 

2.7.0 

2.7.1 

Other pulleys 




PLANT PACKAGE 


(1) Lagging Hot lagged with vulcanised natural rubber 

(2) Lagging thickness 12 mm thick plain 

Rubber for lagging 

(1) Type Natural rubber blended with styrene 

Butadiene rubber. 

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

(3) Elongation Over 300% 

(4) Strength 160-245 kg/cm 2 

(5) Abrasion loss 250 mm3 (max.) as per DIN 53516 

(6) Specific Gravity Max. 1.5 

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

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. 

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

Shaft Material Forged Steel shaft EN-8 or equivalent 

material. 

Belt Protection Equipment 

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 


SECTION-VI 

PART-B 


BELT CONVEYOR 

SYSTEM 

PAGE 

14 OF 16

CLAUSE NO. 

2.7.2 

2.7.3 

2.8.0 

2.8.1 

2.8.2 

2.8.3 

2.9.0 

2.9.1 

2.9.2 

Belt Sway Switches 




PLANT PACKAGE 


(1) Type Limit switches snap action. 

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

pairs) 

Zero Speed Switches 

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

of GTU. 

Drive Motors 

Type Three Phase Squirrel Cage Induction 

Motors 

Mounting (for conveyors) Base mounted 

Continuous motor rating (Name 

plate rating) at 50 O C Ambient 

Conveyor Bridges 

Walkways 


SECTION-VI 

PART-B 

120% of actual power requirement at motor 

output shaft at design capacity. 

(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) 

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 


BELT CONVEYOR 

SYSTEM 

PAGE 

15 OF 16

CLAUSE NO. 

2.10.0 

2.10.1 

Trestles 




PLANT PACKAGE 


Spacing of monkey ladders on 

trestles 

(a) Where height of conveyor 

gallery (walkway level) 

is 10 m or more. 

(b) Where height of conveyor 

gallery (Walkway level) is 

less than 10m. 


SECTION-VI 

PART-B 

: On every trestle 

: On alternate trestle 


BELT CONVEYOR 

SYSTEM 

PAGE 

16 OF 16

PART - B 


DRIVE EQUIPMENT 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 



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 

latest edition of the following standards and codes. Other internationally acceptable 





binding. 

IS:3688 : Dimensions for shaft ends 

IS:3681: General plan for spur & helical gears 

IS:7403 : Code of practice for selection of standard worm and helical gear boxes 

1.02.00 DESIGN AND CONSTRUCTION REQUIREMENTS 

1.02.01 GEAR BOXES 

1.02.02 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces. 

1.02.03 The gearboxes shall be designed for 24 hours continuous duty. For thermal and 

mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with 

cooling coils are not acceptable. 

1.02.04 The gears used shall be helical conforming to IS:3681 (latest revision) or worm 

reduction units or spiral bevel speed reduction units conforming to suitable Indian 

Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest 

revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical 

type only. 

1.02.05 Recommended oil grade shall be compatible with gear internals like material of 

bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick, 

drain plug etc. 


SECTION-VI 

PART-B 



PAGE 

1 OF 4

CLAUSE NO. 

1.02.06 Couplings 

1.02.07 Flexible / Rigid Couplings 




PLANT PACKAGE 


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 



PAGE 

2 OF 4

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : DRIVE EQUIPMENT 

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, mono-rail hoists (travel and 

hoisting), elevators, rack and pinion gates, all 

the drives in sampling units, drives for various 

pumps of DS/DE systems, service water 

systems, cooling water system, potable water 

system and sump pumps & Ventilation Fans 


SECTION-VI 

PART-B 

*110% of actual power 

requirement at drive motor 

output shaft at guaranteed 

(rated) capacity. 

*The actual power at drive motor output shaft shall be calculated after considering 

all the losses of down the line 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 50 o C Minimum 

2.1.4 Mounting On Machined/Ground 

Surfaces 

2.1.5 Output Rating 

a) For belt conveyor systems 

@ Service factor X {1.2 times 

the actual power requirement 

at drive pulley shaft at design 

capacity} 



PAGE 

3 OF 4

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-B 

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 



PAGE 

4 OF 4

PART - B 


BELT SCALE 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


BELT SCALE 

Belt weigh scale for measurement of coal flow rate and quantity shall be provided at 

specified locations. System shall be complete with flow rate indicator, totaliser, 

control panel etc. 

1.01.00 Codes & Standards 

The design, manufacture, inspection and testing of Belt Scales shall comply with all 

the currently applicable statutes, regulations and safety codes in the locality where 

the equipment is to be installed. The Belt Scales shall conform to the latest edition of 

the following standards and codes. Other internationally acceptable 





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 nonvolatile 

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 

PART-B 


BELT SCALES 

PAGE 

1 OF 3

CLAUSE NO. 




PLANT PACKAGE 


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. 

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 


BELT SCALES 

PAGE 

2 OF 3

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : BELT SCALE 

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 : 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 


BELT SCALES 

PAGE 

3 OF 3

PART - B 


DUST CONTROL & MISCELLANEOUS 

SYSTEM 





SECTION-VI 

PART-B

CLAUSE NO. 






PLANT PACKAGE 


DUST CONTROL AND MISCELLANEOUS SYSTEM 

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 

(JT), 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 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

1 OF 18

CLAUSE NO. 

1.02.02 Sump Pump 




PLANT PACKAGE 


(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. 

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 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

2 OF 18

CLAUSE NO. 




PLANT PACKAGE 


necessary protective coating as per relevant standards and as specified 

elsewhere in the specification. 

(9) Painting, anti-corrosive coatings etc. 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. 

IS:1239 : Mild Steel tubes & fittings. 

IS:2379 :Colour for the identification of pipe line. 

IS:2906 :Sluice valves for water work purposes. 

IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm) 

IS:5312 : Swing check type reflux (non return) valves. 

IS:1520 : Horizontal centrifugal pump for clean, cold fresh water. 

IS:5120 :Centrifugal pump for clean, cold & fresh water. 

BS: 5169 & BS:1123 : Air Receivers. 

BS: 5312 CI Check Valve 

BS: 5150 CI Gate Valve 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

3 OF 18

CLAUSE NO. 

BS: 5152 CI Glove Valve 




PLANT PACKAGE 


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, along with air receivers as specified elsewhere. 

(ii) Air receivers 

(iii) Various instrumentation & valves. 

1.05.02 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 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 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. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

4 OF 18

CLAUSE NO. 





PLANT PACKAGE 


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 M 3 /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. 

1.05.05 Service Water (SW) System 

Service water connections are to be provided in conveyor galleries and tunnels at 50 

meter intervals. Adequate number of these connections shall be provided in all 

transfer houses with minimum one no. at each floor and with minimum two (2) nos. 

at each floor in crusher house. Each connection shall be provided with one (1) no. 

32 NB globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be 

provided in each building. 

Service water distribution system shall be designed considering the water scheme 

and water requirement indicated in tender drawings. 

1.05.06 Potable water (PW) system 

Potable water connections are to be provided in all junction towers, wagon tippler 

top, crusher house and all control rooms/MCC rooms and toilets etc. 

Water shall be drawn from the water storage tank by electric motor driven pumps 

and discharged via a pipe work system to the overhead drinking water storage PVC 

tanks of 2500 litres capacities. The drinking water storage tanks shall have provision 

for maintenance & drain. 

1.05.07 Hoists with monorail of adequate capacity shall be provided in the service water/dust 

suppression/potable water pump houses. 

1.05.08 Wet Type Dust Extraction System 

Bidder shall provide wet type dust extraction system for Vibrating Grizzly Screen and 

Belt Feeder in crusher house. The dust extraction system shall be of either Venturi 

scrubber system or cyclone separator system. One independent dust extraction 

system for each stream shall be provided (Total 2 nos. system to be provided). 

Bidder may provide multiple Units in each of the independent dust extraction system 

as per his design. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

5 OF 18

CLAUSE NO. 

1.05.08.01 Venturi Scrubber System 




PLANT PACKAGE 


Venturi scrubber type wet dust collection system shall be provided at crusher house 

for extracting the dust from vibrating screening feeders & belt feeders. 

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. 

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. 

1.05.08.02 Arrangement shall be provided in the slurry discharge system for separating dust 

and water and discharging only clear water to the coal slurry pond. The dust shall be 

removed manually for subsequent transportation to yard. All materials including 

piping, valves, trenches etc. required for the satisfactory operation of aforesaid 

removal system shall be included in bidder’s scope. 

1.05.08.03 Exhaust Fans : 

The construction features of fan shall be same as specified elsewhere in the 


1.05.08.04 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. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

6 OF 18

CLAUSE NO. 

1.05.08.05 Ducting 




PLANT PACKAGE 


(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. 

(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 : 

Diameter of duct Spacing of support 

Less than 200 mm Maximum 3.00 metre 

More than 200 mm Maximum 2.50 metre 

(vi) Electrically operated dampers shall be provided at all dust extraction points. 

(vii) The ducting shall be made of MS Sheet with thickness not less than 14 

gauge. 

1.05.08.06 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: 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

7 OF 18

CLAUSE NO. 




PLANT PACKAGE 


a). Pump casing may be axially or radially split. The casing shall be of robust 

construction. Casing drain and vent connections shall be provided. 

b). Impeller shall be made in one piece and securely keyed to the shaft. Locking 

device shall be provided to prevent its loosening during all conditions of 

operation. 

c). Wearing rings shall be of renewable type. Opposed wearing surface shall be 

of hardened material and shall have a hardness difference of at least 50 

BHN. 

d). Replaceable shaft sleeves shall be provided to protect the shaft where it 

passes through bearings and stuffing boxes. The end of the shaft sleeve 

assembly shall extend through the packing gland. Shaft sleeve shall be 

securely locked or keyed to the shaft to prevent loosening or rotation. Shaft 

and shaft sleeves shall be machined and assembled for concentric rotation. 

e). The design of the shaft shall take into consideration the critical speed, which 

shall be at least 20% away from operating speed. 

f). Pump bearings shall be of antifriction type. Bearings shall be readily 

accessible without disturbing the alignment of pump. 

g). Packed stuffing boxes shall be of sufficient length to prevent leakage along 

the shaft and shall be complete with all packing and lantern rings required. 

h). Pumps shall be furnished complete with an approved type of flexible - 

coupling. 

i). Couplings guards made of expanded metal and bolted to the base plate shall 

be furnished. 

j). The common base plate for pumps and motor shall be in one piece and shall 

be made of fabricated steel. 

k). Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 

m3/hr. 

1.06.01.03 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. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

8 OF 18

CLAUSE NO. 




PLANT PACKAGE 


1.06.01.07 Materials of construction of pump components shall be as stated in data-sheet to 

this section. 


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 

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 20 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 through hume pipes. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

9 OF 18

CLAUSE NO. 

1.06.03.02 Valves and Specialities 




PLANT PACKAGE 


(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. 

(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. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

10 OF 18

CLAUSE NO. 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

11 OF 18

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET: DUST CONTROL & MISCELLANEOUS SYSTEM 

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 

head 

(ii) Pressure at inlet (dry fog) 

(iii) Pressure at inlet (Plain water) 

2.2.0 Plain Water Dust Suppression 

4 (Four) 


SECTION-VI 

PART-B 

Min. 0.5 kg/cm 2 for water 

Min 5 kg/cm 2 for air 

Minimum 4.5 kg/sq. cm 

2.2.1 Pumps 2x100% electric motor driven 

2.2.2 Minimum Pressure at inlet of spray 

nozzles 

2.2.3 Nozzle spacing for Wagon tippler 500 mm 

2.2.4 Nozzles Fogging type 

2.2.5 Flow from each nozzle 2.0 Lpm 

2.3.0 Dry Fog Dust Suppression 

(i) Compressor Screw Type 

4.5 Kg/sq. cm for wagon tippler 

(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 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

12 OF 18

CLAUSE NO. 

2.4.0 Sumps Pumps 




PLANT PACKAGE 


(i) Type 2x100% electric motor driven 

(ii) Capacity 50 cub.m/hr minimum with 10% margin 

(iii) Head 20% margin on computed head 

2.4.1 Drain Pits Minimum 2 x 2 x 1.8 mts. and 1 No. 

settling pit for slurry & high/low level 

switches in drain pit. 

2.4.2 Piping To nearest plant drain 


2.5.1 Water connections 

(a) Conveyor Galleries and tunnels every 50 m 

(b) Junction Towers Min. 1 no. at every floor 

(c) Crusher House Min. 2 nos. at every floor 

2.5.2 Connection details 32 NB plug valve 

2.5.3 Hose pipes with hose reel One in each building of 25 mtr. Length 

with nozzle 

2.6.0 Potable Water System 

2.6.1 Pumps 2 X 100% electric motor driven 

2.6.2 Water connections 

a) Junction Towers Minimum one (1) no. at each floor 

(b) Crusher house Minimum two (2) no. at each floor 

(c) Control room Minimum one (1) no. at each floor 

(d) MCC rooms and toilets Minimum one (1) no. each 

(e) Wagon tippler top Min. one (1) no. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

13 OF 18

CLAUSE NO. 




PLANT PACKAGE 


3.0.0 CONSTRUCTION REQUIREMENTS 

3.1.0 Water Supply Pumps for 

DS/SW/PW/CW 

3.1.1 Casing Axial or radially split with drain & vent 

connection 

3.1.2 Impeller One piece, keyed to shaft along with 

locking device 

3.1.3 Shaft Critical speed atleast 20% away from 

operating speed 

3.1.4 Shaft sleeves At bearings & stuffing boxes. 

3.1.5 Bearings Antifriction type 

3.1.6 Wearing rings Renewable type (preferable) 

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 


3.2.1 Type Wet pit type vertical shaft 

3.2.2 Duty Capacity to handle large solids or 

unscreened liquid. 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

14 OF 18

CLAUSE NO. 





PLANT PACKAGE 


(a) Casing and rotor housing Ni-Cast Iron (350 BHN) 

(b) Rotor Ni-Cast Iron (350 BHN) 

(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 

Pipe size > 65 NB 

(ii) Pipe to valves 

Pipe size < 50 NB 

Pipe size > 65 NB 


SECTION-VI 

PART-B 

Socket welding/screwed 

Butt welding 

Screwed 

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 

3.3.5 Materials for Pipework 

Union bonnet with screwed ends for 

Globe valve & screwed ends for plug 

valve 

(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). 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

15 OF 18

CLAUSE NO. 

(c) For sizes below 

65 NB 

3.3.6 Materials for Valves & Specialities 




PLANT PACKAGE 


(a) Cast Iron Valves 65 NB and above 


SECTION-VI 

PART-B 

ERW carbon steel galvanized pipes to 

IS:1239 (Part-I) Heavy class. 

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

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

(iii) Seating surfaces and rings 13% chromium steel 

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

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

(vi) Back seat bush 13% chromium steel 

(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 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

16 OF 18

CLAUSE NO. 




PLANT PACKAGE 


(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. 

(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 


SECTION-VI 

PART-B 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

17 OF 18

CLAUSE NO. 




PLANT PACKAGE 


(iv) Spring Housing Spring and 

sleeve pipe 

SS – 316 

(iv) Cover Cast Aluminum 

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

(vi) Type of Contact Adjustable throughout the range. 

(viii) Protection class IP – 65 

(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 


DUST CONTROL& 

MISCELLANEOUS 

SYSTEMS 

PAGE 

18 OF 18

PART - B 


VENTILATION SYSTEM 





SECTION-VI 

PART-B

CLAUSE NO. 






PLANT PACKAGE 


VENTILATION SYSTEMS 

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 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 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, 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. 

1.03.00 ENTILATION 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, 


SECTION-VI 

PART-B 



PAGE 

1 OF 9

CLAUSE NO. 




PLANT PACKAGE 


supporting structures, approach/maintenance platforms, civil and structural works 

and necessary accessories shall be furnished for ventilating the underground portion 

of junction towers, underground conveyor tunnels. Exhaust fans shall be provided for 

Toilets, Battery rooms. The exhaust fans for toilets and battery rooms will be 

propeller 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 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. 

1.03.03.03 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear 

surrounding. 

1.04.00 Codes & Standards 

The design, manufacture, inspection and testing of Ventilation & A/C System shall 


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 






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 


SECTION-VI 

PART-B 



PAGE 

2 OF 9

CLAUSE NO. 




PLANT PACKAGE 


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 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. 

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. 


SECTION-VI 

PART-B 



PAGE 

3 OF 9

CLAUSE NO. 

1.05.13 HDPE Filters 




PLANT PACKAGE 


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 pickup 

from solar sources. 

1.05.19 Condenser capacity control shall be provided by means of fans and ‘head pressure’ 

sensing. 

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. 


SECTION-VI 

PART-B 



PAGE 

4 OF 9

CLAUSE NO. 




PLANT PACKAGE 


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 

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. 


1.06.13 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. 


SECTION-VI 

PART-B 



PAGE 

5 OF 9

CLAUSE NO. 

1.06.14 HDPE Filters 




PLANT PACKAGE 


HDPE filters shall be provided as required. To facilitate 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. 

1.06.19 Ventilation and Air Conditioning system ducting 

1.06.20 All GI sheet metal ductwork required for ventilation and air conditioning system shall 

be furnished by the supplier. All ducts and plenums unless otherwise noted shall be 

constructed out of standard quality galvanised steel sheet. All sheet metal ducts 

shall be fabricated and installed in conformity to the requirements of IS:655. Steel 

supports for the ductwork shall be furnished as required. The thickness of ducting 

steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be 

1.25 mm. The flexible connection between fan and ducting shall be on teflon 

impregnated canvas. The zinc coating on GI sheet shall be 275 gm/m 2 . 


SECTION-VI 

PART-B 



PAGE 

6 OF 9

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : VENTILATION SYSTEM 

1.1.1 Mech. Ventilation System To provide ventilation using 

fans for specified areas. 

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 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 2 x 100 % 

window AC 

1.4.0 Outside Ambient Conditions 


2.1.0 Axial Fans 


SECTION-VI 

PART-B 

As per weather data given in 

project synopsis 

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. 



PAGE 

7 OF 9

CLAUSE NO. 

2.2.0 Centrifugal Fans 




PLANT PACKAGE 


2.2.1 Capacity 10% more of actual 

requirement 

2.2.2 Head 20% more than actual 

requirement 

2.2.3 Speed Max. 1500 rpm 

2.2.4 Outdoor temperature 50 deg.C. 

2.2.5 Rating Continuous 

2.3.0 Packaged Air-Conditioning Unit 

2.3.1 Type Roof top mounting 

2.3.2 Service/application Continuous, round the 

clock. 

2.3.3 Capacity 

(i) TR Suitable 

(ii) CFM Suitable 

2.3.4 Type of compressor Hermetically sealed scroll 

compressor 

2.3.5 Condenser Air cooled type 

2.3.6 Fan Forward curved centrifugal 

fan 

2.3.7 Filter High efficiency filter 

2.3.8 Cooling Coil 

(a) Type Direct Expansion 

(b) Material Copper 

(c) Fins Aluminum mechanically 

bonded. 

2.3.9 Refrigerant Piping Copper 

2.3.10 Insulation for PAC parts Expanded polyethylene of 

density at least 15 kg/cub.m. 


SECTION-VI 

PART-B 



PAGE 

8 OF 9

CLAUSE NO. 

2.4.0 Filters 

2.4.1. Metallic Filters 

2.4.2 HDPE filters 




PLANT PACKAGE 


(1) Max. air velocity 2m/sec. 

(1) Efficiency 90% down to 5 microns 

(2) Max. velocity 2.5 m/sec. 

(3) Testing As per BS 2831 / Sqv. 

2.4.3 High Efficiency Filter 

(1) Efficiency 99% down to 5 microns. 

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

(3) Testing As per BS 2831 / Sqv. 

2.5.0 Insulation for A/C Ducting Resin Bonded 

Mineral wool as per IS:8183 

2.5.1 Density 24 kg/cub.m 

2.5.2 Thermal conductivity 0.49 mw/cm deg.C 


SECTION-VI 

PART-B 



PAGE 

9 OF 9

PART - B 


CHP BUILDING 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


CHP BUILDINGS 

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 


Construction/fabrication/erection and designing aspects of various buildings shall be 

as per the Civil/Structural specifications. 


The design and construction of CHP Buildings shall comply with all the currently 

applicable statutes, regulations and safety codes in the locality where the equipment 

is to be installed. The CHP Buildings shall conform to the latest edition of the Indian 

standards and codes. Other internationally acceptable standards/ codes, which 



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 

dimensions for various buildings/structures and relative elevations shall be decided 


SECTION-VI 

PART-B 


CHP BUILDING 

PAGE 

1 OF 5

CLAUSE NO. 




PLANT PACKAGE 


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, crusher houses and 

potable water shall also be provided at all junction towers, crusher house, wagon 

tippler. 

1.02.10 All associated civil & structural work for the elevator, elevator stairs, platforms at 

various landings shall be supplied for crusher house where elevator is provided. 

1.02.11 Necessary facilities for ventilation of tunnels, underground buildings, control/MCC 

rooms, WT control room and Wagon Tippler shall be provided as specified 

elsewhere. 

1.02.12 External fire escape stair case shall be provided for all MCC. External Two (2) Nos. 

and One (1) No. internal staircase to be provided for 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 


CHP BUILDING 

PAGE 

2 OF 5

CLAUSE NO. 

1.03.00 Construction Requirements 

1.03.01 Transfer Houses/Junction Tower 




PLANT PACKAGE 


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 


CHP BUILDING 

PAGE 

3 OF 5

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : CHP BUILDING 

1.1.0 Underground/partially 

underground Transfer Houses 

1.2.0 Overground Transfer Houses, 

Crusher House 


SECTION-VI 

PART-B 

RCC Construction 

Steel Construction 

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 Roofs & Floors RCC construction with facility to wash 

the floors. Min. slope of 1:100 for roof 

and 1:80 for floors in TPs and 1:100 for 

floors in crusher house shall be provided 

towards drain pipes. 

2.1.3 Walls/Enclosure Permanently colour coated cladding 

2.1.4 Stairs Steel construction with minimum 1000 

mm width. 

2.1.5 Doors & Windows Steel construction 

2.1.6 Monorails Capacity as per equipment installed 

2.1.7 Drainage From each floor to drain pit suitable to 

handle coal slurry. 

2.1.8 Elevators Necessary space, platforms / 

interconnections with the respective 

buildings, machine room etc. wherever 

applicable. 

2.1.9 Vertical bracing Only along four sides. 


CHP BUILDING 

PAGE 

4 OF 5

CLAUSE NO. 




PLANT PACKAGE 


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

wide 

2.1.11 Flooring 50 mm thick metallic hardener like ironite 

floor finish. 

2.1.12 Level of ground floor 500 mm above ground level. 

2.2.0 Control/MCC/ WT control Rooms 

2.2.1 Construction RCC construction with Brick Enclosure 

2.2.2 MCC Rooms/ WT control room building 


SECTION-VI 

PART-B 

Pressurised with dust free air 

2.2.3 Control Rooms Air conditioned Environment 


CHP BUILDING 

PAGE 

5 OF 5

PART - B 


VIBRATING SCREENING FEEDER 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


VIBRATING SCREENING FEEDER 

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 m 2 per 100 

tonnes/hr of incoming feed. Inclination of the screening pan shall be so selected so 

as to ensuing proper flow ability of Coal on the deck without any hindrance. 

1.02.04 The equipment shall be designed in such a manner that choking does not occur 

during operation, particularly during rainy season when the coal gets sticky. 


1.03.01 The deck of vibrating screening feeder shall have continuous solid deck section in 

the impact zone under direct coal fall and remaining deck shall be fitted with 

perforated deck assembly. The solid deck section shall be provided with replaceable 

tiscral or eqvt. liner plate of adequate thickness. The perforated deck shall be wear 

resistant and shall be rigidly fixed with main frame along the length of grizzly deck. 


SECTION-VI 

PART-B 


VIBRATING SCREENING 

FEEDERS 

PAGE 

1 OF 3

CLAUSE NO. 




PLANT PACKAGE 


1.03.02 The vibrating screening feeders shall be mounted on the floor with the help of helical 

springs made of alloy steel. No rubber/synthetic material for the support shall be 

acceptable. 

1.03.03 Vibrator bearings shall be grease lubricated, double spherical roller type suitable for 

vibrating equipment. The bearings shall be sized for minimum 8,000 hours of 

operation. 

1.03.04 Suitable sealing arrangement shall be provided between the vibrating structure and 

chute work to avoid dust nuisance in the surrounding area. 

1.03.05 Proper arrangement to avoid dust ingress into lubricant of eccentric shafts shall be 

provided. 

1.03.06 Necessary arrangements shall be provided for maintaining / replacing the complete 

vibrator assembly. 

1.03.07 Marker plate to indicate stroke length and stroke angle shall be mounted. 

1.03.08 In case of V- belt drive, suitable arrangement like taper bush or dobicon coupling 

shall be provided, to avoid loosening of sheave mounted on eccentric shaft. 

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

nuisance. 


SECTION-VI 

PART-B 



FEEDERS 

PAGE 

2 OF 3

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : VIBRATING SCREENING FEEDER 

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 

- Construction 


SECTION-VI 

PART-B 

TISCRAL or equivalent 

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. 



FEEDERS 

PAGE 

3 OF 3

PART - B 


RING GRANULATOR AND VMS 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


RING GRANULATOR AND VMS 

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 


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 

PART-B 


RING GRANULATOR 

AND VMS 

PAGE 

1 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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 : 


SECTION-VI 

PART-B 



AND VMS 

PAGE 

2 OF 7

CLAUSE NO. 

Sl. 

No 




PLANT PACKAGE 


Equipment Type No. * No. of 

location 

per equip. 

1. Coal Crusher Radial ring 


SECTION-VI 

PART-B 

4 2 one at 

DE one at 

NDE 



AND VMS 

Equipment bearing 

type 

As per manufacturer's 

design 

Vibration shall be measured at each location in Horizontal as well as vertical 

direction. 

1.04.02 Specification of the Vibration Monitoring System 

a) Number & type of 

vibration 

One (1), Microprocessor based, monitoring system 

able to distinguish between high frequency 

vibration caused by bearing trouble and low 

frequency vibration caused by imbalance. 

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

c) Transducer a) Velocity pick-up or a peizo- electric 

accelerometer. Type shall be decided during 

detail engineering based on the details of 

equipment to be monitored. 

b) Light weight stud mounting. 

c) Frequency response 1 Hz -10 kHz. 

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

flexible conduit. 

e) Monitors (to be 

located in CHP control 

room) 

Dual channel monitor for each location alongwith : 

a) Buffered signal output and software for 

vibration analysis through CHP control desk 

HMI. 

b) Recorder signal output 

f) Display Analogue and digital 

g) Alarm 0-100% full scale adjustable. 

h) Trip 0-100% full scale adjustable. 

i) Test Functional checking from front inhibiting alarm & 

trip 

PAGE 

3 OF 7

CLAUSE NO. 




PLANT PACKAGE 


j) Relays 0.25 A at 220 Volts DC or 5 Amp at 240V AC. 

Independent potential free contacts for alarm & trip 

purpose. 

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

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


SECTION-VI 

PART-B 



AND VMS 

PAGE 

4 OF 7

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : CRUSHER 

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). 

2.0.0 DESIGN AND CONSTRUCTION 

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

2.2.0 Hammer profile Toothed and plain alternately 

or only toothed 

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

2.4.0 No. of suspension bars passing through 

each row of ring hammers 

2.5.0 No. of holes in each segment of central and end 

discs for suspension bars (for each row of 

hammers) 

2.6.0 Drive arrangement 


SECTION-VI 

PART-B 

Max. of Two (2) number 

Max. of Three (3) number 

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 



AND VMS 

PAGE 

5 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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 


SECTION-VI 

PART-B 

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 



AND VMS 

PAGE 

6 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-B 



AND VMS 

PAGE 

7 OF 7

PART - B 


IN-LINE MAGNETIC SEPARATOR AND 

SUSPENDED MAGNET 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


IN-LINE MAGNETIC SEPARATOR AND SUSPENDED MAGNET 

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 

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. 


SECTION-VI 

PART-B 


IN-LINE MAGNETIC 

SEPERATOR AND 


PAGE 

1 OF 4

CLAUSE NO. 




PLANT PACKAGE 


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 the 

magnetic separator away to facilitate maintenance of the conveyor discharge 

pulley/Belt. 

1.03.03 ON/OFF control push buttons with indicating lamps shall be provided at the local 

station. The materials of chutes and hoppers associated with magnetic separators 

above the drive floor shall be SS-304 in the magnetic zone. 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 



SEPERATOR AND 


PAGE 

2 OF 4

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : ILMS/SM 

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 

(ii) Brake shoe of Railway Wagon (Cast Iron 

15 Kg.) 


SECTION-VI 

PART-B 



SEPERATOR AND 


PAGE 

3 OF 4

CLAUSE NO. 

2.3.0 Control 




PLANT PACKAGE 


(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. 

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 



SEPERATOR AND 


PAGE 

4 OF 4

PART - B 







SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 



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. 

(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. 


SECTION-VI 

PART-B 



PAGE 

1 OF 3

CLAUSE NO. 




PLANT PACKAGE 


(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 



PAGE 

2 OF 3

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : METAL DETECTOR 

1.1.0 Type Coil type 


2.1.0 Sensitivity - 25 mm aluminum sphere 

below coal for synthetic 

belting. 

2.2.0 Enclosure Fiber glass 


SECTION-VI 

PART-B 

- 35mm Aluminum sphere 

below coal for steel cord 

belting. 

2.3.0 Control Through local control panel. 

2.4.0 Calibration Provision for automatic static 

calibration with adjustable 

sensitivity. 



PAGE 

3 OF 3

PART - B 


COAL SAMPLING UNIT 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 



a) Coal Sampling Unit shall be complete with necessary samplers, crushers, flap 

valves, chutes, hoppers, belt feeders and sample collectors etc. to give 

samples from any of the two streams running at guaranteed capacity. 

b) Bidder shall source coal sampling system from a manufacturer / supplier who 

has engineered and supplied two (2) numbers of coal sampling systems for 

sampling coal / other bulk mineral from conveyor of 1200 MTPH and above 

and working successfully for two years as on date of bid opening. 


The design, manufacture, inspection and testing of Coal Sampling Unit shall comply 


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 Project Manager. 

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. 

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. 


SECTION-VI 

PART-B 



PAGE 

1 OF 3

CLAUSE NO. 




PLANT PACKAGE 


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. 

1.03.07 Minimum 4 nos. sample collecting bins shall be provided with auto indexing. The 

bins shall be provided with air tight connection. 


SECTION-VI 

PART-B 



PAGE 

2 OF 3

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : COAL SAMPLING UNIT 

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 



PAGE 

3 OF 3

PART - B 


ELEVATOR 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


ELEVATOR 

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 


1.02.02 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 

the cage. Enclosure access doors shall be electrically and mechanically interlocked 


SECTION-VI 

PART-B 


ELEVATOR 

PAGE 

1 OF 7

CLAUSE NO. 

1.02.06 Mast 

1.02.07 Cab 




PLANT PACKAGE 


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. 

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. 

1.02.08 Cab frame shall be fabricated from tubular steel and/or other structural shapes 

enclosed with expanded metal or wire mesh. 

1.02.09 Cab floor shall be of 6 mm thick Aluminum chequered plate or approved equivalent. 

Cab shall be attached to a framed structure and form an integral part with the drive 

mechanism located atop the cab. 

1.02.10 Framed structure shall include guide rollers and safety hooks to ensure positive 

engagement of the rack and pinion to prevent cab disengagement in case of roller 

failure. 

1.02.11 Cab roof shall be provided with an escape hatch electrically interlocked with the 

hoist control system. Tubular steel handrail shall enclose the cab roof for 

maintenance operations. 

1.02.12 Cab door and landing level enclosure doors shall be electrically and mechanically 

interlocked to prevent the cab from being operated unless the cab door and landing 

level enclosure doors are fully closed and to prevent the doors from being opened 

while the cab is in motion. 

1.02.13 One cabin fan and two recessed fluorescent lamps along with the fittings to be 

provided with one no. emergency light with battery & battery charger. 

1.03.00 Drive Unit & Safety Device 

1.03.01 Drive unit located on the cab shall be complete with AC squirrel cage induction 

motor, reduction gear, drive pinion and an over-speed governor. Drive unit shall 

incorporate an electric disc brake and an external manual brake release. The brake 

on the electric motor will be self adjusting type. In case of the power failure, the 

brake will be automatically applied & will stop the cab. A hand lever, which can be 

operated from the cage, is to be provided to enable the occupants to ease the brake 

and lower the cage to the bottom level. Motor shall be connected to a reduction 

gear, which drives the pinion. 

1.03.02 An over-speed governor must be incorporated to protect the cab against over speed 

during the cab downward motion. At a predetermined speed higher than normal, the 

brake, mechanism shall be actuated and stop the downward motion of the cab 


SECTION-VI 

PART-B 


ELEVATOR 

PAGE 

2 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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 cable key inter to check. 

1.06.00 Power and Control Cabinets 

All electrical components furnished with the elevator shall be completely wired, 

energised and checked. 

All electrical control devices shall be in enclosures. Equipment furnished shall also 

include the following : 

(a.) Momentary contact push button for raise/lower control. 

(b.) Reversing combination motor starter with a three phase thermal overload relay 

for motor protection. However, the control circuit in the elevator will have 

miniature circuit breakers. 

(c.) Electric and mechanical interlocks on cab access door and landing level 

enclosure doors. 

(d.) An ultimate three phase over travel limit switch which cuts off power and 

control supply in case of over travel. The switch can also be manually turned 

to off position. 

(e.) Safety device as mentioned elsewhere in this specification. 

(f.) An alarm push button shall be provided in the cage. Alarm signal will be 

transferred to the auxiliary panel at elevator base. 


SECTION-VI 

PART-B 


ELEVATOR 

PAGE 

3 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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 3pole 

isolating switch. HRC fuses, contactors shall be of AC4 duty class with 

thermal overload relays with single phase preventer. The isolating switch and 

contactor shall be rated at least 20% more than the connected motor full load 


SECTION-VI 

PART-B 


ELEVATOR 

PAGE 

4 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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 

1.08.00 CABLES 

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” nonhygroscopic 

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. 

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 


ELEVATOR 

PAGE 

5 OF 7

CLAUSE NO. 

1.09.00 Earthing 

(a.) GENERAL 




PLANT PACKAGE 


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 


ELEVATOR 

PAGE 

6 OF 7

CLAUSE NO. 

1.0.0 GENERAL 




PLANT PACKAGE 


DATA SHEET : ELEVATOR 

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 


ELEVATOR 

PAGE 

7 OF 7

PART - B 


APRON FEEDER 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


APRON FEEDER 

Apron feeders complete with all accessories shall be furnished for wagon tippler 

hoppers as specified. 

2.00.00 CODES & STANDARDS 

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 



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 dribble 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. 

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. 


SECTION-VI 

PART-B 


APRON FEEDER 

PAGE 

1 OF 3

CLAUSE NO. 




PLANT PACKAGE 


Complete dribble belt system consisting of head pulley, tail pulley, drive, motor, 

stringers, deck plates etc. shall be provided. 


SECTION-VI 

PART-B 


APRON FEEDER 

PAGE 

2 OF 3

CLAUSE NO. 




PLANT PACKAGE 


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/Hydraulic 


SECTION-VI 

PART-B 


APRON FEEDER 

PAGE 

3 OF 3

PART - B 







SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 



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 Project Manager 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 numbers of loaded wagons. 

Thus, side arm charger shall be used for indexing forward the rake of 58 nos. loaded 

wagons, placing decoupled wagons on the tippler table and out hauling the empty 

wagons. 

3.02.00 The rake of 58 loaded wagons will be brought by locomotive and placed on the pretipping 

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 wagons towards tippler table. The first wagon will be decoupled 

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 

PART-B 



PAGE 

1 OF 3

CLAUSE NO. 





PLANT PACKAGE 


4.01.00 The Side Arm Charger shall be suitable to handle 58 number of loaded wagons. 

The pusher arm shall be vertically Rota table 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 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. 


SECTION-VI 

PART-B 



PAGE 

2 OF 3

CLAUSE NO. 


REQUIREMENTS 




PLANT PACKAGE 


DATA SHEETS 

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 



PAGE 

3 OF 3

PART - B 

ELECTRICAL 





SECTION-VI 

PART-B

PART - B 

SUB-SECTION-IIIB-01 

MOTORS 





SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 GENERAL REQUIREMENTS 




PLANT PACKAGE 


MOTORS 

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

centigrade and relative humidity of 95% shall be considered. The equipment shall 

operate in a highly polluted environment. 

1.02.00 All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3% 

& -5%, and 10% combined variation of voltage and frequency unless specifically 

brought out in the specification. 

1.03.00 Contractor shall provide fully compatible electrical system, equipments, accessories 

and services. 

1.04.00 All the equipment, material and systems shall, in general, conform to the latest 

edition of relevant National and international Codes & Standards, especially the 

Indian Statutory Regulations. 

1.05.00 The auxiliary AC voltage supply arrangement shall have 11kV, 3.3 kV and 415V 

systems. It shall be designed to limit voltage variations as given below under worst 

operating condition: 

(a) 11kV, 3.3 kV +/- 6% 

(b) 415/240V +/- 10% 

1.06.00 The voltage level for motors shall be as follows :- 

a) Upto 0.2KW : 240V, Single Phase AC/ 

415V Three phase AC 

b) Above 0.2KW and upto 200KW : 415V, Three Phase AC 

c) Above 200KW and upto 1500KW : 3.3 kV, Three Phase AC 

d) Above 1500KW : 11KV,Three Phase AC 

For CHP conveyor’s motor above 160 kW rating 3.3 KV, three phase AC supply is to 

be used. However all the motors on the S/R machine shall be on 415 AC only. 

1.07.00 Fault level shall be limited to 40kA RMS for 1 second for 11kV & 3.3kV system and 

45 kA RMS 1 second for 415V system. 415V system shall be solidly grounded and 

220 VDC system shall be isolated type. 

1.08.00 Paint shade shall be as per RAL 5012 (Blue) for indoor and outdoor motors. 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

1 OF 9

CLAUSE NO. 




PLANT PACKAGE 


1.09.00 The responsibility of coordination with electrical 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:4691, IEC60034-05 shall be as 

follows :- 

i) Indoor motors - IP 54 

ii) Outdoor motors - IP 55 

iii) CW motors (in case of - IP 23 

screen prot. Drip proof) 

iv) Cable box - indoor area - IP 54 

v) Cable box - outdoor area - IP 55 


3.00.00 TYPE 

3.01.00 AC Motors: 

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 

(a) Squirrel cage induction motor suitable for direct-on-line starting. 

(b) Continuous duty LT motors upto 160 KW Output rating (at 50 deg.C ambient 

temperature), shall be Energy Efficient motors, Efficiency class-Efficiency 1, 

conforming to IS 12615. 

(c) Crane duty motors shall be slip ring/ squirrel cage Induction motor as per the 

requirement. 

3.02.00 DC Motors: Shunt wound. 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

2 OF 9

CLAUSE NO. 

4.00.00 RATING 




PLANT PACKAGE 


(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 thermal class 130(B) & 155(F) insulation . 

6.00.00 OPERATIONAL REQUIREMENTS 

6.01.00 Starting Time 

6.01.01 For motors with starting time upto 20 sec. at minimum permissible voltage during 

starting, the locked rotor withstand time under hot condition at highest voltage limit 

shall be at least 2.5 sec. more than starting time. 

6.01.02 For motors with starting time more than 20 sec. and upto 45 sec. at minimum 

permissible voltage during starting, the locked rotor withstand time under hot 

condition at highest voltage limit shall be at least 5 sec. more than starting time. 

6.01.03 For motors with starting time more than 45 sec. at minimum permissible voltage 

during starting, the locked rotor withstand time under hot condition at highest voltage 

limit shall be more than starting time by at least 10% of the starting time. 

6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above 

requirements are not met. 

6.02.00 Torque Requirements 

6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall 

be at least 10% motor full load torque. 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

3 OF 9

CLAUSE NO. 




PLANT PACKAGE 


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 

(d) 80% from 1501 KW 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. However for flame proof 

motors, space heater terminals inside the main terminal box may be acceptable. 

7.02.00 All motors shall be either Totally enclosed fan cooled (TEFC) or totally enclosed tube 

ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors 

rated 3000KW or above can be Closed air circuit water cooled (CACW). CW motors 

can be screen protected drip proof (SPDP) type. Motors located in hazardous areas 

shall have flame proof enclosures conforming to IS:2148 as detailed below 

(a) Fuel oil area : Group - IIB 

(b) Hydrogen generation : Group - IIC (or Group-I, Div-II as per NEC) 

plant area 

7.03.00 Winding and Insulation 

(a) Type : Non-hygroscopic, oil resistant, flame resistant 

(b) Starting duty : Two hot starts in succession, with motor 

initially at normal running temperature 

(c) 11kV, 3.3 kV AC motors : Thermal Class 155(F) insulation with winding 

temperature rise limited to thermal class 

130(B). The winding insulation process shall 

be total Vacuum Pressure Impregnated i.e. 

resin poor method. The lightning impulse & 

Inter-turn insulation surge withstand level 

shall be as per IEC-60034 Part-15. 

(d) 415V AC & 220V DC 

motors 

: Thermal Class130(B) or better 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

4 OF 9

CLAUSE NO. 




PLANT PACKAGE 


7.04.00 Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft 

currents. 

7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable alarm 

contacts to indicate inlet and outlet primary air temperature. 

7.06.00 Noise level for all the motors shall be limited to 85dB(A). Bearing housing vibration 

shall be limited within the limits prescribed in IEC 60034-14/IS:12075 . Motors shall 

withstand vibrations produced by driven equipment. HT motor bearing housings shall 

have flat surfaces, in both X and Y directions, suitable for mounting 80mmX80mm 

vibration pads. 

7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum 

resistance type temperature detectors shall be provided in each phase stator 

winding. Each bearing of HT motor shall be provided with dial type thermometer with 

adjustable alarm contact and minimum 1(one) number duplex platinum resistance 

type temperature detectors. 

7.08.00 Motor body shall have two earthing points on opposite sides. 

7.09.00 HT motors can be offered with either elastimold termination or dust tight phase 

separated double walled (metallic as well as insulated barrier) cable boxes. In case 

elastimold terminations are offered, then protective cover and trifurcating sleeves 

shall also be provided. In case cable box is offered, then Employer shall provide 

termination kit. Removable gland plates of thickness 3 mm (hot/cold rolled sheet 

steel for three core cables) or 4 mm (non magnetic material for single core cables) 

shall be provided in case of cable boxes. 

7.10.00 The spacing between gland plate & centre of terminal stud shall be as per Table-I. 

7.11.00 All motors shall be so designed that maximum inrush currents and locked rotor and 

pullout torque developed by them at extreme voltage and frequency variations do 

not endanger the motor and driven equipment. 

7.12.00 The motors shall be suitable for bus transfer schemes provided on the 11kV, 3.3 

kV/415V systems without any injurious effect on its life. 

7.13.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall 

be provided on each phase in a separate neutral terminal box. 

7.14.00 11KV and 3.3KV motors Terminal Box shall be suitable for fault level of 750MVA for 

0.12 sec and 250MVA for 0.12 sec respectively. 

7.15.00 The size and number of cables (for HT and LT motors) to be intimated to the 

successful bidder during detailed engineering and the contractor shall provide 

terminal box, cable glands & lugs suitable for the same. 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

5 OF 9

CLAUSE NO. 




PLANT PACKAGE 


7.16.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the 

following (without any further tolerance). 

(a) Upto 110KW : 11.0 

(b) Above 110KW & upto 1500KW : 10.0 

(c) Above 1500KW & upto 4000KW : 9.0 

(d) Above 4000KW : 6 to 6.5 

7.17.00 CW motors shall be designed with minimum power factor of 0.8 at design duty point. 

8.00.00 TYPE TEST 

8.01.00 HT MOTORS 

8.01.01 The contractor shall carry out the type tests as indicated in the "LIST OF TYPE 

TESTS TO BE CONDUCTED” on the equipment mentioned there in. The Bidder 

shall indicate the charges for each of these type tests separately in the relevant 

schedule of BPS and the same shall be considered for the evaluation of the Bids. 

The type test charges shall be paid only for the test(s) actually conducted 

successfully under this contract and upon certification by the Owner's Engineer. 

8.01.02 The type tests shall be carried out in presence of the Owner's representative, for 

which minimum 15 days notice shall be given by the Contractor. The Contractor 

shall obtain the Owner's approval for the type test procedure before conducting the 

type test. The type test procedure shall clearly specify the test set-up, instruments to 

be used, procedure, acceptance norms, recording of different parameters, interval of 

recording, precautions to be taken etc. for the type test(s) to be carried out. 

8.01.03 In case the contractor has conducted such specified type test(s) within last ten years 

as on the date of bid opening, he may submit the reports of the type tests indicated 

in the "LIST OF TYPE TESTS TO BE CONDUCTED " to the owner for waival of 

conductance of such type test(s).These reports should be for the tests conducted on 

the equipment similar to those proposed to be supplied under this contract and the 

test(s) should have been either conducted at an independent laboratory or should 

have been witnessed by a client. The Owner reserves the right to waive conducting 

of any or all of the specified type test(s) under this contract. In case type tests are 

waived, the type test charges shall not be payable to the contractor. 

8.01.04 Further the Contractor shall only submit the reports of the type tests as listed in 

"LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED" and carried 

out within last ten years from the date of bid opening. These reports should be for 

the tests conducted on the equipment similar to those proposed to be supplied under 

this contract and the test(s) should have been either conducted at an independent 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

6 OF 9

CLAUSE NO. 




PLANT PACKAGE 


laboratory or should have been witnessed by a client. In case the Contractor is not 

able to submit report of the type test(s) conducted within last ten years from the date 

of bid opening, or in case the type test report(s) are not found to be meeting the 

specification requirements, the Contractor shall conduct all such tests under this 

contract free of cost to the Owner and submit the reports for approval. 

8.01.05 LIST OF TESTS TO BE CONDUCTED 

The following type tests shall be conducted on each type and rating of HT 

motor 

(a) No load saturation and loss curves upto approximately 115% of rated voltage 

(b) Measurement of noise at no load. 

(c) Momentary overload test (subject to test bed constraint). 

(d) Full load test (subject to test bed constraint). 

(e) Temperature rise test at rated conditions. During heat run test, bearing 

temp., winding temp., coolant flow and its temp. shall also be measured. In 

case the temperature rise test is carried at load other than rated load, 

specific approval for the test method and procedure is required to be 

obtained. Wherever ETD's are provided, the temperature shall be measured 

by ETD's also for the record purpose. 

8.01.06 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED 

8.02.00 LT Motors 

The following type test reports shall be submitted for each type and rating of 

HT motor 

(a) Degree of protection test for the enclosure followed by IR, HV and no load 

run test. 

(b) Terminal box-fault level withstand test for each type of terminal box of HT 

motors only. 

(c) Lightning Impulse withstand test on the sample coil shall be as per clause 

5.1.3.2, IEC-60034,Part-15. 

(d) Surge withstand voltage test on inter-turn insulation as per IEC 60034-15 

8.02.01 LT motors shall be of type tested design. For each type & rating of LT motors rated 

above 50 KW, the contractor shall submit for Owner's approval the reports of all the 

type tests as per relevant standards and carried out within last ten years from the 

date of bid opening. These reports should be for the tests conducted on the 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

7 OF 9

CLAUSE NO. 




PLANT PACKAGE 


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 In case the Contractor is not able to submit report of the type test(s) conducted 

within last ten years from the date of bid opening, or in case the type test report(s) 

are not found to be meeting the specification requirements, the Contractor shall 

conduct all such tests under this contract at no additional cost to the Owner either at 

third party lab or in presence of client/owners representative and submit the reports 

for approval. 

8.03.00 All acceptance and routine tests as per the specification and relevant standards shall 

be carried out. Charges for these shall be deemed to be included in the equipment 

price. 

8.04.00 The type test reports once approved for any projects shall be treated as reference. 

For subsequent projects of NTPC, an endorsement sheet will be furnished by the 

manufacturer conforming similarity and “No design change”. Minor changes if any 

shall be highlighted on the endorsement sheet. 

FOR LV MOTORS: 

TABLE - I 

DIMENSIONS OF TERMINAL BOXES 

Motor MCR in KW Minimum distance between 

centre of stud and gland plate in mm 

UP to 3 KW As per manufacturer's 

practice. 

Above 3 KW - upto 7 KW 85 







Above 125 KW-upto 200 KW 203 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

8 OF 9

CLAUSE NO. 

FOR HT MOTORS: 




PLANT PACKAGE 


The distance between gland plate and the terminal studs shall not be less than 500 

mm. 

PHASE TO PHASE/ PHASE TO EARTH AIR CLEARANCE: 

NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with lugs 

installed shall be as follows: 

Motor MCR in KW Clearance 

UP to 110 KW 10mm 

Above 110 KW and upto 150 KW 12.5mm 

Above 150 KW 19mm 


SECTION-VI 

PART-B 


MOTORS 

PAGE 

9 OF 9

PART - B 


LT SWITCHGEAR & BUS DUCT 





SECTION-VI 

PART-B

CLAUSE NO. 




PLANT PACKAGE 


LT SWITCHGEAR & BUSDUCT 

1.00.00 CODES AND STANDARDS IEC: 60947, IS : 13947, IEC: 60439,IS:8623,IEC:61850 

2.00.00 TYPE 

Circuit Breakers Shall be air break, three pole, spring charged, 

horizontal drawout type, suitable for electrical 

operation. 

Switchgear Fully drawout type single front 

MCC Fully drawout type single front/Double front. 

ACDB/DCDB Fixed type single front 

3.00.00 SYSTEM PARAMETERS 

415VAC +/- 10 %(SOLIDLY GROUNDED) 

50 Hz +3%/-5% 

45KA RMS(105 KA PEAK) / 1SEC (FAULT LEVEL) 

220V DC NOMINAL (190V DC-240V DC) ISOLATED TYPE FOR ASH 

HANDLING SYSTEM 


The temperature rise of the horizontal and vertical busbars and main bus link 

including all power draw out contacts when carrying 90% of the rated current along 

the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C 

with all other types of joints over an ambient of 50 deg C. The temperature rise of 

the accessible parts/external enclosures expected to be touched in normal 

operation shall not exceed 20 deg.C. The temperature rise of manual operating 

means shall not exceed 10 deg. C for metallic & 15 deg. C for insulating material. 

The above temperature rise limits are applicable for busducts also without any 

current derating. 

5.00.00 OPERATIONAL REQUIREMENTS 

5.01.00 Breakers 

5.01.01 Breakers shall have anti-pumping feature. 


SECTION-VI 

PART-B 


LT SWITCHGEAR & 

BUSDUCT 

PAGE 

1 OF 11

CLAUSE NO. 




PLANT PACKAGE 


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 

MCCB is in OFF position. Means shall be provided for defeating this interlock at any 

time MCCB shall be provided with padlocking facility to enable the operating 

mechanism to be padlocked. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

2 OF 11

CLAUSE NO. 

5.03.00 Panels 




PLANT PACKAGE 


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 bus ducts. The bus duct 

enclosure shall be made of minimum 3mm thick aluminium alloy. The section of the 

bus duct should have adequate strength to withstand internal and external forces 

resulting from the various operating conditions. Aluminium sheet hood shall be 

provided for outdoor bus duct enclosure joints to provide additional protection 

against water ingress. The bus duct top shall be sloped to prevent retention of water. 

The bus duct enclosure shall have DOP of IP55 and paint shade RAL 5012. 

5.03.07 It should be possible to carryout maintenance on a feeder with adjacent feeders 

alive. 

5.03.08 DC fuse board shall consist of: 

-1 no.63A switch as incomer with meters, lamps and auxiliary contactors. 

-8 nos. outgoing feeders with 16A HRC fuses. 

5.03.09 AC fuse board shall consist of: 

-1 no 63A TPN SFU as incomer with lamps and meters. 

-9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

3 OF 11

CLAUSE NO. 




PLANT PACKAGE 


5.03.10 Welding distribution board (WBD) to be located in MCC room shall consist of: 

a) One (1) no. welding transformer (415/433 V, delta/star, epoxy insulated, air 

cooled, dry type). Transformer shall be 50 KVA/100 KVA for upto 10/15 nos 

outgoing feeders. 

b) TPN SFU on primary and secondary side of the transformer 

c) 63 A TPN SFU as outgoing feeders including 20 % spare. 

d) Voltmeter, ammeter with selector switches, indicating lamps. 

5.03.11 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. 

5.04.00 Control, Protection & Metering Requirements 

5.04.01 Control circuits shall operate at suitable voltage of 110V AC or 220V DC/110V DC. 

Necessary control supply transformers having primary and secondary fuses shall be 

provided for each MCC, 2 x 100% per bus section. However the breakers shall 

operate on 220V DC The auxiliary bus bars for control supply shall be segregated 

from main bus bars. The control supplies shall be monitored. 

5.04.02 Contractor shall fully co-ordinate overload and short circuit tripping of breaker with 

upstream and down stream breakers/fuses/MCCBs motor starters. Various 

equipments shall meet requirement of Type-II class of coordination as per IEC. 

5.04.03 The protective relays shall be communicable numerical relays These numerical 

relays shall be of types as proven for the application and shall be subject to 

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. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

4 OF 11

CLAUSE NO. 




PLANT PACKAGE 


5.04.04 All equipments shall have necessary protections. However, following minimum 

protections shall be provided: 

1) 

2) 

Contactor controlled motor feeders (Motors up to 160KW) 

a) Instantaneous short circuit protection on all phases through HRC 

cartridge type fuses rated for 80 kA rms (prospective breaking 

capacity at 415V). 

b) Thermal overload protection 

c) Single phasing protection for motors protected by fuses 

Incomers / buscoupler / outgoing breaker feeders other than motor feeders. 

a) Three phase over current protection (50) 

b) Three phase earth fault protection (50N3) 

c) Restricted earth fault protection for transformer incomers(64R) 

d) Sync Check 

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 All Numerical relays shall have communications on two ports, local front port for 

communication to laptop and a second port on IEC 61850 to communicate with 

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. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

5 OF 11

CLAUSE NO. 




PLANT PACKAGE 


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 managed type with required number of ports to achieve the owners’ LAN 

configuration. One(1) no. Ethernet switch per switch board shall be provided & 

these switches shall be mounted inside the switchgear Panels. 

5.05.12 In case of remote controlled breaker panels, following shall be ensured. 

The circuit breaker will normally be controlled from remote control panels (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.. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

6 OF 11

CLAUSE NO. 




PLANT PACKAGE 


5.05.15 It shall be possible to carryout open / close operation of breakers from a laptop by 

interfacing from the relay front port (RS232) during initial commissioning. 

5.06.00 Meters / instruments 

All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size 

with 90 degree linear scales and accuracy class of 2.0. 

5.06.01 All motors of 30kW and above upto 100 kw shall have an Ammeter & current 

transducer. Each bus-section shall have bus VT, voltmeter with selector switch, and 

other relay and timers required for protection. Adequate control and selector 

switches, push buttons and indicating lamps shall be provided. Thermostatically 

controlled space heaters with switches shall be provided to prevent condensation. 

5.06.02 For all motor feeders related to dust suppression system and for all other motor 

feeders having 100KW & above rating, contractor shall provide multifunction Digital 

Energy Meter with communication facility to display the current, voltage, power 

factor, power, energy related data locally and shall communicate these for remote 

metering /audit/analysis purposes. The technical specification for Digital indicating 

energy meter shall be as follow: 

a) Input Voltage: 110 V AC/220 V DC 

b) Input Current:1A 

c) Size: 96X96 SQ.MM 

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 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

7 OF 11

CLAUSE NO. 

5.07.00 Control from Remote 




PLANT PACKAGE 


Necessary hardware shall be provided in the switchgear panel like coupling relays (if 

required ) of 24V DC, with max. burden of 2.5VA, auxiliary relays, current/voltage 

transducers (4-20 mA, dual output) etc. to effect interlocks, exchange information / 

status and exercise control from remote. 


6.01.00 All 415V switch gear motor control centers (MCCs), AC & DC distribution boards 

(DB s), etc shall have following features : 

1) Shall be of metal enclosed, indoor, floor mounted and free standing 

type. 

2) All frames and load bearing members shall be fabricated using mild 

steel structural sections or pressed and shaped cold rolled sheet steel 

of thickness not less than 2mm. 

3) Frame shall be enclosed in cold rolled sheet steel of thickness not 

less than 1.6mm.Doors and covers shall also be of cold rolled sheet 

steel of thickness not less than 1.6 mm. Stiffeners shall be provided 

wherever necessary. Removable gland plates of thickness 3mm 

(hot/cold rolled sheet steel) or 4 mm (non-magnetic material) shall be 

provided for all panels. 

4) All switchboards/panels shall be of dust and vermin proof. All cutouts 

shall have EPDM/Neoprene gaskets. 

5) All switchboards, MCCs and DB s shall have following distinct vertical 

sections. 

a) Completely enclosed bus bar compartment for horizontal and 

vertical bus bars. 

b) Completely enclosed switchgear compartments (one for each 

circuit housing circuit breakers, motor starter or switch-fuse 

feeder). 

c) Compartment for cable alley or cable box for power and 

control cables. 

In case of cable box, they shall be segregated with complete 

shrouding for individual feeders at the rear for direct 

termination of cables. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

8 OF 11

CLAUSE NO. 




PLANT PACKAGE 


d) For cable connection to circuit breaker, a separately enclosed 

cable compartment shall also be acceptable. 

e) Compartment for relays and other control devices associated 

with a circuit breaker, wherever necessary. 

f) The switchboards/MCC/DBs of 1600A & above rating shall be 

of DOP IP42 & of IP52 for less than 1600A rating. 

g) All 415V switchgears, 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. 

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-hygro- 

scopic, non-combustible type and suitable to withstand stresses due 

to over-voltages and short circuit current. Insulators and barrier of 

inflammable material such as Hylam shall not be accepted. 

10) All types of relays and timer shall be subject to 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. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

9 OF 11

CLAUSE NO. 

11) Terminal Blocks 




PLANT PACKAGE 


Terminal blocks shall be 650V grade, 10Amps rated, made up of 

unbreakable polyamide 6.6 grade. The terminals shall be either screw 

type or screw-less (spring loaded) / cage clamp type with lugs. 

Marking on terminal strips shall correspond to the terminal numbering 

in wiring diagrams. All metal parts shall be of non-ferrous material. In 

case of screw type terminals the screw shall be captive, preferably 

with screw locking design. Maxi terminal / cage clamp type terminal 

blocks shall be provided for signals to be interfaced with DDCMIS / 

PLC. 

12) The switchgears/MCC shall be designed to offer adequate level of 

safety to operating/ maintenance personnel. Means shall be provided 

to prevent access to the live part to avoid accidents during service as 

well as maintenance period. Bidder shall bring out the safety means 

provided to achieve above. A detailed instruction plate suitable for wall 

mounting shall be provided for each switchgear/MCC room describing 

various safe operating procedure/safety precautions for safe operation 

and maintenance of switchgear/MCC. 

13) All current and voltage transformers as required for metering & 

protection specified shall be completely encapsulated cast resin 

insulated type. Incomers from transformers shall have CTs for 

transformer REF protection. The accuracy shall be as follows: 

CTs PTs 

Protection 5P20,5VA 3P 

Metering 1.0 0.5 

REF PS 

6.02.00 Indicating lamps shall be cluster LED type.All overload relays shall have overload 

reset push button. 

6.03.00 Switchgear/MCC shall have bottom cable entry. 

6.04.00 Contractor shall provide minimum one spare feeder for each type and rating of the 

out going feeders on each MCC. 

7.00.00 TYPE TESTS 


(a.) All equipments to be supplied shall be of type tested design. The Contractor 

shall submit for Owner’s approval the reports of all the type tests as listed in 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

10 OF 11

CLAUSE NO. 




PLANT PACKAGE 


this specification and carried out within last ten years from the date of bid 

opening. These reports should be for the tests conducted on the equipment 

similar to those proposed to be supplied under this contract and the test(s) 

should have been either conducted at an independent laboratory or should 


(b.) In case the Contractor is not able to submit report of the type test(s) 

conducted within last ten years from the date of bid opening, or in case the 

type test report(s) are not found to be meeting the specification requirements, 

the Contractor shall conduct all such tests under this contract at no additional 

cost either at third party lab or in presence of client/owners’s representative 

and submit the reports for approval. 

(c.) All acceptance and routine tests as per the specification and relevant 

standards shall be carried out. Charges for these shall be deemed to be 

included in the equipment price. 

(d.) The type test reports once approved for any projects shall be treated as 

reference. For subsequent projects of NTPC, an endorsement sheet will be 

furnished by the manufacturer confirming similarity and “No design Change”. 

Minor changes if any shall be highlighted on the endorsement sheet. 

7.03.00 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. 

(c.) Class II - Protection co-ordination test for any three ratings of MCC module 

as selected by employer 

(d.) Test sequence –1 & combined test sequence on each rating of circuit 

breaker mounted inside the panel. 

(e.) Degree of protection tests 

(f.) Type test certificates for Numerical relays. 


SECTION-VI 

PART-B 



BUSDUCT 

PAGE 

11 OF 11

PART - B 


HT CABLES 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


HT 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:7098 (Part -II) Specification for Cross-linked polyethylene insulated PVC 

sheathed cables. Part-II: For working voltages from 3.3 KV upto 

and including 33 KV. 

IS : 3975 Low Carbon Galvanized steel wires, formed wires 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. 

IEC-754 (Part-I) Tests on gases evolved during combustion of electric cables. 

IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on 

bunched wires or cables (Category-B). 

2.00.00 TECHNICAL REQUIREMENTS 

2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and 

under ground (buried) installation with chances of flooding by water. 

2.02.00 Cables shall be 6.6/6.6KV grade, Aluminium conductor, XLPE insulated, PVC inner 

sheath, Armoured, Flame retardant low smoke (FRLS) PVC outer sheathed, 

designed to withstand all mechanical, electrical and thermal stresses develop under 

steady state and transient operating conditions. 

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. 


SECTION-VI 

PART-B 


HT CABLES 

PAGE 

1 OF 7

CLAUSE NO. 




PLANT PACKAGE 


2.04.00 XLPE insulation shall be suitable for continuous conductor temperature of 90 deg. C 

and short circuit conductor temperature of 250 deg C. 

2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. 

It shall not stick to insulation and inner sheath. All the cables, other than single core 

unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as 

per IS: 5831. 

2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For 

multicore armoured cables armouring shall be of galvanised steel as follows: - 

Calculated nominal dia of 

cable under armour 

Size and Type of armour 

i) Upto 13 mm 1.4mm dia GS wire 

ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire/1.6 mm dia GS wire 

iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire/2.0mm dia GS wire 

iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire/2.5mm dia GS wire 

v) Above 55 & upto 70mm 1.4 mm 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-sq.mm/mtr at 20 deg.C. The types and sizes 

of aluminium armouring shall be same as mentioned for galvanised steel above. 

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 wires / 

formed wires. 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 GS 

wires/formed wires. 

2.06.03 Distinct extruded PVC inner sheath of black colour as per IS:5831 shall be provided 

for all cables. 

2.07.00 Outer sheath shall be of PVC black in colour. In addition to meeting all the 

requirements of Indian standards referred to, outer sheath of all the cables shall 

have the following FRLS properties. 

(a.) Oxygen index of min. 29 (Test method as per IS 10810 Part-58) 


SECTION-VI 

PART-B 


HT CABLES 

PAGE 

2 OF 7

CLAUSE NO. 




PLANT PACKAGE 


(b.) Acid gas emission of max. 20% as per IEC-754 (Part-I) 

(c.) Smoke density rating shall not be more than 60% during Smoke Density Test 

as per ASTMD-2843. 

2.08.00 Cores of three core cables shall be identified by colouring of insulation or by 

providing coloured tapes helically over the cores, with Red, Yellow & Blue colours. 

2.09.00 In addition to manufacturer's identification on cables as per IS, following marking 

shall also be provided over outer sheath : 

- Cable size and voltage grade : To be embossed 

- Word 'FRLS' at every 5 metre : To be embossed 

- Screen fault current 300A for 2 sec. 

- Sequential marking of length of the cable in metres at every one metre to be 

embossed / printed 

The embossing / printing shall be progressive, automatic, in line and marking shall 

be legible and indelible. 

2.10.00 All cables shall meet the fire resistance requirement as per Category-B of IEC-332 

Part-3. 

2.11.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm 

maximum over the declared value in the technical data sheets. 

2.12.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes 

etc. are not acceptable. 

2.13.00 The cross-sectional area of the metallic screen strip/tape/wires shall be considered 

in sizing calculations. 

2.14.00 Cable selection & sizing 

2.14.01 HT 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 it shall be limited to 3% of the 

rated voltage. 

c) Short circuit withstand capability 


SECTION-VI 

PART-B 


HT CABLES 

PAGE 

3 OF 7

CLAUSE NO. 

2.14.02 Derating Factors 




PLANT PACKAGE 


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. 

3.00.00 CONSTRUCTIONAL FEATURES 

3.01.00 6.6KV/6.6KV Grade Power Cables 

Cables shall conform to IS: 7098 Part - II. These cables shall be multistranded, 

compacted circular aluminium conductors, XLPE insulated, metallic screened, PVC 

inner sheathed, armoured and FRLS PVC outer sheathed. The metallic screen of 

each core shall consist of copper wires or tape with minimum overlap of 20%. 

However, for single core armoured cables, the armouring shall constitute the metallic 

part of the screening. The metallic screen of each core shall be capable of carrying 

the system earth fault current, 300A for 2sec. Method of curing for cables shall be 

"dry curing / gas curing / steam curing". The eccentricity of the core shall not exceed 

10% and ovality not to exceed 2%. 

3.02.00 The eccentricity shall be calculated as :- 

tmax -tmin 

------------ x 100 

t max 

and the ovality shall be calculated as 

dmax -dmin 

------------ x 100 

d max 

Where t-max/t-min is the maximum/minimum thickness of insulation and d-max/dmin 

is the maximum / minimum diameter of the core. 

4.00.00 CABLE DRUMS 

4.01.00 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 


SECTION-VI 

PART-B 


HT CABLES 

PAGE 

4 OF 7

CLAUSE NO. 




PLANT PACKAGE 


covered with waterproof cover. 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. 

4.02.00 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. 

4.03.00 The standard drum length for power cables shall not be less than 500 meters. The 

length per drum shall be subjected to a maximum tolerance of +/- 5% of the standard 

drum length. Approval from Employer shall be obtained for supplying cable drum 

with shorter lengths. 

5.00.00 TESTS 

(a) All equipments to be supplied shall be of type tested design. The Contractor 







(b.) However if the Contractor is not able to submit report 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 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 


furnished by the manufacturer conforming similarity and “No design change”. 


5.01.00 The reports of the following type tests shall be submitted for each type(voltage 

grade) & size of the cables: 


SECTION-VI 

PART-B 


HT CABLES 

PAGE 

5 OF 7

CLAUSE NO. 




PLANT PACKAGE 


S. No Type Test Remarks 

Conductor 

1. Resistance test 

For Armour Wires / Formed Wires 

2. Measurement of Dimensions 

3. Tensile Test 

4. Elongation test 

5. Torsion test For round wires only 

6. Wrapping test 


8(a) Mass & uniformity of Zinc Coating 

tests 


SECTION-VI 

PART-B 

For GS wires/formed wires only. 

8(b) Adhesion test For GS wires/formed wires only 

For XLPE insulation & PVC 

Sheath 

9. Test for thickness 

10. Tensile strength and elongation test 

before ageing and after ageing 

11. Ageing in air oven 

12. Loss of mass test For PVC outer sheath only. 

13. Hot deformation test For PVC outer sheath only. 

14. Heat shock test For PVC outer sheath only 

15. Shrinkage test 

16. Thermal stability test For PVC outer sheath only 


HT CABLES 

PAGE 

6 OF 7

CLAUSE NO. 




PLANT PACKAGE 


17. Hot set test For XLPE insulation only 

18. Water absorption test For XLPE insulation only 

19. Oxygen index test For PVC outer sheath only 

20. Smoke density test For PVC outer sheath only 

21. Acid gas generation test For PVC outer sheath only 

22 Flammability test as per IEC-332 

Part-3 (Category -B) 

S. No. Type Test For completed cables 


SECTION-VI 

PART-B 

For completed cable only 

1. Insulation resistance test (Volume Resistivity method) 

2. High voltage test 

3. Partial discharge test 

4. Bending test 

5. Dielectric power factor test 

a) As a function of voltage 

b) As a function of temperature 

6. Heating cycle test 

7. Impulse withstand test 

5.02.00 Indicative list of tests/ checks, Routine and Acceptance tests shall be as per Quality 

Assurance & Inspection table of H.T. cables indicated elsewhere. 


