NATIONAL ALUMINIUM COMPANY LIMITED - Rites

NATIONAL ALUMINIUM COMPANY LIMITED 

BID DOCUMENT No No. :OT/05/2012-13/WT/RITES-BBSR/NALCO 

TENDER DOCUMENT FORDESIGN, MANUFACTURE, SUPPLY, ERECTION, 

TESTING AND COMMISSIONING OF WAGON TIPPLER AND CONVEYOR 

SYSTEM FOR M/S. NALCO AT ANGUL. 

CONTENTS 

1. GENERAL 

2. INTENT OF SPECIFICATIONS 

3. SPECIAL STIPULATIONS TO BIDDERS 

4. SYSTEM PARAMETERS, OPERATION AND CONTROL PHILOSOPHY 

5. GENERAL TECHNICAL REQUIREMENTS 

6. ELECTRICAL 

7. CIVIL 

8. CONDITION OF CONTRACT FOR FIELD SERVICES 

9. MISCELLANEOUS 

(A GOVERNMENT OF INDIAENTERPRISE) 

PROJECT OFFICE 

BHAGWANTOWER, 1 ST FLOOR 

CUTTACK ROAD, 

BHUBANESWAR – 751006 

Annexure – I-Technical Specification 

BBSR/NALCO-ANGUL 

1

INDEX 

SECTION DESCRIPTION PAGE NO 

1 GENERAL 1-5 

2 INTENT OF SPECIFICATIONS 1-17 

3 SPECIAL STIPULATIONS TO BIDDERS 1-11 

4 SYSTEM PARAMETERS, OPERATION AND 

CONTROL PHILOSOPHY 

1-64 

5 GENERAL TECHNICAL REQUIREMENTS 1-27 

6 ELECTRICAL 1-97 

7 CIVIL 1-21 

8 CONDITIONS OF CONTRACT FOR FIELD SERVICES 1-23 

9 MISCELLANEOUS 1-55 

2

1.0 GENERAL 

M/S. National Aluminium Company Ltd. (NALCO), Angul have undergone 2 

expansion of their Captive Power Plant (CPP).The 9th & 10th units are added in 2nd phase 

expansion of the Existing Captive Power Plant (CPP) by increasing the station capacity to 

1200MW. Facility for Storage and Handling of about 90,000 t additional 

been envisaged to be added in 2nd phase expansion of Captive Power Plant. The new 

uncrushed coal storage yard shall be equipped with stacker and reclaimer machines and 

shall have uncrushed coal supply connectivity to old and new coal bu 

nd phase 

expansion of their Captive Power Plant (CPP).The 9th & 10th units are added in 2nd phase 

expansion of the Existing Captive Power Plant (CPP) by increasing the station capacity to 

1200MW. Facility for Storage and Handling of about 90,000 t additional uncrushed Coal has 

been envisaged to be added in 2nd phase expansion of Captive Power Plant. The new 

uncrushed coal storage yard shall be equipped with stacker and reclaimer machines and 

shall have uncrushed coal supply connectivity to old and new coal bunkers through 

respective Crusherhouse. house. 

2.0 Basic Data 

Material to be handled - Uncrushed coal (Grade E / F / G) 

Feed size 

- (-) 300 mm 

Specific gravity of coal - 0.8 t/m3 for volume calculation 

1.1 t/m3 for strength calculation 

Moisture (%) 

- 6% to 10% 

No of working days / yr - 330 

No of working shift / day - 3 shift of 8 hrs per day 

3.0 DESCRIPTION OF EXISTING SYSTEM 

The salient features of existing coal handling facilities consist of following: 

3.1 ROM Coal of (-) 300mm mm size is brought from coalfields in Bottom Discharge Captive Railway 

Wagons. 

3.2 Coal from coalfield is received through a Merry Go Go-round round (MGR) system between the CHP 

and coalfield. 

3.3 There are two (2) nos. of existing Track Hopper Buildings with undergrou underground RCC hopper. 

3.4 Each TrackHopperBuilding has four (4) nos. of paddle feeders of travelling type at its bottom 

to scoop coal from the track hopper. Two paddle feeders are mounted on individual 

conveyor. 

3.5 There are two (2) underground conveyors at bottom of each track hopper. Both conveyors 

are running parallel at the bottom of the track hopper hopper–1. 1. The parallel conveyor installed at 

the bottom of track hopper hopper–2 run in opposite direction. 

3.6 There are two (2) Bunker Bays. The old BunkerBay meets the crushed coal requirement for 

Unit 1 – 6 whereas the new BunkerBay meets the crushed coal requirement for unit 7 to 10. 

Thus, there are two separate conveyor paths. Each path has two conveyor streams running 

in parallel. 

Technical Specification:Sec-1 General 

SECTION 1 

Page 1 of 5

3.7 Rated & designed capacity of each conveyor stream is 800 TPH & 960 TPH respectively. 

3.8 Two parallel conveyors with moving tripper are installed on the top of each BunkerBay. One 

moving tripper is provided on each conveyor installed on the top of Bun BunkerBay. Moving 

trippers feed the crushed coal in desired bunkers as per requirement. 