HT CABLES 

PAGE 

7 OF 7

PART - B 


LT POWER CABLES 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 





of opening of bid. In case of conflict between this specification and those (IS : codes, 


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:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for 

working voltages upto and including 1100V. 




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) 



under ground burried installation with chances of flooding by water. 


SECTION-VI 

PART-B 



PAGE 

1 OF 7

CLAUSE NO. 




PLANT PACKAGE 


2.02.00 Cables shall be armoured, flame retardant, low smoke (FRLS), armoured type 

designed to withstand all mechanical, electrical and thermal stresses develop under 

steady state and transient operating conditions as specified elsewhere in this 


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. 




per IS : 5831. 

2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For 

multicore armoured cables armouring shall be of galvanised steel as follows : - 

Calculated nominal dia of 



SECTION-VI 

PART-B 


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. 



PAGE 

2 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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 


formed wire. Zinc rich paint shall be applied on armour joint surface of G.S. 

wire/formed wire. 

2.07.00 Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to meeting 

all the requirements of Indian standards referred to, outer sheath of all the cables 

shall have the following FRLS properties. 

(a.) Oxygen index of min. 29 (As per ASTMD 2863) 

(b.) Acid gas emission of max. 20% (As per IEC-754-I). 



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. 


shall also be provided over outer sheath. 

(a.) Cable size and voltage grade - To be embossed 

(b.) Word 'FRLS' at every 5 metre - To be embossed 

(c.) Sequential marking of length of the cable in metres at every one metre-To be 

embossed / printed 

The embossing shall be progressive, automatic, in line and marking shall be legible 

and indelible. 

2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 

Part -3. 


SECTION-VI 

PART-B 



PAGE 

3 OF 7

CLAUSE NO. 




PLANT PACKAGE 




2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes 

etc.are not acceptable. 


2.14.01 Cables shall be sized based on the following considerations: 

2.14.02 Derating Factors 

(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. 

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. 


are avoided. 

2.14.04 All LT power cables of sizes more than 120 sq.mm. shall be XLPE insulated and 

preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm. 


3.01.00 1.1 KV Grade Power Cables 


SECTION-VI 

PART-B 



PAGE 

4 OF 7

CLAUSE NO. 




PLANT PACKAGE 


(a.) 1.1 KV grade XLPE power cables shall have compacted aluminium 

conductor, XLPE insulated, PVC inner-sheathed (as applicable), armoured/ 

unarmoured, PVC outer-sheathed conforming to IS:7098. (Part-I). 

(b.) 1.1KV grade PVC power cables shall have aluminium conductor (compacted 

type for sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as 

applicable) armoured/ unarmoured, PVC outer-sheathed conforming to 

IS:1554 (Part-I). 

(c.) 1.1 KV grade Trailing cables shall have tinned copper (class 5) conductor, 

insulated with heat resistant elastomeric compound based on Ethylene 

Propyline Rubber (EPR) suitable for withstanding 90 deg.C continuous 

conductor temperature and 250deg C during short circuit, inner-sheathed 

with heat resistant elastomeric compound, nylon cord reinforced, outersheathed 

with heat resistant, oil resistant and flame retardant heavy duty 

elastomeric compound conforming to IS 9968. 


5.00.00 TESTS 

(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy 


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. 











SECTION-VI 

PART-B 



PAGE 

5 OF 7

CLAUSE NO. 





PLANT PACKAGE 













The reports for the following type tests shall be submitted on one size each of 

XLPE/PVC LT Power cables: 

S.No. Type Test Remarks 

For Conductor 

1. Annealing test For copper conductor only. 

2. Tensile test For aluminium conductor only. 

3. Wrapping test For aluminium conductor only. 


For Armour Wires/ Formed Wires 




8. Torsion test For round wires only 

9. Wrapping test For aluminium wires/formed wires only 


11.(a) Mass of Zinc Coating test For G.S. Formed wires /wires only. 


SECTION-VI 

PART-B 



PAGE 

6 OF 7

CLAUSE NO. 




PLANT PACKAGE 


S.No. Type Test Remarks 

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 


14. Tensile strength & elongation tests before ageing and after ageing 


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 


20. Thermal stability test For PVC insulation and sheath only 

21. Hot set test For XLPE insulation only 

22. Water absorption test For XLPE insulation only 

23. Oxygen index test For outer sheath only 

24. Smoke density test For outer sheath only 

25. Acid gas generation test For outer sheath only 

For completed cables 

26. Insulation resistance test 

(Volume resistivity method) 


28. Flammability test as per IEC - 332 Part-3 (Category -B) 

5.01.02 Indicative list of tests / checks, routine and acceptance tests shall be as per quality 

assurance and inspection table of LT power cables. 


SECTION-VI 

PART-B 



PAGE 

7 OF 7

PART - B 


CONTROL CABLES 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 





of opening of bid. In case of conflict between this specification and those (IS: codes, 


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. 





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) 


under ground burried installation with chances of flooding by water. 


SECTION-VI 

PART-B 



PAGE 

1 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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. 




per IS : 5831. 

2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as 

follows: - 

Calculated nominal dia. of 


1) Upto 13 mm 1.4mm dia GS wire 


SECTION-VI 

PART-B 


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 


formed wire. Zinc rich paint shall be applied on armour joint surface. 



PAGE 

2 OF 7

CLAUSE NO. 




PLANT PACKAGE 


2.07.00 Outer sheath shall be of PVC (grade as applicable) and grey in colour . In addition to 

meeting all the requirements of Indian standards referred to, outer sheath of all the 

cables shall have the following FRLS properties. 

(a.) Oxygen index of min. 29 (As per ASTMD 2863) 

(b.) Acid gas emission of max. 20% (As per IEC-754-I). 



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. 


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. 


SECTION-VI 

PART-B 



PAGE 

3 OF 7

CLAUSE NO. 




PLANT PACKAGE 


2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 

Part -3. 



2.13.00 Inplant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. 

are not acceptable. 


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 


are avoided. 


3.01.00 1.1 KV Grade Control Cables shall have stranded copper conductor multicore PVC 

insulated, PVC inner-sheathed ,armoured / unarmoured, PVC outer-sheathed 

conforming to IS:1554. (Part-I). 

3.02.00 1.1KV grade trailing cables shall have tinned copper (class-5) conductor, insulated 

with heat resistant elastomeric compound based on Ethylene Propyline Rubber 

(EPR) suitable for withstanding 90 deg C continuous conductor temperature and 250 

deg C during short Ckt., inner sheathed with heat resistant, oil resistant and flame 

retardant heavy duty elastomeric compound conforming to IS 9968. Minimum 

conductor size shall be 2.5sqmm. 


SECTION-VI 

PART-B 



PAGE 

4 OF 7

CLAUSE NO. 


5.00.00 TESTS 





PLANT PACKAGE 


(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy 


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 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. 





















5.01.01 The reports for the following type tests shall be submitted for one size of control 

cables : 


SECTION-VI 

PART-B 



PAGE 

5 OF 7

CLAUSE NO. 




PLANT PACKAGE 


S. No. Type Test Remarks 

For Conductor 

1. Annealing test For copper conductor only. 


For Armour Wires / Formed Wires 




6. Torsion test For round wire only 

7. Wrapping test 


9(a). Mass of zinc Coating test For GS wires/formed wires only 

9(b). Uniformity of zinc coating For GS wires/formed wires only 

10. Adhesion test For GS wires/formed wires only 

For PVC insulation & PVC Sheath 


12. Tensile strength and elongation 

test 



SECTION-VI 

PART-B 

before ageing and after ageing 

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 


18. Thermal stability test For PVC insulation and sheath only 



PAGE 

6 OF 7

CLAUSE NO. 




PLANT PACKAGE 


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) 


24. Flammability test as per IEC - 332 Part-3 (Category-B) 

5.01.02 Indicative list of tests / checks, routine and acceptance tests shall be as per quality 

assurance and inspection table of LT power cables. 


SECTION-VI 

PART-B 



PAGE 

7 OF 7

PART - B 


INSTRUMENTATION CABLES 





SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 INSTRUMENTATION CABLES 





PLANT PACKAGE 


INSTRUMENTATION CABLES 

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 


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 


1.02.04 The conductor shall be of minimum 0.5-sq.mm size, high conductivity, multi-stranded 

copper for all types of instrumentation cables where as the same shall be min. 

1.5sqmm when used in the trailing cables. 

1.02.05 The insulation of individual conductor shall be extruded PVC meeting the 

requirements of VDE 0207 Part 4 compound Y I3. The outer sheath of 

instrumentation cables shall be extruded PVC (compound YM1) as per VDE 0207 

Part 5 and shall be of flame-retardant low smoke (FRLS) type. The cable shall be 

provided with marking including manufacturer's name, insulation material, and 

conductor sizes, no of pairs, voltage ratings, type of cable etc. at intervals not 

exceeding 625mm. Progressive sequential marking of the length of the cable at 


SECTION-VI 

PART-B 


INSTRUMENTATION 

CABLES 

PAGE 

1 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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 


SECTION-VI 

PART-B 



CABLES 

PAGE 

2 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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 

Conductor Size 0.5 Sq.mm. 

Parameter/ 

Type of Cable 

Mutual 

capacitance at 

0.8 kHz (max.) 

Conductor 

Resistance 

(max.) 

Individual and 

overall shielded 

(Type F) 

Table – A : CABLE PARAMETER 


SECTION-VI 

PART-B 

Overall 

Shielded(Type-G) 



CABLES 

Compensating cables 

(with/without Teflon 

coating) (Type 

A,B,C) 

120 nF/Km. 100 nF/Km. 200 nF/Km 

73.4 ohm/km 

(loop)For Type F 

73.4 ohm/km 

(loop) 

PAGE 

3 OF 12

CLAUSE NO. 

Insulation 

resistance 

Cross-Talk 

figure at 0.8 

kHz (min.) 

Characteristic 

impedance 

(max.) 

Attenuation at 1 

kHz (max.) 




PLANT PACKAGE 


100 M ohm/ Km 100 M ohm/ Km 100 M ohm/ Km 

60 dB 60 dB 60 dB 

320 ohm 340 ohm 

1.2 dB/Km 1.2 dB/Km 

1.02.15 DESCRIPTION OF VARIOUS TYPE OF CABLES 

Type Conductor 

Size 

Description 

TABLE – B 

A 0.5 mm 2 Two pair shielded and twisted pair T/C extension cable, 

ANSI type KX, stranded conductor. 

B 0.5 mm 2 Two pair shielded & twisted T/C extension cable ANSI 

type SX, stranded conductor. 

C 0.5 mm 2 Two pair shielded & twisted heat resistant teflon 

insulation & Outer sheath T/C extension cable ANSI 

type KX, stranded conductor. 

F 0.5 mm 2 Multi pair individual pair & overall shielded twisted pair 

instrumentation cable (4/8/12/24 pair) for analog 

signals with stranded copper conductor. 

G 0.5 mm 2 Multi pair overall shielded & twisted pair 

instrumentation cable (2/4/8/12/24/48 pair) for binary 

signals with stranded copper conductor. 

I 0.5 mm 2 Type F cable/type G cable with heat resistant teflon 

insulation & outer-sheath for high temperature 

application. 

S As per 

specific 

Standard/ 

Requirement 

for each 

application 

Multi core/ Multi pair shielded cable for system specific 

cables. Like conductivity type level switches, Vibration 

monitoring system cable , System Bus cable, Bus 

communications cable etc. as applicable. 


SECTION-VI 

PART-B 



CABLES 

PAGE 

4 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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 

drives (Integral 

Junction box) 

Marshalling 

ubicle/local group 

JB/Ter- 

mination/Control 

Cabinets/System 

Cabinets 

Plug in 

connector 

RTD heads Local junction box Plug in 

connector 

Thermocouples CJC box Plug in 

connector 

RTD 

thermocouple 

Local Junction 

box, CJC box, 

Group JB/ 

MCC/SWGR 

Temperature 

transmitter 

Marshalling 

Cubicle/local 

group 

JB/Termination/ 

Control 

Cabinets/System 

Cabinets 

Plug in 

connector 

Maxitermi/ 

cage clamp 

(Rail moun 

ted) type. 


SECTION-VI 

PART-B 

Post moun 

ted Maxi 

termi/cage 

clamp type. 

Maxitermi/ 

cage clamp 

(Rail moun 

ted) type. 

Screwed/ 

Cage clamp 

Type 

Screwed/ 

Cage clamp 

Type 

Post moun 

ted Maxi 

termi/cage 

clamp type. 



CABLES 

G 

F 

A,B,C* 

F,G 

PAGE 

5 OF 12

CLAUSE NO. 

Local Junction 

box, 

MCC/SWGR 

Field mounted 

Instrument 

Marshalling 

cubicle/ 

Termination 

Cabinet 

Marshalling / 

Termination 

system cabinets 

DDCMIS/PLC 

cabinets 




PLANT PACKAGE 


Group JB Maxitermi/ 

cage clamp 

(Rail moun 

ted) type. 

Group JB Maxitermi/ 

cage clamp 

(Rail moun 

ted) type. 

Electronic system 

cabinet 

UCP mounted 

equipments 

Post 

mounted 

Maxi 

termi/cage 

clamp type. 

Post moun 

ted Maxi 

termi/cage 

clamp type. 

PC, Printers etc. Plug in 

connector 


SECTION-VI 

PART-B 

Maxitermi/ 

cage clamp 

(Rail moun 

ted) type. 

Maxitermi/c 

age clamp 

(Rail moun 

ted) type. 

Post 

mounted 

Maxi 

termi/cage 

clamp type. 

Plug in 

connector/ 

Cage clamp 

type (rail 

mounted). 

Plug in 

connector 



CABLES 

F,G 

F,G 

F,G 

F,G (with 

plug-in 

connector at 

one end) 

Mfr.’s 

Standard 

Notes 1 Normally 10% spare core shall be provided when the 

number of pairs of cables are more than four pairs. 

2.00.00 TERMINAL BLOCKS 

2 For analog signals individual pair shielding & overall 

shielding & for Binary signals only overall shielding of 

instrumentation cables shall be provided. 

3 * For high temperature application only. 

2.01.00 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 & 

PAGE 

6 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART-B 



CABLES 

PAGE 

7 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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 


SECTION-VI 

PART-B 



CABLES 

PAGE 

8 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART-B 



CABLES 

PAGE 

9 OF 12

CLAUSE NO. 

(ii) Material and 

Thickness 




PLANT PACKAGE 


4mm thick fiberglass reinforced polyester. 

(iii) Type Screwed at all four corners for door. Door handle shall be 

self locking with common key. Door gasket shall be of 

synthetic rubber. 

(iv) Mounting 

clamps and 

accessories 

(v) Type of 

terminal blocks 

(vi) Protection 

Class 

7.00.00 CONDUITS 

Suitable for mounting on walls, columns, structures etc. 

The brackets, bolts, nuts, screws, glands and lugs 

required for erection shall be of corrosion resistant 

material, included in Bidders scope of supply. 

Rail mounted maxitermi or cage-clamp type suitable for 

conductor size upto 2.5 mm 2 . A M6 earthing stud shall 

be provided. 

IP:55 minimum for Indoor & IP-65 Outdoor applications 

(vii) Colour To be decided during detailed engineering & subject to 

Employer’s approval. 

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. 

8.00.00 TESTS 












SECTION-VI 

PART-B 



CABLES 

PAGE 

10 OF 12

CLAUSE NO. 

8.02.00 TYPE TEST 




PLANT PACKAGE 













8.02.01 Following type tests reports shall be submitted for one size of each type of 

instrumentation cables: 

8.02.02 For Conductor (including Drain Wire) 

Sl. 

No. 

Test Reference Standard Remarks 

1. Resistance Test VDE:0815 

2. Diameter IS:10810 

3. Tin coating test* 

(Persulphate Test) 

8.02.03 For PVC Insulation And PVC Sheath 

Sl. 

No 

. 

As per relevant 

standard 

Test Reference 

Standard 

1. Test for thickness** IS:10810 

2. Tensile strength and elongation test 

before and after ageing** 

3. Ageing in air ovens** - do- 

4. Loss of Mass Test -do- 

5. Hot deformation test -do- 


SECTION-VI 

PART-B 

VDE:0472 

*Applicable for drain 

wire only 



CABLES 

Remarks 

PAGE 

11 OF 12

CLAUSE NO. 




PLANT PACKAGE 


6. Heat shock test - do- 

7. Shrinkage test** -do- 

8. Cold bend/ cold impact test - do- 

9. Colour fastness to water -do- 

10. Thermal stability test -do- 

11. Bleeding and blooming -do- 

12. Oxygen index test (for sheath & fillers) ASTMD-2863 

13. Smoke density test (for sheath & fillers) ASTMD-2843 

14. Acid gas generation test (for sheath & 

fillers) 

8.02.04 For Al-Mylar Shield 


SECTION-VI 

PART-B 

IEC-754-1 

Sl.No. Test Reference Standard Remarks 

1. Continuity test As per relevant standard 

2. Shield thickness test -do- 

3. Overlap test -do 

4. Noise interference 

test 

IEEE-Transaction 

March'67 



CABLES 

PAGE 

12 OF 12

vee 

v r e 

I tT tT tt I tT tT ti_- 

I rJ i rA,j;ii:3 | rL t /6 | rb i6 ro /.io 

I I | | i I I l : ' 

r I I t | | + ' 

' s:JnrxI-l gNIrHgI-l o-L 

| ="^., .-, lo*., I 

l 

i l l I 

i r t l 

)l g i d 

I I I 

!ffit 

y yrvnNvry r vr i I | | 

1_. r-,rrrnsr t __ _r__ 

i 

J l uorv_rosr N.ir 

,:o@ @"ol I F,n'+ | I | | | 

i | l 

l l l + 

l l 

t t t l 

l l | | l ' ? ' ? ' ? 

, I i I I A-d--]Joo,,o,"'o'lo. 

*oto-'ott .t*o.*, 

I t6fi,?5oi33 

| 

ldS'SDN9l' Sd1v-'lgNILv3i(NI+l | | 

| +ds 'SoN zI I d3r,U1 '3NlS + tN03 v€9 + NdI ve9 '-d ! 'I 

| 

{ I 

' L 

- - 

I T I I s o N E 

'oN 

NOUdIUCSfO 

A3l 

$r 3soddnd d30N3l UoJ vd 

,R ll' d--iy'',""1 '*'' 

I I 1,," d' I :YA) '*-.i 

l \ e \ o 

I r. | (1"^;3: 

Ndg r0 c$rt[ltNpr€ 

( ts!Jdrcr}|3 rrcNt Jo $gr.Qgf€ v ) 

'p11 uopa.rod:oC Jarod Is@raql JBqogBN 

r?Ut{y t-rttE }l\b }nlb-Aldb ut-lrI 

IUVONVIS r a:tnr/ 

S-I]NVd INIIH9II dOJ HVd9VIO fIIVN3HSS f'l.ul 

0z Jo rHs I srx 

i00-V-3Od-ZiZ-0000 .nN .qxnl r-.'o..,. lzi5 

9A(',6I-'t 

l - 

, . | | 

sf-l3vldf33d 0L 

I I I l 

tD3 @r 

r€l,Y mc a I FI 

Y A q q 

J€ 03881-13 

) 

I I 

-oN Vd'Aft

PART - B 


ILLUMINATION SYSTEM 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


ILLUMINATION 

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. 

IS:6616 Ballasts for high pressure mercury vapour lamps. 


SECTION-VI 

PART-B 



PAGE 

1 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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). 


SECTION-VI 

PART-B 



PAGE 

2 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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 


SECTION-VI 

PART-B 



PAGE 

3 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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 DC Lighting System 

Emergency DC lighting is to be provided through self contained DC emergency 

fixture at strategic locations. The fixtures shall be switched ‘ON’ automatically in 

case of failure of AC supply. 

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. 


SECTION-VI 

PART-B 



PAGE 

4 OF 12

CLAUSE NO. 




PLANT PACKAGE 


(a) Air conditioned area : 0.8 

(b.) Non Air conditioned and other indoor area : 0.7 

(c.) Dust prone indoor areas and outdoor areas : 0.6 

6. All outdoor fixtures shall be weather proof. 

7. All lighting fixtures & control gears shall be powder coated. 

8. Wires of different phase shall normally run in separate conduit. For areas 

illuminated by more than one circuit, the adjacent circuits shall be from 

different phases. 

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. 


SECTION-VI 

PART-B 



PAGE 

5 OF 12

CLAUSE NO. 

2.03.00 Ballasts 




PLANT PACKAGE 


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. 

11. 20A, 240V AC industrial type receptacles shall be provided in the following 

areas : 

- Two in each switchgear / MCC room and Pump house 

- These receptacles shall be energized from lighting panel. Maximum 

three receptacles shall be connected in one circuit. 

12. 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. 

2.03.01 All HPSV and HPMV lamp fixtures shall be provided with wire-wound ballasts. All 

fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (Div- 

II/Hazardous Area) shall be provided with electronic ballasts. 

2.04.00 All luminaires and their accessories and components shall be of type readily 

replaceable by available Indian makes. 

2.05.00 Fans & Regulator 

2.05.01 Ceiling Fans, to be provided in non air-conditioned office / control room area shall be 

suitable for operation on 240 V, 50 Hz, AC supply comprising of class ‘F’ insulated 

copper wound single phase motor, 1200mm sweep, aerodynamically designed well 

balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor, 

suspension hook, canopies etc. finished in stove enameled white. Power factor of 

fans shall not be less than 0.9. Each fan shall cover approximately 10sq.m. area. 

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 . 


SECTION-VI 

PART-B 



PAGE 

6 OF 12

CLAUSE NO. 

2.08.00 Conduits, Fittings & Accessories 




PLANT PACKAGE 


Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for normal 

area and galvanised heavy duty steel conduits with an additional epoxy coating for 

corrosive area shall be offered. Alternatively glass reinforced epoxy conduits with 

comparable compressive and impact strength with that of heavy duty steel conduits 

may be offered. 

2.08.01 Rigid Steel Conduits 

(a.) Rigid steel conduits shall be heavy duty type,hot dip galvanised conforming 

to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses, 

threaded on both sides and threaded length shall be protected by zinc rich 

paint. Conduits shall be smooth from inside and outside. 

2.08.02 Flexible Steel Conduits 

2.08.03 Flexible conduit shall be water proof and rust proof made of heat resistant lead 

coated steel. 

2.08.04 Pull-out Boxes 

2.09.00 Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit 

run .Boxes shall be suitable for mounting on Walls, Columns, Structures, etc.. Pullout 

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. 


SECTION-VI 

PART-B 



PAGE 

7 OF 12

CLAUSE NO. 

2.12.00 Lighting Masts 




PLANT PACKAGE 


2.12.01 Lighting Masts shall be of continuously tapered polygonal cross section hot dip 

galvanised presenting a pleasing appearance. The Mast shall be of 30M height with 

lantern carriage to enable raising / lowering for ease of maintenance, including the 

Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built 

power tool, luminaries, suitable aviation warning light, lightning along with necessary 

power cables within the mast. The mast shall be delivered only in three sections & 

shall be joined together by slip stressed fit method at site. No site welding or bolted 

joints shall be done on the mast. 

2.13.00 Lighting fixtures shall generally be group controlled directly from lighting panel. 

However, in office areas, control shall be provided through switch boxes. Each 

switch shall control a maximum of three fluorescent fixtures. 

2.14.00 Wiring shall run throughout in separate conduits. Wires of different phases shall run 

in different conduits. Wiring for lighting circuits and receptacle circuits shall be 

carried out in separate conduits and from separate feeders. 

2.15.00 Lighting panels etc. shall be earthed by two separate and distinct connections with 

earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single phase 

receptacles etc. shall be earthed by means of separate earth continuity conductor. 

The earth continuity conductor 14 SWG GI wire shall be run alongwith each conduit 

run. Cable armours shall be connected to earthing system at both the ends. 

3.00.00 TESTS 



price. 

3.02.00 Selection of samples for acceptance test & routine test and acceptance criteria for all 

the items shall be as per relevant I.S 

3.03.00 Acceptance Test and Routine Test 

3.03.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and 

routine test, as per relevant specified standards. 

3.03.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to 

physical and dimensional checks. 

3.04.00 Galvanizing Tests 

3.04.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and 

shall be inspected visually. 


SECTION-VI 

PART-B 



PAGE 

8 OF 12

CLAUSE NO. 




PLANT PACKAGE 


3.04.02 In addition following tests shall be conducted as acceptance tests. 

(a.) Uniformity of coating - The coating of any article shall withstand four 1minute 

dips in standard copper sulphate solution without the formation of an 

adherent red spot of metallic copper upon the basic metal. 

(b.) The quality of cadmium/zinc plating on items with screw threads shall be free 

from visible defects such as unplated areas, blisters and modules and shall 

be inspected visually. 

(c.) In addition, the plating thickness shall be determined microscopically/ 

chemically or electronically. 

4.00.00 COMMISSIONING CHECKS 

1. On completion of installation work, the Contractor shall request the Project 

manager for inspection and test with minimum of fourteen (14) days 

advance notice. 

2. The Project manager shall arrange for joint inspection of the installation for 

completeness and correctness of the work. Any defect pointed out during 

such inspection shall be promptly rectified by the Contractor. 

3. The installation shall be then tested and commissioned in presence of the 

Project manager. 

4. The contractor shall provide all, men material and equipment required to 

carry out the tests. 

5. All rectifications, repair or adjustment work found necessary during 

inspection, testing and commissioning shall be carried out by the 

Contractor without any extra cost. The handing over the lighting installation 

shall be effected only after the receipt of written instruction from the 

Employer/his authorized representative. 

6. The testing shall be done in accordance with the applicable Indian 

Standards and codes of practices. The following tests shall be specifically 

carried out for all lighting installation. 

(a) Insulation Resistance. 

(b) Testing of earth continuity path. 

(c) Polarity test of single phase switches. 

(d) Functional checks. 


SECTION-VI 

PART-B 



PAGE 

9 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-B 



PAGE 

10 OF 12

CLAUSE NO. 




PLANT PACKAGE 


Sl No. Location Average 

Illumination 

Level(Lux) 

(a) Switchgear rooms 

(b) Control room, 

computer room, 

control equipment 

room 

(c) Offices, conference 

rooms,etc. 

(d) Battery rooms 

(e) Transformer yard 

(f) Diesel generating 

room, Compressor 

room, pump house 

etc. 

(g) Fuel oil pump house 


SECTION-VI 

PART-B 

Type of Fixture 

ANNEXURE-A 

200 Industrial trough type 

fluorescent 

300 Mirror optics with anti-glare 

features 

300 Decorative mirror optics type 

100 Totally enclosed corrosion 

proof 

10(general) 

50(on 

equipment) 

HPSV flood light 

150 HPSV medium bay/Industrial 

trough type fluorescent 

150 Flame proof fluorescent 

fixtures suitable for division-2 

hazardous area 

(h) Cable galleries 50 Industrial trough type 

fluorescent 

(i) Street lighting- 

primary roads - 

secondary roads 

(j) Outdoor storage 

handlingand 

unloading area 

20 

10 

HPSV street lights 

Degree of Protection IP54 

20 HPSV flood light 



PAGE 

11 OF 12

CLAUSE NO. 

(k) DM plant,water 

treatment plant 




PLANT PACKAGE 


150 Industrial trough 

type/corrosion proof 

fluorescent 

(l) Chemical stores 150 Corrosion proof fluorescent 

(m) Permanent stores 150 Industrial trough type/HPSV 

(n) Workshop.general 

work bench 

(o) Laboratory 

General 

Analysis area 

150 Industrial trough type 

fluorescent 

150 

300 


SECTION-VI 

PART-B 

Mirror optics fluorescent 

Corrosion resistant, 

fluorescent 

(p) Garage/Car Parking 50 Industrial trough type 

fluorescent 

(q) Switchyard and all 

outdoor areas 

20(general 

50(on strategic 

equipment) 

HPSV flood light 

(r) Stone picking area 300 HPSV dust tight well glass 

fixture (flood light type) 

(s) Transfer points, 

crusher house, track 

hopper, track hopper 

shed, tunnels, bunker 

house. 

100 HPSV dust tight medium bay 

or well glass fixture. 

(t) Conveyor galleries 70 HPSV dust tight well glass 

fixture. 

(u) Stair cases 100 Min. one fixture at every 

landing. 

NOTE:- Any additional fixtures required to take care of the dark patches / shadows 

shall also be provided. 



PAGE 

12 OF 12

_ a J 

: o i 

Y t ' . 

! o 

,. !t 

* 

J I 

c o 

]t 

c n , 

c 

J 

-uJ 

z. 

n ! 

F 

N Y 

( J t 

u 9 

Lrt 

D- 

{ X 

: . : 

tJ 

q 

F - (u 

z c 

E : ) 0 / 

F 

z L - 

ct 

o 5 

? 

r t 

0 J B 

ct 

o o t 

0 J ' 

s P : 

U l . 

! o 

P 

o l - 

l . d 

c / o . 

u ' - 

1 i ! 

c J -0, , 

-g) 

ul 

'tJ 0 r E 

0/ 

+ 

q - n 

. X 

T A , 

c . 

" o 

P 6 

= P 

d 7 

L 5 

u r d 

-C 0/ 

F ' O 

o 

U 

B{- _4, 

SECIION A-A 

X - FOR 60orhm. IR^Y - 20-25 

J00mm. IRAY - 10-15 

15omh, lMy - 'tS-20 

SLOTIED NUNG. 

X 

TTTI E' 

SIZE 

A4 

:] 

A 

ffi 

ra 

+-{. I 

H T 

L_1 

sEcTroN c-c 

DR TENDER PURPOSE 

t]R TENDER PURPI]SE 

DR TEIiDER PURPNSE 

ScALr 

NTS 

SIDE RUNNER 

l__w_-+*_-4r_+ 

L l/r- l\. 

tai 

L---+* si 

FIXING CI]AIIP, 

STAi!I]ARD 

I.ADDER 

TYPT CABLE TRAY. 

NOTE. 

1. IAIIRIAL t- l|.S. SHEEf MtN, 2mm. tHK 

2. RNISH :-HOT olP GALVANISEO 

5. COUPI.E'R PI,ATE-. UlX. 3mr itlK 

M.S. }IOT DP GALVANISED. 

b{?'P (: I-i--:r--rite il_ 

( A GOVERNMENI OF INDIA EN]ERPRISE ) 

ENGINEERING DIVISION 

'uo' 

oooo--a1 r-p[[--A -t]Ct1

0 r 

_ 4 

.. 

i 

o 

5 

5 

u 

y 

r 

v l 

o 

.. lt 

* 

J 

L 

c 

O 

z q 

C n , 

d - : 

) u l 

z. 

F 5 

U ^î 

H 

v i 

( J i 

N P 

i l u 

E C 

o- 

J i 

z 

u ,",,i 

u : l 

: E E 

F L 

o 

J o . 

z . c 

E U , 

l-{ + 

z i 

* + 

- J 

+ I 

c ! 

o - 

o_ 

o o , 

-c 

o / . 

+ : 

0 

t 

/ L 

o 

d 

m 

+ 

5 - 

! 

0, 

d 

O. 

O C 

f E 

c + -or 

.9 

ut 

o J T 

! )., 

P 

9 E 

i - c 

' x 

1 5 o 

! c 

9 ! 

- = E 

o d 

* o 

-S !' 

-C -O- 0r 

F 

o 

U 

s 

t AJ!f 

Y 

A 

J!t- 

Y 

+ 0 {} 

Y 

A 

u 

0 

A 1!r 

Y 

{i} 

Y 

s $ s s + s + 

Arh 

ttts {tf 

v v 

A A 

Jlt Jf 

Y Y 

A 

1rr 

Y 

A 

1!f 

Y 

A+- -[o E$f9BAIEC.9AEIL]EAI. 

Pl-A|l 

tEc!g!*A 

ss s 

A. 

uA1!t Y + 

+ 

rh 

1!l 

Y 

A 

J!t 

Y 

NOTE. 

1, A[ DHENSONS ARE lN mm. 

2. lN-SlD€ ll (lU0lH) :- t5O, 5o0 & 60omn 

3. IIAIERIAL :- 2mm. ll.S, SHEEr Uln. 

I\TTP C I-arrri-te d- 

( A GOVERNMENI OF INDIA ENTERPRISE ) 

ENGINEERINC DMSION 

S T ANDARD 

ENO VIEW 

PERFORATED TYPE CABLE TRAY. 

0000-211-PlE-A-004 

TRAY3A-211-OOA,DVG

I 

9 

't' 

r f 

P t . 

: u l 

! c ) 

.- L 

; o - 

J ; 

r i q 

a ; 

-) 

z n 

F j j 

_9 

v d 

IJ 

g a 

U + 

O 

':: 

M . 9 

l-J 

E C 

o_ 

-', 

* 

- u l 

I T 

F L 

OJ 

J O " 

z 

E 

l' 

c 

A , 

+) 

z i 

* + 

- f 

L t 

o o , 

I 

O r . 

P : 

g 3 

6 

r,0 

( 

d 

+, 

.. 

o 

o 

o _ g 

t ' 0 , 

-c 

b " d 

ul 

O, 15 

? | o + 

e + 

+ : 1 

a v 

9 E 

= 0 , 

. C 

o d 

* s 

-u 

_c "i .g 

l - O 

U 

ryIEg 

1) ALL DIMENSIONS ARE IN MM. 

ru='_hh 

ll 

,.r1u,r.y t{ I 

l t i l I 

+SINGLE CHANNEL_TYPE C1 

f- -, -l 

RB FDR TENITER PURPoSE I V a\ Fl lu I + '6( 

RA FOR TENDER PURPESE 

IEV 

N0. DESCRIPTION CHKD M E (, c&l ARCH 

APPD DATE 

(Gffil 

tNrPcJ 

PROJECT 

CLEARED BY 

FTTP C I-irrrite d- 

(.A GOVERNMENT OF INDIA ENIERPRISE ) 


STANDARD 

TITLE C1 & C? CHANNEL, CABI,E TRAY 

SUPPORT SYSTEM 

SIZE 

A4 

SUALL 

NTS 

DRG. No' REV N 

oooo-a11-PDE*A-013 K5 

TRAYlA-e11-013 

7W 

I 

I

o r j f 

e j 

c- 

t U 

: u r 

L O 

P h 

n - 

J s - 

L O 

o ' + 

C n, 

6 - J 

I 

A 6 

z 

.T 

! 

4 . 

u ; ; 

= 

& . f 

( J i 

u . 9 

ul 

E C 

L 

J ; 

4 A 

E . ; 

tr_r 

- E 

F ! 

AJ 

__J o- 

z . c 

E o 

l-' + 

z = 

* + 

' f 

P + 

! 

c r..............._ 

q r . 

o 0 , 

: 5 

-c 

u . 

_c 

+ 

O , L 

( - o 

6 

{> 

O L 

L 6 

^ J o 

o . s 

U 

.. 

L 

r o , 

-c 

C { > -0, 

-q 

tn -6 

0r 

o ( y +, 

v s i 

+ i 

a o , 

C . 

d b 

9 E 

-= 0, 

. c 

6 a 

* s 

-q 

_c 

l- 

"; 'o Q, 

o 

SLOTS WITH 

GRIPPING RIBS.---.: 

TAPPED HOLE 

r--tnTt 

l ll rl 

t il ii t 

*= 

STEEL SPRING DESIGNED Io -< 

HOLD NUT IN POSITION IN T 

CHANNEL. 

4 

q 

CHANNEL NUTWITH 

SPRING 

[; 

= 

-,--,-lll 

ur 

slors wtrH I ll ' 

GR|PPING RIBSJ ll ' 

rvP-lcAL_DE'I4lIs oLry 

NUT 

il 

SPRING SECURING 

-sLoT 

) CHAMFERED CORNERS 

TO ALLOW NUT TO BE 

ROTATED IN CHANNEL 

ING ACCESSORIES 

g 

/fl-l--rn 

/tt ,*. | | | 

Jlt,'i'r | | lo 

| | | \ : / | | )- gHAMFEREDg9RNERS 

| | | l- | | /-ro ALLow HFAD ro BE 

I --------T----.-- I I I I V ROTATEDINCHANNEL 

STUD NUT 

';e 

RB FOR TENDER PURPBSE D t'l $" 48 L -+ 

RA FOR TENDER PURPI]SE 

iEV 

NO, DESCRIPTION CHKD 

lffi| 

LN'PC J 

PROJECT 

M E c&l ARCH 

CLEARED BY 

f\TTP C I-irrr-ite d- 

( A GOVERNMENT OF INDIA ENTERPRISE ) 

ENGINEERING DMSION 

STANDARD 

TITLE TYPICAL DETAITS OT' CABLE TRAY 

SUPPORT SYSTEM 

srzE I scALElJtiG. 

A4 | NTS 

N(). 

0000-211-PuE-A-014 

TRAYlA-al1-014 

DA1E 

(LV. NU. 

RB

C2 CHANNEL SECTION 

Yw 

NTTP C I-irrrite d- 

( A GCA/ERNMST OF INDh ENIERPRISE 


IYPICAT DETAIL OF CABI.E TRAY SI'PPORT SYSTEM 

0000-21 1-PoE-A-015 

) 

CAD FILE NAIIE r STANII-211-015,DVG

ART_2 

CHANNEL 

N OTES 

ART- 3 

1. MATIRIAL MILDSTEEL 

2. 

FOR TENDER PURPOSE ONLY 

FOR TENDER PURPOSE ONIY 

MATERIAL HOTDIPGALVANISED 

I\TTP C I-irrrite d- 



0000-21 1 -PoE-A-O16 

CHANNEL 

CAD FILE NAME : STAND-2'I1-016.DWG

ASSEMBLY_1 ASSEMBLY-2 

f: :l 

+ +eqH-@@-]-]frol-i 

f:i lGJJll Ln I f-_-\ 

%*? 

ASSEMBLY_ 1 

UPPER FIXING C2 CHANNEL 

ASSEMBLY_2 

UPPER FIXING C1 CHANNEL 

UPPER FDilNG FOR CHANI{ELVERM 

ALTERNATIVE 

POSITION OF 

C1 RUNNER 

CHANNEL 

C1 CHANNEL 

V 

NT'FP C I-irrr-ite d- 

( A GOIERNMENT OF INDIA ENIERPRISE ) 

ENGINEERINC DMSION 

TYPICAI, DETAIIS OF CABI.E TBAY ST'PPORT 

SYSTEM 

0000-21 1 -PoE-A-0r7 

CAD FILE NAl,lE r STAND-?11-017,DVG

fi 

\cz cHnHH+ | ll N.,.ro**.. 

ilt l 

ASSEMBLY , 

HFAVY DUTY FLOOR 

. 

FrxrNG FoR c2 cHANNEL 

i-+

HOLES TO BE DRILLED IN WALL 

FOR FIXING RAWL BOLT 

CHANNEL CLAMP 

RAWL BOLT 

w:-'- '@6, 

FOR ]ENDER PURPOSE ONLY 

'@9, 


( A GC|\,BNMENT OF INDIA ENIERPRISE ) 


FIXING OF CEAI.INEL IN TRENCH WALL 

CAD FILE NAl.lE ' STAND-211-019,DVG

i 

o 

q .{j 

J J 

.. u 

: 

y 

o 

o 

/ 

+ ) h 

l , r ) * 

E 6 

! ( f 

9 " , 

6 J I 

J - g 

z 

E : 

F S 

c 

o 

- A f 

P : 1 

>r ur- 

P K 

o * 

J r - 

L O 

u ( | 

5 g _a 

A 6 

J - g 

z 

E X 

F 5 

e . ; 

H 

v i 

U P 

( J c 

: 

t r u 

E C 

o- 

J i 

= ; 

i l u l 

T . € 

F ( - a, 

) o 

z . c 

E O , 

l-' 

+ p 

z : 

(! 

o 5 

+ ! 

l - i 

O r . 

O 0 J 

: 6 

o . 

P - = 

0 J { - 

L O 

6 

+ 

o ! 

! 

0, 

6 

O- 

6 

u - 

c 

- 

! 

l o , 

-c 

c + 'd 

.9 

o -5 

0, 

E A r 

P 

9 = 

' X 

o 0 , 

a , 

a 

= 0 , 

- c 

6 a 

: e 

-q 

-c 

l- 

-d 

-O 0, 

U 

NOTE: 

1. BRACKET TO BE WELDED WITH INSERT 

PLATE FOR FIXING OF C',/C2 CHANNEL 

2. ALL DIMENSIONS ARE IN MM. 

ARRANGEMENT TYPE-C1 

FDR TENDER PURPNSE 

FER TENDER PURPDSE 

1) 600mm TRAY-1TO 

6 TIER-C2 

2) 50omm TRAY-I TO 5 TIER-CI 

3) 30Omm TRAY-4TO 

6 TIER-C2 

4) 15Omm TRAY-1TO 

6 TIER-CI 


( A GOVERNMENI OF INDIA ENTERPRISE 

) 

ENGINEERING 

DIVISION 

STANDARD 

STANDARD CABLE SUPPORT 

ASSEMBLY 

0000-e11-PEE-A-031 

TRAYSUPA-411-031

c 

o 

o / F 

- O j 

., u 

- g H 

! o 

+ : 

l n * 

) ! 

e o 

! q 

C n , 

P e 

- J - g 

z. 

n ! 

F O 

F j l 

H 

f r . 9 

P 

o < 

u 9 , 

IJ 

E C 

(L 

) a 

i n 

t-,1 

o 

- . E 

F t 0J 

) o 

z . c 

E 0 i 

r t 

z : 

G 

" f 

# ! 

L I 

0 r = 

o 

O 0 r 

o J i l 

-c 

O J L 

! O 

6 

+ 

n l 

L O 

0, O- 

: - 

u - - 

! 

l 

- 

o r 

_c 

P 

'6 

_q 

ut 

O r a 

:o 0/ 

e € 

P - x 

E O J 

c , 

d b 

- C 

6 6 

g - O 

6 

-q .' 

_c 0, 

n 

o U 

ARRANGEMENT TYPE_DI 

ARRANGEMENT TYPE-Dz 

----f I 

A 

T I 

_---'F I 

T 

NOTES: 

1) UP TO 3 TIER C1 CHANNEL 

2) ABOYE STIER & BOTH SIDE TRAY 

C2 CHANNEL 

3) AI,L DIMENSIONS ARE IN MM, 

CC FLOOR LEVEL 

-\ 

--+ 

I6 

o 


( A GoVERNMENT OF INDIA ENTERPRISE ) 


STANDARD 

STANDARD CABI,E SUPPORT 

ASSEMBLY 

0000-211-PDE-A-03e 

TRAYSUPA-A11_032

oJ 

_ o 

i 

o 

i; 

5 

+ 

: r 

Y 

o( 

E 6 

- 6 ( t s 

E s 

A 6 

.u 

z. 

u i 

F ; 

u i 

( r t 

u P 

trl 

(L 

J ; 

= : tl 

L,J -Ul 

- E 

' - L 

0J 

z . c 

tri 0, 

F J , 

z . t 

(+ 

- J 

( + 

Q r - 

O 0 r 

s . ; 

O r - 

-g 

+ ! 

0 J L 

+ 

o t . 

O r O 

U _ L 

t_ c _c 

c f 

w) 0, 

UI 

0 J a 

E O J 

+, 

q b 

i = 

' X 

! o r 

c . 

d b 

9 u 

- ; 

o 6 

L n 

6 = 

-g 

-C "; 0r 

F a 

oU 

J^ 

NOTE: 

tr 

-w+100---l 

TA+- 

l - H 

I l - 

t l" T-F- 

l l T n 

J l" I 

ll,'l 

I l:' ,l 

-l 

It'.J_ 

- l I 

(w:wrp, 

aorru*_fl 

1. ALL DIMENSIONS ARE IN MM. 

| : 

l l " 

? I' 

INSEF lT PLATE--I 

l[,: 

t t : 

1", F 

-w----_-ll 

-..A----lA rr 

/+-, I 

----:-:=:H . I 

FE\\t 

| , . .l -|NSERT PLATE 

ABLETRAv 

| "l 

ARRANGEMENT 

TYPE_S1 

| 

'l 

ffoLUMN 

lo 

!''l 

l 

l: .17--INSERTPLATE 

Tl 

' I 

\ l+- | 1 CHANNEL 

rH oF CABLE TRAY) 

' 

Zl , I 

a-='o--s-,=-nffi 

' '\ | 

:ql 

,:" :ll l\ 

: . " n", " 

ll | )-tnev 

dj 

1l l/ 

'.'o : 'll ,'f 

;=;w I 

' 

. 

. o.t . .V4 f-----------cABLE rRAy 

/IEW_A 

rs FIxED BY FlxrNG cLAMP 

RB FER TENDER PURPDSE N ffr b' Lx f.-a o( 

RA FOR TENDER PURPT]SE 

IEV 

NO. DESCRIPTION CHKD 

(ffi| 

UtrPc J 

PROJECT 

TITLE 

SIZE 

A4 

SCALE I DRG. NO. 

Nrs | 

M E c&l ARCH 

CLEARED BY 




STANDARD 

J& 

APPD DA]E 

STANDARD CABIE SUPPORT 

ASSEMBLY 

EV. NO 

00oo-211-PlE-A-033 RB 

TRAYSUPA-A11-033

i 

o: 

q r : 

r f 

I H 

y u l 

\ o 

+ h 

t n - 

J t - 

L O 

E g 

6 : 

.q 

z 

g b 

F F 

o z i : 

D Y 

N Y 

O C 

u 9 

tl 

o c 

o- 

J i 

t'; 

tr_q 

- E 

F I 

o 

i o 

z c 

E O , 

t - + 

z ; 

* + 

" 5 

! t 

0 / = 

o_ 

O 0 / 

I 

o / = 

-g 

'P -= 

O r g - 

! o 

6 

f 

I / | L 

L 6 

O , o . 

u ' - 

f { D 

-c 

c + 'or 

.q 

o '?5 

. O, c ' G 

+ 

9 € 

i - c 

. X 

E U 

g . 

d 6 

9 E 

' = F 

9 a 

t e 

.9 !' 

-c 0/ 

F O 

o 

U 

NOTE: 

1) 6o0mm TRAY-I TO 6 TIER-CZ CHANNEL 

2) 3O0mm TRAY-I TO 3 TIER-CI CHANNEL 

3) 3o0mm TRAY-4 TO 6 TIER-C? CHANNEL 

4) 15omm TRAY-I TO 6 TIER-CI CHANNEL 

1. ALL DIMENSIONS ARE IN MM, 

I 

ilII 

I lll I 1I 11 -CANTILEVERARM 

,ur illl + lll \l-' 

r---l_ 

\I]il I lil ltl 

ARRANGEMENT TYPE_Sz 

| 

RB FOR TENDER PURPOSE D i\ F1 l.> l' 

RA FOR TENDER PURPT]SE 

4 

).6 

IEV 

NO. DESCRIPTION CHKD M E a c&l ARCH APPO DAIL 

CLEARED BY 

Gam?) 

t_NrPc-J 

PROJECT 

f\TTP C I-irrrite d- 

( A GOVERNMETfi OF INDTA ENTERPRISE ) 


STANDARD 

TITLE STANDARD CABLE SUPPORT 

ASSEMBLY 

5IZL 

A4 

SCALE 

NTS 

0000-a11-PnE- A-034 

TRAYSUPA-811_034 

tffi 

IEV. NO. 

RB

o 

- 

r 

a 

o 

5 

; 

+ 

9 

h 1 

r,n 

+ : 

u l * 

J ( 

E 6 

a ( r 

C n ' 

r - q 

z. 

n ! 

u i ; 

H ( Y 

o i 

u 9 

IJ 

E C 

o_ 

4 . X 

= . : 

u :J.l 

uJ _v.! 

- E 

F l - OJ 

) o 

z c 

E O , 

- + 

d . ; 

7 ! . 

- f 

+ - \ 

L - i 

O / = 

o 0 , 

o - Y 

O r . 

-c 

+ - = 

O 

l 

r ! 

o 

d 

n 

! 

0, 

+ 

L 

d 

Oo 

c 

u ' - 

L 

t o r 

-c 

c + '6 

.9 

o - 6 

T O 

+r 

q d 

. X 

E O J 

! r - 

a 

- = F 

6 A 

* s 

-.; 

-q 

_ c ( ) 'OJ 

t- 

o 

U 

CHANNELS SUPPORTED BY 

-TTOOKrBEXN 

INSERT PLATE PROVIDED 

FOR FIXING OF MAIN 

SUPPORT CHANNEL 

NOTE: 

MAIN SUPPORT 

SUPPORTED BY 

BRACKET-WELDED 

1) UP TO 31TER-C1 CHANNEL 

ABOVE 3 TIER_Cz CEANNEL. 

2) ArL DIMENSIONS ARE IN MM. ARRANGEMENT TYPE_S3 

ARRANGEMENT TYPE-S4 

FT]R TENDER PURPESE 

-I 

A 

T* 

I 

T 




STANDARD 

STANDARD CABTE SUPPORT 

ASSEMBLY 

0000-211 -PEE-A-035 

TRAYSUPz-A11-035

FrxrNG As pER AcruAL _l 

I I 

-T--- ' 

woRKrNG UDL = r0o KG 

I | 



| | | lir PRooFuoL =200KG 

ll I lil 

PoTNTLoAD =r00KG 

lf I--*]lt-_-3in*"r*' 

/l /rl1 r 

l /1 ^l! , 

l.t Hi 

l E / , / l l 

l /Hj 

l l l l , 

l / i l I l i 

I LI ,,,W 

I 

I 

r 

I 

or 

----*- 

--'xrNc As PER AcruAL 

.DEFLEC19N 

MEASURTNG potNTS. SnE TNSTALLAilON 

( cANTtLEvER 

ARMS 

ON ONE S|DE) 

N OTIS 

ALL DIMENSIONS 

ARE IN MM 

(scALE-NTS) 

NDlnoN. 

'IIFORMLY 

DISTRIBUTED 

)AD TO ARMS 

XING AS PER 

]ruAL 

T LOAD 

F,Bes ( TEN>|'P foAlta-rE .u i**$ A 

RA FOR IEND€R PURPOS€ OI{LY L \tz rrN 

REV 

NO. DESCRIPTION M E c&l AROr 

PROJECT 

IIILf 

A4 

5L:ALL 

NTS 

CLEARED BY 

\-TP_C Lt rrrt-ted. 

( A oo!E$0tD{I Of ND|A E|IERPRFE 

) 

Orc|NEB|ilA Di/EPII 

STANDARD 

TIPICTT, DETAIIS OF STRUCTI'RE FOR TESTING 

oo00-21 

I -POE-A-O33 

0Îr 

REV. NO. 

Rt3 

CAo nLE NAME : STAIO-2il-OJ6.OhC

-\ 

R)ONG AS PER ACTUAL 

, :;I^lItJ*Lon* woRKrNc UDL = roo KC 

I ]lr 

PRooFuoL =200K( 

U 

I 

r F 

P'Nr L'AD 

;Jno:i 

| -l / LoAos( 

LY OISTRISUTED 

)N ALL ARMS 

| @''^ ril I /l,o 

r r ! r , . 

l,"l mi[- 

| 31 6\ +z\ | 

I lur\ I | | 'c 

lT--ffiffi 

lsl T>ril?i' 

l l =',' =l I I 

rl sl T 

l.l s. 

bl lL 

I ll 

)6^' 

--_J 

xs 

r l - _ - H - 

l l f f i 

I Hl +-'-') I ri8l'"8iî 

ll@\ I ll l;e 

r fi 

t t - t - - 

I Hl "'l ll 

l g 

I sl *-J= 

| | """o1 u 

__ __) _L 

o,,o 

N OTES 

ALL DIMENSIONS 

ARE IN MM 

(scALE-NTS) 

C, \- r,o*a AS pER AcruAL 

'DEFLEcrlotl 

MEASURTNG PorNTs. 

SJFol[to*.,ono" 

R el e,s rE N D E F r,rn ruafl.lJ 

frq:6 

RA FDR TENO€R PURPOSE OI.ILY k 

REV 

NO. DESCRIPTION 

PROJECT 

srzE 

A4 NTS 

- 

ANIILEV€R ARMS 

POINT 

OO KG. 

), A' -|r K,r-A\ 

v l E c&l MGi 

CLEARED BT 


. 

( A CO\TIRNMENT oF |ND(A E]nERpRtS€ ) 

ENGINEERING DIIiFION 

STANDARD 

TYPICAL DETA.U.S OF STRUCTURE FOR TESTING 

rr:PO 0^rI 

DRG. No' tEV. 

oooo-z1r-poE-A-03? 

NO. 

Rg 

CAO RtE NA.E : 5TAN0-2!l-OJ7.OVG

NOIIS 

Tt 

^ 

l q 

lgl ^*--F 

l # 

I urr 

- 

lM 

:l sl 

| : l 

I el 

lM 

.HANNEL i- 

SECTION 

TESI 28 MAIN SUPPI )RT CHANNEL 

hr-t-- 

BEAM cLAMPSI | | 

AsAcruAL \ I I 

\l------a-r- 

.*o**.,--/ 

+-- 

--f- 

i si ',l- 

l:!___- b{ 

-_i- 

lsl 

lHl I 

- l[-TK

IISTS 5A 1 

FIXING TO THE W,qr I nc ^-^ 

3S,B lr,"il " l" d 

BOL I IOROUE 

J0 Nm IESI 5A1 

50 Nm TEST 5A2 

65 Nm IEST 5A3 

NOIIS 

ARE IN MM 

f:^?[',i"Ji*' 

ili'. fn'o,[. " 

TEST 4 CHANNIL INSERT 

'l--i^ 

rL)t5 5A 

LOAD APPLICANON 

POSITIONS 

TESTS 

j::.Y,*.^Y-sNG Mr2,zs ii,3"c 

58 

;i. .f,l 

"i:i'ffi ,.ff.f gii[.$' ;-, 

FDf, rtNOER PUftPOStr ONLY 

. 

woRKtNc UDL = loo KG 

UNIFORMLy PROOF 

DiSm UDL = 2Oo KG 

!9A9 faioo'xc PorNT LoAD = roo-rc" 

ON EACH ARM 

CANTILI\IR ARUS 

3i,''3Ii:i?i' 

BRACKE T 

BOLT TORQJ:S 

J0 N.i T:Si 5Bi 

50 Nm TaS; 582 

65 Nm TfSr Se: 

CHANNSL SI 

& 58 1,2,3 CHANNEL NUT SLIP CHARACIf RISTIC 

B ! t:of f€ NDE 

I ytvp/c,s 

r! 

\-TPc 

r r ccr*ru*niixrarft*#F 

i. 

- 

TYPTCAT DETAIIS OF STRUCTURE FOR TESTING 

il.:-]-x^- 

o000-2r I _POE_A_039 

cô nLr xose , sT^n-:;oss.o,.c

NOTE : 

FRONT VIEW WITH COVER REMOVED 

1. ALL DIMENSIONS ARErN MM (SCALE NTS) 

i\-:fP C I-irrrite d. 

( A covERNMENT OF |NDA ENTERPRTSE ) 

STANDARD 

GASKET 

TYPICAL DRAWING FOR JUNCTION BOX 

0000-21 1 -POE-A-040 

CAD RLE NAME : STAN0-211-0.O dwg

NGR 

MOUNTING 

STRUCTURE 

'CU' FLAT 

BUSFIINGS THRO CABLE 

OR 8US DUCT TO SWGR 

. TARTHING 

TERMINAL OF 

RADIATINC TANK 

GRADI L[\TL 

EARTH elecrnoor 

(To EA[*,". 

BE coNNEcrED To TARTH GRID) 

L 1..rrRsHnLLlNG Box 

N_oIES 

NEUTRAL 

GROUNDING 

RfSISTOR 

EARTHTNG 

DETATLS 

TRANSFORMIR 

'< 1. THE TRANSFORMIR NEUTRAL FOR H.T. TRANSFORMER SHALL BE EARTHID THROUGH 

FLATS AS SHOW! ABOVE. (SUPPLIID BY TRANSFORMIR SUPPLIIR) 

,-b coA T€NDI;R fuA.fasE 

ir( pq i 

a" -M 

RA FOR TEND€R PURPOSE ONLY k W ( 

REV 

NO. OESCRIPTION crro 

PROJECT 

TITLE 

: 

SIZE 

A4 

I 

i 

! 

rANK BOOY 

I 

sCALE 

NTS 

I 

I 

t- t>= 

M E c lc&l AnGt pPo o{lI 

CLEARED BY 

.I\T:fPC Lirrrited 

( A GovE$luBr of iluA EfiEpRFE ) 

orcNERDto DtvErril , 

. STANDARD 

EARTHING DETAIIS 

ORG. NO. iEV. NO, 

o000-21 t-PoE-A-045 

Rg 

CID Fltf t{/{u€ : STANO-at-O45.0tyG

. 

TYP. VEFLON TUEINIC 

(IO BE SEALED AFIER 

INSIALLANON OF 

coNDUcroR) 

LIGHTNING PROIECNON DOWN_COMER 

VANISEO 

8OX 2MM THK. SHEET STEEL 

27x8 OPININC 

4.60 HoLES I 

FOR WALL/COL./ 

STRUCTURE 

MOUNTING 

6O HOLES FOR 

FIXING CO\ER 

FRONT V|EW (COVER PLATE REMOVED) 

I t 

_L-r r _o 

e (rYP) 

ol (TYP) 

LIGH TING PROTECTION DOWNCOMER TEST LINK [AI#,T8"JIl'i.,, 

CONNECTED TO EARTHING 

NOTES: - cRrD) 

1. THE DOWN COMER INTRY AND EXIT POINTS IN TO BOX BE MADE 

WATER_TIGHT AFTER LAYING OF CONDUCTOR. 

2. THE TEST LINK SHALL BE OF SAME WDTH AND THICKNESS AS 

THE DOWNCOMER.THE NUTS BOLTS AND WASHERS TO BE OF G.S. 

J. ALL DTMENSTONS ARE lN MM (SCAL[-NTS) 

FOR TENOER PURPOSE ONLY 

lo0 

NTTP C I-J.rn ite d. 

( A GO\rEnNUOfr 0F $tDtA E{IERPRISE ) 

RSNEIRDb DIVISION 

UGETNING PROTq,CTION DETAIIS. 

CAD FILE HAUE : Sl/'l{o-2rt-047.O!tG 

4 

f)

o 

2 MM G.I. STRIP 

BLOCK SPACING 1OOOMM 

CENTRE TO CTNTRE 

TYPICAL DfTAILS OI 

CLIATING HORIZONTAL 

CONDUCTOR OVER 

WATER PROOFING 

NOTE : ALL DIMENSIONS ARE lN MM 

fB rop TEHDE& la?/a.{ 

25x6 MM G.l. FLAT 

r- MO G.l. 

PRECAST CONCRETE 1:2:a 

FINISHED SMOOTH 

BLOCK SIZE 12Ox120x50 

CEMENT MORTAR BEDDING 

(1:6) 

pa w $ v l. I' 

d( 

RA FOR ITNO€R P1JRPOS€ ONLY I Wl^ V M, \N 

RLTV 

NO. 

OESCRIPTION 

(CEmffil 

L_ryre_gJ 

PROJECT 

TTTLE 

5U.L 

A4 

5(ALL 

NTS 

M I E 

CLEARED BY 

c&l mcil 

\TTP C I-irrrite c'r 

( A GOVERNMENI OF INu^ ENTERPRTSE 

) 

ENGINEERING DIVSON 

STANDARD 

UGETNING PROTECTION DETNIS 

DRG, NO. 

0000-2r 1-PoE-A-048 

D{l€ 

CTD FTLE NAME : STA}ID_21T-0.+A.DY.G 

) 

c 

. o 

- A l 

.. u 

Y U 

L O 

.. L 

; a 

c o 

c ^, 

ci .9 

.r 

F ; 

{ c 

u. ;, 

x 

x P c 

e . 9 

( L { 

a h 

= . : 

I C 

0/ 

J O 

O or, 

z L t 

o : 

> . 9 

L t 

o : 

oo 

o 

-c 

o ; 

t . 

O L 

L O 

? 

U L 

o o - 

u ' - 

L 

I f u 

C f 

0 ' E 

n 0 

O , 6 

'11 a 

c , 

o) 

, . 

6 A 

- L 6 

.t4 d 

- c 0 

F ' O 

o 

U 

DETAIL_'A' 

EARIH BACK FII I FD 

AND RAMMED 

PRECAST CONCRTTE 

cov€R i50x250x4MM 

CABLS 

so!t_ 

FaPTaNIER filtUse 

FOR TENDER PURPOSE 

6;EFI 

t-^rtr"_J 

PROJECT 

NOTES: 

RCUTT i'"4ARKtR 

1. ALL DIM5NSICNS ARt IN MM. 

2 ROUTE MARKERS SHALL 8E CONSTRUCTED 

OF CCNCRI-TE WITH CAST IRON PtATf, 

WITH THE ROUTE INFORMATION ENGRAVED 

ON IT. BOLTED ON TOP OF THE CONCR$E 

ELOCK AS SHOWN. 

J. CAST IRON PLATE SHAL 8E OF 6.0 MM 

THICKNiSS 

NTTPC I-irrrited- 

( A covR{llE{r oF nEA INIERPfiUSE ) 

oFNEEnMi Dfvlsloil 

STANDARD 

ilrLE 

BURTED cABLE TRENcH DETAILs FoR LIGHT'NG 

0000-21 1 -POE-A-049 

21 1-O49.DWG

i\ 

o/ 1 1 

A A I 

I 

I 

A 

_&_s>t+_-.1.__ 

lllllllllll, 

11 rr r'r ll 

) 

'l I 

|r) 

'soll s llsllsll s lslrso 

117-1 f----f f--_l-T r)" 

W TO SUIT NO OF CABLES 

DIRECTLY BURIED CABLTS 

IN SINGLE LAYTR 

LEGEND 

O- 

@- 

A 

ty- 

CABLE ROUIE MARKER 

EARTH BACK FILLED & RAMMED 

PROTECI!€ COVERS 

o) BRICKS FOR LOw 

VOLTAGE CABLES 

b) Rcc FoR H|GH VOLTAGE 

CneLtS 

WTH HOLE AT EACH END TO TIE 

THE IO EACH OTHER WITH G.S. WIRE 

@- ARMOURED PowER CABLE 

(D-- ARMoURED 

coNTRoL CABLE 

@- 

NOTE 

F|NE SAND/R|DDLED 

SO|L COMPACTED 

ol lil 

8l /i\ 

t / | 

I LIJ 

A A l . l . , l 

I t i l 1 

-Y- - l-- Y -r -l 

-+--+,t-+---l 

r r i 

l l t 

ol 

ol 

.nl 

;f 6l 

DIRTCTLY BURITD CABLES 

IN TWO LAYIR 

DIMENSION 

MIN. 

IlOOV CRAD€ FOR 3.J KV22KV 

& 33KV 

CABLES llKv 

r0 

D1 750 900 1050 

d BETWEEN CABLES OF SAME CLASS 

XSOOMM BETWEEN CABLES OF OEFT CLASS 

(40oMM BETWEEN t/C POWER CAELE AND 

COMMUNICATION CA8LE. 

(3OQMM BETWEEN MULTICORE POWER 

CABLE & COMMUNICATION CABLE. 

d - OVERALL OIAME1ER OF THE BIGGER OF THE TWO CABLES 

X - SPAONG SHALL BE TAKEN EOTH HORIZONTALIY AND 

\€RTICALLY. 

I. SINGLE CORE CABLES SHALL BE RUN IN TREFOIL FORMATION AND SHALL BE BOUND BY 

SELFLOCKING CABLE NES AT E\ERY 75O MM 

2. CABLE IDENTIFTCATION TAG SHALL BE NED AT BOTH ENDS OF THE CABLE AND ALSO AT AN 

INTERVAL OF IO METRES. 

3. IF THE MINIMUM CLEARENCE AS INDICATED THE ABO!€ TABLE FOR CABLES OF DIFFER€NT 

CLASSES ARE NOT FEASIBLE,BRICK BARRIERS SHALL BE USED BETMEN ADJACENT CABLES. 

4. G.I. PIPE SHALL BE PRO\4DED FOR ROAD CROSSING AT A MINIMUM DEPTH 

OF 600 FROM THE GRADE LE\€L UNLESS OTHER WSE SPECTFIED. 

5. ALL DTMENSTONS ARE tN MM (SCALE NTS) 

KsFcA rer,tOEP Pt,RlasE 

tv'v6$ \-,^ 

) l 

RA FOR IEND€R PURPOS€ ONLY u- h le 

REV 

NO. OESCRIPTION oc(D 

PROJECT 

TITLE 

srzE 

A4 

SCAI.E 

NTS 

, 

l/ 

tl 'ir 

- IVL 

I F Kl .\' 

M E C lC&l lrncrt 

CLEARED BT 

NTTP C I-irrrite

PART - B 


CABLING, EARTHING & LIGHTNING 

PROTECTION 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


CABLING, EARTHING & LIGHTNING PROTECTION 



of opening of bid. In case of conflict between this specification and those (IS codes, 

standards, etc.) referred to herein, the former shall prevail. All work shall be carried 

out as per the following standards/ codes as applicable. 

IS:513 Cold rolled low carbon steel sheets and strips. 

IS:802 Code of practice for the use of Structural Steel in Overhead 

Transmission Line Towers. 

IS:1079 Hot Rolled carbon steel sheet & strips 

IS:1239 Mild steel tubes, tubular and other wrought steel fittings 

IS:1255 Code of practice for installation and maintenance of power 

cables upto and including 33 KV rating 

IS:1367 Part-13 Technical supply conditions for threaded Steel fasteners. (Hot 

dip galvanized coatings on threaded fasteners). 

IS:13947 Degree of protection provided by enclosures for low voltage 

switchgear and control gear 

IS:2309 Code of Practice for the protection of building and allied 

structures against lightning. 

IS:2629 Recommended practice for hot dip galvanising of iron & steel 

IS:2633 Method for testing uniformity of coating on zinc coated articles. 

IS:3043 Code of practice for Earthing 

IS:3063 Fasteners single coil rectangular section spring washers. 

IS:6745 Methods for determination of mass of zinc coating on zinc 

coated iron & steel articles. 

IS:8308 Compression type tubular inline connectors for aluminium 

conductors of insulated cables 

IS:8309 Compression type tubular terminal ends for aluminium 

conductors of insulated cables. 

IS:9537 Conduits for electrical installation. 

IS:9595 Metal – arc welding of carbon and carbon manganese steels - 

recommendations. 


SECTION-VI 

PART-B 


CABLING, EARTHING & 

LIGHTNING 

PROTECTION 

PAGE 

1 OF 18

CLAUSE NO. 




PLANT PACKAGE 


IS:13573 Joints and terminations for polymeric cables for working 

voltages from 6.6kv upto and including 33kv performance 

requirements and type tests. 

BS:476 Fire tests on building materials and structures 

IEEE:80 IEEE guide for safety in AC substation grounding 

IEEE:142 Grounding of Industrial & commercial power systems 

DIN 46267 

(Part-II) 

Non tension proof compression joints for Aluminium conductors. 

DIN 46329 Cable lugs for compression connections, ring type ,for 

Aluminium conductors 

VDE 0278 Tests on cable terminations and straight through joints 

BS:6121 Specification for mechanical Cable glands for elastomers and 

plastic insulated cables. 

Indian Electricity Act. 

Indian Electricity Rules. 

1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, 

DIN, USA, VDE etc. will also be considered if they ensure performance and 

constructional features equivalent or superior to standards listed above. In such a 

case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in 

English of the latest revision of the standards alongwith copies of all official 

amendments and revisions in force as on date of opening of bid and shall clearly 

bring out the salient features for comparison. 

2.00.00 DESIGN AND CONSTRUCTIONAL FEATURE 

2.01.00 Transformer yard and Switchyard 

2.01.01 In transformer yard and switchyard area, cables shall be laid in RCC concrete 

trenches with RCC covers. Inter-pole cabling in switchyard shall be in GI 

conduits/shallow trenches. Minimum clear height of trestle shall be 3mtr and for 

Rail/road crossing it shall be as per rail/road crossing norms. 

2.01.02 False floors are not to be provided for cabling purpose. 

2.01.03 Cable entry 

2.01.04 Trenches 

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. 

PCC flooring of built up trenches shall be sloped for effective drainage with sump 

pits and sump pumps. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

2 OF 18

CLAUSE NO. 




PLANT PACKAGE 


2.01.05 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. 

2.01.06 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/perforated type as specified complete with matching 

fittings (like brackets, elbows, bends, reducers, tees, crosses, etc.) accessories (like 

side coupler plates, etc. and hardware (like bolts, nuts, washers, G.I. strap, hook 

etc.) as required. 

3.01.02 Cable trays, fittings and accessories shall be fabricated out of rolled mild steel 

sheets free from flaws such as laminations, rolling marks, pitting etc. These 

(including hardware) shall be hot dip galvanized as per relevant IS. Cable trays shall 

be ladder type for power/control cables and shall be perforated type for 

instrumentation cables. 

3.01.03 Cable trays shall have standard width of 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. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

3 OF 18

CLAUSE NO. 




PLANT PACKAGE 


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 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

4 OF 18

CLAUSE NO. 




PLANT PACKAGE 


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.. 

3.04.02 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. 

3.05.00 Terminations & Straight Through Joints 

3.05.01 Termination and jointing kits for 33kV, 11 kV and 3.3 kV grade XLPE insulated 

cables shall be of proven design and make which have already been extensively 

used and type tested. Termination kits and jointing kits shall be pre-moulded type, 

taped type or heat shrinkable type. 33kV and 11 kV grade joints and terminations 

shall be type tested as per IS: 13573. 3.3 kV grade joints and terminations shall be 

type tested as per VDE 0278. Critical components used in cable accessories shall 

be of tested and proven quality as per relevant product specification/ESI 

specification. Kit contents shall be supplied from the same source as were used for 

type testing. The kit shall be complete with the aluminium solderless crimping type 

cable lugs & ferrule as per DIN standard. 

3.05.02 Straight through joint and termination shall be capable of withstanding the fault level 

of 40 kA for 0.12 sec with a dynamic peak of 100 kA for 11 kV system and 25 kA for 

1 sec with a dynamic peak of 62.5 kA for 3.3 kV system. Straight through joints shall 

have provisions for shield connection and earthing wherever required and complete 

with all accessories and consumables suitable for storage without deterioration at a 

temperature of 50 deg. C with shelf life of more than five years. 1.1 kV grade 

straight through joints shall also be of proven design. 

3.05.03 1.1 KV grade STJ shall be of proven design. 

3.05.04 Motor terminal boxes should of sufficient size to accommodate the selected cables. 

In case the cable sizes can not be accommodated, power Junction boxes shall be 

provided with cable interconnection between Junction boxes and motor terminal box. 

3.06.00 Cable glands 

3.06.01 Cable shall be terminated using double compression type cable glands. Cable 

glands shall conform to BS:6121 and be of robust construction capable of clamping 

cable and cable armour firmly without injury to insulation. Cable glands shall be 

made of heavy duty brass machine finished and nickel chrome plated. Thickness of 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

5 OF 18

CLAUSE NO. 




PLANT PACKAGE 


plating shall not be less than 10 micron. All washers and hardware shall also be 

made of brass with nickel chrome plating Rubber components shall be of neoprene 

and of tested quality. 

3.06.02 Cable lugs/ferrules 

3.06.03 Cable lugs for power cables shall be tinned copper solderless crimping type 

conforming to IS: 8309 suitable for aluminium compacted conductor cables. Cable 

lugs and ferrules for control cables shall be tinned copper conforming to IS:8309 . 

The cable lugs for control cables shall be provided with insulating sleeve and shall 

suit the type of terminals provided on the equipments. 

3.07.00 Trefoil clamps 

3.07.01 Trefoil clamps for single core cables shall be pressure die cast aluminum or fiber 

glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts, 

washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand 

the forces generated by the system short circuit current of 105 KA peak. 

3.08.00 Cable Clamps & Straps 

3.08.01 The cable clamps required to clamp multicore cables on vertical run shall be made 

up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, selflocking, 

de-interlocking type nylon clamps/straps shall be used. The clamps/straps 

shall have sufficient strength and shall not get affected by direct exposure to sun 

rays and outdoor environment 

3.09.00 Receptacles 

3.09.01 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot 

dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm. 

The boxes shall be provided with two nos. earthing terminals, gasket to achieve IP55 

degree of protection, terminal blocks for loop-in loop-out for cable of specified sizes, 

mounting brackets suitable for surface mounting on wall/column/structure, gland 

plate etc. The ON-OFF switch shall be rotary type heavy duty double break, AC23 

category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast 

Aluminium. Socket shall be provided with lid safety cover. Robust mechanical 

interlock shall be provided such that the switch can be put ON only when the plug is 

fully engaged and plug can be withdrawn only when the switch is in OFF position. 

Also cover can be opened only when the switch is in OFF position. Wiring shall be 

carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of 

adequate size. The Terminal blocks shall be of 750 V grade 

3.09.02 TPN 63A welding sockets with switch having degree of protection of IP-55 shall 

be provided in the following areas. 

1) 1 no. in each Switchgear/MCC rooms and Pump house. 

2) Maximum three (3) nos. of receptacles can be connected to one circuit. 

These receptacles shall be energised from MCC. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

6 OF 18

CLAUSE NO. 

3.10.00 Galvanising 




PLANT PACKAGE 


3.10.01 Galvanising of steel components and accessories shall conform to IS:2629, IS:2633 

& IS 4759. Additionally galvanising shall be uniform, clean smooth, continuous and 

free from acid spots 

3.10.02 The amount of zinc deposit over threaded portion of bolts, nuts, screws and washers 

shall be as per IS:1367. The removal of extra zinc on threaded portion of 

components shall be carefully done to ensure that the threads shall have the 

required zinc coating on them as specified. However nuts and bolts of size lesser 

than M12 can be electro galvanised / electro plated. 

3.11.00 Welding 

3.11.01 The welding shall be carried out in accordance with IS: 9595. All welding procedures 

and welders qualification shall also be followed strictly in line with IS:9595 

3.12.00 EXPANSION FASTNER 

3.12.01 Expansion Fastener shall be 'HILTI' make HSA-KA type or equivalent. Expansion 

fastener shall only be used wherever insert plates are not available for supporting 

the cable structure. 

4.00.00 INSTALLATION 

4.01.00 Cable tray and Support System Installation 

4.01.01 Cables shall run in cable trays mounted horizontally or vertically on cable tray 

support system which in turn shall be supported from floor, ceiling, overhead 

structures, trestles, pipe racks, trenches or other building structures. All cable trays 

shall be in vertical configuration in boiler, CHP & ESP areas. 

4.01.02 Horizontally running cable trays shall be clamped by bolting to cantilever arms at an 

interval of 2000 mm. Vertically running cable trays shall be bolted to main support 

channel by suitable bracket/clamps on both top and bottom side rails at an interval of 

2000 mm. For vertical cable risers/shafts cable trays shall be supported at an 

interval of 1000mm. Fixing of cable trays to cantilever arms or main support channel 

by welding shall not be accepted. Cable tray installation shall generally be carried 

out as per the enclosed drawings. 

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 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

7 OF 18

CLAUSE NO. 




PLANT PACKAGE 


accessories may not be suitable. In such cases the Contractor shall fabricate at site 

suitable sections of trays, supports and accessories to make the installation 

complete for the specific purpose after obtaining Project Manager's prior approval, 

which shall be neat in appearance and shall match with the prefabricated sections in 

the dimensions. They shall be applied with one coat of red lead primer, one coat of 

oil primer followed by two finishing coats of aluminium paint. 

4.02.00 Conduits/Pipes/Ducts Installation 

The Contractor shall be fully responsible for properly embedding conduit pipe 

sleeves wherever necessary for cabling work. All openings in the floor/roof/wall / 

cable tunnel/cable trenches made for conduit installation shall be sealed and made 

water proof by the Contractor. 

4.02.01 GI pull wire of adequate size shall be laid in all conduits before installation. Metallic 

conduit runs at termination shall have two lock nuts wherever required for junction 

boxes etc. 

4.02.02 Conduit runs/sleeves shall be provided with PVC bushings having round edge at 

each end. All conduits/pipes shall have their ends closed by caps until cables are 

pulled. After cables are pulled, the ends of conduits/pipes shall be sealed with Glass 

wool/Cement Mortar/Putty to prevent entrance of moisture and foreign material 

4.02.03 Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by 

other approved means. Conduits /pipe support shall be installed square and true to 

line and grade with an average spacing between the supports as given below, 

Conduit /pipe size (dia). Spacing 

Upto 40 mm 1 M 

50 mm 2.0 M 

65-85 mm 2.5 M 

100 mm 3.0 M 

4.02.04 For bending of conduits, bending machine shall be arranged at site by the contractor 

to facilitate cold bending. The bends formed shall be smooth. 

4.03.00 Junction Boxes Installation 

4.03.01 Junction boxes shall be mounted at a height of 1200mm above floor level or as 

specified in the drawings or as decided by Project Manager and shall be adequately 

supported/mounted on masonry wall by means of anchor fasteners/ expandable 

bolts or shall be mounted on an angle, plate or other structural supports fixed to 

floor, wall, ceiling or equipment 

4.03.02 Cable Installation (for cables upto & including 33kV grade) 

4.03.03 Cable installation shall be carried out as per IS:1255 and other applicable standards. 

Cable drums shall be unloaded, handled and stored in an approved manner on hard 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

8 OF 18

CLAUSE NO. 




PLANT PACKAGE 


and well drained surface so that they may not sink. In no case shall be drum be 

stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as 

possible. For short distances, the drums may be rolled provided they are rolled 

slowly and in proper direction as marked on the drum. In absence of any indication, 

the drums may be rolled in the same direction as it was rolled during taking up the 

cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on 

cable wheels and shall be rolled slowly so that cable comes out over the drum and 

not from below. All possible care shall be taken during unreeling and laying to avoid 

damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed 

plastic caps to prevent damage and ingress of moisture. 

4.03.04 While laying cable, ground rollers shall be used at every 2 mtr interval to avoid cable 

touching ground. The cables shall be pushed over the rollers by a gang of people 

positioned in between the rollers. Cables shall not be pulled from the end without 

having intermediate pushing arrangements. Pulling tension shall not exceed the 

values recommended by cable manufacturer. Selection of cable drums for each run 

shall be so planned so as to avoid using straight through joints. Care should be 

taken while laying the cables so as to avoid damage to cables. If any particular cable 

is damaged, the same shall be repaired or changed to the satisfaction of Project 

Manager. 

4.03.05 Cables shall be laid on cable trays strictly in line with cable schedule furnished. 

Where specific cable layouts are not shown on drawings, Contractor shall route 

these as directed by the Project Manager 

4.03.06 Power and control cables shall be laid on separate tiers. The laying of different 

voltage grade cables shall be on different tiers according to the voltage grade of the 

cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and cables 

of subsequent lower voltage grades on lower tiers of trays. Single core cable in 

trefoil formation shall be laid with a distance of four times the diameter of cable 

between trefoil center lines and clamped at every 2mtr. All multicore cables shall be 

laid in touching formation. Power and control cables shall be secured fixed to 

trays/support with self locking type nylon cable straps with de-interlocking facilities. 

For horizontal trays arrangements, multicore power cables and control cables shall 

be secured at every five meter interval. For vertical tray arrangement, individual 

multicore power cables and control cables shall be secured at every one meter by 

nylon cable strap. After completion of cable laying work in the particular vertical tray, 

all the control cables shall be binded to trays/supports by aluminium strips at every 

five meter interval and at every bend. 

4.03.07 Bending radii for cables shall be as per manufacturer’s recommendations and 

IS:1255. 

4.03.08 Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC 

pipe. 

4.03.09 In each cable run some extra length shall be kept at suitable point to enable one 

LT/two HT straight through joints to made, should the cable develop fault at a later 

stage. Control cable termination inside equipment enclosure shall have sufficient 

lengths so that shifting of termination in terminal blocks can be done without 

requiring any splicing. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

9 OF 18

CLAUSE NO. 




PLANT PACKAGE 


4.03.10 Wherever few cables are branching out from main trunk route troughs shall be used. 

4.03.11 The installation work shall be carried out in a neat workman like manner & areas of 

work shall be cleaned of all scraps, water, etc. after the completion of work in each 

area every day. Contractor shall replace RCC/Steel trench covers after the 

Installation work in that particular area is completed or when further work is not likely 

to be taken up for some time. 

4.03.12 Separation 

4.03.13 Segregation 

In vertically stacked trays, at least 300mm clearance shall be provided between : 

- HT power & LT power cables, 

- LT power & LT control cables 

1) Segregation means physical isolation to prevent fire jumping. 

2) All the cables of one stream shall be segregated from the cables of the other 

stream and shall run on either side of the trestle. 

4.03.14 All field switches for equipments corresponding to a stream located within a radius of 

4-5 mtr. shall be wired out to a field junction box and from field junction box to 

control panel/Input – Output cabinet by screened instrumentation cables. 

4.03.15 Directly Buried Cables 

a) Cable trenches shall be constructed for directly buried cables. Construction 

of cable trench for cables shall include excavation, preparation of sieved 

sand bedding, riddled soil cover, supply and installation of brick or concrete 

protective covers, back filling and compacting, supply and installation of route 

markers and joint markers. Laying of cables and providing protective 

covering shall be as per IS:1255 and the enclosed drawings showing cabling 

details. 

b) RCC cable route and RCC joint markers shall be provided wherever 

required. The voltage grade of the higher voltage cables in route shall be 

engraved on the marker. Location of underground cable joints shall be 

indicated with cable marker with an additional inscription “Cable Joint”. The 

marker shall project 150 mm above ground and shall be spaced at an interval 

of 30 meters and at every change in direction. They shall be located on both 

sides of road crossings and drain crossings. Top of cable marker/joint marker 

shall be sloped to avoid accumulation of water/dust on marker. 

4.03.16 Cable tags shall be provided on all cables at each end (just before entering the 

equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit 

entry, and at every 20 meters in cable tray/trench runs. Cable tags shall also be 

provided inside the switchgear, motor control centers, control and relay panels etc. 

where a number of cables enter together through a gland plate. Cable tag shall be of 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

10 OF 18

CLAUSE NO. 




PLANT PACKAGE 


rectangular shape for power cables and control cables. Cable tag shall be of 2 mm 

thick aluminum with number punched on it and securely attached to the cable by not 

less than two turns of 20 SWG GI wire conforming to IS:280. Alternatively, the 

Contractor may also provide cable tags made of nylon, cable marking ties of ‘TY- 

CAB’ or equivalent type with cable number heat stamped on the cable tags 

4.03.17 While crossing the floors, unarmoured cables shall be protected in conduits upto a 

height of 500 mm from floor level if not laid in tray. 

4.04.00 Cable Terminations & Connections 

4.04.01 The termination and connection of cables shall be done strictly in accordance with 

cable termination kit manufacturer’’ instructions, drawings and/or as directed by 

Project Manager. Cable jointer shall be qualified to carryout satisfactory cable 

jointing/termination. Contractor shall furnish for review documentary 

evidence/experience reports of the jointers to be deployed at site. 

4.04.02 Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing, 

soldering, drilling, cutting, taping, preparation of cable end, crimping of lug, insulated 

sleeving over control cable lugs, heat shrinking (where applicable), connecting to 

cable terminal, shorting and grounding as required to complete the job to the 

satisfaction of the Project Manager. 

4.04.03 The equipment will be generally provided with undrilled gland plates for 

cables/conduit entry. The Contractor shall be responsible for punching of gland 

plates, painting and touching up. Holes shall not be made by gas cutting. The holes 

shall be true in shape. All cable entry points shall be sealed and made vermin and 

dust proof. Unused openings shall be effectively sealed by 2mm thick aluminium 

sheets. 

4.04.04 Control cable cores entering control panel/switchgear/MCC/miscellaneous panels 

shall be neatly bunched, clamped and tied with self locking type nylon cable ties with 

de interlocking facility to keep them in position. 

4.04.05 The panels where a larger number of cables are to be terminated and cable 

identification may be difficult, each core ferrule shall include the complete cable 

number as per the drawings. The ferrules shall be indelible interlocking type and 

shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix letter 

‘S’ alongwith cable numbers and coiled up after end sealing. 

4.04.06 All cable terminations shall be appropriately tightened to ensure secure and reliable 

connections. 

4.04.07 It is the responsibility of the Contractor to terminate the cables at motor terminals in 

correct phase sequence to ensure the proper direction of rotation. 

5.00.00 EARTHING SYSTEM 

5.01.00 Earthing system shall be in strict accordance with IS: 3043 and Indian Electricity 

Rules/Acts. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

11 OF 18

CLAUSE NO. 




PLANT PACKAGE 


All buildings / structures shall be interconnected together by min. two parallel 

conductors. Contractor shall furnish the detailed design calculations for the earthing 

system. Contractor shall obtain all necessary approvals for the system. 

5.02.00 The earth conductors shall be free from pitting, laminations, rust, scale and other 

electrical, mechanical defects 

5.03.00 The material of the earthing conductors shall be as follows : 

1) Conductors above ground level and in built up 

trenches. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

- Galvanized steel 

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 conductor 

buried in earth 

Earth conductor 

above ground level 

& in built-up 

trenches 

a) Main earth grid 40 mm dia.MS rod 65x8mm GS flat 

b) 33KV/11KV 

switchgear/equipment 415V 

switchgear 

c) 3.3 kV switchgear / 415 V 

MCC/ Distribution boards / 

Transformers 

--- 65x8mm GS flat 


d) LT Motors above 125 KW --- 50 x 6mm GS flat 

25 KW to 125 KW --- 25 x 6mm GS flat 

1KW to 25 KW --- 25 x 3mm GS flat 

Fractional House power motor --- 8 SWG GS wire 

e) Control panel & control desk --- 25 x 3 mm GS flat 

f) Push button station / Junction 

Box 

g) Columns, structures, cable 

trays and busduct enclosures 

--- 8 SWG GI wire 


PAGE 

12 OF 18

CLAUSE NO. 




PLANT PACKAGE 


h) Crane, rails, rail tracks & other 

non-current carrying metal 

parts 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

25x6mm GS flat 

5.05.00 Metallic frame of all electrical equipment shall be earthed by two separate and 

distinct connections to earthing system, each of 100% capacity, Crane rails, tracks, 

metal pipes and conduits shall also be effectively earthed at two points. Steel RCC 

columns, metallic stairs, and rails etc. of the building housing electrical equipment 

shall be connected to the nearby earthing grid conductor by one earthing ensured by 

bonding the different sections of hand rails and metallic stairs. Metallic 

sheaths/screens, and armour of multi-core cables shall be earthed at both ends. 

Metallic Sheaths and armour of single core cables shall be earthed at switchgear 

end only unless otherwise instructed by the Employer. Every alternate post of the 

switchyard fence shall be connected to earthing grid by one GS flat and gates by 

flexible lead to the earthed post. Railway tracks within the plant area shall be bonded 

across fish plates and connected to earthing grid at 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. 

PAGE 

13 OF 18

CLAUSE NO. 




PLANT PACKAGE 


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 

6.01.01 Lightning protection system shall be in strict accordance with IS:2309 

6.01.02 Lightning conductor shall be of 25x6mm GS strip when used above ground level and 

shall be connected through test link with earth electrode/earthing system 

6.01.03 Lightning system shall comprise of air terminations, down conductors, test links, 

earth electrode etc. as per approved drawings 

6.02.00 Down Conductors 

1. Down conductors shall be as short and straight as practicable and shall 

follow a direct path to earth electrode. 

2. Each down conductor shall be provided with a test link at 1000 mm above 

ground level for testing but it shall be in accessible to interference. No 

connections other than the one direct to an earth electrode shall be made 

below a test point. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

14 OF 18

CLAUSE NO. 




PLANT PACKAGE 


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 

8.01.01 All equipment to be supplied shall be of type tested design. The contractor shall 

submit for Owner's approval the reports of all the type tests as listed in this 

specification and carried out within last ten years from the date of bid opening. 

These reports should be for the test conducted on the equipment similar to those 

proposed to be supplied under this contract and the test(s) should have been either 

conducted at an independent laboratory or should have been witnessed by a client. 

8.01.02 In case the contractor is not able to submit report of the type test(s) conducted within 

last ten years from the date of bid opening, or in the case of type test report(s) are 

not found to be meeting the specification requirements, the contractor shall conduct 

all such tests under this contract at no additional cost to the owner either at third 

party lab or in presence of client/owners representative and submit the reports for 

approval. 



price. 






SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

15 OF 18

CLAUSE NO. 




PLANT PACKAGE 


8.02.00 Type Test reports shall be furnished for the following 

8.02.01 Cable termination kit and straight through joints should have been tested as per IS: 

13573 for above 3.3 kV class and as per VDE 0278 for 3.3 kV class. 

8.03.00 Routine/ Acceptance Tests 

8.03.01 Routine Tests 

a) Routine tests as per specification and applicable standards shall be carried 

out on all equipments/items covered in the specification. 

b) Physical & dimensional check on all equipments as per approved 

drawings/standards. 

c) HV/IR as applicable. 

d) Check/measurement of thickness of paint/zinc coating/nickel-chrome plating 

as per specification & applicable standard. 

8.03.02 Acceptance Test 

a) Galvanising Tests as per applicable standards 

b) Welding checks 

c) Deflection tests on cable trays: 

One piece each of 2.5m length of cable tray of 300mm & above shall be 

taken as sample from each offered lot. It shall be supported at both end & 

loaded with uniform load of 76 kg/meter along the length of cable tray. The 

maximum deflection at the mid-span of each size shall not exceed 7mm. 

d) Proof load tests on cable tray support system 

i) Tests on Main Support Channel shall be done if only C1 Channel are 

in scope of supply and cantilever arms shall be fitted on one side. 

This test shall be 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. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

16 OF 18

CLAUSE NO. 

9.00.00 COMMISSIONING 




PLANT PACKAGE 


9.01.01 The Contractor shall carry out the following commissioning tests and checks after 

installation at site. In addition the Contractor shall carry out all other checks and 

tests as recommended by the Manufacturers. 

9.01.02 Cables 

a) Check for physical damage 

b) Check for insulation resistance before and after termination/jointing. 

c) HT cables shall be pressure tested (test voltage as per IS:7098) before 

commissioning. 

d) Check of continuity of all cores of the cables. 

e) Check for correctness of all connections as per relevant wiring diagrams. 

Any minor modification to the panel wiring like removing/inserting, 

shorting, change in terminal connections etc., shall be carried out by the 

Contractor at no extra cost. 

f) Check for correct polarity and phasing of cable connections. 

g) Check for proper earth connections for cable glands, cable boxes, cable 

armour, screens, etc. 

h) Check for provision of correct cable tags, core ferrules, and tightness of 

connections. 

9.02.00 Cable trays / supports and accessories 

1) Check for proper galvanizing/painting and identification number of the 

cable trays/supports and accessories. 

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. 


SECTION-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

17 OF 18

CLAUSE NO. 




PLANT PACKAGE 


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-VI 

PART-B 



LIGHTNING 

PROTECTION 

PAGE 

18 OF 18

PART - B 


TRANSFORMERS 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


TRANSFORMER 

1.01.00 Transformers IEC:60076, IEC 60354, IEC:60726 

2.00.00 TYPE 

Bushing CT’s IEC :60044-1 

Insulating oil IEC: 60296 

2.01.00 Out-door Mineral oil filled ONAN type, Three phase unit 

Transformers 

2.02.00 Dry type Epoxy cast resin/resin encapsulated air cooled 

Transformers type, Three phase unit 

3.00.00 FEATURES 

Paint shade RAL 5012 

Degree of protection : 

Dry type transformer IP-23 

Cable box, Marshalling box IP-55 


4.01.00 Out-door Winding 55 o C above ambient 50 o C 

Transformers oil 50 o c above ambient 50 o C. 

4.02.00 Dry type Winding (by resistance method) : 90 o C or lower 

Transformers as permissible for class of insulation offered, above 

ambient of 50 o C 

5.00.00 OPERATIONAL REQUIRTEMENTS 

5.01.00 Tap Changer 

Off-circuit, +/-5% in steps of 2.5% shall be provided. It shall be hand operated by an 

external handle with position markings, pad locking facility in each position and 

mechanical stops to prevent over cranking beyond extreme positions in case of 

outdoor type transformers. In case of indoor transformers, it shall be with shrouded 

bolted links. 


SECTION-VI 

PART-B 


TRANSFORMERS 

PAGE 

1 OF 6

CLAUSE NO. 

5.02.00 Loading Capability 

5.03.00 Flux Density 




PLANT PACKAGE 


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. 

Not to exceed 1.9 Wb/sq.m. at any tap position with +/-10% voltage variation from 

voltage corresponding to the tap. Transformer shall also withstand following 

overfluxing conditions due combined voltage and frequency fluctuations: 

a) 110% for continuous rating. 

b) 125% for at least one minute. 

c) 140% for at least five seconds. 

5.04.00 Noise Level :Not to exceed values specified in NEMA TR-1. 


All transformers shall be suitable for cable or bus duct termination as contemplated. 

If cable connection is envisaged, a dust tight cable box shall be provided. Also, a 

sheet steel, vermin and dust proof marshalling box shall be furnished with each 

transformer to accommodate temperature indicators, terminal blocks for control 

cables etc. The transformer shall be provided with all fittings and accessories to be 

complete in all respects for satisfactory operation. 

6.01.00 OUTDOOR TRANSFORMERS 

6.01.01 a) Tank 

Shall be fabricated from tested quality steel and designed to withstand 

continuous internal pressure of 35KN per sq.m. over normal pressure as well 

as short circuit forces. The main tank body shall be capable of with standing 

vacuum as per CBIP guidelines. All steel surfaces in contact with insulating 

oil shall be painted with two coats of heat resistant oil in soluble insulating 

paint. Tank shields, if provided, shall not resonate at natural frequency of 

equipment. 

b) Tank mounting 

Transformer tank shall be mounted on bi-directional rollers. Suitable locking 

arrangement shall be provided to prevent accidental movement of 


SECTION-VI 

PART-B 


TRANSFORMERS 

PAGE 

2 OF 6

CLAUSE NO. 




PLANT PACKAGE 


transformer. Tank shall also be provided with lifting lugs and minimum four 

jacking pads. 

c) At least two adequately sized inspection openings, one at each end of the 

tank for easy access to bushings and earth connections shall be provided. 

6.01.02 Core shall be High grade non-ageing cold rolled grain oriented silicon steel 

laminations. 

6.01.03 Winding conductor shall be Electrolytic grade copper. Windings of 66kV and below 

shall be uniformly Insulated. 

6.01.04 Conservator tank of adequate capacity for expansion of oil from min. ambient to 100 

deg.C. shall be provided. The transformers rated 7.5 MVA and above shall be 

provided with air bag breathing through silica gel breather. For lower rating 

transformers, conventional single compartment conservator with dry air filling the 

space above oil and connected to silica gel breather shall be provided. 

6.01.05 Bushings shall be Porcelain. 

6.01.06 Bushing CTs Shall be provided in the LV neutral side of adequate rating for REF 

protection, Back up definite time earth fault protection (for HT transformers only), 

WTI, etc. 

6.01.07 Radiators shall be Tank mounted with shut off valves. 

6.01.08 Insulating oil 

No external inhibitors are permitted. 

6.01.09 Marshalling box shall be provided with thermostatically controlled space heaters. 

6.01.10 The insulation of core to core clamp shall be able to withstand a voltage of 2 KV rms 

for one (1) minute. 

6.01.11 Fittings 

Transformer shall be provided with following fittings as minimum 

a) Buchholz relay shall be provided with double float type with alarm and trip 

contacts, alongwith suitable gas collecting device. 

b) At least two numbers of spring operated pressure relief devices with 

extension pipe to bring oil to plinth level along with electrically insulated 


SECTION-VI 

PART-B 


TRANSFORMERS 

PAGE 

3 OF 6

CLAUSE NO. 




PLANT PACKAGE 


contact for alarm and tripping shall be provided for transformer rating 2MVA 

and above. 

c) Diaphragm type explosion vent shall be provided for all transformers below 2 

MVA rating. 

d) Winding temperature indicator (WTI) and Oil temperature indicator (OTI), Dial 

type (150mm) with alarm and trip contacts and max. reading pointer along 

with resetting device shall be provided. 

e) Magnetic oil level gauge with alarm contact shall be provided. 

f) Oil level gauge Prismatic/toughened glass type. 

6.02.00 DRY TYPE TRANSFORMERS 

6.02.01 Enclosure 

6.02.02 Core 

Enclosure shall be of a tested quality sheet steel of minimum thickness 2mm & shall 

also accommodate cable terminations. The housing door shall be interlocked such 

that it should be possible to open the door only when transformer is off. The 

enclosure shall be provided with lifting lugs and other hardware for floor mounting. 

Shall be High grade non-ageing cold rolled grain oriented silicon steel laminations. 

CRGO silicon steel. 

6.02.03 Winding conductor Shall be electrolytic grade copper or aluminium. 

Windings shall be of class F insulation. 

6.02.04 Bushings Shall be Solid porcelain / RIP. 

6.02.05 Bushing CT’s Shall be provided in the LV neutral side with adequate 

rating for REF protection, WTI, etc. 

6.02.06 Fittings 

Winding temperature Shall be Platinum resistance type temperature 

Indicator (WTI) detector in each limb. 

Thermistors Shall be embedded in each limb with alarm and trip 

contacts for remote annunciation. 


SECTION-VI 

PART-B 


TRANSFORMERS 

PAGE 

4 OF 6

CLAUSE NO. 

7.00.00 TRANSFORMER SIZING 




PLANT PACKAGE 


7.01.00 Size of the transformer shall be decided based on following : 

Size shall be greater than or equal to total KVA of continuous load 

+ (coincident factor x total kVA of intermittent load other than valves) 

+ 0.2 x total valves kVA 

+ kVA of largest rated valve or damper motor 

+ Employer's requirement, if any. 

+ 10% margin on the sum of the above mentioned values. 

Coincident factor of intermittent load, such as lifts, cranes, hoists etc shall be taken 

as 0.5. 

Both streams from Track hopper upto and including TP-1 loads shall be considered 

running simultaneously for sizing the respective transformers. 

7.02.00 Normally 2 x 100% feeding arrangement shall be provided as shown in single line 

diagram i.e. the total loads to be considered for sizing each transformer shall be the 

loads working on both the buses. In case of 3 x 50% feeding arrangement, if 

required, the loads to be considered on each transformer shall be the loads working 

on any two of the buses. 


8.01.00 For each type and rating of transformers rated upto and including 2 MVA 

8.01.01 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. 




SECTION-VI 

PART-B 


TRANSFORMERS 

PAGE 

5 OF 6

CLAUSE NO. 




PLANT PACKAGE 




8.04.00 Following is the list of type tests (for dry type & Outdoor transformers) 

(a) Short circuit test 

(b) Temp. rise test 

(c) Lightning impulse(Chopped Wave) voltage test on all three limbs and full 

wave LI on neutral if grounded through NGR. 

(d) Partial discharge test on dry type transformers only. 

(e) Tank Pressure test on oil filled transformers 

(f) Tank vacuum Test on oil filled transformers 

(g) Noise level test as per NEMA TR-1 

(h) Degree of protection test for marshalling box. 

(i) Zero sequence Impedance measurement 

(j) Measurement of harmonics in no load current. 

8.05.00 The following special tests on all transformers shall be conducted under this contract 

as routine tests in addition to all routine tests as per IEC 60076: 

(a) Oil leakage test for 24 hours 

(b) Repeat no load loss tests after electrical tests. 

(c) Measurement of capacitance & tan delta to determine capacitance between 

winding and earth. 


SECTION-VI 

PART-B 


TRANSFORMERS 

PAGE 

6 OF 6

PART - B 


HT SWITCHGEAR 





SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 CODE AND STANDARDS 

2.00.00 TYPE 

2.01.00 Switchgear 




PLANT PACKAGE 


HT SWITCHGEAR 

IEC: 62271, IS:13118 and IS:3427 

Free standing, Floor mounted, metal clad, fully compartmentalized draw-out type 

2.02.00 Circuit Breaker 

SF6 or Vacuum type, restrike free, trip free, stored energy operated and with 

electrical anti-pumping features 


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 under any 

condition. 

4.00.00 OPERATIONAL REQUIREMENT 

4.01.00 Each breaker panel shall be provided with the following devices for control, 

indication and inter locking 

a) Spring return to neutral type control switch (with NAC/NAT position) 

b) Stay – put type selector switches. Voltmeter with selector switch shall be 

provided with each bus-section. 

c) ‘On’, ‘Off’, 'Auto trip' ‘Spring charged and “Control Supply healthy” indicating 

lamps. The lamps shall be high intensity cluster type LED Service & test 

position indication shall be provided on all panels through additional lamps. 

d) Thermostatically controlled space heater with switch, illumination and power 

plug point. 

e) All meters/instruments shall be flush mounted on front panel, atleast 96 

sq.mm size with 90 deg. scales and accuracy class of 2.0. All feeders shall 

have an ammeter and ammeter selector switch, voltmeter with voltmeter 

selector switch for each bus. 

4.02.00 The circuit breaker shall meet the following requirements 

a) The breaker shall be controlled locally and/ or remotely as required . 

Facilities shall be provided for mechanical tripping of breaker and manual 

charging of closing spring to cater to emergency condition. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

1 OF 11

CLAUSE NO. 




PLANT PACKAGE 


b) Surge arrestor shall be provided for each motor feeder. 

c) Shall have an Operation duty O-3 min -CO- 3min-CO. 

d) Closing and tripping coils operating under extreme conditions of control 

voltage variation. 

e) Supervision relays provided for trip coil monitoring. 

f) Suitable mechanical inter lock shall be provided to prevent inadvertent ear 

thing of any live part. 

g) Castle key interlocks shall be provided to prevent opening of cable 

compartment door when breaker is closed and bus bar compartment when 

any of the incomers to bus are closed. 

h) Testing of circuit breaker shall be possible in isolated position by keeping the 

control plug connected. 

i) Only motor wound closing spring charging arrangement is acceptable. 

j) In a switchgear if there are more than one possible feed (including bus 

coupler) then lockout relay (86) contact of incoming breakers shall be 

connected in series in closing circuit of each of incoming breakers. 

k) Automatic change-over shall be provided for bus sections with suitable 

synchronizing check facility. The change-over shall be blocked in case of 

fault on the bus section. Dead Bus change-over after voltage collapse shall 

also be provided as back-up. 

l) Core balance CTs shall be provided for outgoing motor and transformer 

feeders having CT ratios greater than 50/1A. 

m) Each breaker truck shall have Service - Isolated - Withdrawn Position. 

n) Primary fuse replacement shall be possible with VT in isolated position. 

o) Each feeder shall have local/remote selection feature. Closing from local 

shall be possible only in test position whereas closing from remote shall be 

possible in either service or test position. Tripping from local shall be possible 

only when local / remote selector switch is in local position. Tripping from 

remote shall be possible either with breaker in service position or selector 

switch being in remote position. 

5.00.00 CONTACTORS 

(a.) The Bidder shall offer only HRC fuse backed, mechanically latched type 

contactor for outgoing motor feeder panels. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

2 OF 11

CLAUSE NO. 




PLANT PACKAGE 


(b.) The medium voltage contactors shall be of AC-3 utilization category and shall 

be vacuum type. The fuse and contactor assembly shall be mounted on a 

withdrawable truck. Circuits shall be provided with suitable single phasing 

protection. If required the contactor coil shall have a suitable economy 

resistor in series and shall be rated for satisfactory operation at 80 to 110% 

of rated voltage. 

(c.) The fuse and overload protection shall be fully coordinated, so that the 

contactor operates only for a fault current less than its interrupting capability. 

The fuses shall be provided with mechanical trip indication. 

(d.) The contactors shall close satisfactorily with a control voltage between 85 to 

110 per cent and trip satisfactorily with a control voltage between 70 to 100 

percent of the rated control supply voltage. Mechanical indication of 

contactor open / closed shall be provided. An anti-pumping relay shall be 

provided even if it has mechanical anti-pumping feature. Trip circuit 

supervision relay shall be provided to monitor the healthiness of trip coil. 

(e.) Surge suppressors shall be provided on all contactor controlled motor 

feeders. 

6.00.00 SURGE ARRESTOR 

The surge arrestors shall be provided for all motor feeders and shall be metal oxide, 

gapless type generally in accordance with IEC 60099-4 and suitable for indoor duty. 

These shall be mounted within the switchgear cubicle between line and earth, 

preferably in the cable compartment. Surge arrestor selected shall be suitable for 

non-effectively earthed system and rating shall be in such a way that the value of 

steep fronted switching over voltage generated at the switchgear terminals shall be 

limited to the requirements of switchgear. 

7.00.00 PROTECTION, CONTROL AND METERING 

7.01.00 The switchgears shall have Communicable Numerical relays for Protection, 

scheme, Metering and Status monitoring. Employer shall network the Numerical 

relays through Data Concentrators of the main plant to HMI and further integrated 

to DCS/DDCMIS system for diagnostics and status monitoring. All the feeders shall 

be remote controlled from DCS/PLC and from the local console of the numerical 

relays. 

8.00.00 GENERAL REQUIREMENTS OF NUMERICAL RELAYS 

8.01.00 All numerical relays, auxiliary relays and devices shall be of types, proven for the 

application; satisfying requirements specified elsewhere and shall be subject to 

Owner's approval. Numerical Relays shall have appropriate setting ranges, 

accuracy, resetting ratio, transient overreach and other characteristics to provide 

required sensitivity to the satisfaction of the Owner. All the numerical relays shall 

have communications on two ports, local front port communication to laptop and a 

second port on IEC 61850 port to communicate with the data concentrator through 

LAN and Ethernet switches. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

3 OF 11

CLAUSE NO. 




PLANT PACKAGE 


8.02.00 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. 

8.03.00 The protective relays shall have at least 8 Nos potential free contacts 

(Programmable) Auxiliary relays shall have contacts as required. Relay output 

contacts shall be suitable for directly wiring in the breaker closing and trip circuit 

operating from 220 V DC control voltage. 

8.04.00 Failure of a control or auxiliary supply and deenergisation of a relay shall not initiate 

any circuit breaker /contactor operation. All relays shall withstand a minimum test 

voltage of 2 KV AC Rms for one minute. 

8.05.00 All the numerical relays shall have communications on two ports; local front port 

communication to laptop and a second port on IEC 61850 port to communicate with 

the Employer’s data concentrator through LAN. 

8.06.00 Relays shall be suitable for electrical measurement including voltage, current, power 

(active/reactive) and energy parameters. 

8.07.00 Mapping details of all the details shall be submitted in IEC format. 

8.08.00 Relays shall have separate output for individual functionality and the master trip shall 

be software configurable in case of multi output relays. Relays shall have event 

recording feature, recording of abnormalities and operating parameters with time 

stamping 

8.09.00 Preferably comprehensive single numerical relay shall have provision of both current 

and voltage inputs. The current operated relay shall have provision for 4 sets of CT 

inputs, 3 nos. for phase fault & 1 CT input for earth fault. Relay shall be suitable for 

both residually connected CT input as well as CBCT input. The voltage-operated 

relay shall have provision for 3 PT inputs. Relays shall be suitable for CT secondary 

current of 1A/5A selectable at site. Relays used in incomers and bus couplers shall 

have provision of two sets of voltage signal inputs for the purpose of 

synchronization. 

8.10.00 All CT & PT terminals shall be provided as fixed type terminals on the relay to avoid 

any hazard due to loose connection leading to CT opening or any other loose 

connection. In no circumstances Plug In type connectors shall be used for CT / PT 

connections. Vendor to ensure the same for all protective relay models offered. 

8.11.00 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. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

4 OF 11

CLAUSE NO. 




PLANT PACKAGE 


8.12.00 Relays shall have suitable output contact for breaker failure protection. 

8.13.00 Relays shall have self diagnostic feature with self check for power failure, 

programmable routines, memory and main CPU failures. 

8.14.00 Relays shall have at least two sets or groups of two different sets of adaptable 

settings. Relays shall have multiple IEC/ ANSI programmable characteristics. 

8.15.00 Design of the relay must be immune to any kind of electromagnetic interference. 

Vendor to submit all related type test reports for the offered model along with the 

offer. 

9.00.00 PROTECTIONS: RELAY TYPES/ PROTECTIONS 

A. Motor Feeders 

a) Thermal Overload Protection (50I) 

b) Restart Inhibit Protection (49) 

c) Earth Fault Protection (50N/50N2) 

d) Negative Phase Sequence Protection (46) 

e) Reversal Phase Sequence Protection (46 R) 

f) Locked Rotor Protection (50 L/R) 

g) Number of starts limitation (66) 

h) Loss of Load Protection (37) 

i) Under Voltage protection with timer(27 M) 

j) Energy Metering 

B. Transformer Feeder Protections 

a) Three Phase Over current and Earth Fault protection (50 & 50 N1/50 

N2))(The earth fault element should be suitable for both residually 

connected CT input as well as CBCT input.) 

b) Restricted Earth Fault protection (64 R) 

c) Transformer Differential protection (87 T) for Transformers with rating 

more than 5 MW 

d) Stand by earth fault protection (51 N) 

e) Transformer buchholz and WTI/OTI high trips 

f) Energy Metering 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

5 OF 11

CLAUSE NO. 




PLANT PACKAGE 


C. Protections for Incomers, Bus couplers and Tie feeders. 

a) Over current and earth fault protection. 

b) Synchronizing check relay as a part of fast change over scheme. 

c) Energy Metering 

10.00.00 OTHER PROTECTIONS AND CONTROL FUNCTIONS IN THE RELAYS. 

10.01.00 For Breaker control from DCS/PLC, hardwired potential free contacts shall be 

provided from DCS/PLC, to the numerical relays. No separate coupling relays shall 

be provided. 

10.02.00 Trip circuit supervision shall be provided for all feeders to monitor the circuit 

breaker/ contactor trip circuit both in pre trip and post trip conditions. 

10.03.00 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. Auxiliary relays for interlocking purpose shall be of self 

reset type. 

10.04.00 Bus no volt condition shall be configured to a output contact of the relay of all 

incomers 

10.05.00 Timer functions shall be programmable for on/off delays. 

10.06.00 The numerical relay shall be able to provide supervisory functions such as trip circuit 

monitoring, circuit breaker state monitoring, PT and CT supervisions and recording 

facilities with Post fault analysis. 

10.07.00 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. 

10.08.00 150 time tagged events /records should be able to store with time stamping Last 5 

faults storage including the indication, protection operated , fault location relay and 

operating time, currents, voltage and time. 

10.09.00 Diagnostics Automatic testing, power on diagnostics with continuous monitoring to 

ensure high degree of reliability shall be shall be provided. The results of the self 

reset functions shall be stored in battery back memory. Test features such as 

examination of input quantities, status of digital inputs and relay outputs shall be 

shall be available on the user interface 

10.10.00 The alarm/status of each individual protection function and trip operation shall be 

communicated to DCS/PLC The numerical relay system shall have built-in 

features/hardware interface to provide such inputs to DCS/PLC for analog/digital 

values The provision of receiving the D.C. incoming supplies and its monitoring shall 

preferably be made in one bus P.T. Panel. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

6 OF 11

CLAUSE NO. 




PLANT PACKAGE 


10.11.00 Sequence of events shall have 1 ms resolution at device level. 

10.12.00 Measurement accuracy shall be 1 % for RMS Current and voltage. 

10.13.00 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. 

11.00.00 ETHERNET SWITCHES 

Ethernet switches shall be ‘substation hardened ‘ and shall comply to IEC61850-3 

for communications and environment requirements. The Ethernet switches shall be 

of managed type with two(2) No of Fibre optic cable ports and Fourteen/Six of 

Copper ports to achieve the LAN configuration. These switches shall be mounted 

inside the switchgear Panel. 

12.00.00 AUXILIARY POWER SUPPLY 

Relay shall be suitable to accept both AC & DC supplies with 110V AC or 220V DC 

with tolerance of 80% to 120 % of rated voltage. 

12.01.00 Input / Output Interface, Filters And Optical Isolation 

Relay shall be immune to capacitance effect due to long length of connected control 

cables. Any external hardware, if required for avoiding mal operation of the relay due 

to cable capacitance shall be included as a standard feature. All I/Os shall have 

optical isolation. Analog inputs shall be protected against switching surges, 

harmonics etc. 

No separate earth bus shall be required for the relays. It shall be possible to connect 

the relay earth to the common earth bus in the switchgear panel which shall be 

connected to the plant earth mat. 

13.00.00 SOFTWARE SECURITY, LICENSE AND UP GRADATIONS 

Numerical relays shall have two level pass word protections, one for read only and 

other for authorization for modifying the setting etc. 

14.00.00 DESIGN AND CONSTRUCTION FEATURES 

All HT switchgear panels and circuit breakers shall have the following features. 

a) High conductivity aluminum alloy or copper for the horizontal bus bars, 

vertical droppers and connectors to the fixed end of isolating contacts. 

b) Height of the Switchgear Panel not to exceed 2600 mm. 

c) Insulators 

shall be track-resistant, high strength, non-hygroscopic, non-combustible 

type and suitable withstand stresses due to over-voltages and short circuit 

current. Inter pole barrier of inflammable material like hylam not acceptable 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

7 OF 11

CLAUSE NO. 

d) Sealing: 




PLANT PACKAGE 


Bushing or other sealing arrangement shall be provided between breaker 

and bus bar / cable compartments to avoid air communication around 

isolating contacts in the safety shutter area with truck in service position. 

e) Construction 

(i) The switchgear assembly shall be rodent and vermin proof. 

(ii) In switchgear design where the breaker front itself serves as a door 

suitable blanking covers one for each size of panel per switch board 

shall be included. 

(iii) The switchgear enclosure shall be constructed with rolled steel 

section of rolled sheet steel of at least 2.0 mm thickness. 

(iv) Pressure relief device shall be provided in each high voltage 

compartment to vent out safely the gases produced in case of a fault. 

(v) Breaker trucks shall have a secure locking in SERVICE position so 

that they are not displaced during a short circuit. 

(vi) Current ratings of all switchgears, circuit breakers, CT's etc. shall be 

sufficient for carrying the connected load currents without exceeding 

the permissible temperature limits or reduction in service life. Use of 

two breakers in parallel to meet the required rating shall not be 

acceptable. 

(vii) HT switchgear shall also have at least two (2) fully equipped spare 

feeders on each bus section.. 

(viii) Suitable trolley arrangement, if required, shall be provided. One 

trolley per switchgear room shall be provided suitable for each type of 

rating of breakers. 

(ix) Switchgear panels shall be suitable for bottom cable entry and shall 

be provided with removable gland plates. 

f) Earthing Arrangement 

(i) Internal earth bus shall be provided which has a capacity to withstand 

short circuit currents for one second and all enclosures shall be 

connected to this bus. 

(ii) Earthing arrangement through and integral earth switch or through 

separate Earthing truck shall be provided. Suitable mechanical 

interlocks shall be provided to prevent the closing of earth switch 

circuit on live circuit. In case of later arrangement one set of different 

types of Earthing trucks per switch board shall be provided. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

8 OF 11

CLAUSE NO. 




PLANT PACKAGE 


(iii) Earthing switch/Earthing truck shall be short time (One second) 

current withstand capability equal to the breaker. 

(iv) A clearly visible warning label "ISOLATE ELSEWHERE BEFORE 

EARTHING" shall be provided on shutters of incoming and other 

connections which could be energized from other end. 

g) Switchgear panel shall be suitable for bottom entry and provided with 

removable gland plates. 

h) Instrument transformer 

CTs and VTs shall be provided for protection and metering and shall be 

cast-resin encapsulated type. Insulation class 'E' or better. VTs shall have 

suitable HRC current limiting fuses to both primary and secondary sides, 

under voltage relays, timers, etc. for motor tripping and remote annunciation 

on supply failure. Each switchgear section shall have a three phase VT. 

Single phase VT shall be provided for HT incomers for synchronization. 

Accuracy class of CTs and VTs shall be as follows 

CT Core balance CTS 

Protection/ 5P 10 PS 

Metering 1.0 

Differential/REF PS - - 

j) SF6 monitoring 

SF6 gas pressure / density monitoring for low pressure alarm/ interlock shall 

be provided. 

k) Identification plates 

Each panel to be identified on front as well as back side by large engraved 

plate giving detailed feeder description. Identification labels/painted (Not 

stickers) plates to be provided inside each panel. 

l) Safety Requirements 

The switchgears 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 shall be provided for each switch 

gear room mounting on wall describing various safe operating procedure / 

safety precautions for safe operation and maintenance of switchgear. Rubber 

mats shall be provided in front of each panel. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

9 OF 11

CLAUSE NO. 




PLANT PACKAGE 


Safety shutters complying with IEC-60298 shall be provided to cover up the 

fixed high voltage contacts on busbar and cable sides when the truck is 

moved to ISOLATED position 

The breaker / contactor and the auxiliary compartments provided on the front 

side shall have strong hinged doors. Busbar and cabling compartments 

provided on the rear side shall have separate bolted covers with self 

retaining bolts for easy maintenance and safety. Breaker / Contactor 

compartment doors shall have locking facility. Suitable interlock shall be 

provided, which will ensure that breaker is OFF before opening the back 

doors. 

15.00.00 DEGREE OF PROTECTION OF VARIOUS ENCLOSURES: 

i) VT Relay compartmrnt IP-52 

ii) Other compartments IP-41 

16.00.00 PAINT SHADE : 


Complete panels excluding end covers RAL 9002 

Extreme end covers of all boards RAL 5012 

(a) All equipments to be supplied shall be of type tested design. The Contractor 









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 


(c.) All acceptance and routine tests as specified below and in relevant 





furnished by the manufacturer conforming similarity and “No design 

change”. Minor changes if any shall be highlighted on the endorsement 

sheet. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

10 OF 11

CLAUSE NO. 




PLANT PACKAGE 


The contractor shall submit the following type test reports. 

a) The following type tests Reports shall be furnished for circuit breaker / 

circuit breaker panels, of each voltage class and current rating. 

1) Short circuit duty test on circuit breaker 

2) Short time withstand test on circuit breaker 

3) Power frequency withstand test 

4) Lightning impulse withstand test 

5) Temperature rise test on breaker and panel together. 

6) Test to verify pressure relief devices operation of the panel. This 

shall be done on one panel of each voltage class. 

7) Measurement of resistance of main circuit. 

8) Mechanical operation test. 

b) Contactor and Contactor panels of each type and rating. 

1) Verification of rated making and breaking capacities of the 

contactor. 

2) Short time withstand test of panel. 

3) Power frequency test on the contactor 

4) Lightning impulse voltage withstand test 

5) Measurement of resistance of main circuit. 

6) Test to confirm coordination between fuse and contactor. 

c) Type Tests Reports for Surge arrestors as per IEC/IS. 

d) Short circuit withstand test of earthing device (truck / switch). 

e) Type test Reports as per IEC 61850 for numerical relays. 


SECTION-VI 

PART-B 


HT SWITCHGEAR 

PAGE 

11 OF 11

PART - B 


BATTERY 





SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 BATTERY RATINGS 




PLANT PACKAGE 


BATTERY 

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 

battery shall also be sized considering a minimum electrolyte temperature of 15 deg 

C and an ageing factor of 1.2. The minmum capacity shall be 100AH for Nickel 

cadmium & 170AH for Lead Acid plante battery. 

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 MCCs/Swgr and control panels. 

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. 

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. 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

1 OF 9

CLAUSE NO. 




PLANT PACKAGE 


(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 

3.02.02 Vent Plugs 

3.02.03 Plates 

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. 

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. 

The plates shall be designed for maximum durability during all service conditions 

including high rate of discharge and rapid fluctuations of load. The construction of 

plates shall conform to latest revisions of IS:10918. 

The separators shall maintain the electrical insulation between the plates and shall 

allow the electrolyte to flow freely. Separators should be suitable for continuous 

immersion in the electrolyte without distortion. 

The positive and negative terminal posts shall be clearly marked. 

3.02.04 Sediment Space 

3.02.05 Cell Insulator 

Sufficient sediment space shall be provided so that cells will not have to be cleaned 

during normal life and prevent shorts within the cells. 

Each cell shall be separately supported on PVC/porcelain/hard rubber insulators 

fixed on to the racks with adequate clearance between adjacent cells. Minimum 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

2 OF 9

CLAUSE NO. 

3.02.06 Electrolyte 




PLANT PACKAGE 


distance between the adjacent cells shall be more than the budge allowed for two 

cells in accordance with IS: 1146. 

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 

3.02.08 Battery racks 

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. 

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. 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

3 OF 9

CLAUSE NO. 




PLANT PACKAGE 


(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: 

5.00.00 TESTS 


(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. 

(a.) The Contractor shall submit for Owner’s approval the reports of all the type 

tests as per latest IS-1146 (for all applicable tests for containers) / IS-10918 

(for Ni-Cd Batteries) and carried out within last ten years from the date of bid 




have been witnessed by a client. The complete type tests shall be for any 

rating of battery in a particular group, based on plate dimensions. 

(b) In case the Contractor is not able to submit report of the type test(s) 



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 shall be as per Quality assurance and 

Inspection table of batteries. Charges for these shall be deemed to be 






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 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

4 OF 9

CLAUSE NO. 

(b.) Dimensions, Mass & layout 

(c.) MARKING 




PLANT PACKAGE 


(d.) Polarity and absence of short circuit. 

(e.) Air pressure test 

(f.) Ampere - hour capacity 

(g.) Retention of charge 

(h.) Insulation resistance 

The Contractor shall arrange for all necessary equipment, including the variable 

resistor, tools, tackles and instruments. 

PART-B: LEAD –ACID PLANTE BATTERY 


6.01.00 All standards, specification and codes of practice, referred to herein, shall be the 

latest edition including all applicable official amendments and revisions as on date of 

opening of bid. 

In case of conflict between this specification and those (IS Codes Standards etc.) 

referred to herein, the former shall prevail. All works shall be carried out as per the 

following standards and codes : 

IS : 266 Specification for sulphuric acid 

IS : 1069 Specification for water for storage batteries 

IS : 1146 Specification for rubber & plastic containers for lead acid storage 

batteries. 

IS : 1652 Specification for stationary cells and batteries, lead acid type (with 

plant positive plates). 

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 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

5 OF 9

CLAUSE NO. 




PLANT PACKAGE 



VDE etc. will also be considered if they ensure performance and constructional 



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. 

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 centigrade 

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. 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

6 OF 9

CLAUSE NO. 

7.02.02 Vent Plugs 

7.02.03 Plates 




PLANT PACKAGE 


Vent plugs shall be provided in each cell. They shall be antisplash type, having more 

than one exit hole shall allow the gases to escape freely but shall prevent acid from 

coming out. The design shall be such that the water loss due to evaporation is kept 

to minimum. In addition the ventilator shall be easily removed for topping up the cells 

and of such dimensions that the syringe type hydrometer can be inserted into the 

vent to take electrolyte sample. 

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 

7.02.06 Electrolyte 

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. 

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 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

7 OF 9

CLAUSE NO. 




PLANT PACKAGE 


discharge current of the respective Batteries and through fault short circuit current 

which the battery can produce and withstand for the period declared. Contractor 

shall furnish necessary sizing calculations to prove compliance to the same. 

7.02.08 Battery racks 

Wooden racks for all the batteries shall be provided. These racks shall be made of 

good quality first class seasoned teak wood in line with CPWD specification. They 

shall be free standing type mounted on porcelain/hard rubber/PVC pads insulators. 

Batteries shall preferably be located in the single tier arrangement. However, 

batteries having a complete cell weight of lower than 50 Kg could be located in the 

double tier arrangement. The batteries rack and wooden support for cable 

termination shall be coated with three (3) coats of anti-acid paint of approved shade. 

Numbering tags, resistant to acid, for each cell shall be attached on to the necessary 

racks. The bottom tier of the stand shall not be less than 150 mm above the floor. 

Wherever racks are transported in dismantled condition, suitable match markings 

shall be provided to facilitate easy assembly. 

7.02.09 Manufacturer’s Identification Systems 

8.00.00 TESTS 

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 


The Contractor shall submit for Employer’s approval the reports of all the type tests 

as per the latest IS-1146 (for rubber & plastic containers for Lead – acid storage 

batteries) carried out with in the last 10 years from the date of bid opening and the 

tests should have been witnessed by a client. The complete type test reports shall 

be for any rating of battery in a particular group, based on plate dimensions being 

manufactured by supplier. 


within last ten years from the date of bid opening, or in case the type test report(s) 


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. Routine and acceptance tests shall be as per Quality assurance & 

inspection table of battery. 


SECTION-VI 

PART-B 


BATTERY 

PAGE 

8 OF 9

CLAUSE NO. 




PLANT PACKAGE 


8.01.02 All routine tests as per QA table and relevant standards shall be carried out. 

Charges for these shall be deemed to be included in the equipment price. 





8.02.00 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 


BATTERY 

PAGE 

9 OF 9

PART - B 


BATTERY CHARGER 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 





of opening of bid. In case of conflict between this specification and those (IS codes, 

standards etc.) referred to herein, the former shall prevail. All work shall be carried 

out as per the following standards and codes. 

ANSI-C 

37.90a 

Guide for surge withstand capability tests 

IS:5 Colours for ready mix paints. 

IS : 694 PVC Insulated Cable for working voltages upto and including 1100 V. 

IS : 1248 Specification for Direct acting indicating analogue electrical 

measuring instruments. 

IS:13947 

Part-1 

Degree of protection provided by enclosures for low voltage switch 

gear and control gear. 

IS : 13947 Specification for low voltage switch gear and control gear 

IS : 3231 Electrical relays for power system protection. 

IS : 3842 Application guide for Electrical relays for AC System 

IS : 3895 Mono-crystalline semi-conductor Rectifier Cells and Stacks 

IS : 4540 Mono crystalline semi-conductor Rectifier assemblies and equipment. 

IS:6005 Code of practice for phosphating of Iron and Steel. 

IS:6619 Safety Code for Semi-conductor Rectifier Equipment. 

IS:6875 Control switches (switching devices for control and auxiliary circuits 

including contactor relays) for voltages upto 1000 V AC or 1200 V 

DC. 

IS : 9000 Basic environmental testing procedures for electronic and electrical 

items. 


SECTION-VI 

PART-B 



PAGE 

1 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 


VDE. etc. will also be considered if they ensure performance and constructional 



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 


SECTION-VI 

PART-B 



PAGE 

2 OF 12

CLAUSE NO. 




PLANT PACKAGE 


Charger shall not trip on overload or external short circuit. After clearance of 

fault, the Charger voltage shall build up automatically when working in 

automatic mode. 

(e.) When on automatic control mode during Trickle charging, the Charger output 

voltage shall remain within +/-1% of the set value for AC input voltage 

variation of +/-10%, frequency variation of +3/-5%, a combined voltage and 

frequency (absolute sum) variation of 10% and a continuous DC load 

variation from zero to full load. Uniform and stepless adjustments of voltage 

setting (in both manual and automatic modes) shall be provided on the front 

of the Charger panel covering the entire Trickle charging output range 

specified. Stepless adjustment of the load limiter 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. 


SECTION-VI 

PART-B 



PAGE 

3 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

(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 


SECTION-VI 

PART-B 



PAGE 

4 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART-B 



PAGE 

5 OF 12

CLAUSE NO. 

2.06.00 Rectifier-Transformers and Chokes 




PLANT PACKAGE 


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 

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. 


SECTION-VI 

PART-B 



PAGE 

6 OF 12

CLAUSE NO. 

2.11.00 FUSES 




PLANT PACKAGE 


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 

(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 


SECTION-VI 

PART-B 



PAGE 

7 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART-B 



PAGE 

8 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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: 

3.07.00 Wiring 

(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. 

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. 


SECTION-VI 

PART-B 



PAGE 

9 OF 12

CLAUSE NO. 

4.00.00 TESTS 





PLANT PACKAGE 


1. All equipments to be supplied shall be of type tested design. The Contractor 







a) Complete physical examination 

b) Temperature rise test at full load. 

c) Temperature rise test of rectifier assembly at 200% of full load. 

d) Insulation resistance test. 

e) High voltage (power frequency) test on power and control circuits 

except low voltage electronic circuits. 

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 


SECTION-VI 

PART-B 



PAGE 

10 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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 

k) Environmental Tests 

The Charger shall not exhibit any component damage 

and there shall be no change in performance as per (g) 

and (h). 

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 


3. All acceptance and routine tests as specified below and in relevant 




SECTION-VI 

PART-B 



PAGE 

11 OF 12

CLAUSE NO. 




PLANT PACKAGE 


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. 

(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). 


SECTION-VI 

PART-B 



PAGE 

12 OF 12

PART - B 


CONTROL PANEL 





SECTION-VI 

PART-B

CLAUSE NO. 





PLANT PACKAGE 


CONTROL PANELS 

Programmable Logic Controller IEC: 1131 

2.00.00 CONTROL TYPE 

PLC based 

3.00.00 PANEL CONFIGURATION 

3.01.01 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, metal detectors, sump pumps, SM & 

ILMS, belt weighers and hoists shall be free standing, floor/wall mounting type. 

They shall be provided with the necessary power equipment like switches, fuses, 

contactors etc. and the required control equipment like selector switches, meters, 

push buttons, indications, and annunciations etc. 

Local control panels shall be provided for Coal sampling units, hydraulic scoop 

coupling and dust suppression system. However control of these systems shall be 

through main DDCMIS with starters located in the main MCCs only. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

1 OF 10

CLAUSE NO. 




PLANT PACKAGE 


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 

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. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

2 OF 10

CLAUSE NO. 




PLANT PACKAGE 


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 

7.00.00 TRAINING 

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. 

Further to the relevant clause regarding training specified elsewhere, Bidder's 

experienced personnel/engineers shall also provide training courses on offered PLC 

system to Employer's engineers in the following areas: 

(a.) Operator training 

(b.) Hardware Maintenance training 

(c.) Software training 

(d.) Any other specialized training as required for system operation and 

maintenance. 

The maintenance training shall include lectures and hands on experience on similar 

type of equipment / system at manufacturer works and recently commissioned 

operating plant and / or training simulator. The Owner shall require training of two 

hardware and two software engineers and the duration of each course shall be 

minimum two weeks. 

The details of hardware and software training shall be finalised during detailed 

engineering and shall be subject to Employer's approval. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

3 OF 10

CLAUSE NO. 




PLANT PACKAGE 


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) 

c) 

d) 

e) 

f) 

Memory Non volatile EPROM, Lithium or Ni-Cd battery for 360 

hours backup, 20% spare capacity for future use. 

Selection Normal/Test/Program/Off facility shall be provided. In 

test mode all outputs shall be blocked. 

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. 

Processors & I/O 

racks 

Isolation between 

Input, Output and 

controller 

Modular design. Possible to change any module 

without disconnection of any wire. Keying in of 

individual wire connectors shall be provided to ensure 

that only the correct card is plugged on the I/O 

module. Wiring between I/O cards & terminal blocks 

shall be through prefab cables. Twenty (20%) percent 

spare capacity in input output and CPU memory 

modules shall be provided in each rack over and 

above system requirement. One additional Ethernet 

port shall be made available in each PLC system so 

that wireless communication modem can be 

connected by the Employer in future. All Output cards 

shall be sourcing type and Input cards shall be sinking 

type. 

1.5 KV with opto couplers. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

4 OF 10

CLAUSE NO. 

g) 

h) 

i) 

j) 

k) 

l) 

m) 




PLANT PACKAGE 


Indication Individual signal status of each Input / Output, power 

supply status. 

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. 

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. 

Switching capacity 

HMI/CPU and Input 

output 

communication links 

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. 

Hundred percent redundant Communication links 

through routed in separate GI conduits. 

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) 

Number of printers shall be as shown in the tender 

drawing ‘PLC Configuration’. 

Power supply i) 

ii) 

Two (2) nos 415V AC feeders shall be provided for 

each control panel / desk and remotely located I/O 

panels. 

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. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

5 OF 10

CLAUSE NO. 

n) 

o) 

p) 

q) 

r) 

s) 

Command 

hierarchy 




PLANT PACKAGE 


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. 

Manual command shall prevail over auto command. 

Protection command shall have priority over all other 

commands. 

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. 

Time 

Synchronisation 

system. 

Date 

Insensitivity 

System reaction 

time 

Display 

response 

t) Feedback/field 

interrogation 

u) 

v) 

Programming 

format 

Long time 

storage & 

retrieval 

To be synchronised with DDCMIS 

No disturbance due to change of date/year. 

Less than 100 msec. from input signal to output signal 

including logic processing. 

Max 1 sec for control related displays. 2 to 3 sec for 

other displays. 

By 24V DC. Status feedback from MCC/field shall be 

in the form of one changeover contact. Discrepancy 

shall be alarmed. All analog signals shall be routed 

through analog cards. 

Flow chart/Block logic ladder diagram. Tag based 

addressing format shall be used for programming. 

The same shall be submitted for owner's review 

before programming of the system. 

168 hours latest data on hard disc. Data to be stored: 

i) Alarm list. 

ii) 

Five analog points at scan rate. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

6 OF 10

CLAUSE NO. 

w) 




PLANT PACKAGE 


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. 

Software All application software with locks and passwords for 

PLC functioning like input/output scanning, 

acquisitions, condition processing, control and 

communication, operator interface of monitors, display 

trends, curves, bar charts, historical storage/ retrieval 

and alarm functions. Complete set of documents for 

modifications / editing / additions/ deletions of features 

in software. Comprehensive list of all 

application/system software. 

x) Accessories Industrial grade furniture shall be provided along with 

Control desk/OWS/printer. 

y) 

Software 

license 

z) Software 

upgrades 

8.02.00 Annunciation System 

The contractor shall provide software license for all 

software being used in PLC based control system 

including HMI. The software licenses shall be 

provided for the project and shall not be 

hardware/machine specific. All licenses shall be valid 

for the continuous service life of the plant. 

As a customer support the contractor shall periodically 

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. 

i) Facia Translucent glass/plastic window with engraving. 

ii) Operation Through PLC. 

a) 

On occurrence 

of trouble 

b) Acknowledge 

button pressed 

Audible horn and flashing of facia lamp. 

Audible horn and flashing of facia lamp shall stop. 

Facia lamp will become steady. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

7 OF 10

CLAUSE NO. 

c) Reset button 

pressed 

d) Test button 

pressed 




PLANT PACKAGE 


If fault is removed then facia lamp will go off. 

All lamps will glow. 

iii) Monitoring Power supply to annunciator shall be monitored. 

9.00.00 DESK/PANEL CONSTRUCTION 

a) Type Fabricated from cold rolled sheet steel 

Frame thickness 2.0 mm 

Enclosure thickness 1.6 mm 

Gland plate thickness 3.0 mm 

b) Switches AC22 category 

c) Fuses HRC cartridge with visual operation indicator. 

d) Name Plates & 

Labels 

Each panel shall be identified by a name plate. Panel 

internal equipment shall be identified by paint marking. 

Nameplates shall be non rusting metal or 3-ply 

lamicoid, with engraved lettering and shall be subjected 

to 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. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

8 OF 10

CLAUSE NO. 

m) Degree of 

enclosure 

protection 





PLANT PACKAGE 


For panels located in 

i) Air conditioned areas : IP-32 

ii) Other indoor areas : IP-52 

iii) Outdoor areas : IP-55 

iv) Dusty areas like : IP-65 

Conveyor galleries, Transfer points, 

Bunker area, Track hopper area, 

Crusher house etc. 

10.01.01 All equipment to be supplied shall be of type tested quality. 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 five 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. 


within last five years from the date of bid opening, or in case the type test report(s) 


conduct all such tests under this contract free of cost to the Owner and submit the 

reports for approval. 



price. 

10.02.00 Programmable logic controller 

10.02.01 Following test reports shall be submitted for the equipment: 

a). Dry heat withstand test 

b). Variation of temperature immunity test 

c). Variation immunity test 

d). Temperature cycle test 

e). Noise immunity test 

f). Dielectric test. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

9 OF 10

CLAUSE NO. 




PLANT PACKAGE 


10.02.02 Following tests shall be conducted under this contract as routine tests: 

a). Tests on internal and external wiring. 

b). Incoming power supply voltage and frequency variation test. 

c). Test for verification of functional characteristics of I/Os. 

d). Task transition test (for each task, the contractor will list out the user 

accessible conditions which shall be used in the simulation of the task). 

e). Functional testing of software and hardware in accordance with the approved 

block logic diagram with simulation of the system with switches, relays and 

solenoid valves etc. or equivalent loads. 