3.9 The CHP has two (2) Crusher Houses. The old Crusherhouse house is provided on conveyor path 

that is feeding crushed coal to Units 11- 

6. The new Crusherhouse house is provided on con conveyor 

path that is conveying crushed coal to Unit 7 to 10. 

3.10 Each Crusher house has two (2) Crusher& & associated equipment installed on parallel 

conveyor series. Thus, each Crusherseries series has been provided with dedicated Crusher and 

associated equipment. 

3.11 There are three uncrushed coal storage yards with stacker cum reclaimer machine (SCR) in 

present CHP. One SCR machine is provided on each storage yard. 

3.12 Storage yard 1 & 2 receive uncrushed coal from track hopper 1 & 2. Storage yard 3 receives 

uncrushed coal oal from track hopper 2 only. 

3.13 Scooped uncrushed coal from track hopper 1 is conveyed to old Crusher house and then to 

coal bunker bay of Units 11-6 

6 through conveyor path that is conveying crushed coal to coal 

bunkers Bay of Units 1-6. 6. 

Uncrushed coal l is conveyed to storage yard 1 & 2. Preparation of coal Stock Pile is carried 

out by installed Stacker-cum-Reclaimer 

Reclaimer (SCR) machine. Uncrushed coal is reclaimed by SCR 

machine and conveyed to either of boiler bunkers through dedicated conveyor paths which 

is operating for these two boiler bunker bays. 

It is conveyed to boiler bunker Bay of Units 7 to 10 through new Crusher Crusherhouse by conveyor 

path that is feeding crushed coal in boiler bunkers of Unit 7 & 8. SCR machine is positioned 

in by-pass mode while e conveying coal from track hopper 1. 

3.14 Scooped coal from track hopper 2 is conveyed to Crusher house and then to coal bunker bay 

of Units 7 to 10 through conveyor path that is conveying crushed coal to coal bunkers Bay of 

Units 7 to 10. 

OR, 

It is conveyed to boiler bunker Bay of Units 11- 

6 through conveyor path linked with track 

hopper 1. OR, It is conveyed to storage yard 3. Preparation of stockpile is made with the help 

of SCR machine. Coal from the Stock Pile is reclaimed by SCR machine and is fed on to yard 

conveyor. The yard conveyor discharges the coal on to the conveyor path linked with boiler 

bunker bay of Units 7 to 10. 


OR, 

OR, 

Page 2 of 5

It is conveyed to the storage Yard 1&2 through the conveyor paths linked with track hopper 

1. 

4.0 Additions to existing system currently under development: 

Presently an additional coal storage and handling system is being implemented 

under a separate contract to augment the coal handling system. The salient features 

of the new scheme are: 

4.1 The terminal points for Addition Additional al Coal Storage & Handling System of CHP in 2nd Phase 

Expansion commences from and consist of: 

4.2 Modification and shifting of discharge end of existing belt conveyor BC BC-115 in Junction 

House JH-7 7 with a provision of two way chute and flap gate to feed uncr uncrushed coal received 

from Track Hopper No. 2 to either the existing conveyor BC BC-116 116 or to new conveyor BC BC-118A 

under implementation. 

4.3 Modification of existing Junction House JH JH-7 7 to accommodate tail end of new conveyor BC- 

118A for receiving & conveying unc uncrushed rushed coal to the proposed Additional Coal Storage 

Yard. 

4.4 Provision of new Junction House JH JH-7A 7A adjacent to existing Junction House JH JH-7 to 

accommodate discharge / head end of new belt conveyor BC BC-122 122 from the proposed 

Additional Coal Storage Yard and ex extended tail end of conveyor BC-116 116 to receive uncrushed 

coal from new conveyor BC BC-122. 

4.5 Extension of tail end of existing conveyor BC BC-116 116 from existing Junction House JH JH-7 to new 

Junction House JH-7A 7A to receive reclaimed uncrushed coal from the Additional Coal Storage 

Yard through a new conveyor BC BC-122. 122. Uncrushed coal received on conveyor BC BC-116 will be 

conveyed to the new Crusher house through existing belt conveyor system for supplying the 

crushed coal to bunkers of unit 77-10. 

4.6 Extension of tail end of eexisting 

conveyor BC - 104 from existing Junction House JH JH-2 to new 

Junction House JH-13 13 to receive reclaimed uncrushed coal from the Additional Coal Storage 

Yard through a new conveyor BC BC-120 and BC-121.Uncrushed 121.Uncrushed coal received on the extended 

conveyor BC-104 04 shall be Conveyed to the old Crusherhouse house through the existing belt 

conveyor system for supplying crushed coal to the bunkers of unit # 11-6. 

6. 