SECTION-VI 

PART-B 


CONTROL PANEL 

PAGE 

10 OF 10

PART - B 


CLOSED CIRCUIT TELEVISION SYSTEM 

(CCTV) 





SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 GENERAL REQUIREMENTS 




PLANT PACKAGE 


CLOSE CIRCUIT TELEVISION SYSTEM (CCTV) 

1.01.00 The intent of the specification is to define the functional & design requirements for the 

CCTV System meant for gathering video information from the various operational 

areas of the Coal Handling Plant. The Contractor shall be responsible for selection, 

design, engineering, manufacture, testing at manufacturer’s works/site, installation 

and commissioning of the system to the satisfaction of Employer. All the cables, 

cable trays, power packs, erection hardwares etc. are also included in contractor’s 

scope. 

1.02.00 The Contractor’s scope shall also include successful demonstration of performance 

testing specified herein complete in all respects alongwith cables, cable trays, 

junction boxes, earth wire and accessories like standard brackets, nut-bolts, glands, 

lugs, conduit sleeves, etc., as required, to complete the proper installation 

conforming to IS:1881, IS:1882 of all the equipments supplied as covered in this 

specification. All equipment, accessories and facilities required for completeness of 

this system are included in Contractor's scope, whether these are specifically 

mentioned herein or not. 

1.03.00 The CCTV System offered by the Contractor shall be from reputed manufacturer who 

should have designed, manufactured, tested and commissioned a distributed type 

CCTV systems as specified in any coal handling plants or any large industrial 

installation as on the date of bid opening. All major equipment such as Cameras, 

Video Switcher/Control System, Key Boards, Receiver Drivers, Pan Tilt Units, Post 

equalisation Video amplifiers, Digital Video Recorder, (DVR) Archiving System etc. 

shall of the same make. In case the bidder wants to offer Dome type cameras for all 

applications are also acceptable. 

1.04.00 The system and all the equipment shall conform to the latest edition of Indian / 

International and CCITT standards as applicable. 

1.05.00 The Contractor shall guarantee satisfactory performance of the equipment under 

stipulated variations of voltage and frequency. The design and manufacture shall be 

such that equipments/components of same type and rating shall be interchangeable. 

1.06.00 All the cameras shall be connected to a central redundant microprocessor based 

video switcher/control system to be located in CHP control room. 

1.07.00 Any other equipment, module required for the safe and satisfactory operation, 

control, protection, monitoring, testing and maintenance of the system are also 

included in Contractor's scope. 

2.00.00 POWER SUPPLY ARRANGEMENT 

2.01.00 The Contractor shall provide power to the CCTV System from UPS system for 

microprocessor based switching / control unit, monitor, digital video recorder, etc. in 

the control room. 


SECTION-VI 

PART-B 


CLOSED CIRCUIT 

TELEVISION SYSTEM 

(CCTV) 

PAGE 

1 OF 9

CLAUSE NO. 




PLANT PACKAGE 


3.00.00 DESIGN AND TECHNICAL REQUIREMENTS 

3.01.00 The CCTV system shall be able to provide surveillance of different locations of the 

plant. 

3.02.00 The system shall comprise of Redundant Microprocessor based Video 

Switcher/Control System capable of controlling 

- 16 nos. of Cameras for Zoom, Pan/Tilt, Multiple pre positionsand auxiliaries 

1 1 no. of digital video recorder. 

2 Multiplexer 

- Required no. of 21” colour TFT monitors with key board for controlling both 

manually and automatically and all other accessories required to provide best 

quality video with controls for making the system complete. It shall be 

possible to view the CCTV out put on the large video screen also. 

3.03.00 The system operation would be of covering the complete view of the areas with pan / 

tilt, zoom, propositioning of the cameras and with programmability to monitor any 

camera or number of cameras at a time on any monitor either manually or 

automatically in a defined switching. The system shall be suitable for installation and 

shall be able to work successfully in Coal dusty environment. 

3.04.00 The system shall have the following facilities: 

a) Zooming 

b) Pan control 

c) Tilt control 

d) Computer interface 

e) Logging printer part 

f) Multiple prepositions 

g) SALVO switching 

h) Programmability 

i) Alarm interface 

3.05.00 The system supplied shall be complete in all respects for reliable performance. The 

Contractor shall submit the details block schematic, video, signal & power wiring 

diagram, describing the connections between the Microprocessor based Video 

Switcher/Control System and various cameras, pan tilt, receiver driver units, 

monitors, DVR and keyboard. Programming required shall be done by the Contractor 

for satisfactory operation. 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

2 OF 9

CLAUSE NO. 




PLANT PACKAGE 


3.06.00 The system should be completely compatible to be integrated to Fire Alarm System. 

When the fire is detected by a particular detector the camera assigned should 

automatically focus the site of the fire. 

3.07.00 The video switcher/control system shall permit the design of a distributed matrix 

video switching system with control at one central location and individual control at 

the local sites. The main control site could view/control local cameras plus cameras 

located at any of the remotely distributed sites. 

4.00.00 DETAILED DESCRIPTION OF THE SYSTEM COMPONENTS : 

4.01.00 Microprocessor based Video Switcher/Control System 

4.01.01 The Video Switcher/Control System shall be Redundant, Microprocessor based and 

modular in construction. It should offer full matrix switching capability, i.e., the 

system should be programmable to display the video from any camera or number of 

cameras at a time on any monitor, either manually or via independent automatic 

switching sequences. 

4.01.02 The Video switcher/Control System should have provision for minimum 32 camera 

inputs 2 monitor outputs, keyboards, Digital video recorders, 32 direct connect alarm 

input points, an integral signal distribution unit, a computer interface port, and a 

logging printer port including all other hardware / software. 

4.01.03 The Video Switcher/Control System should be programmable with up to 30 

sequences, which can run independently of each other in either forward or reverse 

direction. Any of the sequences should utilise the Salvo Switching capability where 

any number of system monitors may be selected to switch as a group. 

4.01.04 The video switcher/control system should have easy provision for integral signal 

distribution ports, connections to on-site receiver/drivers. It should have built-in 

alarm interface capability, any monitor or group of monitors could be set to display 

cameras under alarm conditions. In addition, 16-character alarm title could be 

selected to appear instead of the camera title during alarm conditions. 

4.01.05 The video switcher/control system should include on screen display for time-date, 

camera number, camera Id, and monitor or status information. The system should 

have provision for logging printer output port to provide permanent record of system 

status showing time and date of changes such as : incoming alarms, 

acknowledgement of alarms, loading of sequences, user log-on to keyboard, 

transfer of system tables and sequence, video loss messages, and a power up reset 

message, so that a hard copy of the system’s configuration tables and sequences 

can be obtained. 

4.01.06 The system shall also have the following provisions. 

- User friendly spreadsheet format providing the ability to enter camera titles, 

operator names, timely events, change system parameters, program camera 

sequences and install lockouts. 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

3 OF 9

CLAUSE NO. 




PLANT PACKAGE 


- It should provide high performance programming, control and monitoring of all 

the system functions by using on-screen icons to reflect real time status of the 

devices being controlled by the system. 

- Software should also provide the ability to monitor system status events. 

System alarms, switching functions, sequence events, keyboard actions, and 

video loss information. 

4.01.07 All the video switcher/control system shall be connected to a 10/100 Base Fiber 

Optic full Duplex Ethernet network, to be provided by the Contractor. In case it is the 

standard practice of the Contractor to provide PC based video switcher / control 

system to achieve all the above functions, the same is also acceptable. 

4.02.00 Keyboard : 

4.02.01 Keyboard should have full function used for system control and programming and 

should be ergonomically designed. It should include integral pan/tilt joystick and 

zoom lens controls. This would be connected to the video switcher/control system for 

signal and power. 

4.02.02 Keyboard shall have full function used for system control and programming for 

selection of various video switcher/ DVR / camera functions including pan/tilt and 

zoom lens controls and shall be ergonomically designed. The Key board shall be 

able to access DVR and video switcher. Incase it is the standard practice of the 

contractor to offer PC based integrated keyboard and monitor, then the same is also 

acceptable, subject to Employer’s approval. 

4.03.00 Cameras : 

4.03.01 The cameras shall be rugged, 1/4 inch image format, full performance color CCD 

cameras. These cameras should provide high resolution and high sensitivity suitable 

for operation in a coal handling plant, both in natural and artificial lighted areas. 

4.03.02 The cameras should have features as mentioned below : 

- Suitable for night-time surveillance 

- Manual or Automatic colour/infra red switching 

- Automatic picture enhancement to give a balanced picture where there is too 

little/too much light 

- Remote camera setup, with on screen menu display. 

- Character generator giving up to 24 character text-in-picture. 

- Backlight composition 

- Automatic white balance, with mode selection options 

- Contour correction and contrast compression control. 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

4 OF 9

CLAUSE NO. 




PLANT PACKAGE 


- Synchronisation selection for Gen lock, external V-lock, mains lock and 

internal free-running. 

- All cameras shall be network compatible. 

4.03.03 Detailed technical specifications are as under : 

Imager : Interline transfer CCD, 1/4 inch image format 

Horizontal resolution : 480TVL in PAL B mode 

Sensitivity (at f1/4, 6dB), scene illumination 0.7 lux (at 50 IRE color) 

Light Range 

4.04.00 Lens : 

Signal-to-noise : > 50dB. 

AGC : Upto 18 dB 

Shutter Speed : 1/50-1/1,00,000 LUX. Auto select 

Lens Mount : Video Iris 

Gamma Correction : 0.45/1.0 

Auto-black contour correction : Colour 

Contrast compensation : 2.5x 

Power Supply : 230V AC 

4.04.01 The lens should be Auto-iris lens of 1/4 inch to be mounted on the above camera. It 

should be zoom lens with CS-Mount. The details are as under: 

Focal Length : 6 – 90 mm zoom lens (approx.) 

Iris range : 1.2 to 360 

4.05.00 Camera Housing 

4.05.01 All the cameras and accessories are to be housed in Weather Proof (IP-65) 

environmental housing made of aluminum. The housing with heater and blower 

installed should provide protection for camera/lens assemblies in the ambient 

temperature range of - 0 deg. C to 60 deg. C. 

4.05.02 The housing should also have thermostatically controlled heater kit, continuous duty 

blower kit, purge air arrangement and Window wipers available within the housing. 

Complete assembly including camera shall be suitable for hot and highly polluted 

environment of Coal Handling Plant. 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

5 OF 9

CLAUSE NO. 

4.06.00 Pan & Tilt Unit : 




PLANT PACKAGE 


4.06.01 The Pan & Tilt unit should be weather proof (IP-65) with pan/tilts designed to meet 

the rigorous requirement and should be constructed with corrosion resistant 

hardware. 

4.06.02 They should be capable of handling loads up to 10 kg and should be having 100% 

duty cycle motors to permit continuous operation. 

4.06.03 The pan & tilt should comply with the following : 

- Electrical – 230V AC, 50 Hz 

- Pan range : 120 deg movement in horizontal plane. 

- Pan speed : 6 deg./sec. 

- Tilt : +3 deg to –90 deg movement in vertical plane 

- Tilt speed : 3 deg./sec. 

- Construction : Cast aluminum base and yoke, corrosion resistant cover. 

4.07.00 On-site Receiver/Driver Unit : 

4.07.01 The on-site receiver/drive unit should be able to control the motor drives for pan/tilt 

and cameras for zoom and aux control. These would be used in conjunction with the 

Microprocessor based video switcher/controller systems. 

4.07.02 The on-site receiver/driver unit should have features like focus/zoom/iris controls, 99 

prepositions lockable enclosure latches, an integral local test function and IP 65 rated 

environmental enclosure. 

4.07.03 The On-site receiver/driver unit should be operated from 230V AC, 50 Hz and 

provision to be within hazardous are in the vicinity of the camera and pan tilt unit. 

The cable from the receiver drive unit to the pan/tilt unit and the camera is to be 

provided with the receiver driver unit. 

4.08.00 Monitor & Key board: 

4.08.01 The monitors should be colour video monitors that the versatile and attractive units to 

be mounted on the wall/desk. It should have built in audio. Monitors are to be 

operable at 230V AC, 50 Hz. They should comply to the following specifications. 

General : Automatic degaussing, Fast warm up time 

Display tube : 51 cm diagonal, 90 deg deflection, integral implosion protection. 

Resolution : 450 TVL minimum 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

6 OF 9

CLAUSE NO. 




PLANT PACKAGE 


Controls : Colour system select, volume, colour, brightness, contrast, power, video 

input select and Y/C termination. 

4.09.00 Digital Video Recorder: 

Parameter Specification 

Horizontal Resolution 720x570 lines 

Color system PAL/ NSTC, compatible with the CCTV system being 

proposed by the contractor. 

Recording system Applied JPEG, MPEG, Wavelet or better with Motion 

detection-Hi performance system. 

Recording speed 1-50 frames per second ( fps) , programmable 

Inputs 16 channel with Inbuilt Multiplexer and storage for 

minimum eight days on HDD for all the connected 

camera signals. 

Characters generation Date, hours, minutes and seconds. 

Record time by alarm Minimum range from 5 sec. To 3 min, to be finalised 

during detailed engineering stage. 

Input signal Compatible with the finally selected cameras/ network 

View Multiple, 2x2, 4x4, single to be finalised during 

detailed engineering stage. 

Power supply Manufacturer’s standard 

Search By date, time or cameras 

Alarm Inputs Minimum 8. 

Video I/P 1V p-p 75 Ohm to be finalised during detailed 

engineering stage. 

Video O/P 1 V p-p 75 Ohm to be finalised during detailed 

engineering stage. 

Zones Minimum 5 User Customizable Zones per camera 

Archiving The recorder shall be fully compatible with any 

standard 10/100 Base FO full Duplex Ethernet port for 

networking to a central DVD or AIT or Hard Disk 

Arrays after seven days of recording is over on the 

HDD. All or selected portions of the recorder material 

shall be shifted on to AIT or DVD and archived. The 

Archiving unit shall be common for the stations. 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

7 OF 9

CLAUSE NO. 




PLANT PACKAGE 


4.09.01 In case the contractor’s standard practice is to provide Digital video recorder which 

integrates the function of video switcher / controller, then the same is also 

acceptable. In that case, the DVR shall record multiple camera signals while 

simultaneously providing live multiscreen viewing and playback. 

4.09.02 The images per second rate and image quality shall be selectable for each 

connected camera. The digital recorders shall allow selectable frames per second 

(fps) record rates from zero fps to minimum twenty five fps. 

4.09.03 DVR shall also have features: on screen display which records time, date, number of 

alarms etc 

4.10.00 Post Equalisation Video Amplifier : 

4.10.01 The post equalisation video amplifier should provide of controls of adjustable overall 

gain and frequency boost while maintaining full video amplitude, contrast and detail. 

It should work on 230V AC, 50Hz. 

4.10.02 The post equalisation video amplifier should comply to the following : 

Gain : adjustable from 1 dB to +8 dB 

Frequency response : Adjustable from flat (+/- 1 dB) at 12 Mhz to greater than +18 

dB at 12 Mhz. 

Controls : Gain, HF boost, LF boost and indication of red LED when power is on. 

5.00.00 OPERATIONAL REQUIREMENTS : 

6.00.00 CABLES : 

The CCTV system should comply to the following operational requirement. 

1. From the master control panel(keyboard) it shall be possible to select any 

camera and display the picture on any of the monitors. 

2. Commands from the video switcher/control unit is sent via a onsite 

receiver/drive unit to the camera which in turn controls the pan/tilt zoom etc., 

functions. 

3. Operator shall be able to control all the cameras, pan / tilt and zoom functions 

manually. 

4. The video recorder shall record the activities of all the places where alarm 

have been alerted. The time-lapse video recorder shall be able to record up to 

720 hrs without reloading. 

6.01.00 Power, control and instrumentation cables shall conform to the relevant section of 

this specification. Any special cables for use in CCTV shall conform to the relevant 

Indian/International standards. However all cables shall be FRLS type as specified 

elsewhere. 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

8 OF 9

CLAUSE NO. 




PLANT PACKAGE 


6.02.00 All the cables shall be installed as per the requirements stipulated in the relevant 

sub-section of this specification. 

6.03.00 The signal / Video transfer from Cameras to the main control room equipment shall 

be through fibre optic cable 

7.00.00 Tentative location of 16 nos. of CCTV cameras: 

Wagon tippler area 6 nos. 

Crusher house 3 nos. 

TPs 7 nos. 

TOTAL 16 nos. 


SECTION-VI 

PART-B 




(CCTV) 

PAGE 

9 OF 9







FOR 



(BOOK 2 OF 2) 

(CIVIL/QA&I/GTR/ECC/SPARES) 








FOR 



(BOOK 2 OF 2) 

(CIVIL/QA&I/GTR/ECC/SPARES) 








PLANT PACKAGE 




BOOK 1 OF 2 : MECHANICAL & ELECTRICAL 

PART-A Sub Section- I Project Synopsis 

PART-A 

Sub Section – II : Scope of Supply & Services 

IIA-01 

Intent of Specification 

Scope 

Terminal Points & Exclusions 

IIB-01 PG Test Procedure 

IIC-01 Spares 

PART-B Sub Section III : Technical Parameters 

PART-B 

III-A MECHANICAL 

IIIA-01 System Parameters and Operation & Control 

Philosophy 

IIIA-02 Wagon Tippler 

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 


SECTION-VI 

MAIN CONTENTS 

PAGE 1 OF 3




PLANT PACKAGE 



IIIA-14 Inline Magnetic Separator and Suspended 

Magnet 

IIIA-15 Metal Detector 

IIIA-16 Coal Sampling Unit 

IIIA-17 Elevator 

IIIA-18 Apron Feeder 

IIIA-19 Side Arm Charger 

PART-B III-B ELECTRICAL 

PART-B 

IIIB-01 Motors 

IIIB-02 LT Switchgear & Bus Duct 

IIIB-03 HT Cables 

IIIB-04 LT Power Cables 

IIIB-05 Control Cables 

IIIB-06 Instrumentation cables 

IIIB-07 Illumination System 

IIIB-08 Cabling, Earthing & Lightning Protection 

IIIB-09 Transformers 

IIIB-10 HT Switchgear 

IIIB-11 Battery 

IIIB-12 Battery Charger 

IIIB-13 Control Panel 

IIIB-14 Closed Circuit Television System (CCTV) 

BOOK 2 OF 2 : CIVIL / QA&I / GTR / ECC / SPARES 

PART-B III-D CIVIL 

PART-B IIID-01 CHP System - Civil & Structural Works 


SECTION-VI 

MAIN CONTENTS 

PAGE 2 OF 3




PLANT PACKAGE 



IIID-02 Foundation System and Geotechnical Data 

(Turnkey) 

PART-B III-E QA & I SECTION 

PART-B 

IIIE-01 Coal Handling Plant 

IIIE-02 Motors 

IIIE-03 LT Switchgear & Busduct 

IIIE-04 LT Power Cables 

IIIE-05 LT Control Cables 

IIIE-06 Instrumentation Cables 

IIIE-07 Station Lighting 

IIIE-08 Cabling, Earthing & Lightning Protection 

IIIE-09 Control Panels 

IIIE-10 Programmable Logic Controller (PLC) 

IIIE-11 Battery Charger 

IIIE-12 HT Cables 

IIIE-13 HT Switchgear 

IIIE-14 Actuators 

IIIE-15 Auxiliary Transformer 

IIIE-16 Battery & Battery System 

IIIE-17 Measuring & Instrumentation 

IIIE-18 Closed Circuit Television System (CCTV) 

IIIE-19 CHP System - Civil & Structural Works 

PART-C General Technical Requirements 

PART-D Erection Conditions of Contract 

PART-E List of Tender Drawings 

PART-F List of Mandatory Spares 


SECTION-VI 

MAIN CONTENTS 

PAGE 3 OF 3

CIVIL WORKS 





SECTION-VI 

PART-B

PART - B 

SUB-SECTION-IID-01 

CIVIL WORKS 





SECTION-VI 

PART-B

CLAUSE NO. 

CLAUSE 

NO. 





PLANT PACKAGE 


CONTENTS 

2.00.00 LAYOUT & LEVELS 

3.00.00 DRAWINGS/DOCUMENTS 

4.00.00 WORK DESCRIPTION 

DESCRIPTION 

4.01.00 – Wagon Tippler, Machinery Hatches and 

Underground Tunnel 

4.02.00 - Overhead / Ground Conveyor Galleries and 

Trestles 

4.03.00 – Transfer Houses 

4.04.00 – Crusher House 

4.05.00 – Control Buildings, MCC Buildings 

4.06.00 – Pump Houses 

4.07.00 – Pent House 

4.08.00 – Toilets 

4.09.00 – Staircases 

4.10.00 – Trenches 

5.00.00 Drainage & Water Supply Works 

5.01.00 – Drainage System 

5.02.00 – Internal and external water supply, drainage 

6.00.00 COLOUR COATED AND OTHER SHEETING WORK 

7.00.00 ROOF DETAILS 

8.00.00 FLOOR AND GRADE DETAILS 

9.00.00 BRICKWORK & ALLIED MASONRY WORKS 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

1 OF 55

CLAUSE NO. 

10.00.00 EARTHING MAT 

11.00.00 FENCING 

12.00.00 LOADING 

13.00.00 DESIGN CRITERIA 

14.00.00 CONCRETE 




PLANT PACKAGE 


15.00.00 EXCAVATION DETAILS 

16.00.00 Galvanising 

15.01.00 – Excavation in soil 

15.02.00 – Excavation in rock 

15.03.00 – Dewatering of deep foundations 

15.04.00 – Backfilling, disposal & stacking of materials 

17.00.00 Chemical Injection Grouting 

18.00.00 Polymer modified cementitious coating 

19.00.00 Architectural Features 

20.00.00 Painting 

19.01.00 – Glazing 

19.02.00 – False ceiling 

19.03.00 – Acid/Alkali Resistant Lining 

19.04.00 – Finishing Schedule 

19.04.01 – Flooring 

19.04.02 – Interior wall/ ceiling finish 

19.04.03 – Exterior finish 

19.05.00 – Door, windows & rolling shutters 

19.05.01 – Doors & Windows 

19.05.02 – Rolling Shutters 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

2 OF 55

CLAUSE NO. 

21.00.00 Miscellaneous 

22.00.00 Shotcreting 




PLANT PACKAGE 


23.00.00 Vibration Isolation System 

24.00.00 Packaging & Transportation 

25.00.00 Plant Life 

26.00.00 PTFE Bearing 

27.00.00 Tests for Materials/Workmanship 



Annexure A Criteria for Earthquake Resistant Design of structures & 

Equipment 

Annexure B Criteria for Wind Resistant Design of structures & 

Equipment 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

3 OF 55

CLAUSE NO. 





PLANT PACKAGE 


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 VINDHYACHAL STPP. 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 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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

4 OF 55

CLAUSE NO. 

3.00.00 DRAWINGS / DOCUMENTS 




PLANT PACKAGE 


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 Wagon Tippler, Machinery Hatches and Underground Tunnel 

Wagon Tippler and machinery hatches shall consist of underground portion, which 

shall be of R. C. C. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

5 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 

Wagon Tippler structure shall be provided with 50 mm thick guniting (shotcreting). 

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. 

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. Arrangement shall be made for disposal of water right up to the coal slurry 

setting tank. Side drains and sump shall have removable type steel grating cover. 

Gratings shall be galvanized to grade 610 gm/m 2 . 

Water proofing / Damp proofing of under ground portion of Wagon tippler, tunnels, 

underground (i. e. basement) portion of transfer houses shall be done by providing 

the following treatments: 

Chemical injection grouting for inner faces (details as specified elsewhere). 

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 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. 

Steel gratings of mesh size 350mm square 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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

6 OF 55

CLAUSE NO. 




PLANT PACKAGE 


Plinth protection along with drains shall be provided around the Wagon Tippler. 

However, 5m wide paving shall also be provided around Wagon Tippler. 

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 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. 

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 10 o , R. C. C. steps shall be provided for the 

entire width of each walkway. 

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 clear width 

800 mm and 1100 mm respectively shall be provided. The clear width of two side 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

7 OF 55

CLAUSE NO. 




PLANT PACKAGE 


walkways for single stream conveyor gallery shall be 800 mm and 1100 mm 

respectively. Both sides of central and side walkways shall be provided with pipe 

handrails all along the conveyor gallery. Hand railing should not be supported on 

conveyor supporting stringers. The walkways shall be chequered plate construction 

with anti - skid arrangement. The anti - skid arrangement will consist of welding of 10 

mm square steel bars at a maximum spacing of 500 mm along the length of the 

gallery. Where the slope of walkway is more than 10 o , chequered plate steps with 

nosing and toe guard shall be provided. The floor of conveyor gallery all along the 

gallery length, shall be provided with minimum 12 gauge thick seal plates and other 

drainage arrangements as specified elsewhere 

Conveyor gallery shall have permanently colour coated steel sheet covers on roof 

and both sides. However in roof, a panel of minimum 1.5 m x 1.5 m area at about 

6.0 m center shall be provided with translucent sheets of polycarbonate material for 

natural lighting. A continuous slit opening of 500 mm shall be provided on both sides 

just below the roof sheeting. Adequate provision of windows shall be kept on both 

sides of conveyor gallery as appended in Mechanical Section (Belt conveyor 

system). Windows shall be provided with wire mesh as specified elsewhere in this 


Cross - over with chequered plate platform and ladder for crossing over the 

conveyors shall be provided at approximately every 100 M intervals of conveyor. 

Crossover shall preferably be located over four-legged rigid trestle location. 

For railway tracks passing below overhead conveyor gallery and along conveyors, 

the railway clearances both underground as well as over ground shall have to be 

adhered to for design, execution and erection of foundations, trestles, galleries etc., 

so that movement of locomotives and wagons is not hampered in any way during 

execution and afterwards. However at the location where the overhead conveyor 

gallery crosses road / rail line, minimum clearance of 8.0m above the road crest / rail 

top shall be provided. 

For calculation of coal load on moving conveyor, a multiplication factor 1.6 shall be 

used to take care of inertia force, casual over burden and impact factor etc. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

8 OF 55

CLAUSE NO. 




PLANT PACKAGE 


Conveyor gallery and supporting trestles located between transfer houses / buildings 

shall be arranged in any one of the following ways. 

(a) All gallery supporting trestles shall be four legged type only. One end of each 

gallery span shall be hinged to the supporting trestle and the other end shall 

be slide type. Slide type support shall be with P. T. F. E. bearings to allow 

both rotation & longitudinal movements. 

(b) In between transfer houses / buildings, four legged trestles shall be placed at 

a maximum interval of 90 metres. The arrangement shall be such so as to 

ensure that force in the longitudinal direction (i. e. along the conveyor length) 

of conveyor gallery of length not more than 90 m is transferred to any four 

legged trestle. In the space between each successive four legged trestles, 

two legged trestles shall be provided at regular intervals. The end supports 

resting on the four-legged trestle can have either ends hinged or one hinge 

and the other on slide type depending on the arrangements. Slide type 

support shall be with P. T. F. E. bearings to allow both rotation & longitudinal 

movements. 

End of conveyor gallery which will be supported over transfer house, shall be so 

detailed that only vertical reaction is transferred from conveyor gallery and no 

horizontal force in longitudinal direction is transferred from conveyor gallery to 

transfer house structure and vice - versa. 

For trestles and trestle foundations for conveyor galleries located adjacent to 

existing structures, over ground and under ground facilities, location and details of 

these trestles and foundations shall have to be decided such that there is no 

interference both underground as well as over ground with existing structures and 

facilities. Trestle columns / ground conveyor portal column base shall be kept 300 

mm higher than the existing ground level. 

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 and roof over structural beams. However the lower portion of side 

cladding for a minimum height of 0.9 m above the finished floor level shall be one 

brick thick wall plastered on both side. In some areas like MCC floors etc., one brick 

thick wall cladding shall be provided. Brick wall cladding shall be supported on 

encased wall beams and suitably anchored to adjoining columns and beams. 

Roof shall be provided with water proofing treatment as specified elsewhere. 

Adequate steel doors and windows for proper natural lighting and ventilation shall be 

provided. In addition to steel windows, panels of suitable size to suit the architectural 

treatment and made of translucent sheets of polycarbonate material shall also be 

provided on the side cladding for natural lighting. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

9 OF 55

CLAUSE NO. 

4.04.00 Crusher House 




PLANT PACKAGE 


The crusher house shall be framed structure of structural steel work with 

permanently colour coated profiled steel sheet side cladding. However, panels of 

suitable size to suit the architectural treatment and made of translucent sheets of 

polycarbonate material shall also be provided on the side cladding for natural 

lighting. The lower portion of side cladding for a height of minimum 0.9m above the 

finished floor level shall be of one brick thick wall plastered on both faces. Floors and 

roof shall be of R. C. C. supported on steel beams. Within this building cubicles are 

to be provided for resting room of operators and these shall be constructed with one 

brick thick brickwork having both sides plastered and roof slab. Roof shall be 

provided with roof water proofing treatment as specified elsewhere. Adequate steel 

doors and windows for natural lighting and ventilation shall be provided. 

Ring Granulator Type Crushers shall be supported on R. C. C. deck, which in turn 

will rest on suitable vibration isolation system consisting of springs and dampers. 

This R. C. C. deck shall be isolated from the floor. However, the vibration isolation 

system consisting of springs and dampers may rest on main building framework. 

Detailed specification of vibration isolation system including the unbalanced force 

(due to ring granulator), frequency and amplitude criteria and other design 

requirements are appended elsewhere in this specification. 

Four Roll type crusher also shall be rested on floor with or without vibration isolation 

system, depending on machine and structural and service requirements. 

4.05.00 Control building, M. C. C. Buildings 

These shall be R. C. C. framed structures with columns, beams, slabs and 

foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof 

shall be provided with roof water proofing treatment, as specified elsewhere in the 

Technical specification. 

In case of control building suitable permanent interconnection shall be provided at 

appropriate level with the existing respective buildings. 

All air - conditioned areas, shall be provided with the suspended permanently colour 

coated aluminium false ceiling system (details specified elsewhere). 

Adequate aluminium doors and windows shall be provided for natural lighting, 

ventilation and view. 

4.06.00 Pump Houses 

These shall be of R.C.C. or steel framed structure with columns, beams, slab and 

foundations etc. cladding shall be of brick work with plastering on both sides. Roof 

shall be provided with roof water proofing treatment as specified elsewhere. 

Underground sump and water tanks shall be of R.C.C. Adequate number of doors, 

Windows and Rolling Shutters shall be provided. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

10 OF 55

CLAUSE NO. 

4.07.00 Pent House 

4.08.00 Toilets 




PLANT PACKAGE 


Galvanized steel ladder / rung ladder shall be provided for access to the roof level of 

the pump house and water tanks. 

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. 

Toilet with potable water line facilities shall be provided in each of the following 

locations: 

Crusher House (Ground & Drive Floor) 

In all M. C. C. Rooms 

Control Building 

Each unit shall have brick enclosure, and the following fittings. 

(i) Squatting type, white, vitreous china Orissa 

pattern, W.C. pan with high level flushing 

cistern (C.I.) and all requisite fittings 

1 No. 

(ii) Bowl type Urinal with automatic flushing 2 Nos. 

cistern (C.I.) and all requisite fittings 

(iii) Wash Basin 630 mm x 450 mm with 2 Nos. 

two taps and all requisite items 

(iv) Mirror 600 mm x 450 mm x 5.5 mm thick 2 Nos. 

with bevelled edges (Superior sheet glass) 

(v) C.P. Brass Towel Rod 600 x 20 mm 1 No. 

(vi) Liquid Soap Container 2 Nos. 

(vii) Washing Tap (CP Brass) 2 Nos. 

(viii) Overhead Polyethylene water tank 1 No. 

(min. 500 litres capacity) 

(ix) Suitable provision for installation of water coolers. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

11 OF 55

CLAUSE NO. 

4.09.00 Staircases 

4.10.00 Trenches 




PLANT PACKAGE 


All roofs & floors of transfer houses shall be accessible through staircase. However, 

for the pump houses, access to the roof will be provided by cage ladder 

All stairs other than those of M. C. C. rooms and control rooms shall be of steel 

(minimum 1000 mm wide)and maximum rise should not be more than 180 mm and 

minimum tread width 250 mm. Stringers shall be of rolled steel channel (minimum 

ISMC 250) and tread shall be of steel gratings. Stairs shall be provided with 32 mm 

dia nominal bore medium duty M. S. pipe hand rail. 

Handrails (for staircases, around openings, in walkways etc.) shall be of standard 

weight steel pipe of flush welded constructions, ground smooth using 32 mm 

nominal bore medium class pipe provided with double rail, top rail about 1.0 metre 

above platform level and pipe posts spaced not more than 1.5 metres apart. Angle 

handrail post may be provided when specifically called for in drawings approved by 

Engineering. Handrails around openings should have toe plates. 

Smooth uniform curves and bends shall be provided at stair returns and also where 

so ever required. Posts connected to curb plates shall have a neat closure at the 

bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. 

All necessary fittings including inner dowels at splices, brackets, belts, bends, 

flanges and chains, where required shall be plugged and welded. A minimum radius 

of 3 times the pipe diameter shall be provided at all points of direction changes in the 

handrail. 

Treads and landing shall be suitable for the prescribed loading. The maximum width 

of openings in gratings shall not exceed 40 mm. The minimum thickness of main 

bars shall be 6 mm. The usual span of grating will not generally exceed 1.5 meters. 

Stair case gratings shall be galvanized to grade 610g/m 2 . 

Out side stairs to transfer points shall be open type. However RCC slab shall be 

provided at the top. 

Stairs of control room and M. C. C. room shall be of R. C. C. construction, and 

minimum 1200 mm wide, maximum rise should not be more than 180 mm and 

minimum tread with 250 mm. 

Numbers and arrangement (including enclosures etc.) of stair cases shall be such as 

to meet the fire safety requirement as per guide lines of statutory regulatory bodies. 

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 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

12 OF 55

CLAUSE NO. 




PLANT PACKAGE 


for 10 T wheel load at centre. Pre - cast covers shall be designed for central point 

load of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection of 

cables, up to top level and covered with pre - cast R. C. C. covers. For cable 

trenches outside buildings, top level shall be 200 mm above G. L. 

Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protection 

all around cut outs / openings in floor slabs, edges of drains supporting 

grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast 

covers, supported edges of pre - cast cover, treads of RCC stairs. 

5.00.00 DRAINAGE & WATER SUPPLY WORKS 

5.01.00 Drainage System:- 

The drainage arrangements shall be so planned so as to ensure quick disposal of 

drainage water without stagnation and / or overflow. It is envisaged to clean the 

conveyor galleries, transfer points, crusher building, penthouse etc. with water 

periodically. 

Minimum 4 nos. down comers shall be provided in each transfer house / crusher 

house. In case of conveyor galleries, the down comer shall be provided at every 

trestle location. 

For Conveyors 38 A/B, 39 A/B, 21 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 

owner’s drain routed alongside the nearby road. 

For Crusher House, Pent House, JT-1, JT-2, & JT-3 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 , 

which will lead the discharge finally into owner’s drain routed alongside the nearby 

road. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

13 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 (Galvanised to 610 gm/m 2 ) 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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

14 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 

Permanently colour coated sheet of approved shade and colour using galvanised 

mild steel sheet of minimum 0.6mm BMT(bare metal thickness i.e. metal thickness 

excluding thickness for coating and galvanizing) galvanised to grade 275 as per IS 

277,of minimum yield strength of 250 Mpa of drawing grade as per IS 513 or high 

tensile steel of minimum 0.5mm BMT(bare metal thickness i.e. metal thickness 

excluding thickness for zinc aluminium coating and colour coating ) coated with zinc 

aluminium alloy @ 150gm/sq.m.of minimum yield strength of 350 as per AS1397. 

Steel shall be colour coated with total coating thickness of 35 microns (nominal) 

comprising of silicon modified polyester (SMP with silicon content of 30% to 50%) 

paint or Super Polyester paint, of minimum 20 microns (nominal) dry film thickness 

(DFT) on external face on 5 microns (nominal) primer coat and 5 microns (nominal) 

SMP or super polyester paint over 5 microns (nominal) primer coat (or 10 micron 

SMP/super polyester paint) on internal face. SMP and Super polyester paint 

systems shall be of category 3 as per AS2728. Coated surface shall be provided 

with a protected guard film (polyethylene) of about 40 microns to avoid any damage 

to the coating during handling. 

For metal deck, minimum 0.8 mm (bare metal thickness i.e. metal thickness 

excluding thickness for coating and galvanizing) galvanised to grade 275 as per as 

per IS 277, of minimum yield strength of 250 Mpa of drawing grade as per IS 513, 

troughed profile having nominal trough depth 44 mm and pitching of 130 mm shall 

be used. However alternative profile meeting the strength, defection and other 

functional requirements such as sections modulers and moment of inertia shall be 

provided. To minimize the number of joints, the length of the sheet shall preferably 

be not less than 4.5 cut pieces shall not be used, unless specifically approved by the 

Engineer. However, the actual length shall be such so as to suit the purling / runner 

spacing. 

No negative tolerance shall be allowed in bare metal thickness. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

15 OF 55

CLAUSE NO. 




PLANT PACKAGE 


For wall cladding insulated / uninsulated and conveyor gallery sides and roof, 

permanently colour coated sheet of troughed profile shall be used. The nominal 

depth of trough shall be 30 mm. 

The polycarbonate sheet to be used for cladding and glazing purpose in conveyor 

galleries shall have toughed profile to match with the metal cladding profile. 

Minimum 2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of 

GE plastic or equivalent approved make shall be used. The polycarbonate sheet 

shall be installed along with the metal cladding so as to have a watertight lapping 

arrangement. Suitable detailing shall be made to cater for the thermal expansion. IS 

: 14434 to be referred for other details. 

Polycarbonate sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous 

use under temperature 100 o C), impact resistant and ultraviolet resistant sheet shall 

be provided (as glazing) in transfer houses, pump houses, etc. 

7.00.00 ROOF DETAILS 

Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD 

reinforcement bars placed at 200 mm center both ways at top and bottom. 

900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided 

over roofs of all buildings. Parapet wall shall have suitable coping. External face of 

parapet wall of the buildings provided with metal cladding shall also be finished with 

metal cladding of design and colour as per approved architectural drawings. 

Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet. 

Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness 

of 30 mm of M-15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished 

with 12 mm 1 : 3 cement : sand plaster. 

Roofs of all transfer houses, crusher houses, control rooms, M. C. C. rooms, 

penthouse etc., shall have roof water proofing treatment. Roof water proofing 

treatment shall be as follows: 

(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). 

(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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

16 OF 55

CLAUSE NO. 




PLANT PACKAGE 


(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. 

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. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

17 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 

11.00.00 FENCING 

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. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

18 OF 55

CLAUSE NO. 

12.00.00 LOADING 




PLANT PACKAGE 


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. 

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 

b) R. C. C. floors 500 Kgs. / Sq. M. 

c) Stair and balconies 500 Kgs. / Sq. M. 

d) Toilet rooms 200 Kgs. / Sq. M. 

e) Chequered plate floors 400 Kgs. / Sq. M. 

f) Walkways (including walkways in 

conveyor galleries) 


SECTION-VI 

PART-B 

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. 

300 Kgs. / Sq. M. 

g) Conveyor galleries In addition to the live loads, loads due 

to cable trays, fire fighting / service 

water pipes shall also be considered @ 


CIVIL WORKS 

PAGE 

19 OF 55

CLAUSE NO. 




PLANT PACKAGE 


h) Road Culverts and its allied 

structures including R. C. C. pipe 

crossing & road crossing of 

trenches. 


SECTION-VI 

PART-B 

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. 

For class 'AA' loading and checked for 

class A loading as per IRC standard. 

i) Channels / trenches In addition to earth pressure and water 

pressure, etc. additional earth pressure 

due to surcharge of 2T / Sq. M. shall 

also be considered for design. 

j) Covers for trenches / channels Covers for channels & trenches, shall 

be designed for a live load of 0.4T Sq. 

M. and loading as mentioned under 

clause in trenches, whichever is critical. 

k) Sumps and tanks and other 

underground basement type 

structures 

l) Unit weight of coal shall be taken as 

1100 Kgs. / cum. for design 

purposes. 

In addition to earth pressure with a 

surcharge of 2T / Sq. M. (or surcharge 

due to Railway loading whichever is 

critical for Railway load bearing 

structures etc.) and sub - soil water 

pressure etc. These are also to be 

designed for the following conditions : 

i) Water / liquid inside and no earth 

outside (applicable only to such 

structures which are liable to be 

filled up with water or any liquid ). 

ii) Earth with surcharge outside and 

no water / liquid inside 

iii) For underground (basement) 

structures protection against 

buoyancy during execution and 

after execution shall be ensured 

without superimposed loadings 

with minimum factor of safety of 

1.2 against buoyancy. 


CIVIL WORKS 

PAGE 

20 OF 55

CLAUSE NO. 




PLANT PACKAGE 


If the erection load is higher than the specified live loads on any floor or part thereof, 

then the erection loads are to be considered for the design. 

Permissible increase in stresses of materials and bearing pressure of soil due to 

wind load or seismic load shall be as per relevant I. R. S. and I. S. code. 

13.00.00 DESIGN CRITERIA 

The loads for all railway load bearing structures e. g. track hopper including 

machinery hatches, wagon tippler, tunnel 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. However, the axle load for analysis and design shall be considered as 30 MT. 

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 (latest) and other 

relevant IS Standards. Minimum size of the angle section to be used as structural 

members shall be 50 X 50 X 6. Minimum weld size shall be 6 mm. Connections shall 

be designed for 70 % of shear capacity of the member or the actual shear force, 

whichever is higher. 

The building shall conform to local bye - laws, rules and regulations for industrial 

buildings and also B. I. S. publications, SP 32 and 41. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

21 OF 55

CLAUSE NO. 

14.00.00 CONCRETE 




PLANT PACKAGE 


The permissible vertical deflection for beams supporting drive machinery shall be 

restricted to span / 500 and for other beams it shall be within span / 325. 

Horizontal bracing system shall be provided at floor levels around the openings. 

Shear force in steel columns shall be transferred to the pedestals / foundations 

exclusively either through foundation bolts or the shear key arrangement. 

For design of liquid retaining structures, IS : 3370 (Part - I to IV) (latest) shall be 

followed. Face of the structure in contact with liquid shall be designed as un - 

cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458, 

IS : 783 should be followed. 

For design of all underground structures / foundations, ground water table shall be 

assumed at the formation level (i. e. the adjoining ground level). 

Design of 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. 

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 Wagon Tippler structure. 

(b) M25 - For 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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

22 OF 55

CLAUSE NO. 




PLANT PACKAGE 


Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting 

etc. unless otherwise mentioned. 

15.00.00 EXCAVATION DETAILS 

15.01.00 Excavation in soil 

Excavation for foundation shall be to the bottom of lean concrete and as shown on 

drawing or as directed by the Engineer. The bottom of all excavations shall be 

trimmed to required levels and when excavation is carried below such levels by 

error, it shall be brought back to the specified level by filling with concrete of 

nominal mix 1:3:6 (cement: coarse sand: 40 mm down aggregates ), as directed by 

the Engineer. 

The Contractor shall ascertain for himself the nature of materials to be excavated 

and the difficulties, if any, likely to be encountered in executing this work. 

Cofferdams, sheet piling, shoring, bracing to maintain suitable slopes, draining etc. 

shall be provided and installed by the contractor, to the satisfaction of the Engineer. 

Surplus excavated materials shall be disposed off by the contractor at locations up 

to a lead of 5 kms from the plant boundary wall as directed by the engineer. 

The Contractor shall have to constantly pump out any water collected in excavated 

pits and other areas due to rain water, springs etc. and maintain dry working 

conditions at all times until the excavation, placement of reinforcement, shuttering, 

concreting, Backfilling is completed. The Contractor shall remove all slush/muck 

from the excavated areas to keep the work area dry. The Contractor, if required, 

shall employ sludge pumps, for this purpose. 

For other details, excavation clauses as given in Sub-Section III-D-02 are to be 

referred. 

15.02.00 Excavation in rock 

For the work of excavation in rock, Contractor shall engage specialised agency 

having experience of excavation in rock involving wedging and blasting. The agency 

shall be subject to approval of Engineer and the Contractor shall furnish details of 

relevant experience in support while seeking approval for the agency. 

Blasting shall be resorted to only with the written permission of the Engineer. All the 

statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. 

pertaining to the acquisition, transport, storage, handling and use of explosives etc. 

shall be strictly followed. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

23 OF 55

CLAUSE NO. 




PLANT PACKAGE 


The Contractor shall have to constantly pump out any water collected in excavated 

pits and other areas due to rain water, springs etc. and maintain dry working 

conditions at all times until the excavation, placement of reinforcement, shuttering, 

concreting, backfilling is completed. 

15.03.00 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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

24 OF 55

CLAUSE NO. 




PLANT PACKAGE 


Materials to be used for filling purpose shall be stone, sand or other inorganic 

materials and they shall be clean and free from shingle, salts, organic matter, large 

roots and excessive amount of sod, lumps, concrete or any other foreign substances 

which could harm or impair the strength of the substances in any manner. All clods 

shall be suitably broken to small pieces. When the materials are mostly rock 

boulders, these shall be broken into pieces not larger then 150 mm size. Sand used 

for filling shall be clean, medium grained and free from impurities. Fines less than 75 

microns shall not be more than 20%. In any case, the materials to be used for filling 

purposes shall have the prior written approval of the Engineer. 

In case the materials have to be brought from pits / quarries, then it shall be the 

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. / m 2 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. / cm 2 . 

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 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

25 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 


18.02.00 Mixing 

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%). 

Portland cement based dry powder. 

Clean, fine specially prepared quartz sand approximately 0.6 mm size. 

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 

18.04.00 Application 

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. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

26 OF 55

CLAUSE NO. 

(a) For Slurry Mix 




PLANT PACKAGE 


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. / m 2 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. 

(b) 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 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 

19.01.00 Glazing 

All architectural features of buildings like control rooms, crusher houses, M. C. C. 

rooms, transfer houses and conveyor galleries etc. shall be detailed by contractor’s 

qualified architect. 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 

along with colour schemes. Nothing extra shall be payable for any changes required 

while getting the drawings / schemes approved and for executing the same. 

In case structural column base plates are proposed below the floor level, the same 

shall be encased with adequate cover up to the finished floor level with minimum M - 

20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skin 

reinforcement of the encasing. 

Window glazing for various locations shall be as below: 

(i) In transfer houses, crusher house and pump houses etc: 

Polycarbonate sheet (Details described elsewhere). 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

27 OF 55

CLAUSE NO. 




PLANT PACKAGE 


(ii) In Switchgear / M. C. C. buildings 

(a) In air conditioned (A / C) areas: 

Double glazing with two 6 mm thick clear toughened safety glass 

hermetically sealed and separated by 12 mm thick gap for thermal 

insulation at partition of A / C and non A / C areas. 

(b) In toilets: 

Ground glass of minimum thickness 4 mm. 

(c) In other areas: 

Toughened glass of minimum thickness 4 mm 

The above mentioned glass thickness are bare minimum only and actual thickness 

will depend on the panel size of the glazing to be provided. 

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. 

50 mm thick mineral wool insulation (as per IS: 8183) having a density of 32 kg/cum 

for glass wool or 48 kg/cum for rock wool, bound in polythene bags shall be laid on 

top of panels. Additional hangers and height adjustment clips shall be provided for 

returns air grills, light fixtures, A. C. ducts etc. 

Under deck insulation shall be provided on the ceiling (underside of roof slab) and 

underside of floor slab of air - conditioned areas depending upon the functional 

requirements. This under deck insulation shall consist of 50 mm thick mineral wool 

insulation mat conforming to IS: 8183 having a density of 32 kg/cum for glass wool 

or 48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G x 25 

mm mesh wire netting and shall be fixed to the ceiling with 14G wire ties. 

19.03.00 Acid / Alkali Resistant Lining 

Battery Room 

For Floor and dado, bitumen primer followed by 12 mm thick bitumastic 6 mm thick 

potassium silicate mortar bedding and 20 mm thick A. R. tiles shall be provided. 

Dado height shall be minimum 2.0 m from floor. 

M. S. Grating / Chequered plate cover and any other steel structure likely to come in 

contact with chemicals shall be provided with epoxy coating 150 microns thick over 

epoxy primer. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

28 OF 55

CLAUSE NO. 




PLANT PACKAGE 


Acid / Alkali resistant lining material shall conform to the following: 

Bitumen primer shall conform to IS: 158. 

Bitumastic compound shall conform to IS: 9510. Where the height of bitumastic layer 

on vertical surface is more than 2.0 m, the bitumastic layer shall be reinforced with 

diamond pattern expanded metal steel sheets conforming to IS: 412. 

A. R. tiles shall conform to IS: 4457. 

Mortar: Potassium silicate and resin type mortars shall conform to IS : 4832 Parts – I 

and II respectively. 

19.04.00 Finishing Schedule 

19.04.01 Flooring 

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. 

I. P. S. (cement concrete flooring) with metallic hardener topping shall be provided 

for all floors in transfer houses, including ground floors of transfer houses, ground 

conveyors, operating floor of pump houses, M. C. C. rooms, cable vault / cable 

spreader rooms, maintenance and unloading areas, general storage areas and all 

other areas in plant buildings where heavy duty flooring is required. 

Heavy Duty Ceramic Tiles (matt finish) shall be provided for toilets, pantry, office 

rooms, laboratories, conference rooms, all control rooms and control equipment 

rooms. 

Well polished Kota stone shall be provided for staircases, passages, lobbies and 

general circulation areas. 

False flooring with 2 mm thick anti - static flexible PVC tiles over particle board shall 

be provided for computer room (if specific requirement is there) 

The nominal total thickness of floor finish shall be 50 mm i.e. underbed and topping. 

The floor shall be laid on an already laid and matured concrete base. 

Sunken R. C. C. slab shall be provided in false flooring area and toilet area so as to 

keep the finished floor level of these areas same as that of the surrounding area. 

Wherever specified metallic hardener topping shall be 12 mm thick using uniformly 

graded iron particles, properly treated. 

Wherever specified Heavy duty ceramic tiles of size 300 x 300 x 7 mm thick 

(minimum) of reputed manufacturer (Kajaria, Spartek or equivalent) of approved 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

29 OF 55

CLAUSE NO. 




PLANT PACKAGE 


finish, shade and colour to be used. The tiles shall have a scratch resistance of 

minimum 5 on Mohr’s scale and shall have a bending strength of 350 Kgs. / cm 2 . 

Paving details shall be similar to grade slab excluding metallic hardener. 

Skirting in general shall be 150 mm high. Dado in toilets and pantries shall be up to 

2.1 m height from finished floor level. Skirting and dado shall match with the floor 

finish. 

19.04.02 Interior Wall / Ceiling Finish 

For all air - conditioned areas and stair case acrylic emulsion paint of approved 

make and shade over 2 mm thick plaster of paris punning shall be provided. 

For toilets and pantries minimum 5 mm thick decorative coloured ceramic tiles of 

approved make and shade with approved pattern up to 2.10 m. height from finished 

floor level shall be provided. Oil bound distemper over plaster of paris punning 

above 2.10 m height shall be provided. 

For all other areas oil bound distemper ( IS : 428 ) of approved shade over 2 mm 

thick plaster of paris punning shall be provided. 

For battery room and other areas coming in contact with acid / alkali fumes, 

chemical resistant chlorinated rubber paint shall be provided above 2.1 m height. Up 

to 2.1 m height from finished floor level acid alkali resistant tiles shall be provided as 


All R. C. C. ceilings shall be white washed. 

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 


Water proofing cement paint / textured paint shall be provided for the under 

mentioned areas : 

All buildings with R. C. C. framework unless specified otherwise in this specification. 

Brick work in the lower portion of metal cladding. 

Fire walls 

Projections and facia : R. C. C. parapets (excepting parapets of buildings where 

metal cladding is specified) 

Exterior brick walls. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

30 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 prelaminated 

particle board (M D F exterior grade). All other buildings shall have steel 

doors, windows and ventilators. 

Single glazed panels with aluminium framework shall be provided as partition 

between two air - conditioned areas wherever clear view is necessary. 

Coal conveyor galleries shall have steel windows of openable type. The window 

shutters shall be provided with M. S. louvers. 

All steel doors shall consist of double plate flush door shutters. The door shutter 

shall be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous 

vertical 20 G stiffeners at the rate 150 mm centre to centre. Side, top and bottom 

edges of shutters shall be reinforced by continuous pressed steel channel with 

minimum 18G. The door shall be sound deadened by filling the inside void with 

mineral wool. Doors shall be complete with all hardware and fixtures like door closer, 

tower bolts, handles, stoppers aldrops, etc. 

Windows of coal galleries shall be provided with welded wire fabric of 1.6 mm thick 

wire as per IS: 4948 and 12 mm x 30 mm mesh size. 

Wherever functionally required rolling shutters shall be provided and these shall be 

electrically operated. 

In transfer points, windows near floors shall be steel and openable types. The 

window shutters shall be provided with MS louvers. Windows / ventilators at higher 

level can be of steel with fixed glazing. All openable windows shall be provided with 

suitable stays. 

All windows and ventilators on ground floor of all switchgear and M. C. C. buildings 

shall be provided with suitable anodized aluminium grill. 

Fire - Proof doors with panic devices shall be provided at all fire exit points as per 

the recommendations of statutory regulatory bodies These doors shall generally be 

as per IS : 3614 (Part I and Part II). Fire rating of the doors shall be as per 

requirements of statutory regulatory bodies. However minimum rating shall be 2 

hours. These doors shall be double cover-plated types with mineral wool insulation. 

Hollow extruded section of minimum 3 mm wall thickness as manufactured by 

INDAL or equivalent shall be used for all aluminium doors, windows, and ventilators. 

All doors should have opening as indicated in the drawings. Doors and windows on 

external walls of the buildings having brick enclosures i.e. enclosure other than with 

permanently colour coated steel sheet cladding, shall be provided with sunshade 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

31 OF 55

CLAUSE NO. 




PLANT PACKAGE 


over the openings with width 600 mm more than the opening width. Projections from 

the wall for the sunshade shall be 450 mm over window openings and 750 mm over 

door openings. Minimum size of door provided should be 2.1 m high and 1.2 m wide, 

except for toiler rooms, where door may be 0.75 m wide. All doors (other than those 

in W/C and urinal area) shall be double plate flush door shutters. For W/C and 

urinals area, wooden panel doors shall be provided. Area of windows shall be at 

least 10 % of the floor area of the respective building. The area of translucent 

polycarbonate sheet panels shall also be at least 10 % of the floor area of the 

respective building. 

Monorail doors shall be provided with steel stays / chains etc for convenient 

operation of the shutters. 

The louvre blade shall be ‘Z’ shaped and made out of 18G sheets in EZ7 steel 

frames. The frames shall be of ISMC 100. 

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. 

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: 

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 polyamide cured 

titanium di-oxide / micaceous iron oxide pigmented high performance (solid by 

volume minimum 60%) epoxy coating as per BS : 5493 ( two pack chemical resistant 

under coats). 

Finish coat (minimum 75 micron DFT) shall be of polyamide cured colored 

pigmented high performance (solid by volume minimum 60%) epoxy coating as per 

BS: 5493 (two pack chemical resistant finishes). 

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). 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

32 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 

the 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. 

Steel may be blast cleaned either before or after fabrication. 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. 

(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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

33 OF 55

CLAUSE NO. 




PLANT PACKAGE 


(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 elchometer. 

The thickness as measured shall not be less than the minimum thickness 

specified for the coat of paint under relevant clauses of the technical specification. 

Measurement of paint thickness shall be as per “SSPC : The society for Protective 

Coatings Paint Application Standard no. 2” titled “Measurement of Dry Coating 

thickness with magnetic gages”. 

Colour, texture shall match exactly with the approved sample. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

34 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 / mm 2 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. 

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 mm thickness. 

Adjacent sheet of wire fabric shall be lapped at least 100 mm and tied. 

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 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

35 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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. 

22.03.00 Application 

The fineness modulus shall be preferably between 2.5 and 3.3. Any other value can 

be used, with prior approval of the Engineer. 

22.03.01 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 / Cm 2 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 

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 38 o C during placing and curing. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

36 OF 55

CLAUSE NO. 

23.00.00 VIBRATION ISOLATION SYSTEM 




PLANT PACKAGE 


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 

23.01.01 The crushers shall be supported on vibration isolation system consisting of steel 

helical springs and viscous dampers. The supporting arrangement for each crusher 

shall consist of an R. C. C. deck supported on steel helical spring units and viscous 

damper units which in turn shall be supported on girders. The girders shall be an 

integral part of the crusher house building. 

The part of the structure consisting of the R. C. C. deck, springs and viscous 

dampers shall hitherto be referred to as “spring supported foundation”. The part of 

the structure, which is below the spring shall hitherto be called “supporting 

structure”. 

23.02.00 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. 

23.03.00 Scope of Work 

23.03.01 Scope of work shall include the following : 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

37 OF 55

CLAUSE NO. 




PLANT PACKAGE 


(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. 

Supply including packing and transportation to site 

(7) Steel helical spring units and viscous dampers, including associated 

auxiliaries for installation of the spring units and dampers like steel shims, 

adhesive pads etc. 

(8) Frame (s) for pre-stressing of spring elements. 

(9) 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. 

Erection and Commissioning 

(10) Complete erection and commissioning of the vibration isolation system 

including : 

(11) 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. 

(12) 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. 

(13) 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. 

Documentation 

(14) Submission of detailed design calculation, analysis ( static and dynamic ) and 

drawings for Employer’s acceptance and approval. 

(15) 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. 

(16) Furnishing installation and maintenance manual indicating equipment, 

procedure etc., necessary for installation, maintenance of vibration isolation 

system. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

38 OF 55

CLAUSE NO. 




PLANT PACKAGE 


(17) 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. 

(18) Bill of materials of various elements such as springs, visco-dampers, with 

their rating, stiffness etc., included in supply. 

(19) Detailed specifications of the vibration isolation system and various items 

included in the supply and the standard (local or international) to which they 

conform. 

(20) Proposed erection strategy of the entire system. 

23.04.00 Design Requirements for Crusher ( Ring Granulator ) Foundation 

23.04.01 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. 

23.04.02 Isolation Efficiency 

23.04.03 De-coupling 

The vibration isolation system shall be designed for about 90 % isolation efficiency. 

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 decoupling 

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. 

23.04.04 Frequency Criteria 

The frequency criterion has already been laid down implicitly by the isolation 

efficiency criteria and de-coupling required. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

39 OF 55

CLAUSE NO. 




PLANT PACKAGE 


The first bending mode frequency of the top deck shall be at least 20 % above the 

operating speed. 

23.04.05 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. 

23.04.06 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. 

(2) Operating speed of 450 RPM 

(a) 200 microns for an imbalance force arising out of balance quality 

grade Q-40 as per VDI -2060-1966. 

(b) 400 microns in case of a one hammers broken condition. 

(c) Amplitude need not be checked for a three hammer broken condition. 

(3) For intermediate operating speed between 450 to 750 RPM the amplitude 

limits can be linearly interpolated. 

The amplitude limits mentioned above are in both vertical and horizontal directions. 

The amplitudes shall be calculated at critical points on the top surface of the R. C. C. 

deck. The amplitudes shall be checked for the most unfavorable superposition of 

modes in any direction. However, phase difference between the maximum amplitude 

occurring in different directions due to the rotating vetor may be considered while 

superimposing the modes. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

40 OF 55

CLAUSE NO. 

23.04.07 Transient Resonance 




PLANT PACKAGE 


Transient resonance, which may occur during the start - up or coasting down 

condition of the crusher, shall be checked, and the amplitudes in such a condition 

should not exceed one - and - half times those at operating speed for each design 

condition. 

23.04.08 Strength Criteria 

The following criteria shall apply for the design of top deck : 

Dead loads, live loads, Seismic loads and dynamic loads shall be considered for the 

design. The most unfavorable combination shall considered for design. 

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 

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. 

Working stress method shall be used for the design of R. C. C. deck. In survival 

condition, 10 % overstressing may be permitted. 

The R. C. C. top deck shall be at least of M25 grade of concrete as per IS : 456 - 

1978. 

Fatigue need not be considered for the three hammer broken condition. 

For calculating unbalance forces, the heaviest hammer ( plain or toothed ) shall be 

considered. 

23.05.00 Approval of Designs and Drawings 

23.05.01 Standards 

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. 

Latest revisions of the following Codes shall be used for the design of the crusher 

foundations. 

IS : 456 Code of Practice for Plain and Reinforced concrete. 

IS : 2974 (Part IV) Code of Practice for Design and Construction of Machine 

Foundations (Part IV) for rotary type machine of low 

frequency. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

41 OF 55

CLAUSE NO. 




PLANT PACKAGE 


IS : 1893 (Criteria for Earthquake Resistant Design of Structures). 

DIN 4024 Machine Foundations : 

Flexible supporting structures for machines with rotating 

masses. 

DIN 2089 Helical Compression Springs out of round wire and rod; 

calculation and Design. 

DIN 2096 Helical Compression Springs out of round wire and rod; 

quality requirements for hot formed compression springs. 

VDI 2056 Criteria for assessing mechanical vibrations of machines. 

VDI 2060 Criteria for assessing the state of balance of rotating rigid 

bodies. 

24.00.00 PACKAGING AND TRANSPORTATION. 

25.00.00 PLANT LIFE 

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. 

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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

42 OF 55

CLAUSE NO. 




PLANT PACKAGE 


27.00.00 TESTS FOR MATERIAL / WORKMANSHIP 

28.00.00 MATERIALS 

All tests required for all materials, quality of workmanship or any other tests as 

desired by the Engineer shall be at contractor’s cost. 

28.01.00 For Civil, Structural and Architectural works 

Employer will not supply any material. All materials including cement, reinforcement 

steel and structural steel, whatsoever required for execution and completion of the 

entire scope of work covered under this specification shall be arranged by the 

contractor at his own cost. All materials procured by the contractor shall meet the 

quality requirements specified in this specification. 

The contractor shall keep sufficient stock of cement and steel at site at any point of 

time when the work is in progress excluding what has been already incorporated in 

the works, so that any disruption / delay in availability of these materials during 

procurement will not affect the progress of work at site. The minimum quantity of 

such materials in stock at site shall not be less then the Requirement of one ( 1 ) 

month in case of Cement and Requirement of two ( 2 ) Consecutive months in case 

of Steel. 

28.02.00 Structural steel 

28.02.01 Mild Steel 

Rolled sections shall conform to Grade-E250 of IS: 2062: 2006 in as rolled and semi 

killed condition. 

Plates up to 20mm thickness shall conform to Grade –E 250A of IS 2062 : 2006 in 

as rolled and semi killed condition. 

Plates beyond 20mm and up to 40 mm shall conform to Grade – E 250B of IS 2062 : 

2006 as rolled in killed condition. 

Plates beyond 40mm shall conform to Grade – E 250B of IS 2062 : 2006 in 

normalized and ultrasonically tested quality. 

Pipes for handrail shall conform to medium grade of IS : 1161. 

Chequered plates shall conform to IS : 3502. Tensile properties shall conform to IS : 

2062 grade-A. 

Seal plates shall conform to IS : 1079 (semi - skilled quality) 

28.02.02 Medium & High Tensile Steel 

(a) Rolled section shall conform to IS: 2062 Grade E 350B, Semi Killed. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

43 OF 55

CLAUSE NO. 




PLANT PACKAGE 


(b) Plates up to 20 mm thickness shall conform to IS: 2062, Grade E 350, Semi 

Killed. 

(c) Plates beyond 20 mm and 40mm shall be as per IS: 2062, Grade E 350, 

Killed type. 

(d) Beyond 40mm shall conform to IS: 2062, Grade E 350, 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. 

28.03.00 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: 455, IS: 1489 (Part - II). Higher grade of cement namely 

GR - 53 of ordinary portland cement conforming to IS: 12269 can also be used. 

However the ordinary portland cement conforming to IS: 269 or IS: 8112 shall 

necessarily be used for following structures: 

(a) All railway load bearing structures. 

(b) 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 deformed bar of IS: 1786 (Gr. Fe 415 and Fe. 500). 


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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

44 OF 55

CLAUSE NO. 




PLANT PACKAGE 


IS : 458 Specification for concrete pipes. 

IS : 516 Method of test for strength of concrete. 

IS : 800 Code of practice for use of structural steel in general building 

construction. 

IS : 814 Specification for covered electrodes for metal arc welding for 

weld steel. 

IS : 816 Code of practice for use of metal arc welding for general 

construction. 

IS : 817 Code of practice for training and testing of metal arc welders. 

IS : 875 (Pt. I to V) Code of practice for design loads other than earthquake) for 

buildings and structures. 

IS : 1038 Steel doors, windows and ventilators. 

IS : 1172 Basic requirements for water supply, drainage and sanitation. 

IS : 1361 Steel windows for industrial buildings. 

IS : 1786 Specification for high strength deformed steel bars and wires 

for concrete reinforcement. 

IS : 1892 Code of practice for subsurface investigation for foundation. 

IS : 1893 Criteria for earthquake resistant design of structures. 

IS : 1904 Code of practice for design and construction of foundations in 

soils; general requirements. 

IS : 1905 Code of practice for structural safety of buildings - Masonry 

walls. 

IS : 1948 Specification for aluminium doors, windows and ventilators. 

IS : 2062 Steel for general structural purposes. 

IS : 2131 Method of standard penetration test for soils. 

IS : 2212 Code of practice for brickwork. 

IS : 2645 Specification for Integral cement water proofing 

compounds. 

IS:2720 (Part-II, 

IV TO VIII, XIV, 

Methods of test for soils - determination for water content etc 

code of practice for earth work on canals. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

45 OF 55

CLAUSE NO. 

XXI, XXIII, XXIV, 

XXVII TO XXIX, 

XL) 




PLANT PACKAGE 


IS : 2911 Code of practice for design and construction of pile 

foundations. 

(Part-1/Sec.1) Driven cast in situ concrete piles. 

(Part-1/Sec.2) Bored cast-in-situ concrete piles. 

(Part-IV) Load test on piles. 

IS : 2974 (Part - I 

TO V) 

IS : 3370 (Part I 

to IV) 

Code of practice for design and construction of machine 

foundations. 

Code of practice for concrete structures for the storage of 

liquids. 

IS : 3658 Code of practice for liquid penetrant flaw detection. 

IS : 3664 Code of practice for ultra sonic testing by pulse echo method. 

IS : 4326 Code of practice for earthquake resistant design and 

construction of buildings. 

IS : 4990 Specification for plywood for concrete shuttering work. 

IS : 5624 Specification for foundation bolts. 

IS : 7215 Tolerances for fabrication steel structures. 

IS : 8112 Specification for 43 grade Ordinary Portland Cement. 

IS : 9103 Specification for admixtures for concrete. 

IS : 9595 Code of procedure of manual metal arc welding of mild steel. 

IS : 10262 Recommended guidelines for concrete mix design. 

IS : 13311 Method of non - destructive testing of concrete. 

IS : 13755 Dust pressed ceramic tiles with water absorption of 3%, E6% 

(Group B11a) 

ASTM 898 -89 Standard guide for use of high solid content, cold liquidapplied 

elastomeric water proofing membrane for use with 

separate wearing course. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

46 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

47 OF 55

CLAUSE NO. 




PLANT PACKAGE 


CRITERIA FOR EARTHQUAKE RESISTANT 

DESIGN OF STRUCTURES AND EQUIPMENT 


SECTION-VI 

PART-B 


CIVIL WORKS 

ANNEXURE A 

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. 

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% 

PAGE 

48 OF 55

CLAUSE NO. 

Method of Analysis 




PLANT PACKAGE 


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 structure falls to the left of the peak in 

the spectral acceleration curve. 

Design/Detailing for Ductility for Structures 

The site specific design acceleration spectra is a reduced spectra and has an in-built 

allowance for ductility. Structures shall be engineered and detailed in accordance 

with relevant Indian/International standards to achieve ductility. 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

49 OF 55

CLAUSE NO. 




PLANT PACKAGE 


SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF 

STRUCTURES AND EQUIPMENT 


SECTION-VI 

PART-B 


CIVIL WORKS 

ANNEXURE – I 

The various site specific seismic parameters for the project site shall be as follows: 

1) Peak ground horizontal acceleration (for design basis 

earthquake) 

2) Multiplying factor to be applied to the site specific 

horizontal acceleration spectral coefficients to obtain 

the design acceleration spectra 

a) for moment resisting steel frames designed and 

detailed as per IS:800 

b) for braced steel frames designed and detailed as 

per IS:800 

c) for moment resisting RC frames designed and 

detailed as per IS:456 and IS:13920 

d) for design of structures not covered under 2 (a) 

to 2 (c) above and under 3 below 

3) Multiplying factor to be applied to the site specific 

horizontal acceleration spectral coefficients for 

design of equipment and structures where 

inelastic action is not relevant or not permitted 

Note: g = Acceleration due to gravity 

: 1.6 

: 1.3 

: 1.0 

: 1.6 

: 0.212g 

: 2.646 

PAGE 

50 OF 55

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-B 

ANNEXURE – I (Contd.) 

HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS in 

units of ‘g’ 

Period Damping Factor (as a percentage of critical damping) 

(Sec) 0.5% 1% 2% 3% 5% 7% 10% 

.040 .08088 .08126 .08164 .08164 .08126 .08126 .08088 

.042 .08504 .08429 .08353 .08315 .08277 .08240 .08202 

.044 .08882 .08731 .08580 .08504 .08429 .08353 .08315 

.046 .09260 .08996 .08807 .08693 .08580 .08504 .08429 

.048 .09638 .09336 .08996 .08844 .08731 .08618 .08542 

.050 .10016 .09600 .09222 .09033 .08882 .08769 .08693 

.055 .10999 .10432 .09865 .09525 .09298 .09147 .08958 

.060 .12019 .11263 .10507 .10092 .09751 .09525 .09298 

.070 .14287 .13153 .11981 .11339 .10734 .10318 .09940 

.075 .15497 .14136 .12775 .11981 .11226 .10734 .10243 

.080 .16706 .15119 .13569 .12624 .11717 .11112 .10545 

.085 .17878 .16101 .14325 .13267 .12208 .11490 .10810 

.090 .19087 .17084 .15081 .13871 .12662 .11868 .11074 

.095 .20183 .17991 .15837 .14476 .13078 .12208 .11301 

.100 .21166 .18823 .16479 .15005 .13531 .12511 .11528 

.110 .23056 .20372 .17727 .16026 .14287 .13115 .11944 

.120 .24719 .21809 .18823 .16933 .14967 .13682 .12359 

.130 .25966 .22829 .19730 .17689 .15572 .14174 .12737 

.140 .27024 .23661 .20523 .18407 .16101 .14665 .13040 

.150 .27856 .24530 .21166 .18974 .16593 .15043 .13342 

.160 .28499 .25135 .21809 .19465 .16933 .15308 .13569 


CIVIL WORKS 

PAGE 

51 OF 55

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-B 





(Sec) 0.5% 1% 2% 3% 5% 7% 10% 

.170 .28914 .25777 .22224 .19843 .17235 .15534 .13720 

.180 .29330 .26193 .22413 .20146 .17424 .15686 .13796 

.190 .29746 .26420 .22829 .20372 .17575 .15761 .13833 

.200 .29746 .26609 .23056 .20561 .17651 .15799 .13796 

.220 .29464 .26380 .22665 .20361 .17352 .15419 .13413 

.240 .28788 .25971 .22313 .19972 .16936 .14961 .12949 

.260 .28197 .25385 .21779 .19507 .16442 .14423 .12440 

.280 .27433 .24871 .21313 .18965 .15905 .13877 .11884 

.300 .26498 .24143 .20664 .18380 .15358 .13354 .11457 

.320 .25602 .23309 .20044 .17821 .14833 .12853 .11012 

.340 .24947 .22679 .19415 .17250 .14329 .12370 .10584 

.360 .24148 .21869 .18774 .16700 .13809 .11904 .10169 

.380 .23342 .21288 .18189 .16134 .13338 .11520 .09835 

.400 .22561 .20525 .17622 .15619 .12882 .11114 .09478 

.420 .22000 .19982 .17071 .15119 .12472 .10752 .09197 

.440 .21293 .19455 .16568 .14665 .12073 .10433 .08924 

.460 .20765 .18780 .16046 .14191 .11685 .10090 .08658 

.480 .20058 .18249 .15568 .13792 .11337 .09819 .08430 

.500 .19559 .17731 .15134 .13371 .10998 .09523 .08176 

.550 .18187 .16485 .14058 .12419 .10244 .08920 .07659 

.600 .16850 .15299 .13064 .11575 .09558 .08378 .07230 

.650 .15631 .14224 .12174 .10798 .08963 .07892 .06821 

.700 .14519 .13221 .11319 .10112 .08452 .07456 .06490 


CIVIL WORKS 

PAGE 

52 OF 55

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-B 





(Sec) 0.5% 1% 2% 3% 5% 7% 10% 

.750 .13475 .12283 .10584 .09481 .07960 .07066 .06141 

.800 .12525 .11464 .09902 .08900 .07544 .06690 .05835 

.850 .11660 .10698 .09299 .08366 .07113 .06355 .05568 

.900 .10906 .10041 .08742 .07906 .06780 .06059 .05309 

.950 .10230 .09430 .08229 .07486 .06429 .05743 .05029 

1.000 .09626 .08890 .07786 .07078 .06115 .05464 .04785 

1.100 .08628 .07988 .07042 .06401 .05539 .04982 .04342 

1.200 .07837 .07234 .06412 .05836 .05069 .04521 .03946 

1.300 .07158 .06644 .05888 .05348 .04619 .04106 .03592 

1.400 .06610 .06130 .05411 .04957 .04264 .03785 .03278 

1.500 .06107 .05686 .05028 .04581 .03949 .03501 .03001 

1.600 .05673 .05282 .04684 .04268 .03643 .03227 .02758 

1.700 .05302 .04942 .04376 .03990 .03423 .02986 .02569 

1.800 .04968 .04611 .04102 .03720 .03185 .02803 .02400 

1.900 .04643 .04340 .03835 .03507 .02977 .02624 .02238 

2.000 .04375 .04075 .03625 .03275 .02800 .02468 .02108 

2.200 .03925 .03675 .03250 .02975 .02525 .02233 .01912 

2.400 .03550 .03325 .02975 .02700 .02315 .02038 .01748 

2.600 .03250 .03025 .02700 .02468 .02120 .01870 .01605 

2.800 .02975 .02775 .02468 .02260 .01940 .01718 .01482 

3.000 .02725 .02550 .02272 .02065 .01787 .01580 .01370 


CIVIL WORKS 

PAGE 

53 OF 55

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-B 


CIVIL WORKS 

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. 

PAGE 

54 OF 55

CLAUSE NO. 




PLANT PACKAGE 


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 “K 1 ” : 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). 


SECTION-VI 

PART-B 


CIVIL WORKS 

PAGE 

55 OF 55

PART - B 


FOUNDATION SYSTEM AND 

GEOTECHNICAL DATA 





SECTION-VI 

PART-B

PART - B 





PLANT PACKAGE 


SECTION-VI 

PART-B

PART - B 

SUB-SECTION-IIIE-01 

COAL HANDLING PLANG 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

1.01.00 Brakes and Clamps 




PLANT PACKAGE 


COAL HANLDING PLANT 

1.01.01 Final testing of brakes shall include load, HV/IR & heat run tests. 

1.02.00 Monorails and Hoists 

1.02.01 All electric hoist shall be tested as per IS 3938 and chain pulley block shall be tested 

as per IS 3832. 

1.03.00 Hoppers & Liners 

1.03.01 Rack & Pinion Gates/Flap Gates/Rod Gates 

a) MPI/DP test shall be conducted on rack and pinion / rod / weld joint 

b) Functional checks on the gates shall be carried out alongwith respective 

actuator, if applicable. 

1.04.00 Belt Conveyor System 

1.04.01 Idlers 


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. 

(a) Check for run out and free movement shall be carried out on idlers. Run out 

shall be restricted as per IS:8598 

(b) Test for dust proofness, water proofness and dynamic friction factor of the 

Idlers shall be conducted at shop. The detailed procedures for the same shall 

be submitted for review and approval. 

(1) 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. 

(2) 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. 

(3) Adhesion test between ply to ply and cover to ply shall be carried out. 

(4) Troughability test and Test for fire resistance shall be carried out. 


SECTION-VI 

PART-B 


COAL HANDLING PLANT 

PAGE 

1 OF 8

CLAUSE NO. 




PLANT PACKAGE 


(5) 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. 

(6) There will be a limitation on the no. of repairs allowed on the belts. Following 

will be the acceptance norm for the cover repairs. 

1.04.03 Belt Vulcanizing Machine 

1.04.04 Pulleys 

a) 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. 

b) 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. 

c) 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. 

d) In addition to above, Steel Cord belt shall also be tested for following. 

(1) Cord dia and breaking strength 

(2) Finished belt shall be tested for cord pull-out strength before 

and after aeging, peeling resistance. 

(3) Dynamic cord pull out test 

(4) Cord dia, pitch and number of cords 

e) In no case shall the cover thickness or the width of belt be less than 

that given in specification. 

i) 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. 

ii) Complete assembly shall be tested at shop for temp. and pressure developed 

i) In addition to chemical, mechanical, hardness, microstructure as per 

applicable material specification, pulleys shaft forgings shall be subjected to 

ultrasonic testing. 

ii) 100% MPI/DPT on all welds shall be conducted and 10% RT/UT on butt 

welds shall be conducted. 

iii) Static balancing of pulleys shall be carried out after rubber lagging. 


SECTION-VI 

PART-B 



PAGE 

2 OF 8

CLAUSE NO. 




PLANT PACKAGE 


iv) Checks on rubber lagging to include abrasion loss, shore hardness test, peeloff 

strength test and physical properties. Peel-off strength shall be 10 Kg/Cm, 

Abrasion loss shall be less than 250 cubic mm when tested as per DIN 

53516. 

1.04.05 Pull Chord & Belt Sway Switches 

a. Acceptance tests 

i) Over all dimension and functional test. 

ii) HV & IR test 

iii) Degree of protection test report. 

1.04.06 Zero Speed Switch, Under Belt Switch and Chute Blockage Switch 

a Acceptance test 

i) Burn in test at 50 degree C for 48 hours shall be done for electronic 

switches. 

ii) Over all dimension and functional test shall be carried out. 

iii) HV & IR 

1.05.00 Drive Equipments 

1.05.01 Gear Boxes : 

iv) Degree of protection test 

a) In addition to checks for physical, chemical, hardness, microstructure as per 

relevant standard, the shaft and gear/pinion forgings shall be subjected to 

ultrasonic testing . 

b) MPI to be carried out on Gears/Pinions after machining. Case depth, 

hardness and MPI after hardfacing shall be checked to ensure freedom from 

defects. 

c) Gear reducer shall be checked for reduction ratio, backlash and contact 

pattern. No load shop trial run to be conducted on gear boxes to check for oil 

leakage, temperature rise, noise level and vibration . 

1.05.02 Flexible Coupling 

1.05.02.01 Ultrasonic testing shall be conducted on forgings for gear sleeve and gear hub, if 

gear coupling is provided. 

1.05.02.02 PI shall be carried out after machining to ensure freedom from cracks. 


SECTION-VI 

PART-B 



PAGE 

3 OF 8

CLAUSE NO. 

1.05.03 Fluid Coupling 

1.06.00 Belt Scales 




PLANT PACKAGE 


(1) Dynamic balancing shall be carried out for the rotating parts. 

(2) Check for leak tightness of the coupling shall be carried out. 

(3) Functional test on fusible plug for each type of coupling shall be conducted at 

shop. 

(4) All couplings to be run tested at shop on no load 

(5) 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. 


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. 

1.06.01 Mounting arrangement/Overall dimensional check shall be carried out on the Belt 

Scales. 

1.06.02 Belt scale shall be calibrated with test weight/test chain in static at works and with 

test weight for dynamic condition at site. 

1.06.03 All electronic modules shall be subjected to burn in test at 50 Degree C for 48 

hours. 

1.06.04 General check for load cell shall be carried out. 

1.06.05 Test report for degree of protection on enclosure shall be furnished. 

1.06.06 Accuracy/performance check shall be demonstrated at site. 

1.07.00 Dust Control & Miscellaneous Systems 

1.07.01 Pumps 

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. 

(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. 


SECTION-VI 

PART-B 



PAGE 

4 OF 8

CLAUSE NO. 




PLANT PACKAGE 


(d) Impellers to be dynamically balanced to ISO 1940 Gr.6.3 

(e) All pressure parts shall be hydraulically tested at 150% of the shut-off head or 

200% of rated head, whichever is higher for 30 minutes. No leakage is 

allowed. 

(f) All pumps to be performance tested as per Hydraulic Institute Standard/Indian 

Standard. Performance test to include check for noise, vibration level and 

temperature rise. 

1.07.02 Valves & Specialities 

(a) Valves and Specialities shall be tested as per relevant standards / codes. 

(b) Seat Leakage and hydraulic test to be carried out as per relevant standards / 

codes. 

1.07.03 Pipes and Fittings 

Pipes and fittings shall be tested as per relevant standards / codes. 

1.08.00 Dust Extraction/Ventilation Systems 

1.08.01 Fan 

(a) All materials should be of tested quality and test certificates should be 

provided. 

(b) Dynamic balancing of the fan impellers to be carried out. 

(c) Shop run test shall be conducted on all centrifugal fans including check for 

noise and vibration level. 

(d) Performance test shall be conducted on one fan of each type at shop for 

capacity, pressure, efficiency and power consumption. 

1.08.02 Valves and Specialities 

Refer 1.07.02 above 

1.08.03 Pipes and Fittings 

Refer 1.07.03 above 

1.09.00 Vibrating 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 


SECTION-VI 

PART-B 



PAGE 

5 OF 8

CLAUSE NO. 




PLANT PACKAGE 


b) Following minimum NDT requirements to be ensured for welds: 

i) Butt welds - 10% UT/RT and 100% MPI/DPT. 

ii) Fillet Welds - 10% MPI/DPT. 

c) Shop trial run test shall be conducted to checks for speed(RPM), 

amplitude(stroke), temperature rise and noise level. 

1.10.00 Crushers (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: 

i) Butt welds - 10% UT/RT and 100% MPI/DPT. 

ii) Fillet Welds - 10% MPI/DPT. 

(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 . 

1.11.00 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. 

1.12.00 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. 


SECTION-VI 

PART-B 



PAGE 

6 OF 8

CLAUSE NO. 

1.13.00 Coal Sampling Units 




PLANT PACKAGE 


i) Free carriage and cutter movement, speed of cutter and dust door closing 

and sealing shall be tested for samplers. 

ii) “No load test” shall be carried out for crushers. 

1.14.00 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. 

1.14.01 All forgings shall be subjected to ultrasonic test to ensure free from internal defects in 

addition to check for chemical and mechanical properties. 

1.14.02 10% of the welds selected at random shall be subject to DP test. 

1.14.02 All forged components shall be subjected to DPI/MPI after machining. 

1.14.02 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. 

1.14.02 Buffer springs shall be subjected to load test as per relevant specifications. Material 

certificates for springs shall also be furnished. 

1.14.02 All components prior to assembly shall be checked for dimensions. 

1.14.02 Function test of Elevator assembly shall be carried out. 

1.14.02 All electrical equipments shall be of proven quality. 

1.14.02 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. 

1.15.00 WAGAN TIPPLER ALONGWITH SIDE ARM CHARGER 

1.15.01 All plates equal to or above 25 mm thickness shall be ultrasonically tested. 

1.15.02 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. 

1.17.03 Machined and hardfaced surface of casting/forging shall be subjected to DPT/MPI. 

1.15.04 Following minimum NDT requirements shall be followed for welds: 

i) Butt Welds in Tension- 100% UT/RT and 100% MPI/DPT. 


SECTION-VI 

PART-B 



PAGE 

7 OF 8

CLAUSE NO. 




PLANT PACKAGE 


ii) Butt Welds in Compression- 10% UT/RT and 10% MPI/DPT. 

iii) Fillet Welds - 10% MPI/DPT. 

1.15.05 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. 

1.16.00 APRON FEEDER 

1.16.01 . All plates equal to or above 25 mm thickness shall be ultrasonically tested. 

1.16.02 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. 

1.16.03 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. 

1.16.04 Suitable check for life time sealing of rollers for protection from dust and water shall 

be done 

1.16.05 Following minimum NDT requirements shall be followed for welds: 

i) Butt Welds in Tension- 100% UT/RT and 100% MPI/DPT. 

ii) Butt Welds in Compression- 10% UT/RT and 10% MPI/DPT. 

iii) Fillet Welds - 10% MPI/DPT. 

1.16.06 For other items like drive system, motor, pulley, belt relevant portion of specification 

shall be applicable 

1.16.07 Functional check for trial assembly of Apron Feeder/sub-assemblies shall be carried 

out at shop. Manufacturer shall furnish detail procedure for various sub assemblies 

such as pans, reduction unit, scrapper conveyor, chain & sprocket drive 

arrangement, cradle assembly etc for NTPC approval 


SECTION-VI 

PART-B 



PAGE 

8 OF 8

PART - B 


MOTOR 




PLANT PACKAGE 


SECTION-VI 

PART-B

TESTS/CHECKS 

TEMS/COMPONENTS 

Plates for stator frame,end 

shield, spider etc. 




PLANT PACKAGE 


INDUCTION MOTOR & SYNCHRONOUS MACHINE SQE_7 

Visual 

Dimensional 

Make/Type/Rating/TC/General 

Physical Inspection 

Mech/Chem. Properties 

NDT /DP/MPI/UT 

Metallography 

Electrical Characteristics 

Welding/Brazing(WPS/PQR) 

Y Y Y Y Y 

Shaft Y Y Y Y Y Y Y 

Magnetic Material Y Y Y Y Y Y Y Y 

Rotor Copper/Aluminium Y Y Y Y Y Y Y 

Stator copper Y Y Y Y Y Y Y 

SC Ring Y Y Y Y Y Y Y Y Y 

Insulating Material Y Y Y Y Y 

Tubes for Cooler Y Y Y Y Y Y Y 

Sleeve Bearing Y Y Y Y Y Y Y 

Stator/Rotor, Exciter Coils Y Y Y Y Y 

Castings, stator frame,terminal 

box and bearing housing etc. 

Fabrication & machining of 

stator, rotor, terminal box 

Y Y Y Y Y Y 

Y Y Y Y 


SECTION-VI 

PART-B 

Heat Treatment 

Magnetic Characteristics 

Hydrualic/Leak/Pressure Test 

Thermal Characteristics 

Run out 


MOTORS 

Dynamic Balancing 

All tests as per IS-325/IS-4722 / 

9283 

Vibration 

Over speed 

PAGE 

1 OF 2 

Tan delta, shaft voltage & 

polarisation index test

TESTS/CHECKS 

TEMS/COMPONENTS 

Visual 

Dimensional 




PLANT PACKAGE 

Make/Type/Rating/TC/General 

Physical Inspection 

Mech/Chem. Properties 


Wound stator Y Y Y Y 

Wound Exciter Y Y Y Y 

Rotor complete Y Y Y Y Y 

Exciter, Stator, Rotor, Terminal 

Box assembly 

Y Y Y 

Accessories, RTD, BTD,CT, 

Brushes, Diodes,Space heater, 

antifriction bearing, cable glands, 

lugs, gaskets etc. 

Y Y Y 

NDT /DP/MPI/UT 

Metallography 

Electrical Characteristics 

Motor ( IS 325 / 4722/ 9283) Y Y Y Y Y Y Y1 

Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality 

Plan indicating the practices & Procedure followed along with relevant supporting 

documents during QP finalization. However, No QP for LT motor up to 50KW. 

2. Makes of all major bought out items will be subject to NTPC approval. 

Y1 = for HT Motor / Machines only. 

Welding/Brazing(WPS/PQR) 


SECTION-VI 

PART-B 

Heat Treatment 

Magnetic Characteristics 

Hydrualic/Leak/Pressure Test 

Thermal Characteristics 

Run out 


MOTORS 

Dynamic Balancing 

All tests as per IS-325/IS-4722 / 

9283 

Vibration 

Over speed 

PAGE 

2 OF 2 

Tan delta, shaft voltage & 

polarisation index test

PART - B 


LT SWITCHGEAR 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

SQE _10 




PLANT PACKAGE 


LT SWITCHGEAR 

(MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, 

LOCAL MOTOR STARTERS) 

ATTRIBUTES / 

CHARACTERIS-TICS 

TC & Rating Type, Model, 

ITEMS/ COMPONENTS/ 

SUB SYSTEM 

ASSEMBLIY Make, 

Dimensions & Finish 

Electrical properties 

Mechanical Properties 

Chemical properties 

Functional & Operational Features 

as per NTPC Spec. 

Sheet Steel (IS : 513) Y Y Y Y Y 

Aluminum Bus bar Material 

(IS : 5082) 

Y Y Y Y Y Y 

Copper Bus bar Material 

(IS : 613) 

Y Y Y Y Y Y 

Support Insulator Y Y Y Y Y 

Air Circuit Breaker (IS: 

13947) 

Energy Meters (IS : 13010, 

13779) 

Power & Aux. Contactors 

(IS : 13947) 

Protection & Aux. Relays 

(IS : 3231) 

Control & Selector Switches 

(IS : 13947) 

CT’s & PT’s (IS 2705 / 

3156) 

Item to conform to relevant 

Standards 

Pretreatment as per IS 6005 


SECTION-VI 

PART-B 

Paint Shade, Adhesion, Thickness 

& Finish 

Functional Checks 

Milli-volt drop Test 

IR – HV – IR Test 



BUSDUCT 

Degree of Protection Routine test 

as per NTPC spec 

Y Y Y Y Y Y Y 

Y Y Y Y Y Y 

Y Y Y Y Y 

Y Y Y Y Y Y 

Y Y Y Y Y 

Y Y Y Y 

MCCB (IS : 13947) Y Y Y Y 

Indicating Meters ( IS : 

1248 ) 

Indicating Lamps (IS : 

13947) 

Air Break Switches 

(IS : 13947) 

Y Y Y Y Y Y 

Y Y Y Y Y 

Y Y Y Y Y 

Control Terminal Blocks Y Y Y Y 

All Routine tests as per NTPC spec. 

PAGE 

1 OF 3

CLAUSE NO. 




PLANT PACKAGE 


LT SWITCHGEAR 

(MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, 

LOCAL MOTOR STARTERS) 

ATTRIBUTES / 

CHARACTERIS-TICS 

ITEMS/ COMPONENTS/ 

SUB SYSTEM 

ASSEMBLIY 

Make, Model, Type, Rating & TC 




Chemical properties 

Functional & Operational Features as per 

NTPC Spec. 

Fuse (IS 13703) Y Y Y Y 

Control Transformer 

(IS : 12021) 

Item to conform to relevant Standards 


SECTION-VI 

PART-B 


Paint Shade, Adhesion, Thickness & Finish 


Milli-volt drop Test 



BUSDUCT 


Degree of Protection Routine test as per 

NTPC spec 

Y Y Y Y Y Y 

Push Buttons (IS : 4794 ) Y Y Y Y Y 

Transducer (IEC : 60688) Y Y Y Y Y Y 

MCB (IS : 8828) Y Y Y Y Y 

Breaker Handling Trolley Y Y Y Y Y Y 

Synthetic Rubber Gasket 

(IS : 11149) 

LT SWITCHGEAR 

(IS : 8623) 

Notes: 

Y Y Y Y Y 

Y Y Y Y Y Y Y Y Y Y Y 

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. 

All Routine tests as per NTPC spec. & IS 

PAGE 

2 OF 3

CLAUSE NO. 

ATTRIBUTES , 

CHARACTERISTICS 

ITEM, COMPONENTS, 

SUB SYSTEM ASSEMBLY 

Aluminum Sheets / Plates / 

Strips / Flexibles / tubes 

(IS : 5082 / 737) 

CRCA Flats / ISMC (IS 

2062) 

Neoprene / Synthetic 

Rubber Gaskets (IS 11149 / 

3400) 




PLANT PACKAGE 

Dimension & Surface Finish 


Make, Type, Rating & TC 

Electrical Properties 

LT BUSDUCT 


Chemical Properties 

Item to conform to relevant IS 

WPS Approval, Welder Qualification 


SECTION-VI 

PART-B 

Weld Quality Check ( DP test & x-ray 

Y Y Y Y Y Y Y 

Y Y Y Y Y 

Y Y Y Y 

Rubber Bellows (IS : 3400) Y Y Y Y 

Support Insulator (BS : 

2782, 

IEC : 660, IS : 10912) 

Galvanized Structure & GI 

Earthing Flat 

(IS : 2629 / 2633 / 4749) 

Y Y Y Y 

Paint Shade, Thickness, Adhesion & Finish 

Tightness by Torque measurement 

Electrical Clearances 

Y Y Y Y 

Space Heater & Thermostat Y Y Y 

LT Busduct (IS : 8623 

PART 2) 

Notes: 

Galvanizing Test as per IS 2629/ 2633/ 



BUSDUCT 


Phase Sequence Check 



Plan indicating the practice and 

procedure along with relevant supporting documents. 


PAGE 

3 OF 3 

Degree of Protection routine test as per 

NTPC spec.

PART - B 






PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

Attributes / 

Characteristics 

Item / Components / 

Sub System Assembly 




PLANT PACKAGE 


QUALITY ASSURANCE & INSPECTION MODULE NO. SQE 13 

Make, Rating, Type & TC 

L.T POWER CABLES Page 1 of 3 

(1.1 KV PVC & XLPE CABLES) 

Dimension/surface finish 


Chemical Composition 


Spark Test 

Hot set test (XLPE) 

Lay length / Sequence 

Armour coverage, Cross over, looseness, Gap 

between two armour wire/strip 

Aluminum (IS-8130) Y Y Y Y Y 

PVC Compound (IS-5831) Y Y Y Y 

XLPE Compound(IS-7098 Part-I) Y Y Y Y Y 

FRLS PVC Compound(IS-5831 ) 

ASTM-D-2843/ ASTM-D-2863 

IEC-754 Part-I 

Y Y Y 

Armour wire/strip (IS-3975) Y Y Y 

Insulated Core Y Y Y Y 

Laid up core Y Y 

PVC Inner sheath Y 

Armouring Y Y 

Outer sheath Y Y Y Y Y 

Finish cable (IS-1554 & 7098 – 

Part-1) 

ASTM-D-2843/ IS 10810 (Part- - 58) 

IEC-754 Part-I 

Swedish Chimney SS 4241475 for 

(F3 category) 

Flammability test IEC-332 Part –3 

Cat-B 

Wooden drum (IS-10418) / Steel 

drum 


SECTION-VI 

PART-B 

Sequential marking/surface finish /cable length 

Tensile strength, elongation before & after 

ageing of insulation & outer sheath 

Y Y Y Y Y Y Y 

Y Y 

Note: This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and 

procedure along with relevant supporting documents. 

2. Not applicable for XLPE insulation 

Thermal Stability of insulation and outer sheath * 

Anti ternite treatment on wooden drums 



Constructional / requirement as per NTPC Spec. 

Routine and acceptance test as per 

Relevant Standard and NTPC specification 

PAGE 

1 OF 3 

FRLS Test 

Y Y

CLAUSE NO. 

ROUTINE TESTS 




PLANT PACKAGE 


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 


SECTION-VI 

PART-B 



PAGE 

2 OF 3

CLAUSE NO. 




PLANT PACKAGE 


C) For PVC / XLPE insulation & PVC Sheath 

1) Test for thickness 

2) Hot set test For XLPE insulation only 

3) Tensile strength & Elongation before ageing 

D) For completed cables 

1) Insulation resistance test (Volume resistivity method) 


E) Following tests shall be carried out and only one sample shall be taken from 

each offered lot of all sizes for these tests:- 

1) Tensile strength & elongation after ageing on PVC / XLPE insulation and PVC 

outer sheath 

2) Thermal stability test on PVC insulation and outer sheath 

3) Oxygen index test on outer sheath 

4) Smoke density rating test on outer sheath as per ASTM –D 2843 

5) Acid gas generation test on outer sheath as per IEC – 754 (Part 1) 

6) Flammability test as per IEC-332 - Part- 3 (Category- B) on completed cable 

7) Fire resistance test as per SS 4241475 (F3 Category) on completed cable 

F) Following tests shall be carried on one length of each size of offered lot: 

1) Surface finish, length measurement, sequence of cores, armour coverage, Gap 

between two consecutive armour wires / formed wires 


SECTION-VI 

PART-B 



PAGE 

3 OF 3

PART - B 


LT CONTROL CABLES 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

Attributes / 


Item / Components / 





PLANT PACKAGE 


QUALITY ASSURANCE & INSPECTION MODULE NO. SQE 14 

Make, Type, Rating, T.C 



L.T CONTROL CABLES Page 1 of 3 

(1.1 KV PVC CABLES) 



Spark Test 

Lay length/Sequence 

Armour coverage, cross over, 

looseness, gap between two 

Sequential marking/surface 

finish/cable length 


SECTION-VI 

PART-B 

Tensile strength, elongation before 

& after ageing of insulation &outer 

sheath sheath 

Copper Conductor (IS- 

8130) 

Y Y Y Y Y 

PVC Compound (IS- 

5831) 

Y Y Y Y 

FRLS PVC Compound 

IS-5831 

ASTM-D-2843/ IS 

10810 (Part-58) 

IEC-754 Part-1 

Y Y Y Y 

Armour wire/strip (IS- 

3975) 

Y Y Y 

Insulated Core Y Y Y Y 

Laid up core Y Y 

PVC Inner sheath Y 

Armouring Y Y 

Outer sheath Y Y Y Y Y 

Finish cable (IS-1554- 1) 

ASTM-D-2843/ IS 10810 

(Part-58) 

IEC-754 Part-1 

Swedish Chimney: SEN 

SS 424-1475 (F3 

category) 

Flammability test IEC- 

332 Part-3 Cat-B 

Y Y Y Y Y Y Y Y Y 

Wooden drum (IS : 

10418) / Steel drum 

Y Y 

• 1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan 

indicating the Practice and procedure along with relevant supporting documents. 

Thermal stability of insulation and 

outer sheath 

Anti termite treatment on wooden 

drums 



Constructional feature as per NTPC 

Spec. 

Routine & Acceptance test as per 

relevant standard & page 2 & 3 of 

PAGE 

1 OF 3 

FRLS Test

CLAUSE NO. 

CONTROL CABLE 

ROUTINE TESTS 




PLANT PACKAGE 








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 


1) Annealing test For copper conductor only 













C) For PVC insulation & PVC Sheath 



SECTION-VI 

PART-B 



PAGE 

2 OF 3

CLAUSE NO. 




PLANT PACKAGE 




1) Insulation resistance test ( Volume resistivity method ) 


E) Following tests shall be carried out and only one sample shall be taken 

from each offered lot of all sizes for these tests:- 

1) Tensile strength & elongation after ageing on PVC insulation and PVC outer 

sheath 

2) Thermal stability test on PVC insulation and outer sheath 





7) Fire resistance test as per SS 4241475 (F3 Category) on completed cable 





SECTION-VI 

PART-B 



PAGE 

3 OF 3

PART - B 


INSTRUMENTATION CABLE 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

TESTS 

(A) & ® Resistance 

ITEMS Conductor 

1. Instrument cable 

twisted and shielded 




PLANT PACKAGE 


INSTRUMENTATION CABLE 

High Voltage ® & (A) 

Insulation Resistance ® & (A) 

Constructional detail, dimensions (A) 

Outer-Sheathe/core marking, end sealing 

(A) 

Thermal Stability (A) + 

Conductor (IS-8130) Y Y Y 

Visual, Surface finish (A) + 

Electrical Parameters ** (A) + 


SECTION-VI 

PART-B 

Persulphate Test (A) + 

Overall/Coverage/Continuity (A) 

Swidesh chimney Test (SS-4241475) (A) 

++ 

FRLS Test * (A) ++ 



CABLES 

Tensile & Elongation before & after aging 

(A) ++ 

Vol. Resistivity. at room & Elevated Temp. 

(A) ++ 

Spark test report review ® 

Insulation (VDE-207) Y Y Y Y Y Y 

Pairing/Twisting Y Y Y 

Shielding Y Y Y 

Drain wire Y Y Y Y Y 

Inner Sheath Y Y Y Y Y Y 

Outer Sheath Y Y Y Y Y Y 

Over all cable Y Y Y Y Y Y Y Y Y 

Cable Drums (IS-10418) Y Y 

Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6) Compensating 

cables shall be checked for Thermal EMF/Endurance test as per IS 8784. 

Note : This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality 

Plan indicating his practice & Procedure along with relevant supporting documents during QP 

finalization for all item. 

Note : ® - Routine Test A - Acceptance Test Y - Test Applicable 

Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable) 

• * FRLS Tests: Oxygen / Temp Index (ASTM D-2863), Smoke Density Rating (ASTM – D 

2843), HCL Emission (IEC-754-1) 

• ** 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. 

PAGE 

1 OF 1

PART - B 


STATION LIGHTING 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

Item Components 

Sub System 

Assembly 

Attributes 


Luminaries (IS-10322 Part-5 

Sec.1) 




PLANT PACKAGE 


STATION LIGHTING SQE_17 

Make, Type , Rating/ TC 

Dimension 

Pre-Treatment of sheat 

Paint Shade Thickness Adhesion & 

Finish 

Galvanise Test 

IP Test 

Bought Out Items/ Bill of Material 


SECTION-VI 

PART-B 

HV & IR 

Functional Check as per spec. 

Constructional Feature as per NTPC 

spec. 

Y Y Y Y 

Routine Test as per relevant std aad 

spec 


STATION LIGHTING 

Acceptance Test as per relevant std 

and spec 

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 & 

lower lantern type) 

Wall Mounted Lighting Panel 

(IS-513, IS-5) 

Switch Box/ Junction 

Box/Receptacles/ Local Push 

Button Station,Lighting Panel 

(IS-513, 2629, 2633, 4759, 

6745) 

Y Y Y Y Y Y 

Y Y Y Y Y Y Y Y Y Y Y Y 


Cable Gland (BS-6121) Y Y Y 

Cable Lug (IS-8309) Y Y Y 

Flexible Conduit Y Y 

Lighting Transformer (IS-1117) Y Y Y 

Epoxy & Galvanised Conduit 

(IS-9537, 2629, 2633, 4759, 

6745) 

Y Y Y Y 

Notes: 

1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan 

indicating the practice and procedure along with relevant supporting documents. 

2. Make of all major Bought Out Items will be subject to NTPC approval. 

Y 

Item to conform to relevant standard 

PAGE 

1 OF 1

PART - B 


CABLING, EARTHING & LIGHTNING 

PROTECTION 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 




PLANT PACKAGE 


QUALITY ASSURANCE & INSPECTION MODULE NO. SQE-16 

Page 1 of 1 

CABLING, EARTHING, LIGHTNING PROTECTION 

ATTRIBUTES / 


ITEMS/COMPONENTS / 

SUB SYSTEMS 

Dimension 

Paint shade, paint thickness, adhesion 

Pre-treatment of sheet 

IP protection 

Proof load* 

Surface finish 

Deflection test* 


SECTION-VI 

PART-B 

HV & IR 

Galvanise Test (If Applicable) 

Functional 

Bought out items/Bill of material 



LIGHTING PROTECTION 

Routine tests as per relevant standard & 

specification 

Acceptance tests as per relevant standard & 

specification 

Constructional feature as per NTPC 

Wall Mounted-Lighting Panel (IS- 

513, IS:5, IS:2629, 2633, 6745) 


Switch box/junction box/ 

Receptacles Panel (IS-513, IS:5, 

IS:2629, 2633, 6745) 


Cable glands(BS-6121) Y Y 

Cable lug(IS-8309) Y Y 

Lighting wire(IS-694) Y Y 

Flexible conduits Y Y Y 

Conduits(Galvanise & Epoxy) IS- 

9537 & IS-2629, 2633, 6745 

Y Y Y Y Y 

RCC Hume Pipe (IS-458) Y 

Cable termination & straight 

through joint (VDE-0278) 

Y Y Y 

Cable Trays, Flexible supports 

system & accessories IS-513, 

2629, 2633, 6745 


Trefoil clamp Y Y 

GI flats for earthing & lighting 

protection (IS 2062, 2629, 

6745,2633) 

Y Y Y Y Y 

GI wire (IS-280) Y Y 

Fire Sealing System (BS –476) Y Y Y 

.Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan 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. 

PAGE 

1 OF 1

PART - B 






PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

Attributes 







PLANT PACKAGE 



CONTROL PANEL 



Dimensions / Finish 

Type/ Rating/Functional check 

HV/IR 

Routine test as per relevant std. 


SECTION-VI 

PART-B 

Constructional Features 

IS:6005 ,Seven tank process 

Paint finish/ shade/thickness 

Mountings / BOM/ Make, 

Completeness / Wiring 



Interlock Functional & Operation 

Testing / Simulation check 

Sheet Steel (IS-513) Y Y Y 

Aluminum / Copper Bus-bar 

(IS-5082/IS-613/IS-1987) 

Y Y Y Y 

Support Insulator 

(BS-2782/IEC-660/IS-10912) 

Y Y Y Y 

Control / Selector Switch 

(IS-6875) 

Y Y Y 

Contractor/ MCB (IS-13947) Y Y Y 

O/L Protection relays (IS-3231) Y Y 

C.T /V.T/ Indicating Meter 

(IS-2705/3156/1248) 

Y Y Y 

Fuse/ Fuse carrier 

(IS-13703) 

Y Y Y 

Terminals/lugs/PVC wires 

(IS-13947//IS-694) 

Y Y Y Y Y 

Timers(IS-3231) Y Y Y 

LVS, Mosaics Y 

Push Button/ Lamp/ (IS-6875) Y Y Y 


(IS-12021) 

Y Y Y 

Mimic, Annunciater Y Y 

Gasket (IS-11149) Y Y Y Y Y 

Fabrication Y 

Pretreatment & Painting Y Y 

Control panel Y Y Y Y Y 

NOTE: 

1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan 

indicating the practice and procedure along with relevant supporting documents. 

2. All major Bought out Items will be subject to NTPC approval. 

Degree of Protection Test 

Specification requirement 

PAGE 

1 OF 1

PART - B 


CONTROL DESK WITH PLC 




PLANT PACKAGE 


SECTION-VI 

PART-B

ITEMS 

TESTS 

Visual ® 




PLANT PACKAGE 

GA, BOM ,Lay Out of components ® 


PROGRAMMABLE LOGIC CONTRLLER 

Dimensions ® 

Paint Shade/ 

Thickness/Adhesion ® 

Alignment of Section ® 

Component Rating/ Make / Type ® 

Wiring ® 


SECTION-VI 

PART-B 

IR & HV ® 

Review of TC for instruments/ Devices/ 

Recorders, Indicators/ Mosaic Items/ 

Transducers ® 

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 

Accessibility of TBS/ Devices ® 

Illumination ® 

Functional Check for Control Element , 

Annunciation ® 

Mimic ® 


PROGRAMMABLE LOGIC CONTROLLER 

(PLC) 

Test as per IEC 1131 ® * 

Test as per Std ® & ( A) 

PAGE 1 OF 1

PART - B 






PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

Attributes / Characteristics 

Items / Components / 

Sub- assembly 




PLANT PACKAGE 


Make, Model, Type, Rating 


Dimensional check and Paint shade, thickness, 

adhesion & Finish checks 

Complete physical examination for constructional 

features as per approved drgs 


SECTION-VI 

PART-B 

Ripple Content Test, Load Limiter operation & 

AVR Operation Test 

Operational & Functional Checks of aux. Devices 

like annunciator, switches, indiactors etc. 

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. 

HV & IR Test 



Burn-In Test 

PAGE 

1 OF 1

PART - B 


HT CABLES 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

Attributes / 


Item / 

Components / 

Sub System 

Assembly 

Make, Type, Rating & T.C 


Mechanial properties 





PLANT PACKAGE 

Spark Test(as applicable) 


Curing Properties 

H.T. CABLES 


Hot Set Test/ Eccentricity & Ovality 

Aluminium (IS-8130) Y Y Y Y Y 

Semiconducting 

Compound 

Y Y Y Y 

XLPE Compound 

(IS-7098 Part-II) 

Y Y Y Y Y 

FRLS PVC 

Compound 

(IS-5831, ASTM- 

D2843, IS10810(Part 

58), EC-60754 Part- 

1) 

Y Y Y Y Y 

Triple Extrusion & 

curing /Manufacturing 

of Core 

Y Y Y Y 

Copper Tape Y Y Y Y 

Polyster tape Y Y 

Armour wire/strip Y Y Y 

Copper tapping Y Y Y 

Inner sheath Y Y 

Armouring Y Y 

Outer Sheathing Y Y Y Y Y Y 

Power Cable 

(Finished) 

(IS : 7098 Part II, 

IEC : 60332 (Part 3 

Cat. B), IS-5831, 

ASTM-D2843, 

IS10810 (Part 58) , 

IEC-60754 Part-1) 

Y Y Y Y Y Y Y Y Y 

Wooden drum (IS- 

10418) /Steel Drum 

Notes: 

Y Y 

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. 


Lay length & Sequence 

Armour coverage, cross over, looseness, 

gap between two wire 


SECTION-VI 

PART-B 

Sequential marking/surface finish/ cable 

length 

T.S & elongation before & after ageing on 

outer sheath & insulation 

Thermal seability on outer sheath 

Metallic ( Cu ) Screening ( If applicable) 

Anti termite coating on wooden drums 


HT CABLES 

Constructional requirements feature as 

per NTPC specification 

Routine & Acceptance Test as per 

relevant standard & NTPC specification 

PAGE 

1 OF 3 

FRLS Test

CLAUSE NO. 

ROUTINE TESTS 




PLANT PACKAGE 






2) High voltage test 

3) Partial discharge test (for 6.35 / 11 KV grade or above rating of cables) 


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: 7098 Part 1I 


1) Tensile Test 















SECTION-VI 

PART-B 


HT CABLES 

PAGE 

2 OF 3

CLAUSE NO. 




PLANT PACKAGE 


C) For XLPE insulation & PVC Sheath 



3) Hot set test (For XLPE insulation) 


1) Insulation resistance test (Volume resistivity method) 

2) High voltage test 

3 Partial discharge test (for 6.35 / 11 KV grade or above rating of cables) 

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 XLPE insulation and PVC outer 

sheath 

2) Thermal stability test on outer sheath 








2) Measurement of Eccentricity & Ovality 


SECTION-VI 

PART-B 


HT CABLES 

PAGE 

3 OF 3

PART - B 


HT SWITCHGEAR 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

ATTRIBUTES / CHARACTERISTICS 

ITEMS, COMPONENTS, SUB- 

SYSTEM ASSEMBLY 




PLANT PACKAGE 

Make, Type, Model, Rating & TC 


HT SWITCHGEAR 


Mechanical properties 


Aluminum Bus bar material 

(IS : 5082) 

Y Y Y Y Y Y 

Copper Bus bar material 

(IS : 613) 

Y Y Y Y Y Y 

Bus bar Support Insulator Y Y Y Y Y Y 

HT Circuit Breaker (IEC-62271-100) Y Y Y Y Y Y Y 

HT Contactors (IS : 9046 / IEC 60470) Y Y Y Y Y Y 

Protection & Auxilliary Relays 

(IS : 3231 / 8686) 

Y Y Y Y Y Y 

HT CT’s & PT’s 

(IS : 2705 / 3156) 

Y Y Y Y 

HT Fuses (IS : 9385) Y Y Y Y 

Surge Arrester (IEC : 99 –4) Y Y Y Y 

LT Contactors (IS : 13947) Y Y Y Y Y 

Control & Selector Switches 

(IS : 6875) 

Y Y Y Y Y 

Indicating Meters (IS : 1248) Y Y Y Y Y Y 

Indicating Lamps (IS : 13947) Y Y Y Y Y 

Push Buttons (IS : 4794) Y Y Y Y Y 


(IS : 12021) 

Y Y Y Y Y Y 

LT Fuses (IS : 13703) Y Y Y Y 

Energy Meters (IS : 722) Y Y Y Y Y Y 

Transducers (IEC : 60688) Y Y Y Y Y Y 

Diodes Y Y Y Y Y 

Terminal Blocks Y Y Y Y 

Synthetic Rubber Gasket 

(IS : 11149 / 3400) 

Y Y Y Y 

Breaker Handling Trolley Y Y Y Y Y 

HT Switchgear Panel 

IEC-62271-200) 

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. 



Functional & Operational Features as per 

NTPC Spec. 


SECTION-VI 

PART-B 

Item to conform to relevant Standards 


Paint shade, thickness, adhesion & finish 


HV & IR Test 


HT SWITCHGEAR 

Degree of Protection Routine test as per 

NTPC spec. 

CB Operation timing check 

PAGE 

1 OF 1 

All Routine Tests as per relevant standard

PART - B 


ACTUATORS 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 




PLANT PACKAGE 


ELECTRICAL ACTUATOR WITH INTEGRAL STARTER 

Test/Attributes 


ITEM/ 

COPONENT/ 

SUB SYSTEM 

ASSEMBLY/ 

TESTING RPM ® 

No Load Current ® 

IR & HV Test® 

Mounting Dimension® 

All routine Test as per Standard & Specification® 

Correct Phase Sequence® 

Operation & Setting of limit Switch/Torque Switch® 

Stall Torque/Current (A) 


SECTION-VI 

PART-B 

Hand Wheel operation/ Auto de clutch function (A) 

Function of Aux. like Potentiometer, space heater, position 

i di t ® 

EPT output ® 

Grease leakage ® 


ELECTRICAL 

ACTUATOR WITH 

INTEGRAL STARTER 

Local/ Remote ( Open-Stop-Close) Operation® 

Safety check (Single phasing, Phase correction, Tripping etc.) 

(A) 

ELECTRICAL 

ACTUATOR WITH 

INTEGRAL 

STARTER(IS_9334) 

Motor Y Y Y Y Y 

Final Testing Y Y Y Y Y Y Y Y Y Y Y Y Y 

Note: 1) Detailed procedure of Environmental Stress Screening test 

shall be as per Quality Assurance Programme in General Technical 

Conditions 

2) This is an indicative list of tests/checks. The manufacturer is to furnish 

a detailed quality plan indicating the practices and procedure adopted 

along with relevant supporting documents. 

® - Routine Test (A) - Acceptance Test Y - Test applicable 

PAGE 

1 OF 1

PART - B 


AUXILIARY TRANSFORMER 




PLANT PACKAGE 


SECTION-VI 

PART-B




PLANT PACKAGE 


AUX. TRANSFORMER Table: QE-4C 

Attributes / 


Items/Components 

Sub Systems 

Tank, H.V. & L.V. Cable Box / Flange throat Y Y Y 

Conservator / Radiator / Cooler / Pipes Y Y Y 

Copper Conductor (IS:191) Y Y Y Y 

Insulating Material Y Y Y Y Y Y 

Visual & Dimensional Checks 

Mechanical properties 

CRGO Lamination & Built Core Y Y Y Y Y 

Bushing / Insulator (IS:2544 / 5621) Y Y Y Y 

Gasket Y Y Y Y Y 

Transformer Oil (IS:335 / IEC296) Y 

Off-Circuit Tap Changer Y Y 

Core Coil Assembly & Pre-tanking Y Y 

Marshalling Box Y Y Y Y 

WTI, OTI, MOG, PRD, Breather, Terminal Connector, Bucholz 

Relay, Globe & Gate Valve, 

Electrical strength 

Thermal properties 



SECTION-VI 

PART-B 

Compatibility with oil 

NDT / DPT / MPI / UT 

Ageing Test. 

Voltage Ratio, Vector Group & 

Polarity, Magnetic Balance Test 

Make / Type / Rating / Model / TC 

/ General Physical Inspection. 

Y Y 

Welding (ASME Sect-IX) Y Y 

Complete Transformer (IS:2026/ IEC-60076) 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) All major Bought Out Items will be subject to NTPC approval. 


AUXILIARY TRANSFORMER 

WPS & PQR 

Routine Test as per relevant test 

Routine Test 

PAGE 1 OF 1

PART - B 


BATTERY & BATTERY CHARGER 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 




PLANT PACKAGE 


DC SYSTEM SQE_19 

ATTRIBUTES / 


ITEMS, COMPONENTS, SUB 


LEAD ACID BATTERY 


Container & Lids (IS : 1146) Y Y 

Vent Plugs Y Y 

Conformance to relevant part drg. & 

Manufacturer’s standards 

Sealing Compound (IS : 3116) Y Y 

Positive & Negative Plates Y Y 

Separators (IS : 6071) Y Y 

Electrolyte (Water / Sulphuric Acid) 

(IS : 1069 / 266) 

Chemical composition 

Y Y 

Inter-cell Connectors & Fasteners Y Y Y 

Lead Coating Thickness (min. 25 microns, 

IS: 6848 App.F) & Adhesion Check 

Battery Stand Y Y Y Y 

Conformance to CPWD Spec. for Teak 


SECTION-VI 

PART-B 

Paint Process checks, Paint Shade, 

Thickness, Adhesion & Finish 

Constructional requirements as per NTPC 

Spec. 

Cell Insulators Y Y Y 

Stack Assembly Y Y 

Insulation Resistance 

Marking ( Routine & Acceptance Test) 


BATTERY & BATTERY 

SYSTEM 

Checking of Polarity & absence of short 

circuit (Routine & Acceptance Test) 

Lead Acid Battery (IS : 1652) Y Y Y Y Y 

Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality 


Test for Capacities for 10 hrs. discharge 

rate along with the test for voltage during 

discharge ( Acceptance Test) 

PAGE 

1 OF 2

CLAUSE NO. 

ATTRIBUTES / 


ITEMS, COMPONENTS, SUB 






PLANT PACKAGE 


Ni- Cd BATTERY 

Impact Strength 

Conformance to relevant part drg. & Manufacturer’s 

standards 

Container & Lids Y Y Y Y 

Vent Plugs Y Y Y 

Resistance to Alkali 

Chemical composition 

Perforated Steel Strips Y Y Y Y 

Active Material for Positive & 

Negative Plates 

Y Y 

Separators Y Y Y 

Electrolyte Y Y 

Inter-cell Connectors & 

Fasteners 

Nickel Plating thickness 

Y Y Y Y 

Battery Stand Y Y Y 

Cell Insulators Y Y Y 

Paint Shade, Thickness, Adhesion & Finish 


SECTION-VI 

PART-B 

Air Pressure Test after heat sealing 

Marking & Mass (Routine & Acceptance Test) 

Air Pressure Test (Acceptance Test) 

Retention of Charge Test ( Acceptance Test) 

AH Test (Acceptance Test) 

Insulation Resistance 

(Acceptance Test) 

Stack Assembly Y Y Y Y Y Y 

Ni-Cd Battery (IS : 10918) Y Y Y Y Y Y Y 

Notes: 





BATTERY & BATTERY 

SYSTEM 

Polarity & absence of short circuit (Routine & 

Acceptance Test) 

PAGE 

2 OF 2

PART - B 


MEASURING & INSTRUMENTATION 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 




PLANT PACKAGE 


MEASURING INSTRUMENTS (PRIMARY AND SECONDARY) 

ITEMS 

TESTS 

1. PR Gauge (IS-3624) Y Y Y Y Y 

2. Temp. Gauge (BS-5235) Y Y Y Y Y 

3. Pr./D.P. Switch (BS-6134) Y Y Y Y Y Y 

4. Electronic Transmitter(BS-6447 / IEC- 

60770) 

Y Y Y Y Y Y 

5. Temp. Switch Y Y Y Y Y Y 

6. Recorder(IS-9319/ANSI C-39.4) Y Y Y Y Y Y 

7. Vertical indicators Y Y Y Y Y 

8. Digital Indicators Y Y Y Y Y 

9. Integrators Y Y Y Y 

10. Electrical Metering Instrument (IS-1248) Y Y Y Y Y Y 

11. Transducer (IEC-688) Y Y Y Y Y Y 

12. Thermocouples (ANSI-MC-96.1) Y Y Y Y Y Y 

13. RTD(IEC-751) Y Y Y Y Y Y 

Dimensions (R) 

14. Thermowell Y Y Y Y Y 

R-Routine Test A- Acceptance Test Y – Test applicable 

Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance 

Programme in General Technical Conditions 

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. 

Make, Model, Type, Rating (R) 

Process / Electrical connection (R) 


SECTION-VI 

PART-B 

Calibration (R) 

Test as per standard(R) 

Insulation Resistance (R) 


MEASURING 

INSTRUMENTS 

IBR Certification (if applicable )(R) 

Hydro Test(R) 

PAGE 

1 OF 2 

Material Test certificate ®

CLAUSE NO. 

ITEMS 

TESTS 




PLANT PACKAGE 


Dimensions (R) 

Make, Model, Type, Rating (R) 

Process / Electrical connection (R) 

15. Cold junction compensation 

box 

Y Y Y Y Y 

16. Orifice plate(BS-1042) Y Y Y Y* Y Y* Y* 

Y Y* Y 

* * 

* 

17. Flow nozzle(BS-1042) Y Y Y Y* Y Y Y Y Y Y 

18. Impact head type element Y Y Y Y Y 

19. Level transmitter/float type Y 

switch 

Y Y Y Y Y Y Y 

20. Flue Gas analyser Y Y Y Y 

21. Dust emission monitors 

*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. 

Y Y Y Y 

** If applicable 

R-Routine Test A- Acceptance Test Y – Test applicable 

Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per 

Quality Assurance Programme in General Technical Conditions 

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. 

Calibration (R) 

Requirement as per standard (R) 


SECTION-VI 

PART-B 

WPS approval (A) 

Non-destructive testing (R) 

Calculation for accuracy (R) 

Insulation Resistance (R) 

IBR Certification as applicable (R) 


MEASURING 

INSTRUMENTS 

Hydro test (R) 

Material test certificate (A) 

PAGE 

2 OF 2

PART - B 


CLOSED CIRCUIT TELEVISION SYSTEM 

(CCTV) 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 






PLANT PACKAGE 


CLOSED CIRCUIT TELEVISION SYSTEM (CCTV) 

Attributes 


Make, Model, Type, Rating, TC® 

Dimension/constructional requirement® 

Functional/operational check® 

Switching capability and sequence® 


SECTION-VI 

PART-B 

No. of inputs/outputs, display® 

Video Switcher/control system Y Y Y Y Y 

Key boards Y Y 

Cameras Y Y Y 

Lens Y Y Y 

Camera Housing Y Y 

Pan & Tilt unit Y Y Y Y 

On site receiver Y Y 

Monitor Y Y Y 

Video Recorder Y Y 

Video Amplifier Y Y 

Provision for connectivity with the LVS® 

Pan range/speed, tilt/tilt speed® 

Operational check from key board/control 

panel® 

Complete System Y Y Y Y Y Y Y Y Y 




(CCTV) 

Commands from Video switcher/control 

unit® 

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. 

R –Routine Test Y -Test Applicable 

PAGE 

1 OF 1

PART - B 


CHP SYSTEM CIVIL & STRUCTURAL 

WORKS 




PLANT PACKAGE 


SECTION-VI 

PART-B

CLAUSE NO. 

1.00.00 INTRODUCTION 




PLANT PACKAGE 


SAMPLING, TESTING AND QUALITY ASSURANCE FOR CIVIL WORKS 

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: 

His organization structure for the management and implementation of the 

proposed quality assurance programme 

Quality System Manual 

Design Control System 

Documentation and Data Control System 

Qualification data / details for Contractor’s key personnel. 

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. 

System for shop manufacturing and site erection controls including process, 

fabrication and assembly. 


SECTION-VI 

PART-B 


CHP SYSTEM 

CIVIL & STRUCTURAL 

WORKS 

PAGE 

1 OF 34

CLAUSE NO. 




PLANT PACKAGE 


Control of non-conforming items and system for corrective actions and 

resolution of deviations. 

Inspection and test procedure both for manufacture and field activities. 

Control of calibration and testing of measuring testing equipment. 

System for Quality Audits. 

System for identification and appraisal of inspection status. 

System for authorizing release of manufactured product to the Owner. 

System for handling, storage and delivery. 

System for maintenance of records, and 

Quality plans for manufacturing and field activities detailing out the specific 

quality control procedure adopted for controlling the quality characteristics 

relevant to each item of work/ equipment/component. 

3.00.00 SAMPLING, LABORATORY AND FIELD TESTING 

3.01.00 The Contractor shall provide the facilities whatsoever required and also bear the cost 

for all sampling, testing and quality assurance in the field and in the laboratory. The 

Contractor shall carry out all sampling and testing in accordance with the relevant 

Indian standards and / or international standards and this technical specification. 

Where no specific testing procedure is mentioned, the tests shall be carried out as 

per the best prevalent engineering practices and to the directions of the Engineer. All 

sampling shall be done in the presence of the Engineer or his authorized 

representative. The Contractor shall establish the QA&QC laboratory at site and all 

field tests shall be done in the presence of the Engineer and / or his authorized 

representative. The tests which cannot be carried out in the field laboratory shall be 

done at a laboratory of repute such as CSMRS, NCBM, IITs, National Test House, 

Kolkata etc. as agreed by the Engineer. The test samples for such test shall be jointly 

selected and sealed by the engineer and thereafter these shall be sent to the 

concerned laboratory through the covering letter signed by FQA representative of the 

engineer. The cost of transportation and other associative cost including the test 

charges shall be borne by the contractor. These cost shall deemed to be included in 

the respective item of work in the contract. If the Engineer desires to witness such 

tests at laboratory, Contractor shall arrange to conduct the test in his presence. At 

least one set of mix design shall be carried out by contractor at NCB, Ballabgarh/ 

CSMRS, Delhi. 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

2 OF 34

CLAUSE NO. 




PLANT PACKAGE 


3.02.00 The recommendations and suitability of material for concreting and other building 

materials like brick, cement, aggregates etc., shall be ascertained by contractor prior 

to start of work. 

Preliminary evaluation of aggregate and its evaluation for potential alkali-aggregate 

reactivity as per following scope of work shall be done:- 

A. Evaluation of Aggregates: 

I. To carry out different tests on coarse aggregate sample i.e. specific 

gravity, water absorption, sieve analysis, deleterious material; 

soundness, crushing value, impact value, abrasion value, elongation 

index and flakiness index, as per IS: 2386. 

II. To carry out different tests on fine aggregate sample i.e. specific 

gravity, water absorption, sieve analysis soundness, deleterious 

material, silt content, clay content and organic impurities as per IS: 

2386. 

III. To prepare evaluation report based on test results of I) and II) above 

and to advise regarding suitability of fine and coarse aggregates. 

B. Evaluation of Aggregates for Potential Alkali-Aggregate Reactivity: 

Evaluation for Potential Alkali-Aggregate reactivity as per following scope of 

work: 

I. To carry out petrographic analysis and accelerated Mortar bar Test on 

aggregate samples (1N NaOH at 80 deg. Centigrade for 14 days as 

per ASTM 1260, or the method established/ developed by CSMRS for 

22days test). 

II. To prepare a report based on test results of I) above and to advise 

regarding suitability of aggregates and further testing required if any. 

The contractor shall initiate the action with regard to the above mentioned evaluation 

of aggregates and other building material, so as to ensure timely completion of these 

tests thereby not affecting any project work. All records shall be submitted, unless 

specified otherwise, as per the format developed by the Contractor and approved by 

the Engineer. 

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 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

3 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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 incharge 

at site, preferably directly reporting to the Project Manager, supported as 

necessary by experienced personnel, to ensure the effective implementation of the 

approved QAP. An indicative structure of Contractors QA&QC manpower required to 

be deployed at site is enclosed at Annexure-II. Based on the finalized L-2 network 

and the approved Field Quality plan the Contractor shall finalize and submit a 

deployment schedule of QA&QC personnel along with their details to Owner for 

approval/ acceptance and further shall ensure their availability well before the start of 

the concern activity. 

The QA&QC in-charge shall have the organizational freedom and authority to 

implement the requirements of these quality assurance arrangements, free from 

commercial and programme restraints. The QA&QC setup of the Contractor shall 

consist of qualified and experienced Civil, Electrical, Mechanical Engineers and 

Laboratory assistants with their supporting staff both at their works and site. 

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- 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

4 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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/ subsupplier/ 

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 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

5 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

6 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

7 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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. 

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 

9.01.00 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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

8 OF 34

CLAUSE NO. 




PLANT PACKAGE 


2. All materials shall be stacked and stored by the Contractor as per IS-4082 

and as per the requirements specified in NTPC Technical Specification. 

3. All material shall be stacked separately. 

4. Lime and cement shall be stored on a raised platform in Weather Proof, Dry & 

Leak Proof Conditions stores. 

5. Different consignment of different types of cement shall be stored separately 

with clear identification mark. 

6. Cement stored for more than 60 days in contractors godown shall be retested 

to check their suitability for use. 

7. Cement shall be consumed on first in first out basis. 

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. 

9.02.00 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 ASTMD-328 at 180 degree bends 

(twice the thickness of sheet). There should not be any crack. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

9 OF 34

CLAUSE NO. 




PLANT PACKAGE 


vii) Dimensional check after profiling of sheets 

viii) Weathering Resistance Test: 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 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

10 OF 34

CLAUSE NO. 




PLANT PACKAGE 


9.03.00 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. 

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. 

9.04.00 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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

11 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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). 

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 


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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

12 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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 

pile bore or any other method approved by the Engineer, to ensure that it is 

free from pile bore spoil/debris and any other loose material before 

concreting. 

13. Low strain pile integrity test on all job piles and test piles shall be conducted 

as specified in the Technical Specification. This test shall be suitably used to 

identify the piles for routine tests. 

14. High Strain dynamic test shall be done as per the technical specification. The 

frequency of the test shall be as per the BOQ /technical specification. 

9.05.00 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 


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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

13 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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. 

9.06.00 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. 

9.07.00 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 


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 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

14 OF 34

CLAUSE NO. 




PLANT PACKAGE 


h) Recurrent surface dampers 

i) Softness or chalkiness 

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. 

9.08.00 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 : 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

15 OF 34

CLAUSE NO. 




PLANT PACKAGE 


a) Check conformity of material to relevant IS codes. 

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. 

9.09.00 QA REQUIREMENTS FOR STRUCTURAL STEEL WORK 

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 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

16 OF 34

CLAUSE NO. 

4. Fillet Welds: 




PLANT PACKAGE 


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 : 

6. Coal Bunker/Bins 

i) 100% UT on web to flange joint of crane girder. 

ii) 10% UT on other full penetration joints. 

a) 10% DPT after back gouging. 

b) 5% spot radiography test on butt welds where access not available. 

UT shall be carried out with prior approval of Engineer incharge . 

7. Every 1 st and further every 10 th set of identical structure shall be checked for 

control assembly in shop before erection. 

8. All structure components/members shall be checked for dimensional 

tolerances during fabrication and erection as per IS-7215 and IS-12843 

respectively. 

9. Check for Surface Preparation and Paint thickness. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

17 OF 34

CLAUSE NO. 




PLANT PACKAGE 


10 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. 

11 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. 

9.10.00 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 


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. 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

18 OF 34

CLAUSE NO. 




PLANT PACKAGE 


• Provision of hardware & fixtures to be installed at site. 

• Glazing beads shall be cut with mitered corners. 

• Glazing clips, fixing devices etc. shall be supplied in adequate nos. 

• Shop coats shall be properly applied. 

• Exposed aluminium surface shall be free from scratches, stains and 

discoloration. 

9.11.00 ROLLING SHUTTERS/GRILLS 

After installing the shutters, the contractor shall test the performance of the shutter in 

the presence of the engineer. The shutter shall be smoothly operable under all 

ambient conditions. All controls and locking devices shall give fault free performance. 

9.12.00 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. 

9.13.00 GLASS AND GLAZING 

1. Materials used in glass and glazing shall conform to the requirements of the 

Technical Specification and IS Codes specified in the Technical Specification. 

2. All installation shall be free from cracked, broken or damaged glass, edges of 

large panes of thicker glass and heat insulating glass be inspected carefully 

for chipped, cracked or underground edges. 

3. Glazing shall be carefully done to avoid direct contact with metal frames. 

4. All glasses shall be embedded in mastic for steel works and fixed by 

neoprene gasket for aluminium works to give a leak proof installation. 

5. On completion, the panes shall be free from dirt, stains, excess putty etc. to 

the complete satisfaction of the engineer. 

9.14.00 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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

19 OF 34

CLAUSE NO. 




PLANT PACKAGE 


2. All elastomeric membrane is fully dried to perform testing with water ponds 

created on minimum 5% of area of nominal size 6m x 6m for height of 25mm 

to 30mm at critical locations for a period of 48 Hrs. No dampness shall be 

visible on the underneath side of roof (i.e. ceiling, parapet and wall junction 

etc.). The above testing shall be carried out prior to application of wearing 

course. 

9.15.00 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 


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 

10.01.00 Excavation and Filling 

Tolerance 

Finished surface level shall be within 20mm of the level shown in the drawing. 

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. 

a) 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. 

10.02.00 Cast-in-situ concrete and Allied works 

10.02.01 Tolerances 

a) Cast-in-situ concrete 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

20 OF 34

CLAUSE NO. 




PLANT PACKAGE 


Unless otherwise specified, the tolerance in construction shall be as follows: 

The dimensions of concrete as cast when compared with those on the 

drawings shall be within the tolerance given below: 

-------------------------------------------------------------------------------------------------- 

Description of Item/ Structural Element Max Min 

(mm) (mm) 

------------------------------------------------------------------------------------------------------- 

Faces of concrete in foundations 

and structural members against which 

back fill is placed +25 -10 

Eccentricity of footing 2% of footing width in 


placement but limited to 

50mm 

Top surfaces of slabs and of concrete 

to receive base plates to be grouted +5 -5 

Alignment of beams, lintels, columns, 

walls, slabs and similar structural 

elements +5 -5 

Cross sectional dimensions of walls, 

slabs and similar structural elements +5 -5 

Deviation from specified dimensions 

of cross-section of columns and beams +12 -6 

Alignment of holding down bolts without 

sleeves +1.5 -1.5 

Alignment of holding down bolts with 

sleeves +5 -5 

Level of holding down bolt assemblies +10 -10 

Embedded Parts ( in any direction). +5 -5 

Level of embedment for equipment 

support +1.5 0 

Level of embedment for other 

embedded parts +5 -5 

Centers of pockets or holes 

with greatest lateral dimension not 

exceeding 150mm +10 -10 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

21 OF 34

CLAUSE NO. 

Variation in steps 




PLANT PACKAGE 


Riser +1.5 +3.0 

Tread -1.5 -3.0 

(b) Reinforcement 

Tolerance on placing of reinforcement and for cover shall be as per clause 

12.3 of IS: 456. 

Reinforcement shall be placed within the following tolerances: 

a) For effective depth 200 mm or less ± 10mm 

b) For effective depth more than 200 mm ± 15mm 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

22 OF 34

CLAUSE NO. 





PLANT PACKAGE 


(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 

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. 

10.03.00 Fabrication and Erection of Structural Steel Work 


I. Fabrication tolerances 

(a) maximum permissible gap in built up members 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

23 OF 34

CLAUSE NO. 




PLANT PACKAGE 


(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 

(e) permissible deviation in column heights 

II. Erection tolerances 

All tolerances for above shall be as per drg / IS : 7215 

(a) permissible tolerances in erected steel columns 

(b) permissible tolerances in erected steel trusses 

(c) permissible tolerances in crane girder and rails 

All tolerances for above shall be as per approved drg / IS : 12843 

III. Requirement of pre-heating 

Thickness of thickest 

part at the area of 

welding / heat affected 

zone 

Welding using other 

than low hydrogen 

welding electrodes IS 

: 2062 

Upto 20 mm (including) None None 

Over 20 mm to 40 mm 

(including) 

Over 40 mm to 63 mm 

(including) 


Not allowed 20 0 C 

Not allowed 66 0 C 

Over 63 mm Not allowed 110 0 C 


SECTION-VI 

PART-B 

Welding using low 

hydrogen welding 

electrodes or submerged 

arc welding IS:2062 

(a) The acceptance criteria of Non Destructive Testing (NDTs) on welds shall be 

as per AWS D1.1 (Dynamically Loaded Structures - tension welds). In case of 

failure of any of the tests, the Contractor at his own cost shall also carry out 

rectification of such defective welds. Retesting of the rectified joint, shall also 

be carried out by the Contractor at his own cost. 

(b) Every 1 st and further every 10 th set of identical structure shall be checked for 

control assembly in shop before erection. 


CHP SYSTEM 


WORKS 

PAGE 

24 OF 34

CLAUSE NO. 

Embedded part 




PLANT PACKAGE 


The tolerances for embedded parts shall be as specified under concrete works. 

10.05.00 Masonry & Allied works 


(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 

dubbing behind rounding of the corners at junctions of wall or in 

plastering of masonry cornices etc. shall be ignored. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

25 OF 34

CLAUSE NO. 





PLANT PACKAGE 


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. 

10.06.00 Finishing & Allied works 


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:- 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

26 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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 noninterchangeable. 

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. 

10.06.02 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 

10.07.00 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 

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. 

10.07.01 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 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

27 OF 34

CLAUSE NO. 




PLANT PACKAGE 


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. 

10.08.00 Water Supply, Drainage & Sanitation 


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. 

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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

28 OF 34

CLAUSE NO. 




PLANT PACKAGE 


11.00.00 QA REQUIREMENTS FOR ROAD WORK 

Quality Assurance and testing requirements for roadwork shall be as per relevant 

IRC Codes for Road . 

12.00.00 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. 

13.00.00 ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE PROGRAMME: 

13.01.00 Indicative list of Field Quality Laboratory and Survey equipment list (Annexure-I) 

13.02.00 Indicative QA&QC Manpower requirements (Annexure-II) 

13.03.00 Indicative list of Bought Out Items for Civil Works (Annexure – III) 

13.04.00 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) 

13.05.00 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1 

13.06.00 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R1 

13.07.00 Status of items requiring Quality Plan and sub supplier approval. Format No.: QS-01- 

QAI-P-02/F1-R0 

13.08.00 List of items requiring quality plan and sub supplier approval. Format No.: QS-01- 

QAI-P-01/F3-R0 

13.09.00 Field Welding Schedule Format No.: QS-01-CQA-W-11/F1-R0 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

29 OF 34

CLAUSE NO. 




PLANT PACKAGE 


13.10.00 Welding Procedure Specification (WPS) Format No.: QS-01-QAI-W-06/F1-R0 

13.11.00 Main supplier’s evaluation report Format No: QA-01-QAI-P-04/F1-R0 

13.12.00 Sub supplier questionnaire Format no: QA-01-QAI-P-04/F2-R0 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

30 OF 34

CLAUSE NO. 




PLANT PACKAGE 


TYPICAL QA/QC LAB EQUIPMENT ANNEXURE - I 

INDICATIVE FIELD QA&QC LABORATORY SET-UP 

S. No Equipment Nos 

1. Standard sieve analysis setup along with the sieve G.I. 

frame , Motorized sieve shaker , Pans and Covers etc. 

2. Slump Testing Equipment - Slump test mould, temping 

rod etc. 

3. Compression test for concrete cubes and bricks –Cube 

moulds, compression testing machine, 

cylinders,temping rods, laboratory concrete mixer etc. 

4. Le-chatelier apparatus, Viacat apparatus, balance, 

standard weights, gauging trowel 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

1 Set 

2 Set 

1 Set 

1 Set each 

5. Rebound Hammer for NDT testing of concrete 1 Set 

6. Thermostatically controlled laboratory Electric ovens 

and Portable ovens. 

1 Set each 

7. Physical balances and Electronic balances. 1 Set each 

8. Micro Meter, Vernier Calipers 1 Set each 

9. Mhos scale for hardness test 1 Set 

10. Electrical moisture meter (IS 287) for timber test 1 Set 

11. Digital Elco-meter for paint thickness 1 Set 

12. Standard Proctor test set-up and Core cutters for in-situ 

density test set-up 

13. NDT tests on welding – DPT set-up, UT and RT (with 

BARC approved source) set-up 

14. Computerized Seismographs for blast vibration 

monitoring, if required 

15. Glass Jar, sedimentation pipette, Measuring Cylinders, 

Containers, Evaporating dish, steam bath, desiccators, 

muffle furnace, chemicals etc. 

16. Thermometer, Steel rules, Measuring wedge for bricks 

etc. 

1 Set each 

1 Set each 

1 Set each 

As required 

As required 

PAGE 

31 OF 34

CLAUSE NO. 

NOTE: 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

PAGE 

32 OF 34

CLAUSE NO. 

NOTE: 




PLANT PACKAGE 


INDICATIVE FIELD QA & QC MANPOWER STRUCTURE 

QUALITY 

ASSURANCE 

• DOCUMENTATIO 

N- QAP, FQP, 

MQP, MONTHLY/ 

QUARTERLY 

REPORTS ETC. 

• CO-ORDINATION 

AND 

INTERACTION 

WITH NTPC AND 

SUB- 

CONTRACTORS 

• TEST ON 

BOUGHT OUT 

ITEMS 

• THIRD PARTY 

SUPPROTING 

STAFF 

PROJECT 

MANAGER 

QA & QC 

MANAGER 


SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

ANNEXURE – II 

QC ENGINEER-IN-CHARGE QA&QC 

LABORATORY 

IN-CHARGE 

EXCAVATION, FILLLING, 

FOUNDATIONS, PILING - 

GEOTECHNICAL ENGINEERS 

CONCRETE & BUILDING 

MATERIALS EVALUATION/ 

TESTING, CONCRETE MIX 

DESIGN PRODUCTION AND 

NDT ENGINEERS FOR 

STRUCTURAL STEEL WORK – R.T. 

LEVEL- II, UT LEVEL-II – NDT 

ENGINEERS 

SUPPROTING 

FIELD AND 

LAB STAFFF 

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. 

PAGE 

33 OF 34

CLAUSE NO. 

Sr. 

No. 

Note: 




PLANT PACKAGE 



SECTION-VI 

PART-B 


CHP SYSTEM 


WORKS 

ANNEXURE – III 

INDICATIVE LIST OF BOUGHT OUT ITEMS FOR CIVIL WORKS 

Bought Out Item Proposed Make Proposed list of 

Manufacturers 

1. Structural steel and 

reinforcement steel 

2. Cement 

3. Doors including fire proof 

doors, windows, ventilators, 

partitions, louvers, rolling 

shutters, etc 

4. Finish paints etc 

5. Concrete Admixtures, 

chemical injection grouting, 

waterproofing chemicals etc. 

6. Permanently Colour Coated 

Sheets 

7. PVC Water stops 

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. 

PAGE 

34 OF 34

Supplier’s Name and Address: ANNEXURE -III INDICATIVE FIELD QUALITY PLAN 

ITEM : CIVIL AND STRUCTURAL WORKS 

QP NO. : XX 

PROJECT: 

PACKAGE: 

REV. NO.: YY CONTRACT NO. 

DATE: DD:MM:YY MAIN- 

PAGE: CONTRACTOR 

Sl. No Activity and Characteristics / instruments Class# Type of Quantum Reference Acceptance 

Format of 

operation of check Check Of check Document Norms Record Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

1.00 a) Setting up of FQA laboratory within 

A Physical One time List of laboratory equipment as per SR Functioning of laboratory equipment in proper working 

ten weeks of LOA 

technical specification and Post bid 

Minutes of meeting 

condition to be verified on monthly basis 

1.00 b) Avialablility of requisite laboratory set 

up and equipment in good working 

condition well before commencement 

of concerned activity 

1.01 a Submission of QA & QC manpower 

deployment schedule based on 

agreed L-2 network . 

1.01 b Availability of QA& QC manpower 

based on deployment schedule . 

1.02 Sampling for testing of buliding 

materials 

1.03 Submission of schedule of tests to 

be done monthly / quaterly and 

maintenace of the same on a 

computer connected to Employer 

LAN (if connection provided by 

Employer) for monitoring 

SUB-SYSTEM :CIVIL WORKS 

A Physical Monthly -do- 

SR 

A Physical One time 

A Physical Monthly As perTechnical specification and 

Post bid Minutes of meeting 

SR 

A Physical Once per source As perTechnical specification and SR/TR Test report along with the recommendations from 


specialist institute, where the building materials shall 

be tested , as agreed in the LoA shall be submitted to 

Employer 

A Physical Monthly As perTechnical specification and 


SR 

Manufact Main-supplier 

LEGEND: D* Records, indentified with “Tick” (√) shall be essentially included by supplier in QA documentation. 

Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR,TR,MfrTC, LB 

‘A’ shall be witnessed by Employer FQA, ‘B’ and ‘C’ shall be witnessed by Employer erection / construction deptt. For 

urer/ Sub- 

(A & B check shall be Employer CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Employer 

supplier 

Certificate , duly correlated , LB= Log book 

USE 

Signature 

VINDHYACHAL SUPER THERMAL POWER PROJECT, STAGE-III (2X500 MW) 

WAGON TIPPLER, CONVEYING CONVEYING PLANT PACKAGE 

FORMAT NO.-QS-01-QAI-P-09/F2-R0 

This document shall be read in conjunction with Employer Tech. Specifications, BOQ, Drawings . 


SECTION-VI 

PART-B 

As perTechnical specification and 


DOC. NO.: 

REVIEWED BY APPROV 

ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

1 of 26

Sl. No 

Supplier’s Name and Address: ANNEXURE-IIIA, INDICATIVE QUALITY PLAN 

PROJECT: 


QP NO. : XX PACKAGE: 





Activity and Characteristics / instruments 

Class# Type of Quantum Of check Reference Acceptance 

Format of 

operation of check Check Document Norms Record Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

2.0 EXCAVATION AND 

FILLING 

2.1 Nature of soil/rock As required B Visual Random As per Contractors scheme for 

excavation/appd. Drg. 

SR 

2.2 Initial ground level DigitalTheodolite/Total Station B Measuremen 

t 

2.3 Marking layout of the 

Structures w.r.t the available 

benchmarks 

2.4 Dimensions of excavated pit. As required B Measuremen 

t 

100% -do- 

SR 

DigitalTheodolite/Total Station C Physical 100% As per the approved drawing SR 

100% -do- 

SR 

2.5 Final pit/bed level. As required B Measuement 100% -do- 

SR 

2.6 Side slope during excavation As required B Measuremen 

t 

Random -do- 

SR 

2.7 Sheet Piling Execution As required B Physical 100% As per approved drawingand SR The sheet piling work has to be carried out as per the 

methodology 

approved drawing and methodology. 

2.8 Dewatering arrangement layout and execution As required B Physical 100% As per approved Employer tech. Approved 

specs and approved methodology Mthodology 





urer/ Sub- 


supplier 


USE 

Signature 






SECTION-VI 

PART-B 

DOC. NO.: 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

2 of 26

Supplier’s Name and Address: . INDICATIVE FIELD QUALITY PLAN 

PROJECT: 







Sl. No Activity and Characteristics / instruments Class# Type of 

of check 

Quantum Reference Acceptance 

Format of 

operation Check Of check Document Norms Record Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

2.6 Fill (Suitability of borrow material) 

2.6.1 Grain size analysis set of sieves, Hydrometer etc B Physical One in every 2000 cum 

for each type and 

source of fill materials 

subject to a min. of 2 

samples 

2.6.2 Liquid & plastic limit Mechanical liquid limit device, 

Grooving tools, Evaporating 

Disc, Spatula, Palette knives, 

Balance, Oven, Containers 

2.6.3 Shrinkage limit Mechanical liquid limit device, 

Grooving tools, Evaporating 

Disc, Spatula, Palette knives, 

Balance, Oven, Containers 

B Physical One in every 2000 cum 




samples 





samples 

2.6.4 Free Swell Index Measuring Cylinders B Physical One in every 5000 cum 



2.6.5 Chemical Analysis 

I Organic Matter Oven, Chemical balance, 

Volumetric flask, Burettes, 

Pipettes, Conical flask, Set of 

Sieves, Measuring cylinder 




IS:2720 (Pt.IV) 

IS:2720 (Pt.V) 

IS:2720 (Pt.VI) 

IS:2720 (Pt.XL) 

IS:2720 Pt.XXII 

Manufact Main-supplier ‘A’ shall be witnessed by Employer FQA, ‘B’ and ‘C’ shall be witnessed by Employer erection / construction deptt. For 

urer/ Sub- 


supplier 


USE 

Signature This document shall be read in conjunction with Employer Tech. Specifications, BOQ, Drawings 







SECTION-VI 

PART-B 

DOC. NO.: 


ED BY 

SR/TR Applicable only in case the back filling is required to 

be done using borrowed earth bought fron outside 

plant boundary 




SR/TR -do- 

SR/TR -do- 

SR/TR -do- 

APPROVAL SEAL 

ANNEXURE-IV 

3 of 26

PROJECT: 







of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

ii Calcium carbonate Regents and indicators, B Physical -do- Part XXIII of IS-2720 


Burette, Flask, Funnels 



iii pH value As required B Physical -do- Part XXVI of IS-2720 

SR/TR -do- 

iv Total soluble sulphate As required B Physical -do- Part XXVII of IS-2720 

SR/TR -do- 

2.6.6 Standard proctor Test to 

determine optimum moisture 

content and max. dry density 

of fill 

2.6.7 Moisture content of fill before 

compaction 

2.6.8 Degree of compaction fill 

i Dry density by core cutter 

method 

OR 

Dry density in place by sand 

displacement method 

ii Relative density (Density 

Index) 

Procter needle appratus A Physical One in every 2000 cum 



Balance Oven etc. A Physical One in every 2000 cum 



Core cutter, Balance A Physical i) For foundation back 

fill one for every 10 

foundations for each 

compacted layer. ii) 

Once every 500sqm 

area for each 

compacted layer subject 

to a minimum of one 

sample 

SR/TR 

SR/TR 

SR/TR 

Sand replacement Appratus A Physical -do- IS 2720 (Pt. XXVIII) 

SR/TR 

Balance, Oven etc A Physical (i) & (ii) above IS 2720 (Pt. XIV) 

SR/TR Test for sandFilling shall be carried out in layers of 

thickness as specified in the technical specification 

and compacted to a relative density as specified in the 

technical specification 

LEGEND: D* Records, indentified with “Tick” (√) shall be essentially included by supplier in QA documentation. DOC. NO.: 




urer/ Sub- 


supplier 


USE 

Signature 

Supplier’s Name and Address: INDICATIVE FIELD QUALITY PLAN 







SECTION-VI 

PART-B 

IS 2720 (Pt.VII) 

IS 2720 (Pt.II) 

IS 2720 (Pt. XXIX) 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

4 of 26

Sl. No 

Supplier’s Name and Address: 

QP NO. : XX 

PROJECT: 

PACKAGE: 





Class# Type of 

of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

iii Dry Density by proctor needle 

penetration 

Procter needle appratus B Physical Random checks to be 

carried out for each 

compacted layer 

2.6.9 Sand Filling Suitability of material used As per IS-2720,383 B Physical Random IS-2720 ,383 

SR/TR 

2.6.10 Stone Filling Suitability of material used As per IS-2720,383 B Physical Random IS-2720,383 

SR/TR 

3.0 CAST-IN-SITU CONCRETE 

3.01 MATERIALS 

3.01.01 CEMENT 

a) MATERIAL Physical and chemical 

properties 

A Review of 

MfrTC 

SR/TR 

Each Lot IS:8112, IS: 1489(Part-1) 

MfrTC Each cosnignment of cement obtained shall be duly 

correlated with manufacturesr's test certificate 

b) Setting Time Vicat's Apparatus A Testing Once per lot and grade IS:8112, IS: 1489(Part-1) 

TR 

c) Compressive Strength As reqd. A Testing Once per lot and grade IS:8112, IS: 1489(Part-1) 

TR 

Soundness Le-Chatleir Apparatus, 

autoclave etc. 

A Testing Once per lot and grade IS:8112, IS: 1489(Part-1) 

TR 

Storage B Visual 100% Covered storage, weather tight on SR/LB .Ensure that cement is stored in weather tight covered 

raised platform. 

storage on raised platform. If cement is stored more 

than 60 days in godown of contractor same shall be 

retested for comp. Strength & setting time. 

3.01.02 Coarse Aggregate 

INDICATIVE FIELD QUALITY PLAN 


I Moisture content As per IS Code B Physical Once for each stack of 

100 Cu.M. or part there 

of Except during 

monsoon when this has 

to be done every day 

before start of 

concreting 




urer/ Sub- 


supplier 


USE 

Signature 







SECTION-VI 

PART-B 

As per ASTM D 1558 

IS:2386 Part-III ,IS : 456, IS : 383 

DOC. NO.: 


ED BY 

SR/LB Accordingly water content of the concrete will be 

adjusted 

APPROVAL SEAL 

ANNEXURE-IV 

5 of 26

Sl. No 


QP NO. : XX 

PROJECT: 

PACKAGE: 




Activity and Characteristics / instruments Class# Type of Quantum Reference Acceptance 

Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

ii Specific gravity, water 

absorption 

iii Particle, size & Shape-Sieve 

analysis, , flakiness index, 

elongation index, angularity 

number 

iv Deleterious materials & 

organic impurities 




Balance, Sieve 

(confirming to IS-460-1962) 

etc. 

Sieves, balance, Oven, 

Thickness gauge, Length 

Gauge, Metal Scoop etc 

Balance, Sieve( confirming to 

IS-460-1962) etc. 

v Soundness Reagents (sodium Sulphate 

or Magnitium Sulphate) 

vi Alkali aggregate reactivity Scales, weights, Sieves, Glass 

Graduates, Mixing Bowl, 

Trovel, Container, Length 

comparetor, etc. 

vii Petrographic examination Screens , Hand lens, 

Microscope etc 

viii Crushing value abrasion 

value and impact value 

Standard Appratus for these 

test shall be used 

B Physical Once for each source & 

for every change of 

source 

B Physical One per 100 cum., or 

part thereof/change of 

source whichever is 

earlier 

B Physical Once per source/ on 

every change of source 

SR/LB/ 

Test 

Report 

These tests will be carried out white establishing 

design mix and the results to be intimated to 

Employer. 

SR/LB sieves should be confirming to IS-460-1962, balance 

should be accurate to 0.1% weight of sample, 

SR/LB/ 

Test 

Report 

B Physical -do- IS: 2386 Part-V, IS:383 

SR/LB/ 

Test 

Report 

A Review of 

Test Report 

A Review of 

Test Report 


IS: 2386 Part-III, 

IS:456, IS:383 

-do- IS: 2386 (Part-VII)/ASTM C 1260 Test 

Report 

-do- IS: 2386 Part-VIII, IS:383 

Test 

Report 

B Physical -do- IS:383, IS-2386 Part IV 

SR/LB/ 

Test 

Report 


urer/ Sub- 


supplier 


USE 

Signature This document shall be read in conjunction with Employer Tech. Specifications, BOQ, Drawings . 






SECTION-VI 

PART-B 

IS: 2386 Part-I, IS:383 

IS: 2386 Part-II, IS:383 

DOC. NO.: 


ED BY 

Experts opinion regarding suitability of the aggregates 

shall be obtained from the expert agency as tied up in 

the post bid minutes of meeting 

The aggregate type(deleterious/ innocuous)to be 

reported, results should be supported by petrographic 

examination 

Reporting of petrographic Examination shall be done 

as illstrated in IS 2386(part VIII)- 1963 

-do- 

APPROVAL SEAL 

ANNEXURE-IV 

6 of 26

Sl. No 

PROJECT: 





Activity and Characteristics / instruments Class# Type of 

of check 



1 2 3 

4 5 6 7 8 9 D* 10 

3.01.03 Fine Aggregate 

i Moisture content Balance, Sieve( confirming to B Physical To be done every day IS: 2386 Part-III IS:383 SR/LB/TR Volume of sand and weight of water shall be adjusted 

IS-460-1962) and Oven etc. 

before start of work 

as per moisture content. 

ii Mortar making properties As per IS Code B Physical Once per source& for 

on every change of 

source 

iii Silt, Clay content and organic 

impurities 

iv All other tests similar to 

coarse aggregates as 

mentioned above.. 

3.01.04 Water 

i Test for acidity & alkalinity by Chemical Reagent, Buret, 

using neutralization of water Conical flask, Pipette etc 

using indicator and test for 

chloride and sulphate content 

ii Tests for ascertaining limit of 

solids 

As per IS Code B Physical Once per source& for 

on every change of 

source 

SR/LB/TR Acceptability criteria shall be as per IS:383 

SR/LB/TR Acceptance limit as per relevant IS code 

B Refer S.No. 3.01.02 IS-2386, IS-383 

SR/LB/TR except test for flankiness index,elongation 

index,angularity no.,abrasion value, impact value 

,Crushing value 

As per IS Code B Physical -do- IS:3025, IS:456 

SR/LB/TR 

iii Tests for pH Value pH meter B Testing Random IS:3025, IS:456 

SR/LB/TR 

iv) Check for initial set time for 

used water and distilled water 

v) Check for Concrete 

compressive strength with 

water to be used and distilled 

water 

vicat apparatus A Physical Refer Remarks IS:456 

SR/LB/TR Initial set time with used water should not be less than that with 

standard sand and 

compression testing machine 





urer/ Sub- 


supplier 


USE 

Signature 




B 

Testing 


Note : Aggregates, water, Admixture and Mix design & concrete ingradients shall be tested at the agency tied up at the Post -bid minutes of meeting 




IS: 2386, IS:383 

IS: 2386 Part-II, IS:383 

Once per season for IS:3025, IS:456 

every change of season 

and for every change of 

source 

distilled water. This check is to be carried out only if the results of 

the tests mentioned at sl. no. 1.01.04 i),ii)& iii) mentioned above 

do not conform to IS 

A Physical Refer Remarks IS:456 

SR/LB/TR This check is to be carried out only if the results of the tests 

mentioned at sl. no. 1.01.04 i),ii)& iii) mentioned above do not 

conform to IS 


SECTION-VI 

PART-B 

DOC. NO.: 

Format of 

SR/LB/TR 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

7 of 26

QP NO. : XX 

PROJECT: 

PACKAGE: 






of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

3.02.01 Concrete 


i Mix Design As required A Review of 

report 

Once for each Type and 

grade of concrete 

Mix design needs to be repeated in case of change of 

grade, change in workability requirements, Change in 

source of ingredients of concrete, Change in 

constituents of concrete (with fly ash / without fly ash, 

with admixtures/ without admixtures etc.) change in 

exposure conditions.Mix design shall carried out by 

the specialist agency as tied up in the LoA 

ii Validation of mix design Check whether the design mix As required A Physical For each mix design IS:10262, Is:456, Employer 

For trial mix min. of 6 cubes for each mix, 3 specimen 

meets the requirement of 

technical specifications 

shall be tested at 7 days remaining 3 shall be for 28 

workability and compressive 

strength 

days comp. Strength. 

iii Concrete Production 

a) Workability - slump test As per IS Code B Physical One sample every 2 

hrs. from every mixing 

plant 

IS:456/Employer Tech. Spec. SR/LB/TR 

b) Crushing strength (works 

Tests cubes) 

c) Computer output from batching plant Verify Water cement ratio 

and cement content 

vi Admixtures for Concrete( Platicizers, 

Retarders etc.) 


As required A Physical One set of 6 cubes per IS:516, IS:456, Employer Tech. 

100 CuM or part thereof Spec. 

for each grade of 

concrete per shift 

whichever is earlier. And 

one cube per column 

and 2 cubers per 

climbing section 

As required B Physical At random at the time of 

batching. 

Chemical properties A Review of 

MfrTC 

One per type of Lot/ 

Batch of supply 


urer/ Sub- 


supplier 


USE 

IS:10262, Is:456, Employer 

technical specifications 

As per IS:1199 and approved and 

validated design mix. 

IS9103, ASTM C 494 

Physical Properties As required A Physical Once at the time of mix 

design and thereafteronce 

per type of lot/ batch of 

supply 

IS9103, ASTM C 495 


DOC. NO.: 







SECTION-VI 

PART-B 

SR/LB/ 

Test 

Report 

SR/LB 


ED BY 

Min. of 6 cubes for each mix, 3 specimen shall be 

tested at 7 days remaining 3 shall be for 28 days 

comp. Strength. 

MfrTC Admixture of appd. Brand and tested quality shall be 

used.The Chemical properties of an admixture shall 

be tested once at the time of mix design 

TR 

APPROVAL SEAL 

ANNEXURE-IV 

8 of 26

Sl. No 

QP NO. : XX 

PROJECT: 

PACKAGE: 





of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

3.02.02 Concrete conveying, placing & compaction 

i Calibration of Batching Plant Batcher should comply with 

requirement of IS 457 

ii Transportation of concrete Buckets , Chutes, belt 

conveyer etc 

A Physical To be calibrated at the 

time of starting and 

subsequently once in 

three months, and shall 

confirm to IS:4925 

B Physical 100% as per construction/erection 

methodology 

SR 

iii Placement of concrete Visual B Physical 100% as per construction/erection 

methodology as per tech.specs 

SR 

iv Check for placement - B Physical 100% As per approved construction 

methodology 

SR 

v Compacting As required B Physical At Random Check for segregation as per IS 

456 

SR 

vi Curing 

Curing Compound Material A Review of Once per lot Employer Tech. specification and MfrTC 

MfrTC 

relevant code 

Execution Check for curing duration and As required B Physical 100% Employer Tech. specification and SR 

uniform curing of the surfaces 

IS 456 

vii Cleanliness, provision of 

chute and arrangement for 

transportation & placement of 

concrete. 

viii Checkf or the slope of cold 

water basin 

Level instrument /Digital 

theodolite 

B Measuremen 

t 

100% Employer tech. specs/ Approved 

drawing 

SR 


urer/ Sub- 


supplier 


USE 

Signature 








Review of calibration chart/ 

Certificate 

Calibratio 

n 

Certificat 

e 

As required C Visual 100% Employer technical specifications/ Inspectio 

approved construction 

methodology 

n Report 




SECTION-VI 

PART-B 

DOC. NO.: 


ED BY 

Cement consumption at batching plant shall also be 

obtained through computer Output. Provision of on 

line printer is mandatory. The calibration shall be done 

by NPL traceable weights 

construction methodology to be approved one 

week prior to start of work 

To be checked before clearance for concreting 

APPROVAL SEAL 

ANNEXURE-IV 

9 of 26

PROJECT: 






Sl. No Activity and Characteristics / instruments 

Class# Type of Quantum Reference Acceptance 

Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

3.02.03 TEST/CHECK ON RCC 

STRUCTURE IN HARDENDED 

CONDITIONS 

3.03 


i Visual examination for 

surface finish 

ii Dimensional check on 

finished structures & 

Dimensional tolerances 

iii Water Tightness Test of liquid 

retaining structure/ tanks 

REINFORCEMENT STEEL(TMT & HYSD BARS) 


As built survey of each lift of 

shell 

Check for vertacility & 

horizontalness of SS/Pre- cast 

channel support for PVC fill 

i Mechanical & Chemical 

properties 

C visual 100% 

As required B Measuremen 

t 

Approved Drawing As per IS:456/ Tech. Specification. SR/LB 

As required A Test 100% IS:3370/ Tech. Specification SR/LB Limits of permeability as per IS:2645 shall also be met 

with. 

A Review of 

TCS 

ii Tolerance on Mass As required B Measuremen 

t 



Each consignment IS : 1786, IS:432, IS:1566 ;IS:432 Mfr. TCS 

At Random IS : 1852, IS: 432, IS:1786,IS:432& SR/LB 

Tech Specifications 


urer/ Sub- 


supplier 


USE 





As per IS:456/ Tech. Specification. 

As required B Physical For each lifts on the Tech. Specification and approved SR/LB 

locations as decided by drawing 

E-I-C 

measuring tape , plumb bob etc B visual At random As per appd drg SR/LB 


SECTION-VI 

PART-B 

DOC. NO.: 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

10 of 26




PROJECT: 






Class# Type of 

of check 


1 2 3 

4 5 6 7 8 9 D* 10 

iii Freedom form cracks surface 

flaws, Lamination. (Visual 

Examination). 

3.03.01 Placement of Reinforcement Steel 

I Check for bar bending As required B Visual & 

schedule with necessary laps. 

Measuremen 

Spacers & Chairs 

t 

ii Check for cover, spacing of 

bars 

iii Check for bending of bars As required B Visual & 

Measuremen 

t 

iv Check for spacers and chairs 

after the reinforcement cage 

is put inside the formwork 

As required B Visual 100% IS: 1852, IS:432, IS:1786,IS:432 SR/LB To be checked at site. Steel collected from source 

should be free from excessive rust. To be stored as 

per Technical Specs. 

100% Approved Drawings 

SR 

As required B Visual & 100% Approved Drawings 

SR The strength cover blocks( cast from concrete), should 

Measuremen 

be equal to or more than that of the concrete in which 

t 

they shall be embedded 

As required B Visual & 

Measuremen 

t 


SR 


SR 

v Lapping of bars As required B Measuremen 100% IS : 456/ Drawings & approved bar SR 

t 

bending schedule 

vi Check all joints, Crossing As required B Visual Random Approved drawing/bar bending SR Crossing of the bars are to be tied up properly with 

schedule 

right gauge of annealed wire . 




urer/ Sub- 


supplier 


USE 






SECTION-VI 

PART-B 

DOC. NO.: 

Format of 

REVIEWED BY APPROV APPROVAL SEAL 

ANNEXURE-IV 

11 of 26

Sl. No 


PROJECT: 








of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

3.04 STAGING AND FORMS 

3.04.01 Materials and accessories As required B Visual Once As per relevant IS 

SR 

i Soundness of staging, 

shuttering and scaffolding 

ii Connection between 

individual scaffolding units 

and safe slenderness ratio. 

Two independent safety 

measures against collapse 

iii Concrete strength during 

climbing process. 

iv Hoisting for personnel and 

materials 

As required B Visual Once As per manufacturer's spec.and as SR 

per 3696,4014, 4990 

As required B Visual Fortnightly As per National Safety council & 

relevant IS Codes I.e. IS:14687& 

IS:3696 

SR 

As per IS provision B Physical 

Testing 

For each lift of 

shuttering 

As required B Visual Fortnightly As per manufacturer 

recommendation & safety codes 

SR 

v Alignment/Shape 

a) Plumbing of ring As required B Physical At least once per day As per approved drawings SR/LB 

b) Dimensions shape and 

alignment using laser 

equipment 

c) To check perpendicularity and 

the location of laser device 

from outside points 

vi Check form's seam marks 

and water tightness 

As required B Physical For each lift before and 

after concreting on the 

points decided by E-I-C 

As required B Physical Once per week or 

earlier as decided by E-I- 

C 

As per approved drawings 

SR 

SR/LB 

SR/LB 

As required B Physical Random As per approved drawings SR/LB 




urer/ Sub- 


supplier 


USE 

Signature 






SECTION-VI 

PART-B 

As per provisions and tolerances 

As per approved drawings 

DOC. NO.: 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

12 of 26

Sl. No 


PROJECT: 





Activity and Characteristics / instruments Class# Type of Quantum Reference Acceptance 

Format of 

ti of check Ch k Of h k D t N Record R k 

1 2 3 

4 5 6 7 8 9 D* 10 

3.05 Embedded part 


i Position and level of 

embedded parts 



ii Position depth and size of bolt 

hole 

iii Location verticality of pipe 

sleeve/opening of bolt hold 

iv Welding / tieing of 

embeddment to reinforcement 

3.06 Pre-cast concrete 

I Workmanship free from visual 

defects 

As required B Dimensional 100% As per drawing/ Technical 


SR 

As required B Dimensional At random As per drawing/ Technical 


SR 



SR 



SR 

Visual B Physical 100% Tech. Spec. 

Register The precast units shall be free from defects like 

honeycombing, reinforcement exposure and should 

have good finish. All relevant tests like workability, 

cube test shall be carried out as per IS 456-2000 

Same as applicable to cast in situ concrete.The grade 

of concrete used shall be as per the technical 

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. 



urer/ Sub- 


supplier 


USE 

Signature 







SECTION-VI 

PART-B 

DOC. NO.: 

REVIEWED BY APPROV APPROVAL SEAL 

ANNEXURE-IV 

13 of 26

Sl. No 





PROJECT: 







Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

ii Dimension of finish structure As required B Measuremen 100% As per IS:456/Employer Tech. SR 

t 


iii Load Test As required B Physical Random IS:456/ As decided by Employer Inspectio 

Site Engr. Incharge. 

n Report 

4.00 Brick Masonry 

4.01 Test on Bricks 

i) Dimensions, compressive 

strength, water absorption, 

warpage, efflorescence. 

Test on Mortar Compressive strength and 

consistency 

iii) Masonry construction Workmanship, verticality and 

alignment 

As required A Measuremen 

t/ Physical 

Test 

These tests shall also be carried out, in case of doubt 

regarding grade of concrete and poor quality. 

Table 1 of IS:5454 IS: 1077, IS:13757,IS12894, 

IS:3495 

Efflorescence shall be checked at each source. 

As required B Test At random IS 2250 

-do- The sand used for masonry work shall conform to 

IS:2116 

As required B Visual/ 

Physical 



100% IS 2212, IS 1905 As per Technical 

Specifications 

SR/LB 


urer/ Sub- 


supplier 


USE 

Signature 






SECTION-VI 

PART-B 

DOC. NO.: 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

14 of 26



QP NO. : XX 

PROJECT: 

PACKAGE: 





of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

4.02 Painting of concrete surfaces / Plastered Masonry & Embedded 

Steel Parts 

a) Under ground structures ,Super 

structure (RCC Works) 

I Coating of concrete surfaces in 

direct contact with water/ water spray 

A) ELASTOMERIC POLYURETHANE 

COATING 

Paint material - B Visual 100% As per Tech Spec./ Drawing/and SR/LB The materail sfor painting shall be procured from 

relevant IS Code.& IS:2395 

reputed manufacturers as identified in the LoA or as 

approved by E-I-C 

Surface preparation and 

execution 

As reqd. B Physical 100% 

i)Material As reqd. A Review of Test 

certificate 

ii)Surface Preparation As reqd. B Physical 100% 

ASTM D -16, Type V and Employer Test 

technical Specification 

Certificate 

s 

As per Employer Tech. Specs., 

Relevant Codes and manufacturer's 

recommendation 

The material of the coating shall conform to the requirement 

of technical specification 

ii)Laying of Primer a)Material As reqd. B Physical 100% As per Employer Tech. Specs., SR/LB The laying of coating shall be as per relevant IS code /As 

Relevant Codes and manufacturer's 

recommendation 

per manufacturer's recommendations 

b)Thickness of primer coating As reqd. B Physical 

e) Elastomeric Polyurethane coating 

application 


a)Check for temperature and 

humidity at the time of paint 

application 

b)Check for moisture content 

of concrete surface before 

application 

As reqd. B Physical Before start of painting/ 

coating 

As reqd. B Physical Before start of painting/ 

coating 

c)DFT and wet film thickness As reqd. B Physical Random As per Employer Tech. Specs., 

Relevant Codes 

SR/LB 

d)Check adhesion of the paint 

to concrete surface (Pull out 

test) 

SR/LB 

SR/LB 

As reqd. B Physical Random As per Employer Tech. Specs., 


SR/LB 





urer/ Sub- 


supplier 


USE 

Signature 






SECTION-VI 

PART-B 

As per Tech Spec./ Drawing/and 

relevant IS Code. 





DOC. NO.: 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

15 of 26

Sl. No 

PROJECT: 






of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

5.00 FINISH ITEMS 

5.01 Plastering 

i) Ensure that the plastering of 

brick walls shall be of min. 

18mm thick for outside & 

12mm for inside face 

ii) Ensure that the curing of 

plastering surface are carried 

out for 7 days (Min.) 

Steel Tape B Visual/ 

Measuremen 

t 

B Visual 100% 

100% As per IS 1661 / Technical 

Specifications/approved drawings 

SR/LB 

iii) Sand (Grading of sand) B Physical 50 Cum. As per IS:1542 

-do- 

5.02 



i) Check for levels slope Digital/Total Station B Measuremen 

t 

ii) Ensure that the floors are 

chipped prior to 

commencement of actual 

finishing work. 

iii) Ensure that the cement 

concrete floors are cured 

minimum for 7 days. 

iv) Check for laying of ironite 

flooring and metallic hardner 

used in it. 

100% Drawings 

-do- No ponding of water on finished surfaces to be 

ensured 

C Visual 100% -do- -do- 

B Visual 100% SR/LB Sueveillance by FQA 

As reqd. B Physical Random/Once per 

batch 



urer/ Sub- 


supplier 


USE 

Signature 

Flooring & Finishing Work 







-do- 

-do- 


SECTION-VI 

PART-B 

DOC. NO.: 

-do- 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

16 of 26


PROJECT: 









Format of 

operation 

of check 

Check Of check Document Norms Record Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

6.00 SPECIAL ITEMS 

I Bitumastic flooring 

a) Bitumen grade As per Tech. Specs. B Visual/TC 100% As per Tech Specs. 

TC 

b)Pressure relief Valves As per Tech. Specs. A Review of Once per Lot Tech. Specs.,IS:4558, Relevant IS Mfr TC The laying of Pressure relief valve shall be as per 

Mfr. TC 

relevant IS code /As per manufacturer's 

recommendations 

II Earthing Mat 

a) Weld sizes & length Visual/Tape B Visual/Tape 100% As per Tech Specs. 

Low hydrogen electrode as per Employer approval 

shall be used. 

b) DP DP Kit A Physical 10% at random Free from defect 

TR 

c) Earth test Earthing test kit A Physical 100% Relevant IS 

SR Earthing required as per IS 

7.00 GROUTING 

7.01 Grouting pressure Test Set Up B Physical At Random Approved drawings 

SR Random to be checked by FQA 

7.02 Composition of grout B Physical Each Lot/ Batch As per manufacturer's technical 

specifications 

SR 



urer/ Sub- 


supplier 


USE 

Signature 







SECTION-VI 

PART-B 


ED BY 

APPROVAL SEAL 

ANNEXURE-IV 

17 of 26

LOGO Supplier’s Name and Address: 


PROJECT: 

ITEM : CIVIL WORK INCLUDING PILING WORKS 

QP NO. :01 

REV. NO.: 00 

PACKAGE: 

CONTRACT NO. 


DATE: MAIN- 


Sl. No Activity and Characteristics / instruments Class# of 

check 

Type of Quantum Reference Acceptance 

Format of 

operation Check Of check Document Norms Record 

Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

8.00.00 FOUNDATION 

8.01.00 Open / Shallow Foundation 

8.01.01 Check for the foundation As required / agreed 

excavation - Location, Layout, 

size, depth etc 

B Physical Each location As per technical specifications and SR 

construction drawings 

Ö√ lines and levels to be checked 

8.01.02 Check for the foundation As required / agreed B Physical Each foundation As per technical specifications and SR lines and levels to be checked. Concrete Grade to be 

casting - Layout, Shape, 

dimensitions, Reinforcement, 

concreting, curing etc 


checked as per Mix Design 

8.02.00 

Pile Foundation 

8.02.01 Check for Piling Layout, Theodolite B Measuremen 

t 

8.02.02 Check for Lines and Levels As required / agreed B Measuremen Each pile As per technical specifications and SR 

t 


8.02.03 Boring, Cleaning/Flushing 

Piles 

of As required / agreed B Visual Random As per IS 2911 

SR 

8.02.04 Check for Size and As required / agreed B Physical Each borehole As per technical specifications and SR 

termination of boreholes 


8.02.05 Check for pile casting - 

As required / agreed B Physical Each pile As per technical specifications and SR 

reinforcement, concreting etc 


8.02.06 Pile Termination level As required / agreed A Soil data Each pile As per technical specifications and 


SR 

8.02.07 Check for Pile Caps - Lines, As required / agreed B Physical Each pile cap As per technical specifications and SR 

levels, shape, size, 

reinforcement, concreting, 

curing etc. 



DOC. NO.: 




urer/ Sub- 


supplier 


USE 

Signature 

This document shall be read in conjunction with Employer Tech. Specifications, BOQ, Drawings . REVIEWED BY APPROV APPROVAL SEAL 

ED BY 




100% 


SECTION-VI 

PART-B 

As per technical specifications and 


SR 

√ 

√ 

√ 

√ 

√ 

ANNEXURE-IV 

18 of 26



QP NO. : XX 

PROJECT: 

PACKAGE: 


SUB-SYSTEM :CIVIL DATE: DD:MM:YY MAIN- 



of check 


Format of 


1 2 3 

4 5 6 7 8 9 D* 10 

8.02.08 

Tesing : 

i Check for properties of 

Bentonite 

ii Collection and testing of mud 

sample mud sample from 

bottom of pile bore 

iii Check for Slump test of 

concrete, cube Test (work test 

cubes) 

iv check the placement if at 

v 

leaset three core blocks in the 

reinforcement bar cage 

check for caliberation status 

of the test equipments, Jacks, 

LVDT etc before start of pile 

load test. 

vi Initial pile load test, Vertical 

(compression), Lateral 

(horizontal) and pullout 

As required / agreed B Physical Once per each Lot As per technical specifications and 

and relevant IS code 

SR / LB 

As required / agreed B Physical Each pile As per technical specifications and 


SR / LB 

As required / agreed B Physical As per above for 

concrete works 

As per technical specifications and 


SR / LB √ Concreting should start within 6 hrs of cleaning the 

bore. 

As required / agreed C Physical 100% As per technical specifications and 


SR/ LB 

As required / agreed C Physical 100% As per technical specifications and 


SR/ LB 

Calibrated dial gauges, 

Jacking system as required 

A Testing As specified in technical 


IS 2911 & as per Tech Spec. 

vii 

(tension) 

Routine pile test, 

Calibrated dial gauges, A Testing As specified in technical IS 2911 & as per Tech Spec. SR / LB 

Compression , horizontal and 

high strain integrity test. 

Jacking system as required 


viii Pile Integrity Test- Low strain 

NDT A Testing Each pile As per technical specifications and Test 

integrity test on each working 

pile. 


Report 




‘A’ shall be witnessed by Employer FQA, ‘B’ shall be witnessed by Employer erection / construction deptt. and ‘C’ For 

urer/ Sub- 

shall be witnessed by erection supplier (A & B check shall be Employer CHP stage) ;SR = Site Register , TR= Test Employer 

Signature This document shall be read in conjunction with Employer Tech. Specifications, BOQ, Drawings . REVIEWED BY APPROV APPROVAL SEAL 

ED BY 





SECTION-VI 

PART-B 

SR / LB 

√ 

√ 

√ 

√ 

Draft/interim report tobe submitted at site along with 

plots 

ANNEXURE-IV 

19 of 26

LOGO Supplier’s Name and Address: 


PROJECT: 

ITEM : CIVIL WORK INCLUDING PILING WORKS 

QP NO. :01 

REV. NO.: 00 

PACKAGE: 

CONTRACT NO. 


DATE: MAIN- 


Sl. No Activity and Characteristics / instruments Class# of Type of Quantum Reference Acceptance 

Format of 

operation check Check Of check Document Norms Record 

Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

9.00 DOORS , WINDOWS VENTILATORS & GRILL 

i) Materials and accessories B Review of 

once per lot IS :2202(PT-II),IS:1038, other relevant SR/MTC Mfr.’s T.C. shall be correlated with the consignment received. 

MTC 

codes &Appd Drgs 

ii) Check for dimensions As required B Physical Random Employer tech. Specifications/Relevant 

IS/Appd Drgs 

SR 

iii) Thickness of paint /anodized coating As required B Physical Random Employer tech. Specifications/ 

SR All buildings shall be provided with suitable anodised 

IS:1868/Appd Drgs 

aluminium grill 

iv) Workmanship As required B Physical 

/visual 

100% Approved drawings/Tech spec 

SR erection shall be as per Employer tech spec 

v) verticality & alignment As required B Physical 100% Approved drawings/Tech spec 

SR 

vi) Performance for smooth operable under 

all ambient condition 

B visual 100% Approved drawings/Tech spec 

SR 

10.00.00 GI,CI,PVC PIPES AND FITINGS 

10.01.00 

M aterials / components including valve 

B Review of 

MTC 

each 

Relevant IS &Appd Drgs/Tech spec 

Mfr.’s T.C. shall be correlated with the consignment received. 

10.00.01 

B visual 10% subject to a minimum Relevant IS &Appd Drgs/Tech spec SR Tolerance limit as per relevant IS :1729,IS : 1536,IS:1230 

Surface finish freedom from cracks and other 

of 3 nos for each type of 

defects 

items 

10.01.02 D imension and construction B Physical 10% subject to a minimum Relevant IS &Appd Drgs/Tech spec 

of 3 nos for each type of 

items 

SR Tolerance limit as per relevant IS :1729,IS : 1536,IS:1230 

11.00.00 AFTER INSTALLATION OF PIPES 

11.01.00 Water pipe and fitting 

i) Hydraulic pressure test A Physical each stretch IS : 2065 &Appd Drgs/Tech spec SR/LB Tolerance limit as per cl.14.3 0f IS : 2065 

11.02.00 Water tightness hydro test A physical each Relevant IS &Appd Drgs/ leakage test 

Tech spec 

SR/LB Tolerance limit as per relevant IS 

12.00 Joints in concrete 

12.01 Materials 

i) Bitumen Impregnated board - A Verification of Once per Lot As per manufacturer's TC , technical SR/Mfr.TC 

MfTC 

specification,IS:1838 

ii) PVC water stops - A Verification of Once per Lot As per manufacturer's TC , technical SR/Mfr.TC 

MfTC 

specification ,IS:12200 

iii) Bitumen Sealing compound - A Verification of Once per Lot As per manufacturer's TC , technical SR/Mfr.TC Grade of the bitumen sealing compound shall be as per the 

MfTC 


technical specification. 

iv) Two part Polysulphide sealant - A Verification of Once per Lot As per manufacturer's TC , technical SR/Mfr.TC 

MfTC 


v) Expanded polystyrene board - A Verification of Once per Lot As per manufacturer's TC , technical SR/Mfr.TC 

MfTC 


12.02 Installation and fixing As required B Viusal Random As per technical specification/ 

manufacturer's recommendation 

SR 

Manufacture 

r/ Subsupplier 

LEGEND: D * Records, indentified with “Tick” (√) shall be essentially included by supplier in QA documentation. 


DOC. NO.: 

Main-supplier ‘A’ shall be witnessed by Employer FQA, ‘B’ and ‘C’ shall be witnessed by Employer erection / construction deptt. For Employer 

(A & B check shall be Employer CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test 


USE 

Signature This document shall be read in conjunction with Employer Tech. Specifications, BOQ, Drawings & FQP No.2 REVIEWED BY APPROVED 

BY 

APPROVAL SEAL 





SECTION-VI 

PART-B 

ANNEXURE-IV 

20 of 26


PROJECT: 

ITEM : CIVIL AND STRUCTURAL 


WORKS 


SUB-SYSTEM :STRUCTURAL DATE: DD:MM:YY MAIN- 

STEEL WORKS 



Format of 


Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

1.00 Structural steel 

(Fabrication & 

Erection) 

Material Mechanical and chemical 

properties 

Material- Identification and 

marking 

A Review of 

MfrTC 

Once per heat number NTPC technical specification MfrTC In the event of non submission of 

IS:2062, IS:8500 

MTC, sample shall be collected and 

tested for physical and metallurgical 

properties. 

B visual 100% If IS:8500 grade steel is used,all 

steel is to be painted for 

Visual Examination 

material 

of raw 

B Visual 100% 

Free from surface defects 

1.01 FIT UP 

1.01.00 Marking and Cutting B Visual & 

100% Approved Drawing Site 

Measurement 

Register 

1.01.01 Ensure Proper fit up before Measure 

welding 

ment tape 

1.01.02 Check that the gap is 

minimum for all fillet welds 

Manufacture 



B Measurement 100% Drg. & NTPC tech. Specification Log 

Book/ 

Site 

Register 

-do- B -do- 100% -do- 

-do- 

Main-supplier ‘A’ shall be witnessed by NTPC FQA, ‘B’ and ‘C’ shall be witnessed by ntpc erection / construction deptt. (A & B check shall be For NTPC 

NTPC CHP stage) ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate , duly correlated , LB= Log 

book 

USE 

Signature 


WAGON TIPPLER, CONVEYING CRUSHING PLANT PACKAGE 

FORMAT NO.-QS-01-QAI-P-09/F-2-R0 

This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings . 

structural steel plates and 

sections shall be painted with 

emulsion paint by making a 

conspicuous band of 40 mm 

width @ 2 m c/c in following 

colours for identification:- 

IS:8500- red colour 

dimensional Checking as per 

Technical Specs. 




SECTION-VI 

PART-B 

REVIEWED BY APPROVE 

D BY 

identification . Any rest piece / 

offcuts shall be similarly marked with 

red colour for steels conforming to 

IS:8500 for identification at a later 

date . Unpainted steel pieces shall 

be treated as those confirming to 

IS:2062 

Proper identification mark to be put. 

If laminations are found during 

cutting of the material same shall 

not be used. 

APPROVAL SEAL 

ANNEXURE-IV 

21 of 26

Sl. No 


PROJECT: 



WORKS 



STEEL WORKS 



Class# of Type of Quantum Reference Acceptance 

Format of 


Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

1.01.03 Ensure that the butt weld 

joints are properly aligned 

and the offset does not 

exceed 10% of the thickness 

of the thinner part of the 

joint maximum 

permitted value is 3.2mm. 

1.01.04 Ensure match markings are 

punched for all trial 

assembled components 

-do- B -do- 100% -do- 

-do- 

-do- B -do- 100% -do- 

-do- 

1.01.05 Check Weld Fit Up -do- B -do- 100% Approved Drg. 

-do- 

1.02 Preheating 

1.02.01 Ensure pre-heating ishermal 

Cha B Visual 100% NTPC Tech. Specs. 

-docarried 

applicable 

out wherever 

1.02.02 Ensure that the preheating 

temperature is uniform prior 

to the start of welding 

1.02.03 Post Weld Heat Treatment 

(PWHT) 

1.03 Welding 

1.03.01 Ensure that the qualified 

welders and qualified 

welding procedures are 

used to all welding. 

Manufacture 



-do- B Measurement 100% -do- 

-do- 

-do- A Time & 

Temperature 

100% NTPC Tech. Specification -do- 

-do- A Testing 100% Approved WPS/WPS AWS- Test 

D1.1/ASME-IX 

Report 



book 

USE 

Signature 








SECTION-VI 

PART-B 

DOC. NO.: 


D BY 

In case pf WPS already available for 

similar base material and filler, 

records may be submitted for NTPC 

review and approval. 

APPROVAL SEAL 

ANNEXURE-IV 

22 of 26

Sl. No 


PROJECT: 



WORKS 



STEEL WORKS 


Activity and Characteristics / instruments Class# of Type of Quantum Reference Acceptance 

Format of 


Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

1.03.02 Ensure that the welding -do- A Visual 100% Approved WPS/latest NTPC SR WPS to be submitted for NTPC 

consumables used are as 

Rationalized list of Electrodes. 

approval and low hydrogen 

per procedure (WPS) 

electrodes to be used for welding of 

approved by NTPC. 

high/medium tensile steel 

1.03.03 Ensure proper edge Bevel C Visual 

100% Approved Drg. & NTPC Tech. Site 

preparation 

applicable 

wherever Protractor Measurement 

Spec. 

Register 

1.03.04 Ensure proper sequence of 

welding 

1.03.05 Check that the temporary 

attachment welding are 

removed and ground 

1.03.06 Check & ensure that the 

overlap/excess weld metal is 

removed by grinding and 

painting 

1.03.07 Check the measurement of Measurin 

parts/structures after g Tape 

welding for the correctness 

of dimensions & and 

matching, absence of 

distortion & alignment. 

1.04 Non Destructive and 

Destructive Testing 

1.04.01 Carry out RT/UT/LP test Testing 

equipmen 

t 

Manufacture 


Main-supplier 

Signature 





B Visual 100% -do- 

-do- 

do- B Visual 100% -do- 

-do- 




B Visual 100% -do- 

-do- 

B Measurement 100% -do- 

7215/Approved Drg. 

IS- -do- 

A Testing AS PER TECH SPEC NTPC Tech. Specs.ASME- Protocol 

IX,ASME-V,VIIIDIV.1,AWS D1.1 Reports 

‘A’ shall be witnessed by NTPC FQA, ‘B’ and ‘C’ shall be witnessed by ntpc erection / construction deptt. (A & B check shall be 


book 


SECTION-VI 

PART-B 

DOC. NO.: 


D BY 

APPROVAL SEAL 

ANNEXURE-IV 

23 of 26


PROJECT: KORBA 


QP NO. : XX PACKAGE: CW system & OffsiteCivil Works Package 

WORKS 



STEEL WORKS 



Format of 


Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

Manufacture 




book 

USE 

Signature 









SECTION-VI 

PART-B 


D BY 

APPROVAL SEAL 

ANNEXURE-IV 

24 of 26


PROJECT: KORBA 


QP NO. : XX PACKAGE: CW system & OffsiteCivil Works Package 

WORKS 



STEEL WORKS 



Format of 


Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

1.04.02 Trial assy/Control Assy of - B Assy. NTPC Tech Specification NTPC Tech Specification & SR/ LB 

Structures. 

approved Drg 

1.05 Cleaning and 

Painting 

1.05.01 Dry Film Thickness. As reqd. B Physical Random NTPC technical specification 

Ensure that the surface are cleaned 

and painted as specified. 

1.05.02 Ensure that the following C Visual/ 100% NTPC technical specification & -doa) 

Assembly designation 

b) Part number 

c) Weight 

approved Drg. 

d) Any other important 

identifications. 

1.2 ELECTROFORGED GRATINGS 

Material A Review of Once per lot Grade'A' IS:2062, tech 

Mfr TC 

Mfr.TC 


Finishing B Visual Random Free from warps twists or any SR manufacturing quality plan to be 

defects 

submitted 

Erection , alignment and 

B Physical Random tech specifications& Relevant IS -do- 

Installation 

Painting/surface preparation - B Review of 

Mfr.TC 

/Physical 

Random per lot Tech specifications 

Mfr TC 

1.3 GALVANISED STEEL HAND RAILS 

Material A Physical Once per lot Grade IS:2062, Technical SR/LB Galvanising shall be carried out as 

specifications,Galvanised as per 

IS 4736 

per the technical specifications. 

DPT As A Physical Random AWS D1.1 / Technical 

SR/LB 

required 



DOC. NO.: 

Manufacture 




book 

USE 

Signature 








SECTION-VI 

PART-B 


D BY 

APPROVAL SEAL 

ANNEXURE-IV 

25 of 26


PROJECT: 


WORKS 

QP NO. : 

REV. NO.: 

XX 

YY 

PACKAGE: 

CONTRACT NO. 


STEEL WORKS 



Format of 


Remarks 

1 2 3 

4 5 6 7 8 9 D* 10 

1.4 Stop Log Gate,Trash rackand Lifting beam 

I 

Material 

Check Quantity ( of components 

for stop log gate, trash rack and 

lifting beam, their embedment 

parts and guides etc.) and 

completeness and damage, 

surface defects 

C Visual 100% Challan / No damage, 

Release 

note 

surface defect 

II Erection 

a Alignment levellling Plumb, C Measurement 100% Specfication/ Approved drawing Inspect- 

Piano 

ion 

wire,water 

level 

Report 

b Painting/ surface 

treatment 

I Shade - B Visual 100% Specfication/ Approved drawing Inspection 

Report 

ii DFT Elcometer A Measurement Random Specfication/ Approved drawing -do- 

c Free movement of stop 

log / trash rack in 

guides under dry and 

under full water 

condition 

Lowering or raising for full 

length for 2/3 times 

A Physical 100% Smooth operation, NTPC Tech. 

Specification, IS:4622 

-do- 

SR Transport and packing as per 

technical specifications, in case of 

any damage damage report is to be 

prepared and submitted to NTPC for 

remedial measure. 

Welding ,if any, involved at site will 

be done by welders and procedure 

qualified as per ASME-IX in 

presence of NTPC(FQA) 

d Leakage for stop Log Measurement of leakage As reqd. A Physical 100% Leakage rate within limit 

-do- Maximum leakage rate 5 

litre/minute/metre length of seal 

under max.head 

e Load test for lifting Load Test As reqd. A Physical 100% No deflection /No Deformation -do- Tests of Lifting beam for automatic 

beam 

engaging and disengaging of stop 

log and trash rack shall be carried 

out under water. 

Manufacture 





book 

USE 

Signature 








SECTION-VI 

PART-B 

DOC. NO.: 


D BY 

The type of painting/ surface treatment of 

parts shall be as per cl. Technical 

specification.Painting/ surface treatment 

are to be carried out at works however in 

case of any damage or rectification / 

welding work at site the surface treatment 

shall be made good as per the original 

process 

APPROVAL SEAL 

ANNEXURE-IV 

26 of 26




PLANT PACKAGE 

PART - C 

GENERAL TECHNICAL REQUIREMENTS 

TECHNICAL SPECIFICATION 

SECTION-VI 

PART-C

CLAUSE NO. 

1.00.00 INTRODUCTION 




PLANT PACKAGE 


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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

1 OF 46

CLAUSE NO. 





PLANT PACKAGE 


5.01.00 In addition to the codes and standards specifically mentioned in the relevant 

technical specifications for the equipment / plant / system, all equipment parts, 

systems and works covered under this specification shall comply with all currently 

applicable statutory regulations and safety codes of the Republic of India as well as 

of the locality where they will be installed, including the following: 

(a.) Bureau of Indian Standards (BIS) 

(b.) Indian electricity act 

(c.) Indian electricity rules 

(d.) Indian Explosives Act 

(e.) Indian Factories Act and State Factories Act 

(f.) Indian Boiler Regulations (IBR) 

(g.) Regulations of the Central Pollution Control Board, India 

(h.) Regulations of the Ministry of Environment & Forest (MoEF), Government of 

India 

(i.) Pollution Control Regulations of Department of Environment, Government of 

India 

(j.) State Pollution Control Board. 

(k.) Rules for Electrical installation by Tariff Advisory Committee (TAC). 

(l.) Any other statutory codes / standards / regulations, as may be applicable. 

5.02.00 Unless covered otherwise by Indian codes & standards and in case nothing to the 

contrary is specifically mentioned elsewhere in the specifications, the latest editions 

(as applicable as on date of bid opening), of the codes and standards given below 

shall also apply: 

(a.) Japanese Industrial Standards (JIS) 

(b.) American National Standards Institute (ANSI) 

(c.) American Society of Testing and Materials (ASTM) 

(d.) American Society of Mechanical Engineers (ASME) 

(e.) American Petroleum Institute (API) 


SECTION-VI 

PART – C 

GTR 

PAGE 

2 OF 46

CLAUSE NO. 




PLANT PACKAGE 


(f.) Standards of the Hydraulic Institute, U.S.A. 

(g.) International Organisation for Standardization (ISO) 

(h.) Tubular Exchanger Manufacturer's Association (TEMA) 

(i.) American Welding Society (AWS) 

(j.) National Electrical Manufacturers Association (NEMA) 

(k.) National Fire Protection Association (NFPA) 

(l.) International Electro-Technical Commission (IEC) 

(m.) Expansion Joint Manufacturers Association (EJMA) 

(n.) Heat Exchange Institute (HEI) 

5.03.00 Other International/ National standards such as DIN, VDI, BS, etc. shall also be 

accepted for only material codes and manufacturing standards, subject to the 

Employer's approval, for which the Contractor shall furnish, alongwith the offer, 

adequate information to justify that these standards are equivalent or superior to the 

standards mentioned above. In all such cases the Contractor shall furnish 

specifically the variations and deviations from the standards mentioned else where 

in the specification together with the complete word to word translation of the 

standard that is normally not published in English. 

5.04.00 As regards highly standardized equipments National /International standards such 

as JIS, DIN, VDI, ISO, SEL, SEW, VDE, IEC & VGB etc shall also be considered as 

far as applicable for Design, Manufacturing and Testing of the respective 

equipment. In addition, these standards shall be referred for the design of machine 

foundations, wherever specifically mentioned in the specifications. However, for 

those of the above equipment not covered by these National / International 

standards, established and proven standards of manufacturers shall also be 

considered. 

5.05.00 In the event of any conflict between the codes and standards referred to in the 

above clauses and the requirement of this specification, the requirement of 

Technical Specification shall govern. 

5.06.00 Two (2) English language copies of all-national and international codes and/or 

standards used in the design of the plant, equipment, civil and structural works shall 

be provided by the Contractor to the Employer within two calendar months from the 

date of the Notification of Award. 


SECTION-VI 

PART – C 

GTR 

PAGE 

3 OF 46

CLAUSE NO. 




PLANT PACKAGE 


5.07.00 In case of any change in codes, standards & regulations between the date of bid 

opening and the date when vendors proceed with fabrication, the Employer shall 

have the option to incorporate the changed requirements or to retain the original 

standard. It shall be the responsibility of the Contractor to bring to the notice of the 

Employer such changes and advise Employer of the resulting effect. 

6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE 

6.01.00 The functional guarantees of the equipment under the scope of the Contract is given 

elsewhere in the technical specification. These guarantees shall supplement the 

general functional guarantee provisions covered under General Conditions of 

Contract. 

6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the 

performance and guarantee tests shall be assessed and recovered from the 

Contractor as specified elsewhere in this specification. 

7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS 

7.01.00 Design of Facilities 

All the design procedures, systems and components proposed shall have already 

been adequately developed and shall have demonstrated good reliability under 

similar conditions elsewhere. 

The Contractor shall be responsible for the selection and design of appropriate 

equipments to provide the best co-ordinated performance of the entire system. The 

basic requirements are detailed out in various clauses of the Technical 

Specifications. The design of various components, assemblies and subassemblies 

shall be done so that it facilitates easy field assembly and dismantling. All the 

rotating components shall be so selected that the natural frequency of the complete 

unit is not critical or close to the operating range of the unit. 

7.02.00 Maintenance and Availability Considerations 

Equipment/facilities offered shall be designed for high availability, low maintenance 

and ease of maintenance. The Contractor shall specifically state the design features 

incorporated to achieve high degree of reliability/ availability and ease of 

maintenance. The Contractor shall also furnish details of availability records in the 

reference plants stated in his experience list. 

Contractor shall state in his offer the various maintenance intervals, spare parts and 

man-hour requirement during such operation. The intervals for each type of 

maintenance namely inspection of the major equipment in the coal flow path, clearly 

defining the spare parts and man-hour requirement for each stage. 


SECTION-VI 

PART – C 

GTR 

PAGE 

4 OF 46

CLAUSE NO. 




PLANT PACKAGE 


Lifting devices i.e. hoists and chain pulley jacks, etc. shall be provided by the 

contractor for handling of any equipment during erection and maintenance activities. 

Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist / 

crane shall be provided by the contractor for lifting the equipment and accessories 

covered under the specification. 

8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY CONTRACTOR 

8.01.00 Contractors may note that this is a contract inclusive of the scope as indicated 

elsewhere in the specification. Each of the plant and equipment shall be fully 

integrated, engineered and designed to perform in accordance with the technical 

specification. All engineering and technical services required ensuring a completely 

engineered plant shall be provided in respect of mechanical, electrical, control & 

instrumentation, civil & structural works as per the scope. 

Each main and auxiliary equipment/item of the plant including instruments shall be 

assigned a unique tag number. The assignment of tag numbers shall be in 

accordance with KKS system. In all drawings/documents/data sheets etc. KKS tag 

number of the equipment/item/instrument etc. as applicable shall be indicated. 

The Contractor shall furnish engineering data/drgs. in accordance with the schedule 

of information as specified in Technical Specification and data sheet. 

8.02.00 The number of copies/prints/flopy discs/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 submit to the Employer, draft 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 


SECTION-VI 

PART – C 

GTR 

PAGE 

5 OF 46

CLAUSE NO. 




PLANT PACKAGE 


The erection manuals shall be submitted atleast three (3) months prior to the 

commencement of erection activities of particular equipment/system. The 

erection manual should contain the following as a minimum. 

a) Erection strategy. 

b) Sequence of erection. 

c) Erection instructions. 

d) Critical checks and permissible deviation/tolerances. 

e) List of tool, tackles, heavy equipments like cranes, dozers, etc. 

f) Bill of Materials 

g) Procedure for erection. 

h) General safety procedures to followed during erection/installation. 

i) Procedure for initial checking after erection. 

j) Procedure for testing and acceptance norms. 

k) Procedure / Check list for pre-commissioning activities. 

l) Procedure / Check list for commissioning of the system. 

m) Safety precautions to be followed in electrical supply distribution 

during erection 

(b.) Operation & Maintenance Manuals 

The O&M manual shall have the following Chapters: 

1.0 Plant Description 

(To contain the following sections specific to the equipment supplied). 

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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

6 OF 46

CLAUSE NO. 




PLANT PACKAGE 


(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) :- 

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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

7 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

8 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 

8.03.03 Drawings 

The Contractor shall submit a Project Completion Report at the time of handing over 

the plant. 

(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 Annxure-I . The soft copies to be supplied shall be either in CDs, Floppies 

or through direct transfer via E-mail, etc. depending upon the 

nature/volume/size of the document. The drawings submitted for approval 

could be in the Image form. 

(b.) Final copies of the approved drawings shall be submitted in vector form on CD- 

ROM along with the requisite number of hard copies 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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

9 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 stamped “FOR APPROVAL” or “FOR 

INFORMATION” prior to submission. 

(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 

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 


SECTION-VI 

PART – C 

GTR 

PAGE 

10 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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. 

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). 


SECTION-VI 

PART – C 

GTR 

PAGE 

11 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 one (1) 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 

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 


SECTION-VI 

PART – C 

GTR 

PAGE 

12 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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. 

8.04.00 Engineering Information Submission Schedule 

Prior to the award of Contract, a Detailed Engineering Information Submission 

Schedule 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 Engineering Information Schedule shall be updated monthwise. 

The schedule should allow adequate time for proper review and incorporation of 

changes/ modifications, if any, to meet the contract without affecting the equipment 

delivery schedule and overall project schedule. The early submission of drawings 

and data is as important as the manufacture and delivery of equipment and 


SECTION-VI 

PART – C 

GTR 

PAGE 

13 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 : 


TELEX : 


VENDOR ENGINEERING CO-ORDINATOR (VENDOR EC) 

Name : 

Designation : 


SECTION-VI 

PART – C 

GTR 

PAGE 

14 OF 46

CLAUSE NO. 

Address : 

a) Postal : 





PLANT PACKAGE 


TELEX : 


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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

15 OF 46

CLAUSE NO. 

8.05.04 Erection Drawings 




PLANT PACKAGE 


(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 

8.06.00 Engineering Progress And Exception Report 

8.06.01 Report giving the status of each engineering information including 

A list of drawings/engineering information which remains unapproved for more than 

four (4) weeks after the date of first submission 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 


SECTION-VI 

PART – C 

GTR 

PAGE 

16 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

17 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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. 

8.12.00 Lubrication 

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. 

8.12.01 Equipment shall be lubricated by systems designed for continuous operation. 

Lubricant level indicators shall be furnished and marked to indicate proper levels 

under both standstill and operating conditions. 

8.13.00 Material of Construction 

8.13.01 All materials used for the construction of the equipment shall be new and shall be in 

accordance with the requirements of this specification. Materials utilised for various 

components shall be those which have established themselves for use in such 

applications. 

8.14.00 Rating Plates, Name Plates & Labels 

8.14.01 Each main and auxiliary item of plant including instruments shall have permanently 

attached to it in a conspicuous position, a rating plate of non-corrosive material upon 

which shall be engraved 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 


SECTION-VI 

PART – C 

GTR 

PAGE 

18 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 

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 

package, whichever more 

2 Bearing puller set to pull up to maximum bearing size in the 

system 


SECTION-VI 

PART – C 

GTR 

1 No 

1 No 

3 Hydraulic jack 50 T 2 No 

4 Lifting trolley for LT circuit breakers 2 No 

PAGE 

19 OF 46

CLAUSE NO. 

8.16.00 Welding 




PLANT PACKAGE 


5 Electric powered winch with wire rope (7.5 T, 1500m 

galvanised wire) 


SECTION-VI 

PART – C 

GTR 

1 No 

6 Bearing grease gun for all applications 2 No 

7 Any other special tools as per manufacturer’s manual 1 No 

8.16.01 If the manufacturer has special requirements relating to the welding procedures for 

welds at the terminals of the equipments to be per formed 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. 

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 

PAGE 

20 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 

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 bidder’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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

21 OF 46

CLAUSE NO. 




PLANT PACKAGE 


(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 

implement such programme duly approved by the Employer. The detailed Quality 

Plans for manufacturing and field activities shall be drawn up by the Bidder and will 

be submitted to Employer for approval. Schedule of finalisation of such quality plans 

will be finalised before award on enclosed format No. QS-01-QAI-P-01/F3. 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 e.g. floppy or E-mail in addition to hard copy, for 

review and approval. After approval the same shall be submitted in compiled form on 

CD-ROM. 


SECTION-VI 

PART – C 

GTR 

PAGE 

22 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 Bidder 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 The contractor shall submit to the Employer Field Welding Schedule for field welding 

activities in the enclosed format No.: QS-01-CQA-W-11/F1. 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. 

9.02.06 The contractor shall have suitable Field Quality Organisation with adequate 

manpower at Employer’s site, to effectively implement the Field Quality Plan (FQP) 

and Field Quality Management System for site activities. The contractor shall submit 

the details of proposed FQA setup (organisational structure and manpower) for 

employer’s approval. The FQA setup shall be in place at least one month before the 

start of site activities. 

9.02.07 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). 

9.02.08 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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

23 OF 46

CLAUSE NO. 




PLANT PACKAGE 


9.02.09 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. 

9.02.10 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 


9.02.11 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. 

9.02.12 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. 

9.02.13 Unless otherwise proven and specifically agreed with the Employer, welding of 

dissimilar materials and high alloy materials shall be carried out at shop only. 

9.02.14 No welding shall be carried out on cast iron components for repair. 

9.02.15 All the heat treatment results shall be recorded on time temperature charts and 

verified with recommended regimes. 

9.02.16 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 corelation 

of the test report with the job. 

All bar stock / forging of diameter equal to or greater than 50 mm shall be 

ultrasonically tested. In general all plates equal to or greater than 40mm and for 

pressure parts, plate of thickness equal to or greater than 25mm shall be 

ultrasonically tested unless otherwise as specified in respective specification. 

9.02.17 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 subcontractor 

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, 


SECTION-VI 

PART – C 

GTR 

PAGE 

24 OF 46

CLAUSE NO. 




PLANT PACKAGE 


shall be subject to Employer's approval on enclosed format No. QS-01-QAI-P-01/F3. 

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 subcontractors 

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. 

9.02.18 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. ** 

9.02.19 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. 

9.02.20 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. 

9.02.21 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 

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 


SECTION-VI 

PART – C 

GTR 

PAGE 

25 OF 46

CLAUSE NO. 




PLANT PACKAGE 


Contractor in ensuring complete conformance of the materials/equipment supplied to 

relevant specification, standard, data sheets, drawings, etc. 

9.02.22 For all spares and replacement items, the quality requirements as agreed for the 

main equipment supply shall be applicable. 

9.02.23 Repair/rectification procedures to be adopted to make the job acceptable shall be 

subject to the approval of the Employer/ authorised representative. 

9.02.24 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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

26 OF 46

CLAUSE NO. 

2) Burn in Test Cycle 




PLANT PACKAGE 


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. 

9.03.00 QA DOCUMENTATION PACKAGE 

9.03.01 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. 

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. 

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 


SECTION-VI 

PART – C 

GTR 

PAGE 

27 OF 46

CLAUSE NO. 




PLANT PACKAGE 


(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. 

(a) 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. 

(b) 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. 

(c) If a decision is made despatch, whereas all outstanding actions cannot be 

readily cleared for the release of the quality document by that time. The 

supplier shall immediately, upon shipment of the equipment, send a copy of 

the quality document Review Status signed by the Supplier Representative to 

the Inspector and notify of the committed date for the completion of all 

outstanding actions & submission. The Inspector shall stamp the quality 


SECTION-VI 

PART – C 

GTR 

PAGE 

28 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

29 OF 46

CLAUSE NO. 




PLANT PACKAGE 


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 


SECTION-VI 

PART – C 

GTR 

PAGE 

30 OF 46

CLAUSE NO. 




PLANT PACKAGE 


specified shall provide free of charge such items as labour, material, electricity, fuel, 

water, stores, apparatus and instruments as may be reasonably demanded by the 

Project Manager /Inspector or his authorised representatives to carry out effectively 

such tests on the equipment in accordance with the Contractor and shall give 

facilities to the Project Manager/Inspector or to his authorised representative to 

accomplish testing. 

9.05.07 The inspection by Project Manager / Inspector and issue of Inspection Certificate 

thereon shall in no way limit the liabilities and responsibilities of the Contractor in 

respect of the agreed Quality Assurance Programme forming a part of the contract. 

9.05.08 To facilitate advance planning of inspection in addition to giving inspection notice as 

specified at clause no 9.05.03- of this chapter, the Contractor shall furnish quarterly 

inspection programme indicating schedule dates of inspection at Customer Hold 

Point and final inspection stages. Updated quarterly inspection plans will be made 

for each three consecutive months and shall be furnished before beginning of each 

calendar month. 

9.05.09 All inspection, measuring and test equipment used by contractor shall be calibrated 

periodically depending on its use and criticality of the test/measurement to be done. 

The Contractor shall maintain all the relevant records of periodic calibration and 

instrument identification, and shall produce the same for inspection by NTPC. 

Wherever asked specifically, the contractor shall re-calibrate the measuring/test 

equipment in the presence of Project Manager / Inspector. 

9.06.00 ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE PROGRAMME: 

9.06.01 List of items requiring quality plan and sub supplier approval. Format No.:QS-01- 

QAI-P-01/F3-R0 (Annexure-II). 

9.06.02 Status of items requiring Quality Plan and sub supplier approval. Format No.: QS- 

01-QAI-P-02/F1-R0 (Annexure-III). 

9.06.03 Field Welding Schedule Format No.: QS-01-CQA-W-11/F2-R0 (Annexure-IV). 

9.06.04 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R1 (Annexure-V). 

9.06.05 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R0 (Annexure-VI). 

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 


SECTION-VI 

PART – C 

GTR 

PAGE 

31 OF 46

CLAUSE NO. 




PLANT PACKAGE 


performed shall be as mutually agreed and included in the Contractor’s quality 

assurance programme as well as those included elsewhere in the Technical 


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 


SECTION-VI 

PART – C 

GTR 

PAGE 

32 OF 46

CLAUSE NO. 




PLANT PACKAGE 


both the parties. The report shall have sheets, recording all the details of 

interruptions occurred, adjustments made and any minor repairs done during 

the Trial Operation. Based on the observations, necessary 

modifications/repairs to the plant shall be carried out by the Contractor to the 

full satisfaction of the Project Manager to enable the latter to accord permission 

to carry out the Guarantee tests on the facilities. However, minor defects which 

do not endanger the safe operation of the equipment, shall not be considered 

as reasons for with- holding the aforesaid permission 

(i.) Contractor shall furnish the commissioning organization chart for review & 

acceptance of employer at least eighteen months prior to the schedule date of 

synchronization of 1st unit. The chart should contain 

10.01.00 Guarantee Tests 

(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. 

(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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

33 OF 46

CLAUSE NO. 

10.02.00 Test Codes 




PLANT PACKAGE 


(e) The specific tests to be conducted on equipment have been brought out in 

the technical specification. 

The provisions outlined in the ASME Performance Test Codes shall be used as a 

guide for all the above test procedures unless otherwise specified in the technical 

specifications. 

11.00.00 TAKING OVER 

Upon successful completion of Initial Operations and all the tests conducted to the 

Employer's satisfaction, the Employer shall issue to the Contractor a Taking over 

Certificate as a proof of the final acceptance of the equipment. Such certificate shall 

not unreasonably be with held nor will the Employer delay the issuance thereof, on 

account of minor omissions or defects which do not affect the commercial operation 

and/or cause any serious risk to the equipment. Such certificate shall not relieve the 

Contractor of any of his obligations which otherwise survive, by the terms and 

conditions of the Contract after issuance of such certificate. 

12.00.00 TRAINING OF EMPLOYER'S PERSONNEL 

12.01.00 The scope of service under training of 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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

34 OF 46

CLAUSE NO. 




PLANT PACKAGE 


12.04.00 Exact details, extent of training and the training schedule shall be finalised based on 

the Contractor's proposal within two (2) months from placement of award. 

12.05.00 In all the above cases, wherever the training of Employer's personnel is arranged at 

the works of the manufacturer's it shall be noted that the lodging and boarding of the 

Employer's personnel shall be at the cost of Contractor. 

13.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION 

In addition to the requirements given in Erection Conditions of Contract (ECC) the 

following shall also cover: 

a). Working platforms should be fenced and shall have means of access. 

b). Ladders in accordance with 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, 


SECTION-VI 

PART – C 

GTR 

PAGE 

35 OF 46

CLAUSE NO. 




PLANT PACKAGE 


17.00.00 INSTRUMENTATION AND CONTROL 

All instrumentation and control systems/ equipment/ devices/ components, furnished 

under this contract shall be in accordance with the requirements stated herein, 

unless otherwise specified in the detailed specifications. 

17.01.00 All instrument scales and charts shall be calibrated and printed in metric units and 

shall have linear graduation. The ranges shall be selected to have the normal 

reading at 75% of full scale. 

All scales and charts shall be calibrated and printed in Metric Units as follows: 

a) Temperature - Degree centigrade (deg C) 

b) Pressure - Kilograms per square centimetre (Kg/cm 2 ). 

Pressure instrument shall have the unit suffixed 

with 'a' to indicate absolute pressure. If nothing is 

there, that will mean that the indicated pressure is 

gauge pressure. 

c) Draught - Millimetres of water column (mm wc). 

d) Vacuum - Millimeters of mercury column (mm Hg) or water 

column (mm Wcl). 

e) Flow - Tonnes/ hour 

f) Flow (Liquid) - Tonnes / hour 

g) Flow base - 760 mm Hg. 15 deg.C 

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 


SECTION-VI 

PART – C 

GTR 

PAGE 

36 OF 46

CLAUSE NO. 




PLANT PACKAGE 


effectively eliminating the noise problems shall be included in the proposal. The 

equipment shall be protected against ESD as per IEC-801- 2. Radio Frequency 

interference (RFI) and Electro Magnetic Interference (EMI) protection against 

hardware damage and control system mal-operations/errors shall be provided for all 

systems. 

19.00.00 INSTRUMENT AIR SYSTEM (AS APPLICABLE) 

The instrument air supply system as supplied by the Contractor for various 

pneumatic control & instrumentation devices like pneumatic actuators, power 

cylinders, E/P converters, piping / tubing etc. shall be as per the details furnished 

elsewhere. 

Each pneumatic instrument shall have an individual air shut - off valve. The pressure 

regulating valve shall be equipped with an internal filter, a 50 mm pressure gauge 

and a built-in filter housing blow down valve. 

20.00.00 TAPPING POINTS FOR MEASUREMENTS 

Tapping points shall include probes, wherever applicable, for analytical 

measurements and sampling. 

For direct temperature measurement of all working media, one stub with internal 

threading of approved pattern shall be provided along with suitable plug and washer. 

The Contractor will be intimated about thread standard to be adopted. 

The following shall be provided on equipment by the Contractor. The standard which 

is to be adopted, will be intimated to the Contractor. 

Temperature test pockets with stub and thermowell 

Pressure test pockets 

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. 


SECTION-VI 

PART – C 

GTR 

PAGE 

37 OF 46

CLAUSE NO. 

22.00.00 JUNCTION BOXES 




PLANT PACKAGE 


The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates 

shall be removable type and made of 3 mm thick sheet steel. The boxes shall be 

provided with detachable cover or hinged door with captive screws. Top of the box 

shall be arranged to slope towards the rear of the box. The box shall be hot dip 

galvanized and shall be provided with suitable neoprene gaskets to achieve degree 

of protection of IP-55 as per IS: 2147. Adequate spacing shall be provided to 

terminate the external cables. The boxes shall be suitable for mounting on various 

types of steel structures. The terminal blocks provided shall be of 650 V grade, rated 

for 10 A for control cables. Suitable numbering for terminal blocks shall be done. In 

case of junction box for power cable, the box shall be rated for maximum current 

carrying capacity. Terminal blocks shall be of one piece, klippon RSF-1 or ELMEX 

CSLT-1 type with insulating barriers. 

23.00.00 SPECIFIC REQUIREMENT FOR DC PANELS 

23.01.00 DC starter shall essentially consists of following:– 

a) One (1) - Double pole 220 V D.C. air break switch and HRC fuses. 

b) One (1) - Double pole 220 V D.C. contactor with 2 NO and 2 NC contacts. 

c) Contactors and timers as required for the control scheme. 

d) Overload relay (for alarm only). 

e) Shunt and ammeter for motors rated 15 KW an above. 

f) One (1) - Red indicating lamp to give motor 'ON' indication. 

g) One (1) - Green indicating lamp to give motor 'OFF' indication. 

h) Starting resistor. 

The resistance shall be air cooled, stainless steel grid type, suitable for 220 V DC 

and continuously rated. The resistance shall be provided with sheet steel covers with 

louvers and canopy type top cover. 


SECTION-VI 

PART – C 

GTR 

PAGE 

38 OF 46

CLAUSE NO. 




PLANT PACKAGE 


S. NO. DESCRIPTION OF 

MANUALS 


SECTION-VI 

NO OF 

PRINTS(SETS 

PART – C 

GTR 

ANNEXURE-I 

NO. OF CD- 

ROMs/FLOPPIES 

(SETS) 

1. Drawings "FOR APPROVAL" 8 3 FLOPPIES 

2. Drawings "FOR INFORMATION" 8 3 FLOPPIES 

3. Drawings "FINAL DRAWING" 15 3 CD-ROMs 

4. Drawings "AS BUILT " 15 3 CD-ROMs 

5. DATASHEETS,DESIGNCALCU 

LATIONS, etc. and Other type of 

documents 

i) For Approval 8 3 FLOPPIES 

ii) FINAL 15 3 CD-ROMs - 

iii) Analysis reports of 

equipments/ piping/ structures 

components/ systems 

employing software packages 

as detailed 

in the specifications 

a) Input 8 3CD ROMS 

b) Output 8 3CD ROMS 

c) Drawings/ Sketches 8 3CD ROMS 

6. Erection manual "DRAFT" 

7. Erection manual "FINAL" 3CD ROMS 

8 Operation & Maintenance 

manual "DRAFT" 

9 Operation & Maintenance 

manual "FINAL" 

3CD ROMS 

PAGE 

39 OF 46

CLAUSE NO. 




PLANT PACKAGE 


10 Plant Hand Book "DRAFT" 

11 Plant Hand Book "FINAL" 3CD ROMS 

12 Commissioning and 

Performance 

13 Commissioning and 

Performance 


SECTION-VI 

Procedure 

manual "DRAFT" 

Procedure 

manual "FINAL" 

PART – C 

GTR 

3CD ROMS 

14 Performance and Functional 8 3 FLOPPIES 

GURANTEES 

TEST REPORT 

15 Progress Reports 8 3 FLOPPIES 

16 Project completion report 15 3CD ROMS 

17 QA programme 

includingOrganisation for 

implement-ation and QA 

systemmanual (with revisionservicing) 

18 Vendor details in respect of 

proposed vendors including 

contractor’s evaluation report. 

19 Manufacturing QPs, Field QPs, 

Field welding schedules and 

their reference documents like 

test procedures, WPS, POR 

etc. 

i) For review/comment 3 

(ii) For final approval 4 1 set floppies 

20 Welding Manual, HeatTreatment 

Manuals, 

Storage & preservation manuals 

Draft - 4 sets 

Final 2 CD ROMS 

1 

1 

PAGE 

40 OF 46

CLAUSE NO. 




PLANT PACKAGE 


21 Monthly Vendor Approval1 

floppy 

and QP approval status 

22 QA Documentation Package for 

items / equipment manufactured 

and dispatched to site 

23 QA Documentation 

Package for field 

activities on equipment / 

systems at site 


SECTION-VI 

2 1 FLOPPY 

2 2 CD ROMS 

2 2 CD ROMS 

PART – C 

GTR 

PAGE 

41 OF 46

S. N. 

Project : Stage : 

Package : 

Supplier : 

Contractor No. : 

Item QP/ 

Insp. 

Cat. 

QP No. 




PLANT PACKAGE 

LIST OF ITEMS REQUIRING QUALITY PLAN 

AND SUB-SUPPLIER APPROVAL 

SUB-SYSTEM : 

QP Sub. 

Schedule 

QP 

approval 

schedule 


SECTION VI 

PART – C 

GTR 

DOC. NO.: 

REV. NO.: 

DATE : 

PAGE : OF 

Proposed sub-supplier Place Subsuppliers 

approval 

status / 

category 

Annexure-II 

Subsupplier 

Details 

submission 

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 

Page 

42 of 46 

Remarks

S. N. 


Package : 

Contractor : 


Item / Service QP/ 

Insp. 

Cat. 

QP Sub. 

Schedule 

Approval 

schedule 




PLANT PACKAGE 

Date of 

submission 

Date of 

commt 

Appl. 

STATUS OF ITEM REQUIRING QP& 

SUB-SUPPLIER APPROVAL 

Status 

Code 

C/II/I 

Proposed Subsuppliers 


SECTION VI 

Place of manufacturing 

works 

FORMAT NO.: QS-01-QAI-P-02/F1-R0 1/1 Engg. Div. / QA&I 

PART – C 

GTR 

DOC. NO.: 

REV. NO.: 

DATE : 

PAGE : OF 

Approval 

Status 

Sub-supplier 

detail 

submission 

schedule 

Annexure-III 

Page 

43 of 46 

Remarks

Sl. No. DRG No. for Weld Location 

and Identification mark 

NOTES: 

SIGNATURE 


Contractor : 


System : 

Descriptio Matl. 

n of parts Spec. 

to welded 




PLANT PACKAGE 

FIELD WELDING SCHEDULE 

(To be raised by the contractor) 

Welding Code: ……………………………………… 


SECTION VI 

PART – C 

GTR 

DOC. NO.: 

REV. NO.: 

DATE : 

PAGE : OF 

Page 

44 of 46 

Annexure-IV 

Dimensions Process of Type of Electrode WPS. No. Min. Heat treatment NDT method/ REF 

Remarks 

welding Weld filler spec. 

Pre-heat Temp. Holding Quantum Spec. No. ACC Norm 

time 

Ref. 

FORMAT NO.: QS-01-QAI-P-02/F2-R0 1/1 Engg. Div. / QA&I

SL. 

NO 

MFGR.’s 

LOGO 

MANUFACTURER’S NAME AND 

ADDRESS 

COMPONENT & 

OPERATIONS 





PLANT PACKAGE 

MANUFACTURING QUALITY PLAN 

ITEM : 

SUB-SYSTEM: 

CLASS 

TYPE OF 

CHECK 

QP NO.: 

REV.NO.: 

DATE: 

PAGE: …. OF…. 

QUANTUM 


SECTION VI 

PART – C 

GTR 

PROJECT : 

PACKAGE : 

CONTRACT NO. : 

MAIN-SUPPLIER: 

Page 

45 of 46 

Annexure-V 

OF CHECK REFERENCE ACCEPTANCE Format of 

REMARKS 

DOCUMENT Norms 

Record 

M C / N 

M C N 

1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11. 

MANUFACTURER/ 

SUB-SUPPLIER 

SIGNATURE 

MAIN-SUPPLIER 

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” ( √ ) SHALL BE 

ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. 

** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, N: NTPC 

P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE, 

CHP: NTPC SHALL IDENTIFIED IN COLUM “N” AS ‘ W” 

FOR 


DOC. NO.: REV…… CAT….. 

USE REVIEWED BY APPROVED BY APPROVAL 

SEAL 

Format No.: QS-01-QAI-P-09/F1-r1 1/1 Engg. Div./QA&I

MFGR.’s 

LOGO 

SL. 

NO 

ACTIVITY AND 

OPERATION 

SUPPLIER’S NAME AND ADDRESS 




PLANT PACKAGE 

FIELD QUALITY PLAN 

ITEM : 

CHARACTERISTICS / INSTRUMENTS 

SUB-SYSTEM : 

CLASS# OF 

CHECK 

QP NO.: 

REV.NO.: 

DATE: 

TYPE OF 

CHECK 

PAGE: …. OF…. 

QUANTUM 

OF CHECK 


SECTION VI 

REFERENCE 

DOCUMENT 

PROJECT : 

PACKAGE : 

CONTRACT NO. : 

MAIN-SUPPLIER: 

ACCEPTANCE 

NORMS 

PART – C 

GTR 

FORMAT OF 

RECORD 

Page 

46 of 46 

Annexure-VI 

1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10. 

MANUFACTURER/ 

SUB-SUPPLIER 

SIGNATURE 

MAIN-SUPPLIER 

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (√) SHALL BE 

ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION. 

LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR; 

‘A’ SHALL BE WITNESSED BY NTPC FQA, ‘B’ SHALL BE WITNESSED BY 

NTPC ERECTION / CONSTRUCTION DEPTT. AND ‘C’ SHALL BE 

WITNESSED BY ERECTION SUPPLIER (A & B CHECK SHALL BE NTPC 

CHP STAGE) 

FOR 


DOC. NO.: 

REV…… 

REMARKS 

USE REVIEWED BY APPROVED BY APPROVAL SEAL 

Format No.: QS-01-QAI-P-09/F2-r0 1/1 Engg. Div./QA&I

PART - D 

ERECTION CONDITIONS OF CONTRACT 




PLANT PACKAGE 


SECTION-VI 

PART-D

CLAUSE NO. 





PLANT PACKAGE 



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 Coordinator, 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

1 OF 44

CLAUSE NO. 

3.02.00 Welder's Qualification 

3.03.00 Records 

3.04.00 Marking 




PLANT PACKAGE 


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 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. 

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. 

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. Oxyacetylene 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

2 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

3 OF 44

CLAUSE NO. 




PLANT PACKAGE 


to the scheduled start of erection work at site. Such schedule will be strictly followed 

by the Contractor during the process of erection. The above field-welding schedule 

to be issued by the Contractor shall contain the following: 

(a.) Drawing No (s) 

(b.) Location of the weld 

(c.) Size of the weld (outside diameter and thickness) 

(d.) Type of joints 

(e.) Material specifications 

(f.) Size of fillet on backing ring, when the type of joint is with backing ring 

(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 


SECTION-VI 

PART-D 

ECC 

PAGE 

4 OF 44

CLAUSE NO. 




PLANT PACKAGE 


rows shall be avoided so that deflection of pipes between hangers does not exceed 

6 mm. No miscellaneous pipe shall be routed and installed above or adjacent to 

electrical equipment. 

9.00.00 THERMAL EXPANSIONS 

All piping installation shall be such that no excessive or destructive expansion forces 

exist either in the cold condition or under condition of maximum temperature. All 

bends, expansion joints and any other special fittings, necessary to provide proper 

expansion, shall be incorporated. During installation of expansion joints and 

anchors, care must be taken to make sure that full design movement is available at 

all times for maximum to minimum temperature and vice-versa. 

10.00.00 PIPING SUPPORTS 

10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe, 

reliable and complete pipe installation. All supports shall be properly leveled and 

anchored when installed. The anchors shall be so placed that thermal expansion will 

be absorbed by bends without subjecting the valves or equipment to excessive 

strains. 

10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the 

pipe into place. Other means shall be used to securely hold the pipe in place till the 

pipe support is completely assembled and attached to the pipe and building 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

5 OF 44

CLAUSE NO. 




PLANT PACKAGE 


11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the 

pressure parts shall be tested along with pressure parts. All blank flanges or any 

removable plugs required for openings not closed by the valves, and piping 

provided, shall be furnished by the Contractor. The pressurization equipment 

including water piping from the supply, needed for the above test shall also be 

furnished by the Contractor. Any defects noticed during the testing are to be rectified 

and the unit re-tested. If any welding is done on the pressure parts after the 

Hydraulic test, the Hydraulic test for that portion of pressure parts shall be repeated. 

11.03.00 Thy hydraulic test shall be considered successful only on certification to that effect 

by the concerned inspecting Authority as per the provisions of the Indian Boiler 

Regulations and the Employer. 

12.00.00 THERMOWELLS AND FLOW NOZZLES 

12.01.00 All the thermowells and flow nozzles in the equipment furnished under the technical 

specifications shall be installed as a part of this work. 

12.02.00 All thermowell connections incorporated in the steam service shall be plugged during 

the pressure testing and the blow out of steam piping systems. Upon completion of 

the blow out operation, all thermowells shall be installed and seam welded. Similarly, 

all flow nozzles in the steam lines shall also be installed only on completion of steam 

blowing operations unless otherwise agreed to by the Employer, depending upon the 

sequence of cleaning and purging operations to be adopted by the Contractor at the 

field. 

13.00.00 INSULATION, LAGGING AND CLADDING 

The provision of insulation, lagging and cladding of the various equipments and 

portion of the equipment covered under the Contract, shall be furnished by the 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

6 OF 44

CLAUSE NO. 




PLANT PACKAGE 


Employer's Drawings and other applicable Indian recognised codes and laws and 

regulations of the Government of India. 

15.00.00 ELECTRICAL SAFETY REGULATIONS 

15.01.00 In no circumstances will the Contractor interfere with fuses and electrical equipment 

belonging to the other Contractor or Employer. 

15.02.00 Before the Contractor connects any electrical appliances to any plug or socket 

belonging to the other Contractor or Employer, he shall: 

(a.) Satisfy the Employer that the appliance is in good working condition; 

(b.) Inform the Employer of the maximum current rating, voltage and phases of the 

appliances; 

(c.) Obtain permission of the Employer detailing the socket to which the appliances 

may be connected. 

The Employer will not grant permission to connect until he is satisfied that 

(a) The appliance is in good condition and is fitted with a suitable plug. 

(b) The appliance is fitted with a suitable cable having two earth conductors, one 

of which shall be an earthed metal sheath surrounding the cores. 

15.03.00 No electric cable in use by the other Contractor/ Employer will be disturbed without 

permission. No weight of any description will be imposed on any such cable and 

ladder or similar equipment will rest against or be attached to it. 

15.04.00 No repair work shall be carried out on any live equipment. The equipment must be 

declared safe by the Employer and a permit to work issued before any work is 

carried out. 

15.05.00 The Contractor shall employ the necessary number of qualified, full time electricians 

to maintain his temporary electrical installation. 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

7 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

8 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 indicated 

by the Employer or his representative. Photographs shall be adequate in size 

and number to indicate various stages of erection. Each photograph shall contain 

the date, the name of the Contractor and the title of the photograph. 

23.02.00 The above photographs shall accompany the monthly progress report detailing out 

the progress achieved on all erection activities as compared to the schedules. The 

report shall also indicate the reasons for the variance between the scheduled and 


SECTION-VI 

PART-D 

ECC 

PAGE 

9 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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, skillwise 

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, skillwise 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. 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

10 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 

27.02.00 Electricity 

27.03.00 Water 

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 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 etc. for Contractor's as 

well as his Sub-Contractor’s use. Land for Staff & Labour colony shall not be 

provided by the owner and Bidder has to make his own arrangement for the same at 

his own cost. 

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. 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

11 OF 44

CLAUSE NO. 

27.04.00 Communication 




PLANT PACKAGE 


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 preassembly 

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: 

28.05.00 First-aid 

Contractor shall provide and maintain a site laboratory for the testing of construction 

material under the direction and general supervision of employer. 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

12 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

13 OF 44

CLAUSE NO. 




PLANT PACKAGE 


of such trained personnel must be available at the Site during the entire period of the 

Contract. 

30.04.00 The Contractor shall provide enough fire protection equipment of the types and 

number for the warehouses, office, temporary structures, labour colony area etc. 

Access to such fire protection equipment, shall be easy and kept open at all time. 

31.00.00 SECURITY 

The Contractor shall have total responsibility for all equipment and materials in his 

custody stores, loose, semi-assembled and/or erected by him at Site. The 

Contractor shall make suitable security arrangements including employment of 

security personnel to ensure the protection of all materials, equipment and works 

from theft, fire, pilferage and any other damages and loss. All materials of the 

Contractor shall enter and leave the Employer Site only with the written permission 

of the Employer in the prescribed manner. 

32.00.00 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 



SECTION-VI 

PART-D 

ECC 

PAGE 

14 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 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 


SECTION-VI 

PART-D 

ECC 

PAGE 

15 OF 44

CLAUSE NO. 




PLANT PACKAGE 


such equipment ready for operation. The Contractor shall be responsible for 

supplying such flushing oil and other lubricants unless otherwise specified elsewhere 

in these specifications and documents. 

34.02.00 Commissioning Documentation 

34.02.01 The contractor shall submit the commissioning documentation, comprising of 

Standard checklists, pre-commissioning procedures, testing schedules, 

commissioning schedules and commissioning networks for various 

equipment/systems covered under the contract, for the approval of employer. 

34.02.02 Standard checklist, as the name suggests, shall be a fairly general documents, 

containing the list of all checks required to be carried out for similar and repetitive 

type of equipment to ensure consistent and thorough checking. An indicative list of 

such equipment is enclosed as Annexure I. 

34.02.03 The testing schedule is a document, designed for safe and systematic 

commissioning of individual equipment/sub-system Commissioning schedule is a 

document envisaged for commissioning of a system The testing/Commissioning 

schedule shall have a standard format in order to maintain consistency of 

presentation, content and reporting. A brief write up on the contents of the Testing 

Schedule/Commissioning Schedule is enclosed as Annexure-II. 

34.02.04 The contractor shall submit the list of commissioning documentation to be submitted 

by him, alongwith their submission schedule for various equipment/systems covered 

under the contract, with in 6(six) month from the date of award of contract, for the 

acceptance of employer. 

34.02.05 The Contractor shall submit the commissioning documentation, for various 

equipment/covered under the contract, for the approval of employer, at least 18 

months before the scheduled date of commissioning of the equipment/systems. 

34.03.00 Commissioning Activities 

34.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall initiate 

commissioning of facilities. During commissioning the Contractor shall carry out 

system checking and reliability trials on various parts of the facilities. 

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, 


SECTION-VI 

PART-D 

ECC 

PAGE 

16 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 


35.02.00 Contractor shall be responsible for examining all the shipment and notify the 

Employer immediately of any damage, shortage, discrepancy etc. for the purpose of 

Employer's information only. The Contractor shall submit to the Employer every 

week a report detailing all the receipts during the week. However, the Contractor 

shall be solely responsible for any shortages or damage in transit, handling and / or 

in storage and erection of the equipment at Site. Any demurrage, wharfage and 

other such charges claimed by the transporters, railways etc. shall be to the account 

of the Contractor. 

35.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the 

list of all equipment received by him for the purpose of erection and keep such 

record open for the inspection of the Employer. 

35.04.00 All equipment shall be handled very carefully to prevent any damage or loss. No 

bare wire ropes, slings, etc. shall be used for unloading and/or handling of the 

equipment without the specific written permission of the Employer. The equipment 

stored shall be properly protected to prevent damage either to the equipment or to 

the floor where they are stored. The equipment from the store shall be moved to the 

actual location at the appropriate time so as to avoid damage of such equipment at 

Site. 


SECTION-VI 

PART-D 

ECC 

PAGE 

17 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 deterioration 

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. 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

18 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 coordination 

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 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 


SECTION-VI 

PART-D 

ECC 

PAGE 

19 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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. 


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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

20 OF 44

CLAUSE NO. 

41.00.00 INSURANCE 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

21 OF 44

CLAUSE NO. 




PLANT PACKAGE 


41.05.00 The above are only illustrative list of insurance covers normally required and it will 

be the responsibility of the Contractor to maintain all necessary insurance coverage 

to the extent both in time and amount to take care of all his liabilities either direct or 

indirect, in pursuance of the Contract. 

42.00.00 UNFAVOURABLE WORKING CONDITIONS 

The Contractor shall confine all his field operations to those works which can be 

performed without subjecting the equipment and materials to adverse effects during 

inclement weather conditions, like monsoon, storms, etc. and during other 

unfavourable construction conditions. No field activities shall be performed by the 

Contractor under conditions which might adversely affect the quality and efficiency 

thereof, unless special precautions or measures are taken by the Contractor in a 

proper and satisfactory manner in the performance of such Works and with the 

concurrence of the Employer. Such unfavourable construction conditions will in no 

way relieve the Contractor of his responsibility to perform the Works as per the 

schedule. 

43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS 

The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc. 

which he may come across during the course of performance of his Works either 

during excavation or elsewhere, are properly protected and handed over to the 

Employer. Similarly the Contractor shall ensure that the bench marks, reference 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

22 OF 44

CLAUSE NO. 




PLANT PACKAGE 


plant/equipment for which material in the container is required to be used and if in 

his opinion, its use is not safe, he may forbid its use. No claim due to such 

prohibition shall be entertained by the Employer and the Employer shall not entertain 

any claim of the Contractor towards additional safety provisions/conditions to be 

provided for/constructed as per the Employer's instructions. 

Further, any such decision of the Employer shall not, in any way, absolve the 

Contractor of his responsibilities and in case, use of such a container or entry 

thereof into the Site area is forbidden by the Employer, the Contractor shall use 

alternative methods with the approval of the Employer without any cost implication to 

the Employer or extension of work schedule. 

44.03.00 Where it is necessary to provide and/or store petroleum products or petroleum 

mixtures and explosives, the Contractor shall be responsible for carrying-out such 

provision and/or storage in accordance with the rules and regulations laid down in 

Petroleum Act 1934, Explosives Act, 1948, and Petroleum and Carbide of Calcium 

Manual published by the Chief Inspector of Explosives of India. All such storage 

shall have prior approval of the Employer. In case, any approvals are necessary 

from the Chief Inspector (Explosives) or any statutory authorities, the Contractor 

shall be responsible for obtaining the same. 

44.04.00 All equipment used in construction and erection by Contractor shall meet 

Indian/International Standards and where such standards do not exist, the 

Contractor shall ensure these to be absolutely safe. All equipments shall be strictly 

operated and maintained by the Contractor in accordance with 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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

23 OF 44

CLAUSE NO. 




PLANT PACKAGE 


44.08.00 Where explosives are to be used, the same shall be used under the direct control 

and supervision of an expert, experienced, qualified and competent person strictly in 

accordance with the Code of Practices/Rules framed under Indian Explosives Act 

pertaining to handling, storage and use of explosives. 

44.09.00 The Contractor shall provide safe working conditions to all workmen and employees 

at the Site including safe means of access, railings, stairs, ladders, scaffoldings etc. 

The scaffoldings shall be erected under the control and supervision of an 

experienced and competent person. For erection, good and standard quality of 

material only shall be used by the Contractor. 

44.10.00 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical 

equipment belonging to the Employer or other Contractors under any circumstances, 

whatsoever, unless expressly permitted in writing by the Employer to handle such 

fuses, wiring or electrical equipment. 

44.11.00 Before the Contractor connects any electrical appliances to any plug or socket 

belonging to the other Contactor or Employer, he shall: 

(a.) Satisfy the Employer that the appliance is in good working condition: 

(b.) Inform the Employer of the maximum current rating, voltage and phases of the 

appliances; 

(c.) Obtain permission of the Employer detailing the sockets to which the 

appliances may be connected. 

44.12.00 The Employer will not grant permission to connect until he is satisfied that; 

(a.) The appliance is in good condition and is fitted with suitable plug; 

(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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

24 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 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 


SECTION-VI 

PART-D 

ECC 

PAGE 

25 OF 44

CLAUSE NO. 




PLANT PACKAGE 


Employer. However, in case of accident taking place causing injury, to any 

individual, the provisions contained in paragraph 44.22.00 shall also apply in 

addition to compensation mentioned in this paragraph. 

44.22.00 If the Contractor does not take all safety precautions and/or fails to comply with the 

Safety Rules as prescribed by the Employer or under the applicable law for the 

safety of the equipment and plant and for the safety of personnel and the Contractor 

does not prevent hazardous conditions which cause injury to his own employees or 

employees of other Contractors, or the Employer's employees or any other person 

who are at Site or adjacent thereto, the Contractor shall be responsible for payment 

of compensation to Employer as per the following schedule:- 

1 Fatal injury or accident These 

are causing death applicable 

2 Major injuries or accident 

causing 25% or more 

permanent disablement to 

workmen or employee 


SECTION-VI 

Rs. 1,00,000/- 

Rs. 20,000/- 

PART-D 

ECC 

These are 

applicable for 

death/ injury to any 

person 

whomsoever. 

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 

PAGE 

26 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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. 

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 having a minimum characteristic compressive 

strength of 30 N/mm2 at 28 days. The grout shall be chloride - free, cement based, 

free flowing, non-metallic grout. 


SECTION-VI 

PART-D 

ECC 

PAGE 

27 OF 44

CLAUSE NO. 




PLANT PACKAGE 


The Grout shall have good flowability even at very low water/ grout powder ratio. 

The Grout shall have characteristics of controlled expansion to be able to occupy its 

original volume to fill the voids and to compensate for shrinkage. Grout shall be of 

pre-mix variety so that only water needs to be added before use. 

The mixing of the Grout shall conform to the recommendations of the manufacturer 

of the Grout. 

46.05.00 Placing of Grout 

46.05.01 After the base has been prepared, its alignment and level has been checked and 

approved and before actually placing the grout, a low dam shall be set around the 

base at a distance that will permit pouring and manipulation of the grout. The height 

of such dam shall be at least 25mm above the bottom of the base. Suitable size and 

number of chains shall be introduced under the base before placing the grout, so 

that such chains can be moved back & forth to push the grout into every part of the 

space under the base. 

46.05.02 The grout shall be poured either through grout holes if provided or shall be poured at 

one side or at two adjacent sides to make the grout move in a solid mass under the 

base and out in the opposite side. Pouring shall be continued until the entire space 

below the base is thoroughly filled and the grout stands at least 25 mm higher all 

around than the bottom of the base. Enough care should be taken to avoid any air 

or water pockets beneath the bases. 

46.05.03 In addition to the above, recommendations of Grout manufacturer shall also be 

followed. 

46.06.00 Finishing of the Edges of the Grout 

The poured grout should be allowed to stand undisturbed until it is well set. 

Immediately thereafter, the dam shall be removed and grout which extends beyond 

the edges of the structural or equipment base plates shall be cut off, flushed and 

removed. The edges of the grout shall then be pointed and finished with 1:2 cement 

mortar pressed firmly to bond with the body of the grout and smoothened with a tool 

to present a smooth vertical surface. The work shall be done in a clean and scientific 

manner and the adjacent floor spaces, exposed edges of the foundations, and 

structural steel and equipment base plates shall be thoroughly cleaned of any 

spillage of the grout. 

46.07.00 Checking of Equipment After Grouting 

After the grout is set and cured, the Contractor shall check and verify the alignment 

of equipments, alignment of shafts of rotating machinery, the slopes of all bearing 

pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as 


SECTION-VI 

PART-D 

ECC 

PAGE 

28 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 

48.00.00 DOWELLING 

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 thoroughly 

cleaned and suitably lubricated before starting. 

All the motors and other equipment shall be suitably doweled after alignment of 

shafts with tapered machined dowels as per the direction of the Employer. 

49.00.00 CHECK OUT OF CONTROL SYSTEMS 

After completion of wiring, cabling furnished under separate specification and laid 

and terminated by the Employer, the Contractor shall check out the operation of all 

control systems for the equipment furnished and installed under these specifications 

and documents. 

50.00.00 COMMISSIONING SPARES 

50.01.00 It will be the responsibility of the Contractor to provide all commissioning spares 

including consumable spares required for initial operation till the Completion of 

Facilities. The Contractor shall furnish a list of all commissioning spares within 60 

days from the date of Notification of Award and such list shall be reviewed by the 

Employer and mutually agreed to. However. such review and agreement will not 

absolve the Contractor of his responsibilities to supply all commissioning spares so 

that initial operation do not suffer for want of commissioning spares. All 

commissioning spares shall be deemed to be included in the scope of the Contract 

at no extra cost to the Employer. 

50.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to 

the schedule date of commencement of initial operation of the respective equipment 

and utilised as and when required. The unutilised spares and replaced parts, if any, 

at the end of successful completion of guarantee tests shall be the property of the 

Contractor and he will be allowed to take these parts back at his own cost with the 

permission of Employer. 


SECTION-VI 

PART-D 

ECC 

PAGE 

29 OF 44

CLAUSE NO. 

51.00.00 CABLING 




PLANT PACKAGE 


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 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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

30 OF 44

CLAUSE NO. 




PLANT PACKAGE 


52.00.00 EQUIPMENT DELIVERY AND ERECTION 


52.02.00 Crating 

(a.) This part covers Contractor's responsibilities for packing, shipping, warehousing 

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 


(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. 

(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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

31 OF 44

CLAUSE NO. 




PLANT PACKAGE 


(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 

(h.) Packaging or shipping units shall be designed within the limitations of 

unloading facilities and the equipment which will be used for transport. 


SECTION-VI 

PART-D 

ECC 

PAGE 

32 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

33 OF 44

CLAUSE NO. 




PLANT PACKAGE 


(b.) All separately packaged accessories items and parts shall be shipped with the 

equipment. Containers for separately packaged items shall be marked so that 

they are identified with the main equipment. An itemized packing slip, 

indicating what is in that carton only, shall be attached to the outside and inside 

of each container used for packing. 

A master packing slip covering all accessories items for a given piece of equipment 

which are shipped in separate containers, shall be attached to one container. 

52.04.00 Equipment Installation 

(a.) General Requirements 

The Contractor shall furnish all construction materials, tools and equipment 

and shall perform all work required for complete installation of all control and 

instrument equipment furnished under this specification. 

Contractor shall prepare detailed installation drawings for each equipment 

furnished under this specification for 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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

34 OF 44

CLAUSE NO. 




PLANT PACKAGE 


(e.) Equipment Assembly 

Equipment installed under these specifications shall be assembled if shipped 

unassembled. The equipment shall be dismantled and reassembled as 

required to perform the installation and commissioning work described in 

these specifications. 

(f.) Equipment Setting 

Field mounted instruments and accessories shall be bracket or sub panel 

mounted on the nearest suitable firm steel work or masonry. The brackets, 

stands, supports and other miscellaneous hardware required for mounting 

instruments and accessories such as receiver gauge, air set, valve manifold, 

purge-meter etc. shall be furnished and installed. No field mounted 

instruments shall be installed such that it depends for support or rigidity on 

the impulse piping or on electrical connection to it. 

Indicating type field mounted instruments shall be installed in such a way that 

centre of indicating dial shall be about 1600-1800mm from operating floor 

level. Non-indicating type field instruments shall be installed such that 

operating handle of manifold block / isolating cock comes within 1600 mm 

from operating floor level. 

All free standing instrumentation cabinets and panels shall be located within 

the construction tolerances of +/- 3 mm of the location dimensions indicated 

on the Employer's plant arrangement drawings. 

(g.) Free-Standing Equipment 

Free-standing Cabinets shall be attached to the floor, concrete equipment 

bases or supporting steel as indicated on the manufacturer's drawings and 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

35 OF 44

CLAUSE NO. 




PLANT PACKAGE 


Rough edges and welds on all fabricated supports shall be ground smooth. 

The supports shall be finished with two coats of primer and two coats of paint 

as specified in this part. 

(i.) Equipment Location 

All individual items of equipment not located in cabinets or on panels and 

racks are located approximately according to the floor elevation and the 

nearest building column designated by the Employer. 

Solenoid valves not located in enclosures or mounted on valves shall be 

mounted in easily accessible protected locations near the components with 

which they are associated. 

All brackets, stands, supports and other miscellaneous hardware required for 

mounting devices shall be furnished and installed. 

Thermometers shall be installed in the process lines and ducts as required 

and adjusted for ease in reading. 

Permanent temperature wells on the main steam, hot reheat and cold reheat 

piping shall not be installed until steam blowing has been completed. 

Temporary temperature wells shall be installed in the main and reheat steam 

piping during steam blow and discarded after completion. 

Any required adapting hardware such as pipe bushings, nipples, drilled caps 

and the like shall be provided for complete installation of control devices into 

process connections. 

For location of C&I related equipment/devices, the requirement specified 

elsewhere in the technical specification may be referred. 

(j.) Installation of Field Mounted Instruments and Devices 

The Contractor shall submit installation drawings for all field mounted 

equipment furnished under this specification for Employer's approval. These 

drawings shall meet the requirements of this specification, installation 

drawings, applicable codes and standards and recommendations of 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

36 OF 44

CLAUSE NO. 




PLANT PACKAGE 


(k.) Piping Connections 

All equipment having piping connections shall be levelled, aligned and 

wedged in place but shall not be grouted or bolted prior to the initial fitting 

and alignment of connecting piping. All equipment shall, however, be 

grouted or bolted to its foundation prior to final bolting or welding of the 

connection piping. 

All flanged joints shall be checked and retightened after approximately 10 

days of operation at normal operating temperature. 

(l.) Equipment Checkout 

All equipment shall be cleaned after installation. Equipment subject to 

pressure differentials shall be checked for leakage. 

After erection, all equipment having moving parts, having electrical 

apparatus, or subject to pressure differentials shall be trial-operated. 

(m.) Defects 

All defects in erection shall be corrected to the satisfaction of the Employer 

and the Project Manager. The dismantling and reassembly of Contractor 

furnished equipment to remove defective parts, replace parts, or make 

adjustments shall be included as a part of the work under these 


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 


(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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

37 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

38 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 


SECTION-VI 

PART-D 

ECC 

ANNEXURE-I 

PAGE 

39 OF 44

CLAUSE NO. 




PLANT PACKAGE 


PIPE WORK SYSTEM 

(xvii.) Water services 

(xviii.) Oil Resistant Fluid System 

(xix.) Air services (compressor) 

(xx.) High pressure services 

(xxi.) Constant load support 

(xxii.) Spring supports 

(xxiii.) Hangers and other supports 

STRAINER AND FILTER 

(xxiv.) Strainer/Filter Basket Type 

HEAT EXCHANGER (SCOOP COUPLING) 

(xxv.) Heat exchanger (general) 

(xxvi.) Heat Exchanger-Oil/Water 

FANS AND COMPRESSORS 

(xxvii.) Fans-Non-pressure Lubricated 

(xxviii.) Fans-Axial flow pressure Lubricated 

(xxix.) Compressors-General 

GATES 

(xxx.) Manually operated gate 

(xxxi.) Electrically operated gate 

DUCT WORK 

(xxxii.) Ventilation ducting 

(xxxiii.) Expansion Joints 


SECTION-VI 

PART-D 

ECC 

PAGE 

40 OF 44

CLAUSE NO. 




PLANT PACKAGE 


(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 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

41 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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 

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 


SECTION-VI 

PART-D 

ECC 

PAGE 

42 OF 44

CLAUSE NO. 




PLANT PACKAGE 


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. 

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. 


SECTION-VI 

PART-D 

ECC 

PAGE 

43 OF 44

CLAUSE NO. 




PLANT PACKAGE 



SECTION-VI 

PART-D 

ECC 

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. 

PAGE 

44 OF 44

PART - E 

LIST OF TENDER DRAWINGS 




PLANT PACKAGE 


SECTION-VI 

PART-E

CLAUSE NO. 




PLANT PACKAGE 

LIST OF TENDER DRAWINGS 

---------------------------------------------------------------------------------------------------------------- 

S.NO. DRG. NO. TITLE 

---------------------------------------------------------------------------------------------------------------- 

‘A’ MECHANICAL 

1. 2240-155C-POM-A-001 (Rev-A) General Plant Layout 

2. 2240-155C-POM-A-002 (Rev-A) Coal Handling Diagram 

3. 2240-155C-POM-A-003 (Rev-A) GA of Wagon Tippler-1 & 2, 

Con. 37A/37B and Junction Tower JT-I 

& JT-2 

4. 2240-155C-POM-A-004 (Rev-A) GA of Crusher House 

5. 2240-155C-POM-A-005 (Rev-A) GA of Conv. 38A/38B, 37A/37B 

and JT-1, JT-3, JT-4, Typ. Conv. 

Gallery & tunnel cross section. 

6. 2240-155C-POM-A-006 (Rev-A) GA of existing Conv. 21, JT-4, TP-5 & 

TP8 

7. 2240-155C-POM-A-007 (Rev-A) Single line diagram for DS SW & 

potable water system 

8. 2240-155C-POM-A-008 (Rev-A) General Notes 

‘B’ ELECTRICAL 

1. 2240-155C-POE-A-001 (Rev-A) Coal Handling Plant Single Line 

Diagram 

2. 2240-155C-POE-A-002 (Rev-A) Coal Handling Plant Typical PLC 

configuration 

‘C’ CIVIL 

1. 2240-155C-POC-A-001 (Rev-A) GA & Details of Tunnels 

2. 2240-155C-POC-A-002 (Rev-A) Typical Architectural Details 


SECTION-VI 

PART – E 

LIST OF TENDER 

DRAWINGS 

PAGE 

1 OF 1

PART - F 

LIST OF MANDATORY SPARES 




PLANT PACKAGE 


SECTION-VI 

PART-F

CLAUSE NO. 




PLANT PACKAGE 


S.N. ITEM QUANTITY Unit 

1 Mechanical 

Conveyor System including belt feeders 

A) IDLERS 

1 i) 35 o Troughing idlers complete with base 

frame and mounting brackets etc. 


SECTION-VI 

30 Nos. 

ii) Rolls for (i) above 50 Nos. 

2 i) Troughing idlers complete with base 

frame & mounting brackets ctc. (for belt 

feeder). 

10 Nos. 

ii) Rolls for (i) above 15 Nos. of each type 

3 i) 35 0 impact idlers complete with 

mounting brackets and base frame etc. 

20 Nos. 

ii) Rolls for (i) above 40 Nos. 

4 35 0 troughing training idler complete with base 

frame and brackets etc. (if used) 

20 % of total installed 

quantity 

5 Transition idler complete as in (1) above 5 Nos. 

6 Flat return idlers complete with mounting 

brackets etc. 

7 Flat return idlers complete with mounting 

brackets etc.(for belt feeders) 

8 Flat return trainer complete with mounting 

brackets etc. 

9 Belt cleaning spiral rubber disc return idler 

complete with mounting brackets etc. 

20 Nos. 

10 Nos. 

10 Nos. 

10 Nos. 

10 i) Two roll 10 o troughing return idler assy 20 Nos. 

ii) Rolls for (I) above 20 Nos. 

11 SS idlers 2 Sets of each type 

PART-F 

MANDATORY SPARES 

PAGE 

1 OF 26

CLAUSE NO. 

B) CONVEYOR GEAR BOXES 

(including belt feeders) 




PLANT PACKAGE 


i) Oil seals 2 Sets of each type and 

rating 

ii) Bearings 1 Set of each type and 

rating 

iii) Hold back device 2 Nos. of each type and 

rating 

iv) Cooling fan with cover 2 Nos. of each type and 

rating 

v) Complete gear box assy. with hold back 

device 

C) CONVEYOR DRIVE AND CONVEYOR 

BELT(including belt feeders) 

a) Gear Coupling/ other type of coupling 

i) All type of drive couplings including 

gear Coupling 


SECTION-VI 

1 Set of each type and 

rating 

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 coupling) 2 Nos each type and size 

iii) Resilient Drive plate assy. 1 No. of each type and 

size 

iv) Bearings 2 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 

PART-F 


PAGE 

2 OF 26

CLAUSE NO. 

c) Belting 




PLANT PACKAGE 


vii) Complete actuator and engaging 

assembly (including motor, gear box 

etc.) 


SECTION-VI 

1 Set of each type 

viii) Oil Cooler assembly (if applicable) 1 Set of each type 

ix) Oil pump-motor set (if applicable) 1 Set of each type 

x) Water pump motor (individual or group) 1 Set of each type 

xi) Oil filters 5 Sets of each type 

xii) Oil/Cooler valves (if applicable) 2 Nos. of each type 

Conveyor Belt 

d) Brakes 

i) Main Conveyors One drum length of 250 m of 

each type, size and 

rating 

ii) belt feeder belt One complete length of each 

i) Brakes 1 No of each size & type 

ii) Brake shoes 2 Sets of each size 

e) Mobile Header, Mobile Belt Feeder 

i) Drive assembly of mobile header 1 Set of each type and 

rating 

ii) Drive assembly of mobile belt feeder 1 Set of each type and 

rating 

iii) Limit switches 2 Nos. of each type and 

rating 

D) PULLEYS 

i) Pulleys complete with shaft excluding 

bearing & plummer blocks (complete 

with lagging) 

1 No. of each type and 

size in pulley drum and 

shaft dia. (for population 

upto 10 Nos) 

PART-F 


PAGE 

3 OF 26

CLAUSE NO. 




PLANT PACKAGE 


ii) Plummer Block complete with bearings 

& sleeves 

E) BELT CLEANERS AND SKIRT BOARD 


SECTION-VI 

2 No. of each type and 

size in pulley drum and 

shaft dia.(for population 

more than 10 Nos) 

2 No. each type and size 

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 


iii) Skirt Rubber 5 %of total population of 


iv) Complete belt cleaner (internal / 

external ) 

F) IN-LINE MAGNETIC SEPARATORS 

i) Cleated conveyor belt 1 Set 

ii) Motor, gear box drive assy. complete 1 Set 

2 %of total population of 


iii) Pulleys with plummer block & bearings 1 Set of each size & type 

iv) Sheaves 1 No. of each size & type 

v) V-belts (if applicable) 2 No. of each size & type 

G) COAL SAMPLER 

i) Plummer block 1 No. of each type and 

size 

ii) Hammers 1 Set of each type and 

size 

iii) Liner plate 1 Set 

iv) Cutter lip 1 No. 

v) Cutter seal 1 No. 

PART-F 


PAGE 

4 OF 26

CLAUSE NO. 




PLANT PACKAGE 


vi) V-belts (for crusher) 1 Set 

vii) Hammer pins 1 Sets of each type and 

size 

viii) Pulley 1 No. of each type and 

size 

ix) Conveyor belt 1.2 times length of each type 

and rating 

x) Gear box assembly for conveyor 1 No. of each type and 

rating 

xi) Gear box drive assy, for primary and 

secondary samplers 


SECTION-VI 


rating 

xii) Solenoid valves with coils (if applicable) 2 Set of each type 

xiii) Hydraulic pump with motor and coupling 

(if applicable) 


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 sampler 2 Sets 

xix) Screw conveyor gear box assembly 1 Set 

H) COAL CRUSHER 

I) Plummer Block assembly complete 

including bearing, lock nut, lock washer 

etc. (DE+NDE) 

2 Sets (i.e. for two 

crushers) 

ii) Shaft seal 4 Sets 

iii) Hammer sets 

5 Sets or 375 Nos 

whichever is more (1 set 

means hammers 

required for one crusher) 

PART-F 


PAGE 

5 OF 26

CLAUSE NO. 




PLANT PACKAGE 


iv) Rotor assembly complete consisting of 

rotor shaft & keys, End discs, Centre 

discs,distance rings, suspension bars, 

disc clamping nuts and shaft extension 

etc. but without hammers, bearings and 

pillow blocks 


SECTION-VI 

1 Set 

v) Cage bars, if applicable 4 Set 

vi) Breaker plate 4 Sets 

vii) Crusher frame Liners 2 Sets 

viii) Suspension bars 4 Set 

ix) Kick-off plate 4 Set 

x) Screen plate upper & lower 4 No. each 

xi) Tramp iron pick up plate 2 No. each 

xii) Fluid coupling 

a) Fluid coupling complete 1 Set 

b) Bearings 2 Set 

c) Seal kit (sealing rings) 2 Sets 

d) Fusible plugs 8 Nos. 

e) Oil pump motor set (if applicable) 1 Set of each type 

f) Water pump motor set (if applicable) 1 Set of each type 

g) Oil filter 3 Sets 

h) Complete actuator and engaging 

assembly (including motor, gear 

box etc.) 

1 Set 

i) Cooler assembly (if applicable) 1 No. 

j) Oil / Water valves (if applicable) 2 Nos. of each type 

xiii) Gear Coupling of crusher drive along 

with bolts and sealing kit. 

2 Sets 

PART-F 


PAGE 

6 OF 26

CLAUSE NO. 




PLANT PACKAGE 


xiv) Multi Disc assembly (for fluid coupling) 2 Sets. of each type and 

rating 

xv) Resilient Drive plate assy 2 Sets. of each type and 

rating 

xvi) One complete hydraulic door operating 

mechanism for one crusher including 

hydraulic cylinders, hoses, valves, 

hydraulic pump, panels, limit switches 

I) VIBRATING SCREENING FEEDER 


SECTION-VI 

1 Set 

i) Bearings 2 No. of each type & size 

ii) Seals 2 No. of each size 

iii) Liners 1 Set 

iv) Screen plates 5 Sets 

v) VSF rotating part assy. along with drive 

& driven unbalanced shafts/ vibrating 

blocks, bearings, coupling shafts, gear 

boxes, sheave & unbalanced weights 

as applicable. 

vi) Hoses (if applicable) 2 Sets 

vii) Drive unit assembly (including electric 

motor, hydraulic pump, hydraulic motor, 

flexible shaft, gear box, as applicable) 

viii) Base and supporting springs, rubber 

pads 


rating and direction 

1 Set 

2 Sets of each type & size 

ix) V belts 4 Sets of each type & size 

J) ELECTRIC HOISTS 

i) Brake linings 2 Sets of each type 

ii) Rope guide & rope tightner 1 No. of each type 

iii) Limit switch 2 Nos. of each type & size 

PART-F 


PAGE 

7 OF 26

CLAUSE NO. 




PLANT PACKAGE 


iv) Gear box/gear set 2 Sets of each type 

v) Motor/geared motor 1 No of each type & rating 

vi) Drum bearing 1 set of each type & rating 

K) FLAP GATES 

i) Limit switch 8 Nos. of each type & 

rating 

ii) Actuator (complete with motor, gear 

box, limit switches etc.) 


SECTION-VI 

2 Nos. of each type & 

rating 

iii) Oil seals of Actuator 2 Nos. of each type & 

rating 

iv) Flap gate shaft 2 Nos. of each type & 

rating 

v) Pressure nut 5 Nos. of each type & size 

L) RACK & PINION GATE 

i) Limit switch 2 Nos. of each type & size 

ii) Rollers with bearings 2 Nos. of each size 

iii) Motor gear box assembly 1 Set of each type 

iv) Actuator (complete with motor, gear 

box, limit switches etc.) 

M) SUMP PUMP AND DRAINAGE SYSTEM 

i) Complete pump assembly with pump, 

motor, coupling base etc 

1 No. of each type & rating 

1 Set 

ii) Impeller with key & nut 1 Set of each size & type 

iii) Oil seal 2 Nos. of each size 

iv) Coupling bolt with bushes 2 Sets of each type 

v) Pump shaft 1 No. of each size 

PART-F 


PAGE 

8 OF 26

CLAUSE NO. 




PLANT PACKAGE 


vi) Shaft sleeve 2 Sets of each size 

vii) Bearing bush 2 Sets of each size 

viii) Set of bearings 1 Set 

IX) Valves 2 Nos. of each size and 

type 

N) DUST SUPRESSION & SERVICE WATER 

SYSTEM 

a) Pump impeller with key & nut 1 Set of each type & size 

b) Pump Shaft 1 No of each type & size 

c) Bearings 1 Set each type & size 

d) Wearing rings 2 Sets of each type & size 

e) shaft sleeve 2 Sets of each type & size 

f) Bushings 2 Sets of each type & size 

g) Coupling bolts & nuts (with bushes) 2 

sets 


SECTION-VI 

1 Set each type & size 

h) Spray nozzles 20 Nos. of each type & size 

i) Solenoid valves 5 % of each type and size 

j) Globe valve / plug valves 10 % of each type and size 

k) Gate valve 2 Nos. of each size 

l) Strainers 1 No. of each type 

Compressor 

(i) Air filter element 8 Nos. 

(ii) Oil filter 6 Nos. 

(iii) Discharge check valve 3 Nos. 

(iv) Oil Pump Parts (including distance 

ring, eccentric rings, Pump 

element, Pin, Key O, Ring) as 

applicable) 

2 Sets 

PART-F 


PAGE 

9 OF 26

CLAUSE NO. 




PLANT PACKAGE 


(v) Inlet valve assembly 2 Nos. 

(vi) Electronic regulator 3 Nos. 

Pressure regulating station 1 Set of each type & size 

Hoses with connectors 4 Set of each type & size 

O) VENTILATION SYSTEM 

i) V-Belt 1 Set of each type 

ii) Pre-filter element of pressurizing fans 2 Sets of each type 

iii) Foundation Rubber pads 1 Set of each type & size 

iv) Bearings 1 Set of each type & size 

v) Plummer Blocks 1 Set of each type & size 

P) 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. 


SECTION-VI 

PART-F 


PAGE 

10 OF 26

CLAUSE NO. 




PLANT PACKAGE 


2. Roller 3 Nos. 

3. Bushing 2 Nos. 

d. Limit Cams 

e. CAD 

1. Sensor 1 No 

2. Switch 2 Nos. 

3. Switch arm 2 Nos. 

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 

Drive 

pinion 1 No. of each type 


SECTION-VI 

PART-F 


PAGE 

11 OF 26

CLAUSE NO. 

Q) DUST EXTRACTION SYSTEM 




PLANT PACKAGE 


1 Fan Motor 1 No. of each type & rating 

2 Plummer Blocks 2 Sets. of each type 

3 Bearing of fans & motor 1 Set of each type 

4 Pulley 2 Nos. of each type 

5 Belts 2 Sets. of each size 

6 Impeller and shaft of coal slurry 

disposal pump 


SECTION-VI 

1 Set. of each type 

7 Bearing of pumps 1 Set of each type 

8 Pump Motor 1 No. of each type 

9 Motor terminal blocks with studs for all 

motors 

1 Set of each rating and 

type of motor 

10 Spray nozzle 10 Nos of each type 

11 Solenoid valve with coil 2 Nos of each type 

R) Side Arm Charger Given in the 

end 

S) Wagon Tippler & accessories -Do- 

T) Apron Feeder -Do- 

II "ELECTRICAL" 

A) CONVEYORS 

(including belt feeders) 

1 Drive Motor (LT and HT) 1 No. of each type & rating 

(for population upto 10 

Nos.) 


(for population more 10 

Nos) 

PART-F 


PAGE 

12 OF 26

CLAUSE NO. 




PLANT PACKAGE 


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, paddle 

feeders 


SECTION-VI 

10 % of each type 

7 Sensor/probe for zero speed switch 20 % (min. 1 No) of each 

type and speed range 

8 Micro/limit switch of pull cord switch, 

belt sway switches, chute block 

switches 

9 Motor terminal block with studs for all 

motors 

B) CRUSHING EQUIPMENT 

1 Motor of crusher 1 No. 

2 Set of pressure, temperature flow 

switches, zero speed/under speed 

switches, limit switches etc.) 


motors 

C) MAGNETIC SEPARATORS/ SUSPENDED 

MAGNETS 

1 Rectifier with surge absorber 1 Set 

2 Rectifier transformer 1 No. 

20 % (min. 1 No) of each 

type and speed range 

1 Set. of each type and 

rating of motor 

2 Nos. of each type and 

rating 

1 Set. of each rating and 

type of motor 

3 Auxiliary and power relays 2 Nos. of each type 

4 Control transformers 1 No. of each type 

5 Ammeter 2 Nos. of each type 

6 Under current relay 1 No. of each type 

PART-F 


PAGE 

13 OF 26

CLAUSE NO. 




PLANT PACKAGE 


7 Isolating switch 1 No. of each type 


motors 

D) COAL SAMPLER 


SECTION-VI 

1 Set. Of each rating and 

type of motor 

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 


motors 

E) METAL DETECTOR 


type of motor 

1 Electronic 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 

5 LCD Display unit 1 No. of each type 

F) BELT WEIGHER 

1 Set of electronic cards 2 Nos. of each type 

2 Load Cells 2 Nos. of each type 

3 LCD Display Unit 2 Nos. of each type 

4 Speed sensor 1 Nos. of each type 

5 Cables for load cells & speed sensor 2 Sets 

6 Transducer, if applicable 2 Nos. of each type 

PART-F 


PAGE 

14 OF 26

CLAUSE NO. 

G) AUXILIARY TRANSFORMERS (DRY) 




PLANT PACKAGE 


i) HT Bushing 3 Nos. of each type & 

rating 

ii) LT Bushing 3 Nos. of each type & 

rating 

iii) Neutral bushing 1 No. of each type & rating 

iv) Neutral CT 1 No. of each type & rating 

v) Winding temp. indicator with alarm & 

trip contacts 

H) HT LOAD BREAK SWITCH AND JUNCTION 

BOX 


SECTION-VI 

1 No. of each type 

i) Trip coil 3 Nos. 

ii) Support Insulators 1 Set. 

I) BUS DUCT 

i) Support insulators 3 Nos. for each type & 

rating 

ii) Flexible terminal connectors for 

switchgear end with fastners. 

iii) Flexible terminal contactors for 

transformer end with fasteners. 

iv) Enclosure expansion bellows(if 

applicable) 

J) L.T. SWITCHGEAR / MCCs,/ DISTRIBUTION 

BOARDS 

a) Circuit Breaker Components 

2 Sets of each rating 

2 Sets of each type 


i) Spring charging motor 4 Nos. of each type 

ii) Primiary disconnect (power) 1 No. of each type 

iii) Auxiliary contact set 2 Sets of each type / rating 

of breaker 

PART-F 


PAGE 

15 OF 26

CLAUSE NO. 




PLANT PACKAGE 


iv) Limit switch 5 Nos. of each type 

v) Arc chutes for each rating 2 Sets 

vi) Moving contacts of each rating 1 Set 

vii) Fixed contact of each rating 2 Sets 

viii) Arcing contact of each type 2 Sets 

ix) Closing coils for each type 4 Nos. 

x) Tripping coils for each type 4 Nos. 

xi) Closing & tripping springs 5 Nos. of each type 

xii) Releases 2 Nos. of each type 

xiii) Carbon brushes for spring charging 

motor 


SECTION-VI 


xiv) Over current devices 1 No of each type and 

rating 

xv) All type of protection/aux/relays,timers 1 No of each type and 

rating 

xvi) Coupling relays 10 Nos of each type and 

rating 

b) LT panel components 

i) Auxiliary contactor 2 Nos of each type and 

rating 

ii) Coupling relays without base 10 Nos of each type and 

rating 

iii) Bi-metallic overload relay 2 Nos of each type and 

rating 

iv) Overload relay reset chord complete 10 Nos of each type 

v) Switch fuse unit 5 Nos of each type and 

rating 

vi) Control fuse base with carrier 20 Nos 

PART-F 


PAGE 

16 OF 26

CLAUSE NO. 




PLANT PACKAGE 


vii) LT module incoming male/female power 

contacts 

viii) LT module outgoing male/female power 

contacts 

ix) Moving/detachable control disconnects 

contacts of each rating 


SECTION-VI 

3 Sets of each type and 

rating 


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 No of each type & range 

f) Relays (Protection, aux, coupling relay and 

timers) 

g) Contactors 

(i) Contactors and aux. Contactors 

(complete) 

(ii) Coil for the Contactors and aux. 

Contactors 

(iii) Main Contacts sets for power. 

Contactors 

1 No of each type 

2 Nos of each type & 

rating 


rating 


rating 

h) Control, isolating & selector switches 1 No of each type & rating 

PART-F 


PAGE 

17 OF 26

CLAUSE NO. 




PLANT PACKAGE 


i) Push button of Various colours 2 Nos of each type & 

rating 

k) CONTROL PANEL 

(Main 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 

elements) 

x) Auxiliary contactors and bimetallic 

overload relay set for panel 

xi) Control fuse base with carrier complete 

set for panel 


SECTION-VI 

1 No. of each type & 

colour 

1 Complete set 

1 Complete set 

xii) Any special meter 1 No. of each type 

xiii) Bi-metallic overload relay 2 Complete sets 

Note Spares already covered under 

respective equipment spares shall not 

be duplicated under control panel 

spares. 

PART-F 


PAGE 

18 OF 26

CLAUSE NO. 

L) PLC (WAGON TIPPLER) 




PLANT PACKAGE 


i) PLC cards (Processor, memory and all 

cards other than I/O cards) 


SECTION-VI 


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 % 

M) VIBRATION MONITORING SYSTEM FOR 

CRUSHER 

i) Vibration pick up 2 Nos 

ii) Pick up cable 1 Length 

iii) Vibration monitor module and other 

cards 

iv) Power supply 1 No. 


v) Relays 2 Nos. of each type 

vi) Indicating lamps / LEDs 5 Nos. of each colour 

N) DUST SUPRESSION & SERVICE WATER 

SYSTEM 

i) Electric motor 1 No. 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 

PART-F 


PAGE 

19 OF 26

CLAUSE NO. 

O) SUMP PUMP 




PLANT PACKAGE 


i) Electric Motor 1 Nos. of each type & 

rating 

ii) Level switch 1 Set. Of each type 

P) VENTILATION SYSTEM 

i) Electric motor 1 No. of each type & rating 

Q) ELEVATORS 

i) Contactors 2 Nos. of each type 

ii) Auxiliary Transformer, control 

transformer 


SECTION-VI 


iii) Relays(Aux., Over current) 3 No. of each type & rating 

a) Time device 2 Nos. of each type & 

rating 

iv) Resistor 3 Nos. of each type & 

rating 

v) Switch 1 No. of each type 

Push button 3 Nos. of each type 

vi) Rectifier 2 Nos. 

vii) Limit switch 4 Nos. of each type 

viii) Battery Charger 1 No. of each type 

ix) Tone frequency transmitter 2 Set. Of each type 

x) Tone frequency receiver 2 Set. Of each type 

R) VIBRATING SCREENING FEEDER 

i) Motor terminal block with studs for all 

motors 

ii) Cards of variable frequency drive of 

vibrating screening feeders 


type of motor 

1 Set 

PART-F 


PAGE 

20 OF 26

CLAUSE NO. 

S) Battery Charger 

Mechanical 




PLANT PACKAGE 


i) Thyristor blocks 1 Set of each type 

ii) Cards 1 No of each type 

T) SIDE ARM CHARGER 

1 Gear box spares 

i) Complete gear box assy. 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 Sets of each size and 

type 

(c) Plummer Block 1 Set of each type and size 

(d) Carriage wheel fitted with shaft 

(without Plummer Block) 


SECTION-VI 

1 Set 

3 Coupling 1 Set each type 

4 Travel Wheel Assembly 1 No 

5 Bearing 1 No. of each type 

6 Motor 

(a) Motor including slip ring motor 1 Set of each type and size 

(b) Bearings 1 Set of each type and size 

(c) Oil Seal 1 Set of each type and size 

PART-F 


PAGE 

21 OF 26

CLAUSE NO. 

7 Brakes 




PLANT PACKAGE 


(a) Complete assembly 1 No. of each type and size 

(b) Linings & springs 1 Set of each type and size 

8 Couplings 


(b) Pins, bushes and nuts 1 Set of each type and size 

9 Hydraulic Power Pack 

i) Hydraulic Pump with electric motor, 

coupling, valves & servo motor 

(mounted on pump)etc. 


SECTION-VI 


rating 

ii) Solenoid Valves complete with coils 1 Set of each type and size 

iii) Filter element (1 No. Pressure Filter 

+ 1 No. Return Filter) 


iv) Hydraulic Hoses 2 Sets 

v) Hydraulic Motor 1 Nos of each type 

vi) Traverse pump with electric motor, 

coupling, valves (mounted on 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 No of each type 

x) Servo motor 1 No of each type 

U) Wagon Tippler and Accessories 

1 Speed Reducers 

(a) Complete gear box assy.. 1 Set of each type and 

rating 

PART-F 


PAGE 

22 OF 26

CLAUSE NO. 




PLANT PACKAGE 


(b) Oil Seals 4 Sets of each type and 

rating 

2 Motor 

(c) Bearings 2 sets of each type and 

rating 

(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 

5 Thyristor/VVVF Panel 

(a) Thyristor/VVVF cards/modules 1 No. of each type 

(b) Relays 2 Nos. of each type and 

rating 

6 Hydraulic Power Pack 

(a) Hydraulic Pump with electric motor, 

coupling, valves (mounted on pump) 

etc 


SECTION-VI 


size 

(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. 

PART-F 


PAGE 

23 OF 26

CLAUSE NO. 




PLANT PACKAGE 


(e) Filter Elements 10 Nos. of each type 

(f) Pressure Switch 1 No. of each type 

(g) Temperature Switch 1 No. of each type 

7 Bearings (not covered separately) 1 Set of each type and size 

8 Limit Switches 2 Nos. of each type. 

9 Cylinder Manifold block with all valves 

mounted on it 


SECTION-VI 

1 Set 

10 Hydraulic cylinder with piston 1 Set of each type and size 

11 Seals of hydraulic cylinder and pumps etc. 2 Sets of each type. 

12 Hydraulic hoses 2 Sets 

13 Gear box total 1 Set 

14 Gear flexible coupling 1 Set 

15 Rod end bearings with housing 1 Set for all four clamps 

16 Pressure Switches 1 No 

17 Common manifold block complete with all 

valves mounted on it. 

1 No. 

18 Main Pivot bearing 1 No. 

19 Pinion support & bearing 1 No. each type. 

20 Pinion 2 Nos. 

21 Latch (Pinion & rack segment locking 

device) 

1 No. 

22 Chain & Sprocket 1 Set 

V) APRON FEEDER 

1 Head Pulley complete with shaft 1 No. 

2 Tail pulley complete with shaft 1 No. 

PART-F 


PAGE 

24 OF 26

CLAUSE NO. 

Note : 




PLANT PACKAGE 


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 including 

input and output shafts 


SECTION-VI 

1 Set of each type & size 

6 Reduction gears 1 Set 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 Set of each type and size 

15 Seal kit of hydraulic cylinders 0 Set. 

16 Plummer Blocks 1 No. of each type and size 

17 Bearings 1 Set of each type and size 

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. 

PART-F 


PAGE 

25 OF 26

CLAUSE NO. 




PLANT PACKAGE 


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. 


SECTION-VI 

PART-F 


PAGE 

26 OF 26





ATTACHMENT-12 

SECTION-VII 

TECHNICAL DATA SHEETS 

FOR 

WAGAON TIPPLER, CRUSHING & 

CONVEYING PLANT PACKAGE 






ATTACHMENT-12 

SECTION-VII 


FOR 

WAGAON TIPPLER, CRUSHING & 

CONVEYING PLANT PACKAGE 





CONTENTS 

SECTION - A TECHNICAL INFORMATION AND DATA TO BE 

SUBMITTED WITH THE PROPOSAL 

SECTION - B TECHNICAL INFORMATION AND DATA TO BE 

SUBMITTED 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 



WAGON TIPPLER, CRUSHING & CONVEYING 

PLANT PACKAGE 

SECTION - A 

TECHNICAL INFORMATION 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

1.00.00 The Bidder shall furnish complete technical literature supported by Manufacturer's 

catalogues/leaflets, general arrangement schematics, layout etc. for complete Wagon 

Tippler, Crushing & Conveying Plant including the following: 

1.01.00 General Plan, showing layout of the proposed conveyor system. 

1.02.00 Coal Flow Diagram 

1.03.00 Sectional Elevation drawings of all conveyors with chutework. 

1.04.00 General Arrangement Drawings of all Coal Handling Plant Buildings including wagon 

tipplers, tunnels etc. with the housed equipment. 

1.05.00 General Arrangement drawings for all major mechanical & electrical equipments 

showing constructional features and space requirement for operation and 

maintenance of the equipment. 

1.06.00 Descriptions and write-up of the control systems. 

1.07.00 Details of instrumentation such as speed monitoring system, pressure/Flow/ 

Temperature sensors/switches, levels sensor/switches, and other switch devices 

such as belt sway switches, pull cord switches etc. 

1.08.00 Electrical single line diagrams, typical control schematic. 

GA drgs and typical foundation plan for all major electrical equipt. eg. control panels, 

3.3 KV, 415 V motors, switchgear/MCC, transformers etc. showing constructional 

features and space requirement for their operation and maintenance. 

1.09.00 Descriptive literature of all major electrical equipment (viz. circuit breaker, Air break 

switches, contactors, Thermal over load relays with single phasing preventor, fuses, 

Relays and Releases, Instrument Transformers, Control Transformers, Cable trays 

fitting & accessories, cable termination and jointing kits etc.), instruments panels etc, 

supplied along with catologues. 

1.10.00 The drawings and information related to the civil, structural and architectural work to 

be executed under this contract: 

a) Preliminary general arrangement and architectural drawings indicating the 

conceptual design, grade of concrete and steel used, thickness of concrete 

structural members, steel sections, and typical architectural details etc. 

b) All assumptions made and loading taken for the design (Including equipment 

loads) shall be clearly indicated. 

SECTION-A 

PAGE 

1 OF 39

CLAUSE NO. 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

c) The capacity, type, length, diameter & reinforcement details of piles. Typical 

design calculations justifying the capacity of pile assumed shall be furnished 

along with the bid. 

d) A broad outline of steel erection scheme. 

e) Names of manufacturers for all bought out items like doors, windows, louvers, 

rolling shutters, fixtures and fittings, paints etc. Manufacturer’s catalogues for 

all hardware and fixtures shall also be supplied. 

2.00.00 The Bidder shall enclose with his proposal a list of items of non-Indian origin. 

3.00.00 Bidder to fill up all the data in the data requirement while submitting the bid. 

4.00.00 Bidder shall indicate proposed makes of all the items/equipments pertaining to the 

Wagon Tippler, Crushing & Conveying Plant Package and shall Annex with the 

document separately. 

SECTION-A 

PAGE 

2 OF 39

CLAUSE NO. 





PLANT PACKAGE 

TECHNICAL DATA 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

I. COAL HANDLING EQUIPMENT, DUST CONTROL & MISC SYSTEMS, 


(Section IIIA-01 to IIIA-19) Bidder to fill separate sheets for separate 

items/equipment. 

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 Max. angle of inclination 

a) above horizontal 

b) below horizontal 

1.07.00 Details of take-up 

a) Type of take-up 

b) Length of travel (mm) 

1.08.00 Conveyor belting 

1.08.01 Type of fabric / chord 

1.08.02 Belt Rating 

- Nylon - Nylon 

- Steel Cord 

Conveyor Nos. 

SECTION-A 

PAGE 

3 OF 39

CLAUSE NO. 


1.08.03 Code/Standard to which the beltings conforms to 

1.08.04 Cover thickness, mm, 

– face cover 

– back cover. 

1.08.05 Cover Grade 

1.08.06 Code/standard for Fire Resistance 

properties of the covers 

1.09.00 Angle of wrap, over 

drive pulley, degrees 

1.10.00 Drive Pulleys 

1.10.01 Diameter (mm), 

1.10.02 Face Width (mm) 

1.10.03 Bearing Centres, mm 

1.11.00 Tail and Take-up pulleys 




1.12.00 Bend and snub pulleys 




1.13.00 Discharge Pulley 

1.13.01 Diameter 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

4 OF 39

CLAUSE NO. 

1.13.02 Face width 

1.13.03 Bearing centre 

1.14.00 Troughing idlers 

1.14.01 Spacing, mm 


– Normal 

– Over convex curves 

1.14.02 Troughing angle, degrees 

1.14.03 Shell diameter, mm 

1.15.00 Return Idlers 



1.15.03 Shell diameter, mm 

1.16.00 Self aligning return idlers 



1.17.00 Rubber disc type Impact idlers 



1.17.03 a) Roll dia with rubber 

discs on, mm 

b) Shell outer dia, mm 

1.17.04 Shell thickness of Roll, mm 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

5 OF 39

CLAUSE NO. 


1.18.00 Self cleaning type 

rubber disc. return idlers 

1.18.01 Diameter of rubber disc 

1.18.02 No. of self cleaning idlers 

for each conveyor 

1.18.03 Shell dia. mm 

1.19.00 Conveyor Galleries 

1.19.01 Gallery Cross-section 

a) Width, mm 

1.19.02 Deck plates 

b) Clear headroom inside 

gallery from walkway level, mm 

a) Material 

b) Thickness 

1.19.03 Seal Plates 

a) Material 

b) Thickness 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

1.19.04 Stone picking arrangement provided 

as envisaged in Tech. spec. Yes/No 

1.20.00 Drive Equipment for 

Belt Conveyor system 

a) Motor speed, RPM 

b) Drive pulley speed, RPM 

1.20.01 Reduction gears 

a) Type 

SECTION-A 

PAGE 

6 OF 39

CLAUSE NO. 


b) Nominal rating, kw 

– Mechanical 

– Thermal 

c) Method of lubrication 

1.20.02 Fluid Couplings 

a) Type 

1.20.03 Brakes 

b) Rating, kw 

a) Type 

b) Rating 

1.20.04 Flexible couplings 

a) Type 

b) Rating 

1.20.05 Drive motors 

a) Motor nameplate rating, 

KW at 50 deg.C Ambient 

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 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

2.01.02 Trolley provided for each 

ILMS reject chute Yes/No 

SECTION-A 

PAGE 

7 OF 39

CLAUSE NO. 

2.02.00 Skirtboard 


a) Plate thickness, mm 

b) Length of each 

skirtboard, m 

c) Height, mm 

d) Width, mm 


2.03.01 Type of actuator 

2.03.02 Actuator shaft 

a) Dia, mm 

b) Material 

2.04.00 Rack & Pinion Gates 

2.04.01 Type of actuator 

3.00.00 COAL CRUSHERS 

3.01.00 Numbers & Type offered 

3.02.00 Name of Manufacturer 

3.03.00 Guaranteed capacity, MTPH 

3.04.00 a) Crusher 

(i) Model No. 




PLANT PACKAGE 

(ii) Rotor dia x Rotor length (mm) 

b) size of crusher inlet 

opening, mm×mm (inside) 

c) Guaranteed output 

coal size, mm 

3.04.01 No. of hammers 

i) Row-wise 

ii) Total 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

8 OF 39

CLAUSE NO. 

3.04.02 Suspension Bars 


a) No. of suspension 

bars passing through 

each hammer row 

b) No. of holes in each 

segment of central & 

end discs for suspension 

bars (in each row of 

hammers) 

c) Length of suspension 

bars extractable at 

i) Drive end 

ii) Non-Drive end 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

d) Suspension bar locking 

provided at both ends ? Yes/No 

3.04.03 Rotor speed, rpm 

3.04.04 Weights in kg. 

a) Crusher rotor with hammers 

b) Complete crusher 

3.04.05 Drive Chain Arrangement 

a) Motor synchronous 

speed, rpm 

b) Hydraulic scoop fluid 

coupling 

i) Type 

ii) Thermal tripping 

arrangement 

against excessive 

oil temperature 

rise provided Yes/No 

c) Flexible couplings 

i) Type 

SECTION-A 

PAGE 

9 OF 39

CLAUSE NO. 


3.04.06 Cage Actuating mechanism 

3.04.07 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 

h) Liners 

3.04.08 Drive motor 

i) Material 

ii) Hardness, BHN 

iii) Plate thickness, mm 

i) Material 

ii) Thickness, mm 

a) Motor nameplate rating 

at 50 deg.C Ambient KW 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

3.04.09 Vibration isolation system for 

crusher foundation provided as 

per Technical Specification Yes/No 

4.00.00 VIBRATING SCREENING FEEDERS 

4.01.00 Numbers & Type offered 


SECTION-A 

PAGE 

10 OF 39

CLAUSE NO. 


4.03.00 Guaranteed capacity, MTPH 

4.04.00 Solid Deck (Pan) size 

(mm x mm) 

4.05.00 Screening Area (mm x mm) 

4.06.00 Inclination of deck 

4.07.00 Vibrator 

a) Type of drive 

b) Type of vibrator 

c) Range of feed 

rate adjustment 

4.08.00 Perforated Deck 

a) Material 

4.09.00 Solid Deck 

a) Material of solid plate 

of the deck 

b) Liners on the solid 

plate provided ? Yes/No 

c) Material of liners 

4.10.00 Supporting Springs 

a) Type 

4.11.00 Drive Motors 

b) Material of springs 

a) Motor name plate rating, 

KW at 50 deg.C Ambient 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

5.00.00 BELT WEIGHING SCALES Conveyors 


SECTION-A 

PAGE 

11 OF 39

CLAUSE NO. 


5.02.00 Measuring capacity 

5.03.00 Location 

a) Max. MTPH 

b) Min. MTPH 

5.04.00 Accuracy (%) 

a) at maximum load 

b) at minimum load 

5.05.00 No. of test chains provided 

per belt weigher 

5.06.00 Rate Indicators 

a) Type 

b) No. of rate indicators 

provided per weigher 

c) Location 

5.07.00 Totaliser 

a) Type 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

6.00.00 IN-LINE MAGNETIC SEPARATORS 

& SUSPENDED MAGNETS ILMS SM 



6.03.00 a) Mounting height, mm 

6.04.00 Magnet 

b) Strength in gauss at 

400 mm distance 

a) Type 

b) Material of magnet 

core 

SECTION-A 

PAGE 

12 OF 39

CLAUSE NO. 


c) Material of coil 

d) Class of insulation 

e) KW rating at 50 deg.C 

Ambient 

6.05.00 Self-Cleaning Belt 

a) Belt width, mm 

b) Belt specification 

c) Belt speed, m/sec 

d) Drive motor name plate 

rating, KW at 50 deg.C 

Ambient 

6.06.00 Type of handling arrangement for 

a) Height adjustment 

b) Cross travel 

7.00.00 COAL HANDLING PLANT BUILDINGS 

7.01.00 Junction Tower/Crusher house 

7.01.01 Cladding 

a) Material 

b) Thickness 

7.01.02 Identify Structures where 

piling is envisaged 

1) TP 

2) Conveyor galleries 

3) Control Bldgs. 

4) Any other structure 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

13 OF 39

CLAUSE NO. 


7.01.03 Piles (if applicable) : 

a) Type: 

b) Method of boring 

b) Dia/ Capacity 

7.01.04 No. of staircases provided 

a) For TP 

b) For Crusher house 

c) For Main Control Room building 

d) For MCC 

e) For Wagon Tippler Control 

Room Building 

7.02.00 Main Control/MCC Rooms/ 

Wagon Tippler Control Room 

7.02.01 Locations 

8.00.00 COAL SAMPLING UNIT 

8.01.00 a) Name of Coal sampler 

Supplier/manufacturer 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

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 

SECTION-A 

PAGE 

14 OF 39

CLAUSE NO. 





PLANT PACKAGE 

- Suitable for belt width, 

- belt capacity (TPH) 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

(v) Certificate from client Yes/No Yes/No 

Enclosed 

8.02.00 Standard /Code to which the For uncrushed 

sampling system conforms Coal 

8.03.00 a) Location 

b) Make 

c) Model No. 

9.00.00 ELEVATORS 

d) Catalogue/Technical 

literature furnished ? Yes/No 

9.01.00 Salient Particulars 

i) Load Carrying 

Capacity (kg) 

ii) Location 

iii) Type of elevator 

iv) Speed (M/Min.) 

9.02.00 Location of the Drive Unit 

10.00.00 DUST CONTROL & MISC. 

SYSTEMS 

10.01.00 Plain Water Dust 

Suppression System 

10.01.01 DS-system/zone 

10.01.02 Pump house / Tanks Location 

10.02.00 Water Pumps 

10.02.01 Numbers 

WT 

SECTION-A 

PAGE 

15 OF 39

CLAUSE NO. 

10.02.02 a) Type 



a) Casing 

b) Impeller 

c) Shaft 

d) Shaft sleeve 

10.02.04 Suitable for parallel operation : Yes/No 

10.03.00 Dry Fog System for Junction 

Tower & Crusher House 

(i) Spray Bar Assembly 




PLANT PACKAGE 

(a) No. of spray bar assemblies 

per transfer point 

(b) Material of spray bar 

assemblies 

(c) No. of nozzles per 

assembly 

(d) Type of nozzles with 

flow ratings 

(Air / Water) 

(e) Material of nozzles 

(ii) Pressure Regulating Units 

(a) No. of PRUs 

(b) Type of regulation 

(c) Regulation ranges 

(iii) Flow Activation Stations 

(a) No. of Flow Activation 

Stations 

(b) Type 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

16 OF 39

CLAUSE NO. 


(iv) Compressor with accessories 

(a) Make 

(b) Model 

(c) Type 



10.04.02 Nos. 

10.04.03 Type 

(d) Capacity 

10.04.04 Capacity, m 3 /hr 

10.04.03 Size of each drain pit 


a) Casing & rotor 

housing 

b) Rotor 

c) Shaft 

d) Shaft sleeve 

11.00.00 METAL DETECTORS 


11.01.00 Nos. provided 


11.03.00 Type 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

17 OF 39

CLAUSE NO. 


12.00.00 VENTILATION & AIR 

CONDITIONING 

12.01.00 Type of Ventilation Type 

(supply-cum exhaust) 

12.01.01 Area Description – Location 

12.01.02 Fans 


a) Type 

b) Numbers provided 

a) Type 

- Supply 

- Exhaust 

12.02.00 Pressurized Ventilation 

12.02.01 Area Description - Location 

12.02.02 Type of Ventilation System 

(supply-cum exhaust) 

12.02.03 Fans 


a) Type 

b) Numbers provided 

a) Type 

- Supply 

- Exhaust 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

18 OF 39

CLAUSE NO. 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

12.03.00 Air Conditioning System Main MCC WT 

Control Room Control 

Room Room 

12.03.01 PAC Units 

a) Location 

b) Nos. provided 

12.03.02 Compressor 

c) Capacity of each unit (TR) 

a) Type 

b) Nos. per PAC unit 

c) Capacity, TR each 

13.00.00 DUST EXTRACTION SYSTEM IN 

CRUSHER HOUSE AT VSF & 

MOVABLE BELT FEEDER FLOOR : 

a) Type of DE System 

b) Dust Collection method 

c) Dust disposal arrangement 

upto Coal Settling Pond Yes/No 

14.00.00 WAGON TIPPLER 


14.02.00 Type 

14.03.00 Hopper Capacity 

14.04.00 Type of drive 

14.05.00 Drive Rating 

15.00.00 SIDE ARM CHARGER 


SECTION-A 

PAGE 

19 OF 39

CLAUSE NO. 

15.02.00 Range of travel 

15.03.00 Type of drive 

15.04.00 Pulling effort 

15.05.00 Haulage capacity 

16.00.00 APRON FEEDER 



16.02.00 Length of apron feeder 

16.03.00 Width of pan 

16.04.00 Drive KW 

16.05.00 Material of Construction 

i) Chain link 

ii) Apron pan 

iii) Rollers 

17.00.00 MAKES OF EQUIPMENT 

17.01.00 Bakes & clamps 

17.02.00 EOT & HOT – Hoists 


17.04.00 Couplings 

- Fluid Compling 

- Flexible Compling 

- Scoop Compling 

17.05.00 Vibrating Screening Feeder 

17.06.00 Crusher 

17.07.00 ILMS / Magnets 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

SECTION-A 

PAGE 

20 OF 39

CLAUSE NO. 

17.08.00 Metal Detectors 


17.09.00 Coal Sampling System 

17.10.00 Elevator 

17.11.00 Pumps – DS/SW/CW/PW/Sump 

17.12.00 Ventilation Fans 

17.13.00 PAC 


17.15.00 Side Arm Charger 

18.00.00 SUB-QR FOR DESIGN AGENCY FOR 

CIVIL WORKS & STEEL STRUCTURAL WORKS 

(1) Name of client/clients & 

Full address, contact person(s) 

Fax No. and Tel. No. 

(2) Name and address 

of project/projects for which 

the qualifying job was executed. 

(3) (a) Order No. & date. 




PLANT PACKAGE 

(b) Date of completion of design work 

(4) Scope of work 

- Steel structures 

- Concrete structures 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

(5) Total duration of the work From ……….. To ………… 

(6) Client’s Certificates 

enclosed at Annexure ………… 

to this attachment 

in support of details sought 

at items 3 to 5 Yes/No 

SECTION-A 

PAGE 

21 OF 39

CLAUSE NO. 


II. ELECTRICAL EQUIPMENTS 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

1.00.00 Information and drawings to be submitted alongwith the following : 

The following information and drawings of the proposed equipment shall be 

submitted in required number of copies by the Bidder alongwith his proposal. 

1.01.00 Complete technical literature supported by catelogues for all the equipments and 

accessories covered in his scope of supply. 

1.02.00 Instruction manuals for all the equipments covered in the Bidder's scope of supply. 

1.03.00 Technical data sheets (guaranteed technical particulars) of the equipment offered. 

2.00.00 Information and drawings to be submitted after the award of the contract. 

2.01.00 Contractor shall submit all the drawings, data documents, manuals, catalogues etc. 

as per the requirements given under applicable sections of the specifications. 

2.02.00 Drawings showing adequate details of equipment/panels and accessories offered 

and typical drawings of major schemes offered. 

2.03.00 Contractor shall also submit the technical data sheets (Guaranteed Technical 

Particulars) of all the equipments being supplied. 

2.04.00 Type test and routine test reports for all the equipments and accessories covered 

under Bidder scope of supply. 

3.00.00 Check list for Information and drawings to be submitted with the bid 

(This checklist must be attached to the data sheet). 

3.01.00 Complete technical literature Yes/No 

supported by catalogue for 

all the equipments and 

accessories enclosed 

3.02.00 Instruction manuals for all Yes/No 

the equipments enclosed 

SECTION-A 

PAGE 

22 OF 39

CLAUSE NO. 


MOTORS 

(To be filled in for each 

type & rating) 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

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 50 

.............................. ............................ 

oC 6.00.00 Power factor at rated .............................. ............................ 

load 

7.00.00 Starting current at 

100% voltage .............................. ............................ 

85% voltage .............................. ............................ 

8.00.00 Torques (kg-meter) at 

(a) Starting .............................. ............................ 

(b) Pull - up .............................. ............................ 

(c) Pull - out .............................. ............................ 

9.00.00 Type of enclosure and .............................. ............................ 

method of cooling 

10.00.00 Degree of protection .............................. ............................ 

SECTION-A 

PAGE 

23 OF 39

CLAUSE NO. 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

11.00.00 Rated voltage and frequency .............................. ............................ 

12.00.00 Rated speed .............................. ............................ 

13.00.00 Efficiency at design .............................. ............................ 

duty point (without -ve 

tolerance) & 100% full 

load 

14.00.00 Type of mounting .............................. ............................ 

15.00.00 Type of terminal box for .............................. ............................ 

stator leads 

SECTION-A 

PAGE 

24 OF 39

CLAUSE NO. 


SWITCHGEAR 

(Bidder to furnish following data 

for each type and class of switch- 

gear separately) 

1.00.00 SWITCHGEAR 

a) General 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

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.) 

SECTION-A 

PAGE 

25 OF 39

CLAUSE NO. 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

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) Continuous current at ambient ............................................. 

temp. 

f) Rated symmetrical breaking ............................................. 

current 

g) Rated peak making current ............................................. 

h) Rated short time rating ............................................. 

(for 1 sec.) 

i) Power operating mechanism ............................................. 

j) Spring charging motor details 

i) Type ............................................. 

ii) Rating Watts ............................................. 

SECTION-A 

PAGE 

26 OF 39

CLAUSE NO. 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

iii) Rated voltage ............................................. 

iv) Class of insulation ............................................. 

k) Emergency Manual charging Yes/No 

facility provided 

l) Manual operating mechanism ............................................. 

m) 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 ............................................. 

c) Rated voltage of main and ............................................. 

auxliary contacts 

d) Rated voltage of coils ............................................. 

SECTION-A 

PAGE 

27 OF 39

CLAUSE NO. 

8.00.00 FUSES 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

a) Make ............................................. 

b) Type ............................................. 

c) Category ............................................. 

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 

13.00.00 VOLTMETER 

Make & type designation ............................................. 

a) Make ............................................. 

b) Type ............................................. 

SECTION-A 

PAGE 

28 OF 39

CLAUSE NO. 

14.00.00 AMMETER 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

a) Make ............................................. 

b) Type ............................................. 

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) Continuous current rating of ............................................. 

busbars (Amps) 

f) Short circuit current ratings ............................................. 

& duration (kA/Sec.) 

g) Temperature rise over the ambient 

temperature 

i) Busbars ............................................. 

ii) Enclosures ............................................. 

h) Material of support insulator ............................................. 

i) 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 ............................................. 

SECTION-A 

PAGE 

29 OF 39

CLAUSE NO. 


1.00.00 POWER, CONTROL AND TRAILING CABLES 

(Use separate sheet for each type and size of cables) 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

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 .............................................. 

1.07.00 Insulation 

a) Material .............................................. 

b) Nominal cross section area .............................................. 

in sq.mm 

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 .............................................. 

SECTION-A 

PAGE 

30 OF 39

CLAUSE NO. 



1.00.00 Lighting distribution board 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

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) Catalogue for each type of .............................................. 

fixture 

c) 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 .............................................. 

SECTION-A 

PAGE 

31 OF 39

CLAUSE NO. 


7.00.00 Rigid Steel Conduits/Fittings 

& Accessories 

8.00.00 Hume Pipes 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

a) Make .............................................. 

b) Material .............................................. 

c) Applicable Standard .............................................. 

a) Make .............................................. 

b) Applicable Standard .............................................. 

9.00.00 Flexible steel conduit 

a) Make .............................................. 


10.00.00 Lighting Wires 

a) Make .............................................. 


c) Voltage grade .............................................. 

d) Size .............................................. 

e) Conductor material .............................................. 

f) Insulation .............................................. 

11.00.00 Lighting Poles 

a) Make .............................................. 


c) Type .............................................. 

d) Pole height .............................................. 

SECTION-A 

PAGE 

32 OF 39

CLAUSE NO. 

12.00.00 Lighting Masts 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

a) Make .............................................. 

b) type .............................................. 

c) Overall height .............................................. 

SECTION-A 

PAGE 

33 OF 39

CLAUSE NO. 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

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 .............................................. 

SECTION-A 

PAGE 

34 OF 39

CLAUSE NO. 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

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 .............................................. 

ii) Size & material for Air .............................................. 

termination and down 

conductor 

SECTION-A 

PAGE 

35 OF 39

CLAUSE NO. 


TRANSFORMER 

Use Different Sheets for 

transformers 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

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 

a) Principal tap .............................................. 

b) Maximum tap .............................................. 

c) Minimum tap .............................................. 

10.00.00 Temperature rise over an ambient 

A) Windings (by resistance measure- .............................................. 

mend method) (deg.C) 

11.00.00 Withstand time for three phase .............................................. 

short circuit at terminals (sec.) 

SECTION-A 

PAGE 

36 OF 39

CLAUSE NO. 

12.00.00 Bushings 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

a) Manufacturer .............................................. 

b) Type .............................................. 

c) Minimum creepage distance .............................................. 

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 

SECTION-A 

PAGE 

37 OF 39

CLAUSE NO. 


CONTROL DESK/CONTROL PANELS/PLC 

1.00.00 Different Control Panels 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

a) Application ................................................ 

b) Overall dimensions ................................................ 

2.00.00 Control Switch 

3.00.00 Annunciators 

a) Manufacturer ................................................ 

b) Type and designation ................................................ 

c) Catalogue attached ................................................ 



c) Solid state or electromechanical ................................................ 

d) Catalogue attached ................................................ 

4.00.00 Meter & Instruments 




5.00.00 Energy Meters 




6.00.00 Indicating Lamps 




SECTION-A 

PAGE 

38 OF 39

CLAUSE NO. 

7.00.00 Push Buttons 

8.00.00 Panels 





PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 





9.00.00 Control Panel Details 

10.00.00 PLC System 

a) Make of control panel 

b) Manufacturer's type designation 

c) Antivibration pad provided (Yes/No) 

d) Panel IP protection 

a) Make of the PLC system 

b) Description of list and diagnostic 

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) Country of manufacturer ............................................. 

d) Power supply ............................................. 

SECTION-A 

PAGE 

39 OF 39

SECTION - B 


SUBMITTED AFTER AWARD OF CONTRACT

CLAUSE NO. 

GENERAL 




PLANT PACKAGE 

TECHNICAL INFORMATION AND DATA TO BE SUBMITTED 

AFTER AWARD OF CONTRACT 

SECTION - B 


SUBMITTED AFTER AWARD OF CONTRACT 


ATTACHMENT-12 

SECTION-VII 

BIDDER’S NAME : ……………………………….. 

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. 

SECTION-B 

PAGE 

1 OF 3

CLAUSE NO. 



(b) Instruction for operation, maintenance and repair. 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

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 informations 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. 

SECTION-B 

PAGE 

2 OF 3

CLAUSE NO. 



(f) Interlock schematics. 




PLANT PACKAGE 


ATTACHMENT-12 

SECTION-VII 

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. 

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. 

SECTION-B 

PAGE 

3 OF 3

GATE 

ST.

K C ROOM 

1 l6 

I 

? I I 

-. A 

4 WT CONTROL r z 

ROOM 6 

I 

- ., 

J - 

- 

TOP0 RAtL MCC ROOM 

EL.(+] 10M 

I 

I T 

G.A. OF CONVEYOR 56A156B 

L 

a\ I 

I 

SECTION A-A 

(FOR WAGON TI PPLER-I &2) 

I 

JM 

- 

/' 

0 

0 Ln 

* 1 

\ 

EL.(-30.5M 

'I 

MYlUm FAN5 J 

(SU)PLY & DIHAUST) 

WH flLlER UNIT p) 

wrm suwmrrs 

8v CONTRACTOR 

SECTIONAL - VlEW OF WAGON TIPPLER 1550 1550 

- 4000 - 

4000 

[SECTION 6-8) 

TYPICAL CROSS SECTION OF DOUBLE CONV. TUNNEL 

0 

0 

a 

G.A. OF JUNCTION TOWER JT-2 

KIIIIIArn FAN Awl 

NOTES : 

1. ALL DIMENSIONS ARE IN MM AND LEVELS IN METRES UNLESS OTHERWISE SPECIFIED. I I 

2. REQUIRED FLooRs/HANDLING ARRANGEMENT AND ALL OTHER REQUIRED ACCESSORIES IN BIDDERS SCOPE. 

NOT SHOWN FOR CLARITY. 

3. FOR GENERAL NOTES REFER DRG. NO. 2240-155C-POM-A-008. I I 

4. THIS DRG. SHALL BE R W 

IN CONJUNCTION WIM OTHER TENDER DRGS. I I 

5. EL. 0.0 CORRESPONDS TO RL (+) 281.00M. U 

$ HEAD PULLEY 

6. up- 

I I I MONORAIL & ELECTRIC HOIST WITH SUPPORTING ARRANGEMENT IN WAGON TIPPLER AREA ARE IN BIDDER 

SCOPE. DETAILS OF THE SAME WILL BE FINALISED DURING DETAIL ENGG. 

7. VARIOUS DIMENSIONS NOT SHOWN IN WAGON TIPPLER ARRANGEMENT ARE TO BE DECIDED BY THE 

BIDDER BASED ON HIS OFFER. 

8. SUFflClENT SPACE TO BE EARMARKED FOR GARLANDING OF WAGON TIPPLER HOPPER BY DS HEADER. 

9. DIMENSIONS WITH '*' INDICATION TO BE DECIDED BY BIDDER. DIMENSIONS SHOWN AS MINIMUM. 

10. SUMP PUMP HOUSE TO BE PROVIDED FOR WT-1,W-2 AND JT-1 AS PER SPECIFICATION REQUIREMENT. 

11. PROVISION FQR ADDING TUNNEL BEYOND JT-I/JT-2 FOR FUTURE EXTENSION SHALL BE PROVlDED AND 

END SHALL BE BLOCKED IN THlS PACKAGE. 

12, AT JT-2, CONVEYOR 37A/37B SHALL HAVE MOBILE HEAD FEEDING TO CONVEYOR 38A/388 OR FUTURE 

CONWOR. BIDDER TO NOTE THAT HIS SCOPE COVERS COMPLETE ARRANGEMENT INCLUDING BELT,DRIVE 

UNIT,TAKE UP ARRANGEMENT OF MOBILE HEAD FOR FEEDING FUTURE CONVEYOR ALSO. 

13. CONVEYOR 37A/37B SHALL BE EITHER NYLON/NYLON OR STEEL CORD EELJING DEPENDING UPON 

AVAllABtLlTY OF SPACE WR TAKE UP TRAVEL 

I 

FOR TENDER PURPOSE ONLY I 

TYPICAL ARRANGEME'NT OF MOVABLE DISCHARGE PULLEY NTPC Lirrtifed 

( A GOVT. OF INDIA ENTERPRISE ) 


PROJ E VINDHYACHAL SUPER THERMAL POWER PROJECT 

I I 6 

1 

TlnE WAGON TIPPLER CONVEYING AND CRUSHING PLANT PACKAGE 

I h \ G.A.OF WAGON TIPPLER-1&2, CONV. 37Al37B 

RELEASD FOR TENDER - oP, $ykv;/&' 

AND JUNCYlON TOWER JT-I & JT-2 

c M E cdrr G- - - SIZE SCALE DRG.No. 

+ 

DESCRIPTION DRAWN 7 DESIGN CHKD. - 

APPD DATE ~1 1 :250 

CLEARED BY 

2240-1 55C-POMA-003 

1 CAD FILE NAME : 2240-155C-POM-A-003 dwg. 

I 

- 

REV. 

A

PUMP HOUSE-B 

SERVlCE WAKER CONNECTION FOR COW. 37A/37B, 3BA/38B, 

39A/39B, COM1.21 (EXTENDED PM~ON) AND JUNCRON TOWER'S 

JT- 1 ,JT-2 AND JT-3. R-4,CH TOlLEIS,WAGON TIPPLER 

COMPLEXES, MCC'S CONTROL ROOM ETG. 

SERVlCE WATER TAPPING CrVpJ 

FROM PUMP HOUSE-A 1. ALL NECESSARY PIPING, VALVES, FITTINGS AND ACCESSORIES FOR THE COMPLETE SERVICE WATER, 

TRACK HOPPER 

SERVICE WATER SYSTEM POTABLE WATER AND DUST SUPPRESSION SYSTEM BEYOND THE TERMINAL POINTS ARE INCLUDED IN THE 

PUMP HOUSE WATER l N LET OUTLET WATER 

SCOPE OF CHP BIDDER. 

RCC WAlERTAMK 

Y-STRAINER 

2. MAIN HEADER RUNNING SHAU BE ROUTED OVERGROUND ON RCC PEDESTALS (500mm MIN.) ABOVE 

GROUND. ALL RELATED CIVIL WORKS, STRUCTURAL SUPPORTS SHALL BE PROVIDED BY BIDDER. AT 

BULDOZER APPROACHLS THE DS HEADER SHALL BE BURRFED. 

3. THE CAPACITY AND HEAD OF PUMPS AND PIPE SIZING FOR COMPLETE DUST SUPPRESSION, SERVlCE 

WATER AND POTABLE WATER SYSTEM SHALL BE SUBJECT TO EMPLOYER'S APPROVAL DURING DETAIL 

ENGINEERING. 

4. CANOPY SHALL BE PROVIDED FOR OUTDOOR MOTORS. 

(1 WORKING + 1 STANDBY) 

COOLING WATER CIRCUIT 

5. BIDDER SHALL PR3VDE OVERFLOW & DRAlN CONNECTION WITH ISOLATION VALVE & THE SAME SHALL 

BE CONNECTED TO NEAREST DRAIN OF EMPLOYER fOR ALL WATER TANKS. 

6. TANK SHALL BE COMPLETELY ENCLOSED AND PROVlDED WITH MAN HOLE AND STAIR CASE. SlZE OF 

TYPICAL SOLENOID BOX ASSEMBLY 

(MINIMUM SlZE 32NB) 

PRESSURE SWITCH 

TANK AS INDICATED I5 MINIMUM. IN CASE BIGGER CAPACITY TANK IS REQUIRED AS PER SYSTEM 

REQUIREMENT, THE SAME SHALL BE PROVIDED BY BIDDER. ALL AREA AROUND TANK SHALL BE PAVED WITH 

CONCRETE & SHALL EAVE PROPER DRAINS. ALL DRAINS SHALL BE CONNECTED TO CHP DRAIN. 

7. INSTRUMENTATION REQUIRED FOR VARIOUS SYSTEMS IS NOT SHOWN FOR CLARITY AND ME SAME 

SHALL BE PROVIDED AS PER SPECIFICATION/SYSTEM REQUIREMENT. ALL INSTRUMENTS SHALL BE PROVIDED 

WlTH ISOLATING VALVES. 

8. WATER SYSTEM SCHEME AS SHOWN IS INDICATIVE ONLY. ADDITIONAL PRESSURE GUAGES, PRESSURE 

SWITCHES, FLOW SWITCHES, SOLENOID VALVES (FOR INTERLOCKING) UNDERBELT SWITCHES, 

VALVES/TANKS/PUMPS SHAU BE PROVIDED BY THE BIDDER AS PER SYSTEM REQUIREMENT. IN CASE, ANY 

(ZX 100% CAPACITY) ADDITIONAL WATER PUMP REQUIRED TO BE PROVIDED, BIDDER SHALL PROVIDE 2~100% WATER PUMPS (1 

(f WORKING + 1 STANDBY) WORKING t 1 STANDBY). IT SHOULD ALSO BE POSSIBLE TO ISOLATE €VERY BUILDING AND GALLERY IN 

THE PIPING NETWORK FOR DS/SW/DW SYSTEM. 

DE SYSTEM FOR CRUSHER HOUSE-CH.WT 

(I WORKING + 1 STANDBY) 

PUMPS FOR DE SYSTEM v v v 

DRY FOG DS SYSTEM 

( 2 1 ~ 00% CAPACITY) 

(1 WORKING + 1 STANDBY) 

HOUSE 

ALL TOILEKS 

(TO BE FED FROM 

RESPECTIVE PW 

O/H TANKS 

OF THE BUILDING) 

DISCHARGE 'A' STREAM 

RECEIPT 'A' STREAM 

DISCHARGE 'B' STREAM 

RECEIPT 'B' STREAM 

9. DUST SUPRESSION FOR CONVEYORS SHALL BE DESIGNED FOR DOUBLE STREAM OPERAllOM. 

TO. DUST SUPRESSION/SERVCE WATER/POTABLE WATER TAPPING SHALL BE PROVIDED AS PER TECH. 

11. REQUIRED NO. OF VENTS AT HIGHEST POINTS & DRAINS AT LOWEST POINTS SHALL BE PROVIDED FOR 

TANKS. 

12. ALL PUMPS SHALL BE PROWDED WlTH SUCTION & DISCHARGE PRESSURE GAUGES. 

13. FOR GENERAL NOTES REF. DRG. NO. 2240-1 55C-POM-A-008. 

14. THE DRG. SHALL BE READ IN CONJUNCTION WITH OTHER TENDER DRGS. 

15 EACH WATER TANF SHALL BE PROVIDED WlTH 3 NO. LEVEL SWITCHES ONE FOR LOW, ONE FOR HIGH 

& ONE FOR HIGH-Hi(Y CONDITIOMS. 

16. SPACING OF SERVICE WATER CONNECTlON SHALL BE AT 50M INTERVAL FOR CONV. TUNNEL & GAUERY 

AND MINIMUM ONE NO. TAPPING SHALL BE PROVIDED FOR EACH FLOOR OF TP'S AND 2 NOS. ON EACH 

FLOOR OF THE CRUSHER HOUSE BLDG. & ONE NO. TAPPING FOR ALL MCC ROOMS, TOILETS, CONTROL 

ROOM ETC. 

17. UNDERGROUND PROTECTlON FOR PlPE WORK SHALL BE PROVIDED AS PER SPECIFICAION WHERE EVER 

APPLICABLE. 

18. EACH SPRAY HEADER SHALL HAVE A PROVISION OF INSTALLING PRESSURE GAUGE. 

19. ALL SOLENOID VALVES SHALL BE PROVIDED IN A BOX WITH MIN. IP-55 PROTECTION AND MOUNTED ON 

THE NEAREST WALL. 

20. FLEXIBLE HOSE : 

i) 32NB SIZE HOSE SHALL BE PROVIDED TO CONFORM TO RELEVANT IS. EACH HOSE SHALL BE 

MINIMUM ii) HOSES 25M LONG. SHALL BE SUPPLIED IN HOSE REELS. ONE NO. HOSE REEL WITH HOSE SHALL BE PROVIDED 

IN EACH TP & WT AND MIN. 2 NOS. EACH IN CRUSHER HOUSE. 

21. DRINKING WATER SHALL BE PUMPED TO ME OVERHEAD TANK PROVIDED ON EACH BUILDING ONCE OR 

TWICE A DAY AS PER REQUIREMENT. OVERHEAD DRINKING WATER TANK SHALL BE OF WC AND MINIMUM 

2500 LTS. CAPACITY. THE TANK SHALL BE SUITABLY INSUtATED TO PREVENT HEATING OF WATER IN 

EXTREME SUMMERS. PROPER ARRANGEMENT FOR DRAIN & CLEANING SHALL BE PROVIDED FOR THE 

OVERHEAD (OH) TANK. 

- DETAIL-X 22. EACH DRINKING WATER TAP POINT SHALL HAVE AN ISOLATING VALVE BEFORE IT. 

TYPICAL ARRANGEMENT DRY FOG DUST SUPPRESSION 

- 23. ALL TOILET SHALL BE PROVIDED WITH 2500 LTR. WC OVERHEAO TANK FOR STORAGE OF SEWCE 

(AT ALL JTdC H) WATER. 

24. 30 MINUTES (1/2 HR.) STORAGE CAPACITY FOR EACH TANK SHALL BE PROVIDED. 

25. OWNER SHALL PROVIDE ONLY ONE TAP POINT OF WATER REQUIRED FOR DS,SW,CW AND ONE TAP 

POINT FOR POTABLE WATER NEAR PUMP HOUSE.BEYOND WHICH ALL PlPE ROUTING/N€fWORKING TO BE 

DONE BY BIDDER. 


POTABLE WATER SCHEME 

- NTPC Limited 

F - f-. , , 

, - - - - . . . - -, 

DESCRIPTION 

( A COVT. OF INDIA ENTERPRISE ) 

WAGON TIPPLER, CONVEYING AND CRUSHING PLANT PACKAGE 

SINGLE LINE DIAGRAM FOR DS, SW, CW AND POTABLE WATER SYSTEM 

-

NOTES : 

ALL DlUENSlONS ARE IN mrn AND LEVELS AKt IN METRES UNLESS NOTED OTHERWISE. 19. DUST & DEBRIS DISPOSAL CHUTE OF IMX1M SlZE 6MM THK. MILD STEEL PLATE SHALL BE PROVIDED FROM DRIVE FLOORS OF CONVEYORS UPTO 

GROUND FLOOR OF CRUSHER HOUSE AND ALL JUNCTION TOWER'S. ALL INTERMEDIATE FLOORS TO BE SUITABLY CONNECTED. I 

2. THE SCOPE OF WORK COVERED UNDER MIS CONTRACT INCLUDES EXCAVATION & FILLING/BACK FILLING WITH EITHER EXCAVATED MATERIALS 

OR SPECIALLY SELECTED MATERIALS AS DIRECTED BY THE EMPLOYER. THE EXCAVATED MATERIAL SHALL BE NEATLY STACKED AT PLACE 20. TYPICAL DETAILS FOR GTU TOWER AS SHOWN IN TENDER DRAWING IS APPLICABLE FOR ALL CONVEYORS. INTERMEDIATE ACCESS PLATFORMS AT 

INTERVAL SHALL BE PROVIDED FOR GTU PULLEY ACCESS. SUITABLE ACCESS LADDERS SHALL ALSO BE PROVIDED FROM GROUND TO ALL 

DIRECTED BY WE EMPLOYER, SOME OF THESE EXCAVATED MATERIALS MAX BE REQUIRED TO BE BROUGHT BACK FOR BACKFILLING/FILLING 

PLATFORMS. 

PURPOSE AS DIRECTED BY THE EMPLOYER. THE SCOPE OF THIS CONTRACT ALSO INCLUDES THE FINAL DISPOSAL OF REMAINING EXCAVATED 

AND STACKED MATERIALS A4 i ICE UPTO 5 KMS BEYOND POWER PLANT BOUNDARY AS DIRECTED BY THE ENGINEER. 21. ACCESS PIATFORMS AND LADDER/STAIRS (NOT SHOWN IN TENDER DRG) AS REQUIRED FOR ACCESS/SERVICING CHUTES, EQUIPMENT ETC. SHALL 

BE PROVIDED BY THE CONTRACTOR. 

3. WELDED WIRE FABRlC OF MPNIIJIIU 1 6MM THICK WIRE (CONFORMING TO IS-4948) & HAVING t2mm X 30 rnm MESH SIZE SHALL BE FIXED 

TO FRAMES FOR WINDOWS TO 3VIDED IN BOTH SIDES OF CONVEYOR GALLERY AS SPECIFIED. 22. ALL CHUTES SHALL BE PROVIDED WITH ADEQUATE DUST PROOF HINGED INSPECTlON DOORS AT ALL FLOORS OF BUlLDlNGS FOR ROUINE 

INSPECTION. INSPECTION DOORS SHALL ALSO BE PROVIDED AT SKIRT BOARD. 

4. WHEREVER COLOUR WASHING uvt~ rLASTERED SURFACE IS SPECIFIED, THE NUMBER OF COATS TO BE APPLIED SHALL BE MINIMUM THREE OR 

MORE. 

23. TRESTLE LOCATION AND TYPE SHALL BE AS PER TECH. SPECIFICATION. 

5. MINIMUM 20MM DIAMETER M.S. RUNGS SHALL BE PROVlDED 1N LADDERS. FOR HEIGHT OF 1 OM & ABOVE, CAGE LADDERS SMALL BE 

PROVDED. LADDERS SHALL BE MINIMUM 450rnrn WIDE. 

24. SEPARATE PERSONNEL ENTRY AND EQUIPMENT HANDLING ACCESS POINTS SHALL BE PROVIDED ON GROUND FLOOR OF ALL TPs. 

25. THIS DRG. !S TO BE READ IN CONJUNCTION WlTH OTHER TENDER DRGS. 

6. ALL DIMENSIONS & RELATIVE ELEVATIONS OF VARIOUS JUNCTION TOWER'S STRUCTURES AND OTHER BUILDINGS AS SHOWN IN VARIOUS TENDER 

DRGS. ARE MINIMUM ACCEPTABLE TO THE EMPLOYER, CONTRACTOR SHALL SELECT SIZES OF VARIOUS JUNCTION TOWER'S STRUCTURES AND 

26. ACCESS PLATFORMS WITH LADDERS ABOVE RCC FLOOR SHALL BE PROVIDED WHEREVER BOllOM OF EQUOPMENT/P~LLN/DRIVE ETC. EXCEEDS 

1.2M. CARE SHALL BE TAKEN TO PROVIDE PROPER ACCESS TO ALL CHUTES, HOISTS (AT PARKING PLACE), CONWOR DRIVES, PULLEYS ETC. 

OTHER BUILDINGS TO SUIT EQUIPMENT sELECTED/HANDLING REQUIREMENT BY HIM AND THE SAME 1N ANY CASE SHALL NOT BE LESS THAN 

SIZES INDICATED IN VARIOUS TENDER DRGS. NO COMMERCIAL IMPLICATIONS SHALL BE ENTERTAINED FOR INCREASE IN BUILDING SIZES DURING 27. IN ADDITION TO CLEARANCES SHOWN IN INDIVIDUAL DRG. TRESTLES SHALL HAVE TO CLEAR ALL FACILITIES SHOWN IN GENERAL CAYOUT. 

DETAILED ENGG. ON ACCOUNT OF EOUIPMENT SELECTED BY CONTRACTOR. 

28. THE NO. & MONORAll HOISTING SYSTEMS SHALL ALSO BE DECIDED CONSIDERING THE MOVEMENT OF THE EQUIPMENT BEING LIFTED OVER/BOTH 

7. PLINTH LML OF ALL BUILDINGS 8 STRUCTURES SHALL BE 500rnm ABOVE THE ADJACENT GROUND LEVEL. 

UC., PROPOSED IN THE TENDER DRAWINGS ARE WITH RESPECT TO THIS PLINTH LEVEL. 

ALL FLOOR LML, ROOF LEVELS SIDES OF OTHER EQUIPMENTS WITHOUT REMOVING THE IATER. 

CONSIDERING THE ABOVE REQUIREMENT. 

THE NECESSARY LEVELS OF FLOOR IN VARIOUS BUILDINGS SHALL BE DECIDED 

8. ADEQUATE NO. OF MONO RAI 

INCLUSIVE OF GTU/TAIL PULLUS, 

L BE PROVIDED WITH ELECTRIC HOISTS TO FACILITATE MAINTENANCE OF ALL COAL HANDLING EQUIPMENTS 

FG nc. THE LOCATION AND NO. OF MONO RAILS WITH ELECTRIC HOISTS ARE NOT SHOWN IN DRGS. FOR 

CLARITY, HOWEVER, THESE SHALL BE FINALESED DURING DEAIIED ENGG. AND THE SAME IS SUBJECT TO EMPLOYER'S APPROVAL. MONORAIL 

WlTH CHAIN PULLEY BLOCKS AS REQUIRED SHALL ALSO BE PROVIDED. SlZES OF MONORAILS AND CAPACIM OF CHAIN PULEY BLOCK SHALL 

29. ALL JUNCTION TOWER SHALL BE PROVIDED WITH EXTERNAL STAIRCASES. PROPER ROOF HOOD TO BE PROVIDED FOR PROTECTION FROM SUN/RAIN. 

FOR UNDER GROUND JUNCTION TOWER'S ONE NUMBER INTERNAL STAIRCASE TO BE PROVIDED. I 

30. ALL BEND PULLEYS, TAIL PULLEYS, FIXED TRIPPER PULLEYS ETC. SHALL BE PROVIDED WlTH SUITABLE PROTECTION GUARD. 

BE FlNALlSED DURING DnAILED ENGG. AND THE SAME IS SUBJECT TO EMPLOYER'S APPROVAL. 31. MINIMUM 100MM HIGH CURB SHALL BE PROVIDED AROUND ALL FLOOR OPENINGS IN NERY CHP BUILDING. 

9. THE WIDm OF GALLERIES & TUNNELS INDICATED IN THE DRGS. IS MINIMUM REQUIRED. BIDDER MAY INCREASE THE WIDTH BASED ON HIS 32. BOl7OM OF BASE PIATE LEVEL FOR ALL TRANSFER POINTS AND CRUSHER HOUSE SHALL BE SUCH THAT STIFFENER PLATES REMAIN BELOW THE 

EQPT. SIZE KEEPING CLEAR V VALKWAY DIMENSIONS AS SPECIFIED WITHOUT ANY COST IMPLICATION TO NTPC. FFL AT GROUND. FURTHER, ALL COLUMNS SHALL BE ENCASED BY RCC WITH WIRE MESH FROM PEDESTAL LEVEL TO 500 MM ABOVE FFL. THICKNESS 

OF RCC ENCASEMENT SHALL BE LIMITED TO 75 MM FOR PORTION ABOVE FFL. 

10. 

-- - 

TECHNICAL SPECIFfCATION REQUIREMENTS SHOWN IN TEMD€R DRGS. ARE NOT EXHAUSTIVE. 

11. 

12. 

13. 

14. 

ALL CONVMORS SHALL BE PROVDED WITH ALL ACCESSOREIS SUCH AS PULL CHORDS, BELT SWAY & ZERO SPEED SWITCHES, BELT SCRAPPER 

UNITS ETC. AS PER TECH SPECS. THESE ARE NOT SHOWN IN TENDER DRAWINGS FOR CLARITY. 

FOR CLARllY VARIOUS DUAfLS SHOWN IN ONE VIEW HAVE NOT BEEN DUPLICATED IN ALL WE WEWS. 

FLOOR DRAIN, DOWN COMERS AND CONNECTION UPTO COAL SLURRY SETTLING TANK, EXTERNAL VERTICAL SHAF? ETC. FOR VARIOUS BUILDINGS 

HAVE NOT BEEN SHOWN IN THE TENDER DRAWlNGS FOR CLARITY. THESE SHALL BE PROVIDED BY THE CONTRACTOR AS SPECIFIED IN THE 

SPECIFtCATION. 

FENCING WITH LOCAKABLE GAFS SHALL BE PROVIDED AROUND ALL GTU TOWERS GRAVITY TAKEUP WEIGHT. FURTHER SAND BED OF 600 mrn 

DEPTH SHALL BE PROVIDED AT GROUND LEVEL TO TAKE THE IMPACT OF FALLlNG TAKE UP WEIGHT IN CASE OF BELT SNAPPING. AREA IN 

STONE PICKING ZONE SMALL ALSO BE BARRlCATED WlTH SUITABLE APPROACH & ACCESS. 

15. ALL SEWER LINES COMING OUT FROM RESPECTIVE BUILDINGS SHALL BE CONNECTED TO THE EMPLOYER'S SEWER LINE. IN CASE THE 

EMPLOYER'S SEWER LINE IS MORE THAN 25M AWAY FROM THE OUTER EDGE OF THE BUILDING, THE SAME SHALL BE TERMINATED THERE 

WITHIN INSPECTION CHAMPER OF SUFFICIENT SIZE AT ME TERMllNATlON POINT. 

16. 

17. 

TRAMP IRON CHUTE OF MIN. lMX1M SIZE, 6mrn WICK MS OR AS SPECIFIED IN THE TECH. SPECIFICATIONS, SHALL BE PROVIDED TO RECEIVE 

TRAMP METAL FROM ILMS AND DROP IT UPTO GROUND LEVEL. ONE NO. TROLLEY OF ADEQUATE CAPACITY SHALL BE PROVIDED IN THAT 

BUILDING. THE RAMP IRON CHUTE ANGLE SHALL BE 5CT MIN. FROM HORIZONTAL AND SHALL BE ROUTED INSIDE BUILDING UPTO GROUND. 

SUITABLE POKE DOORS SHALL BE PROVIDED 1N THE TRAMP CHUTE AT EACH FLOOR FOR AllENDING TO ENTRAPPED TRAMP WIRES, PIECE ETC. 

FOR MONORAIL PROJECTING OUT OF BUILDING STEEL FRAME DOORS, PREFERABLY SLIDING TYPE OR OTHERWISE OPENABLE INSIDE SHALL BE 

PROVIDED. OPENABLE DOORS SHALL PREFERABLY BE COMPARTMENTALISED. MONORAIL COMING OUT OF BUILDING SHALL BE PROJECTED BY 

CLEAR MIN. 3.OM OUTSIDE THE SHEnING. 

./ - &fiy;l" 

A RELEASED FOR TENDER 

L 

I 

1. 

REV. DESCRfl DRAWN DESIGN CHKD. 

C M E 

CLEARED BY 

C&l 

PROJECT 


NTPC LIMITED 

( A GOVI. OF INDIA ENTERPRISE ) 


VINDHYCHAL SUPER THERMAL POWER PROJECT 

- TltLE 

WAGON TIPPLER CONVEYING AND CRUSHING PLANT PACUAGE 

GENERPIL NOTES 

SIZE SCALE DRG.NO. 

2240-1 55C-POM-A-008 

APPD DATE A2 A 

cad file name : 2240-155C-POM-A-008.dwg 

REV.

C 

I 

OPERATING & PROGRAMMING OPERATING & PROGRAMMING 

I-- 

NOTES 

/ \ 

KBD 

- 

--- 

1 PLC PROCESSORS-1&2 SHALL BE IN HARDWARE AS WELL AS 

SOFTWARE BASED REDUNDANCY CONFIGURATION 

INGEPENDENT DUAL I/O COMMUNICATION LINK 

1/0 RACK # 

PRINTER (2 NOS ) 

1/0 MODULES 

INTERFACE WITH 

WAGON TIPPLER PLC 

2 NUMBERS AND LOCATIONS OF REMOTE I/Q RACKS SHALL 8E 

DECIDED DYRING DETAILED ENGINEERING 1 FOR TENDER PURPOSE ONLY 1 

Vindhjachal Super Thermal Power Rojecl 

SPACE-UI (21500MW) 

TIPPLER , CONVEYING k CRUSHING PLANT 

TYPICAL PW CONFIGURATION-WN CBP CONTROL

-. --- --- - -- - - -- - 

NOTES 

l 

FOR WAGON TIPPLER -1 CONTROL FOR WAGON TIPPLER -2 CONTROL 

OPERATING & PROGRAMMING OPERATING S( PROGRAMMING OPERATING & PROGRAMMING OPERATING & PROGRAMMING A4 SIZE 

PC BASED WORK STATION#? PC BASED WORK STATION#2 PC BASED WORK STATION#^ PC BASED WORK STATION#^ 

PRINTER (2 NOS) 

PRINTER (2 NOS 

- . - - - - . 

INDEPENDENT D AL. DATA 

. . -. . - .- - - - .- . - - - - - 

1 PLC PROCESSORS-1&2 SHALL BE IN HARDWARE A5 WELL AS 

SOFiWARE BASED REDUNDANCY CONFIGURATION 

PLC PROCESSOR-2 

* 

COMMUNICATION 1 INK 

. - - -. -. - - . - - - -. -. LC ---- 

-- 

- 

'J - ~ 

FLAT 20- 

TFT MONITOR TFI MONrrOR 

-- 


-6-r 

~ ~ ~ P o m R o ~ 

n~cs-m (~500~1) 

5 nxr arrcm 10. 

~~py-nmmourr 

mmrm NA OP4O-186C-POI-*-OD2 

SH. O OF P 

SLDID" 

1 . 

- 

VINDHYA-CHP=PLCZ.DWG

P 

'ON 'NU ON .380 1 

I 

CC WALL 

0 

0 

BOlTOM WATER ' 

PROOFlNG AS PER 

SPECIFICATION b 

- 

WATER PROOFING 

TREATMENT ASISPEC. 

UCC ROOF SLAB 

.. - CONSOLEDATE SAND FILL '. - 

. . p. . . 

. ". 

. ... . . . . . . . . . 

. . 

. . . . I . 

100 THK R.C.C. (M-20) r-- 

TUNNEL TYPICAL DETAIL OF FLOORING 

(WAGON TIPPLER) 

CROSS SECTION OF TUNNEL FOR 

CONV. 37AJB. 38A/B 

RiElNFT.BAR7 , 

25 GAP 

5 A & 

I 

POLYSULPHIDE 

SEALING COMPOUND 

TYPICAL EXPANSION 

JOINT DETAIL 

BITUMEN IMPREGNATED 

BOARD 

600 WIDE COPPER 

STRIP 

. . 

.... 

1 FOR TENDER PURPOSE ONLY I 

- P 7, 

wg@# KifQt

'ON .3EiO 1 

r FIXED POLYCORBONATE SHEET

'ON 'Ntl 

H 

EL(+) VARIES -J 

(ROOF) 

FLOOK FINISH - 

FLOOR FINISH \V/ 

FLOOR FTNISH - 

CONVEYOR u rt~rNG 

F IXtU POLYCORBONATE SHQT 

AS/SPECS (UP) 

iCki ELEVATION OF TP 

SHEETING RAt 9002 

AS/SPECS (NP) 

I 

STAIRCASE 

FIXED POLYCORBONATE SHHET 

AS/SPECS (NP) 

SHEETING RAL 501 2 

AS/SPECS (TYP) 

SHEETING RAL 9002 

AS/SPECS (VP) 

STEEL LOUVERED WINDOW AS/SPECS.(lYP) 

( MIN. WINDOW AREA 10% OF 

FLOOR AREA AS/SPECS.(NP) 

TYPICAL PLAN OF TP 

TYPICAL ARCHITECTURAL DETAILS AS SHOWN IN THE 

DRAWING ARE INDICATIVE ONLY AND FOR TENDER 

PURPOSE ONLY. 

9 THE ELEVATION HEIGHT, NUMBER OF BAYS, NUMBER 

OF FLOORS, SlZE OF BUILDING, NO. OF STAIRCASES, 

NO. OF ROLLING SHUTTERS, OPENING FOR CONVEYORS, 

ETC. IS SHOWN IN THE DRAWING ARE INDICATIVE ONLY 

AND FOR TENDER PURPOSE ONLY. 

THE WORKS SHALL BE CARRIED OUT AS PER THE 

RELEASED FOR CONSTRUCTION DRAWINGS DURING 

DETAIL ENGINEERING STAGE. 

SMC RUNNERS 

ROOF TREATMENT 

TYPICAL DETAIL OF GUTTER 

1. ALL DIMENSIONS ARE IN MM AND LEVELS ARE IN METRES. 

2. TYPICAL 750 MM WIDE PLINTH PROTECTION SHALL BE PROVIDED 

ALLROUND THE BUILDING AS PER TECHNICAL SPECIFICATIONS. 

3. ALL PANTING, FLOORING AND ALLIED WORKS, INTERNAL AND 

EXTERNAL FIN1SHES ETC. SHALL BE AS PER TECHNICAL SPECIFICATIONS. 

4. THIS DRAWING SHALL BE READ IN CONJUNCTION WITH SCHEDULE OF 

ITEMS AND TECHNICAL SPECIFICATIONS. 

5. THIS DRAWING IS FOR TENDER PURPOSE ONLY. 

I FOR TENDER PURPOSE ONLY I 

J 


( A GOVERNMENT OF INDIA ENTLRPRISE ) 


PROJECT VINDHYACHAL SUPER THERMAL POWER PROJECT 

STAGE - I11 (2 X 500 MW) 

TITLE WAGON TIPJLER, CONVEYING & CRUSHING PLANT PACKAGE 

0,: ,-, L - TYPICAL DETAIL OF TP'S 

A RELEASED FOR TENDER PURPOSE ONLY r 3$ 1 *b$f+' -- 

tW3l - .04.0s TYPICAL ARCHITECTURAL DETAILS 

REY.NO 

D E S C R I P T I O N 

DRAWN DESIGN CHKD. 

M E C 

CLEARED BY 

C&l ARCH 

APPD DATE SIZE 

A 1 

SCALE 

NTS 

DRG NO 

2240- 155C-POC-A-002 

(SHEET - 2 OF 4) 

REV NO. 

A 

CAD FILE NAME 

IPE

12 

-"_ 

- 

- 

n # 

NTPC Limifed 

( A GOVERNMENT OF INDIA ENTtRP'RISE ) 


PROJECT VINDHYACHAL SUPER THERMAL POWER PROJECT 

STAGE - I11 (2 X 500 MPT) 

TITLE WAGON TIPPLER. CONVEYING & CRUSHING PLANT PACKAGE 

01.04.09 MCC ROOM 

A RELEASED FOR TENDER PURPOSE ONLY vt TYPICAL ARCHITECTURAL DETAILS 

RN.NO 


6 5 4 

A __I ---- - . * . 

- -- --. - -- - --A 

DRAWN DESIGN CHKD. APPD DATE SIZE SCALE DRG. NO. RN. NO. 

M E c C&I ARCH ~1 N TS 2240- 155C-POC-A-002 

CLEARED BY [SHEET - 3 OF 4) 

- 

3 2 1 

CAD FILE NAME . 

-- 

A

A 

'2 Y 

TYPICALFLOOR PLAN OF PUMP HOUSE 

TYPICAL FRONT ELEVATION 

A 

REV NO 

Q Q 

TYPICAL SIDE ELEVATION 

RELEASED FOR TENDER PURPOSE ONLY 


1 

M 

CLEARED BY 

HALF ROUND C.I. GRATING *\ I 

TERRACING AS/SPEC 

R.W. KMURRA 

(450x450) 

150 0 R.W.P. 

DOWN COMER -i 

. .. 

TYPICAL GUTTER DETAIL 

1. ALL DIMENSIONS ARE IN MM AND LEVELS ARE IN METRES. 

2. TYPICAL 750 MM WIDE PLINTH PROTECTION SMALL BE PROVIDED 

ALLROUND THE BUILDING AS PER TECHNICAL SPECIFICATIONS. 

3. ALL PAINTING, FLOORING AND ALLIED WORKS, INTERNAL AND 

EXTERNAL FINISHES ETC. SHALL BE AS PER TECHNICAL SPECIF1;CATIONS. 

4. THlS DRAWING SHALL BE READ IN CONJUNCTION WITH SCHEDULE OF 

ITEMS AND TECHNICAL SPECIFICATIONS. 

5. THlS DRAWING IS FOR TENDER PURPOSE ONLY. 

TYPICAL ARCHITECTURAL DETAILS AS SHOWN IN THE 


PURPOSE ONLY. 

* THE ELEVATION HEIGHT, NUMBER OF BAYS, NUMBER 

OF FLOORS, SIZE OF BUILDING ETC. IS SHOWN IN THE 


PURPOSE ONLY. 

THE WORKS SHALL BE CARRIED OUT AS PER THE 

RELEASED FOR CONSTRUCTION DRAWINGS DURING 

DETAIL ENGINEERING STAGE. 

1 FOR TENDER PURPOSE ONLY I 

I 

3 2 

11 10 li 

- ,- F. .. . ,- --. 

-. 

-. -, - 

DRAWN DESIGN CHKD 

E 

C 

C&I 

ARCH 

APPD 

91 04 09 

DATE 

S1ZE 

A 1 


( A GOVERNMENT ENGINEERING OF INDIA DIVISION ENTtRPRtSE ) 


STAGE - 111 (2 X 500 MX) 

WAGON TIPPLER-CONVEYING & CRUSHING PLANT PACKAGE 

DETAIL OF PUMP HOUSE 

TYPICAL ARCHITECTURAL DETAILS 

SCALE 

NTS 

DRG NO 

2240-155C-POC-A-802 

(SHEET - 4 OF 4) 

CAD FILE NAME . 

1 

REV NO. 

A

NTPC Limited - BHEL - Industrial Systems Group

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?