4.7 For Receipt of uncrushed coal for the proposed Additional Coal Storage and Handling 

System, uncrushed coal con conveyed to JH-7 by existing conveyor BC-115 115 from Track Hopper 

No.2 can be diverted either to existing conveyor BC BC-116 116 or to new conveyor BC BC-118A at 

Junction House JH-7. 7. The new conveyor BC BC-118A 118A will convey material to the proposed 

Additional Coal Storage Yar Yard d through a new conveyor system under development. For this, 

the existing Junction House JH JH-7, 7, shall be modified to accommodate the tail end of new 

conveyor BC-118A. 118A. The discharge chute of the existing conveyor BC BC-115 115 shall be replaced 


OR, 

Page 3 of 5

with new chute arrangement gement having a two way chute with a flap gate. Two Two-way chute with 

flap gate will divert the material discharged from conveyor BC - 115 either to existing 

conveyor BC-116 116 or to the new conveyor BC BC-118A 118A depending on position of the gate. 

The discharge pulley of existing conveyor BC BC-115 115 will be relocated suitably to ensure the 

flow of uncrushed coal, either to conveyor BC BC-116 116 or to the new conveyor BC BC-118A is 

smooth through the new flap gate and chute arrangement. The rated capacity of conv conveying 

system is 800 t/hr. 

4.8 For storage of uncrushed coal in the Additional Coal Storage Yard under development, the 

coal received through conveyor BC BC-118A 118A will be conveyed to the Yard through conveyors BC BC- 

119 & BC-120 120 and new Junction Houses JH JH-10 & JH-11. 1. The conveyor BC BC-120 will be 

equipped with a Slew Stacker Machine. The Slew Stacker Machine will be capable of forming 

two identical stock piles of uncrushed coal on either side of its track. The length of each 

stock pile will be 275 m. The storage capac capacity ity of each Stock Pile will be 45,000 t of uncrushed 

coal. The rated capacity of stacking system is 800 t/hr 

4.9 For Reclaiming the uncrushed coal from Additional Coal Storage Yard, a Bucket Wheel 

Reclaimer will be provided. The Bucket Wheel Reclaimer will be installed on conveyor BC - 

120 such that its discharge is collected on the yard conveyor BC BC-120. 120. The BWR will be 

operating on the same track as that of the Slew Stacker Machine. Simultaneous operation of 

stacking and reclaiming is also proposed on the yard conveyor BC-120. 120. Uncrushed coal 

reclaimed on conveyor BC BC-120 120 will be conveyed to new Junction House JH JH-12. The rated 

capacity of the reclaiming system shall be 800 t/hr. 

4.10 Conveyor BC-120 120 will convey reclaimed material to new Junction House JH JH-12. Head/ 

discharge scharge end of conveyor BC BC-120 120 will be provided with two way chute with flap gate 

arrangement. Depending on position of flap gate in the discharge chute, uncrushed coal 

reclaimed from the Additional Coal Storage Yard will be diverted either to conveyor BC BC-121 

or to conveyor BC-122 122 at new Junction House JH JH-12. Conveyor BC-121 121 will transport the 

material to new JH-13 13 and transfer material to the tail end of existing and extended 

conveyor BC-104, 104, Conveyor BC BC-122 122 will convey the material to new Junction House JJH-7A 

and transfer the material to tail end of existing and extended conveyor BC BC-116. The rated 

capacity of conveying system is 800 t/hr. 

4.11 Conveying of uncrushed coal to new Crusherhouse. . Uncrushed coal received on conveyor 

BC-122 122 will be conveyed to new Junction House JH JH-7A, 7A, located adjacent to existing JH JH-7. At 

Junction House JH-7A, 7A, conveyor BC BC-122 122 shall discharge the uncrushed coal at the extended 

tail end of existing conveyor BC BC-116. Uncrushed coal received on conveyor BC BC-116 will be 

conveyed to the new Crusher Crusherhouse house through the existing coal flow path. The rated capacity 

of conveying system is 800 t/hr. 

4.12 For Conveying the uncrushed coal to the old Crusher house, uncrushed coal received on 

conveyor BC-121 121 shall be conveyed to new Junction House JH JH-13. 13. At this new Junction 

House JH-13, 13, conveyor BC BC-121 121 will discharge the material to the extended tail end of the 


Page 4 of 5

existing conveyor BC-104. 104. Coal received on conveyor BC BC-104 104 will be conveyed to the old 

Crusherhouse house through existing coal flow path. 

The tail end of existing conveyor BC BC-104 at JH-2 2 will be extended up to the new Junction 

House JH-13 13 and a new conveyor gallery between existing Junction House JH JH-2 and the new 

Junction House JH-13 13 wi will ll be provided to house the extended length of existing conveyor BC BC- 

104. The system rated capacity is 800 t/hr. 

4.13 Dust Suppression System will be provided at all transfer points at various Junction Houses 

and uncrushed coal storage yard. 

4.14 Suitable ventilation on and air conditioning facilities will be provided in Switch gear cum MCC 

room, Battery room, Transformer rooms. 

4.15 PLC based operation & control system is being provided for additional coal storage & 

handling system. Controls are being suitably interfaced with existing conveyor system 

through limit switches. 


Page 5 of 5

1.0 INTENT OF SPECIFICATIONS 

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

all the equipment of Wagon Tippler and Conveyor System Package to be installed for 

National Aluminium Company Limited (NALCO), Captive Power Project located in Angu Angul 

of Orissa State in India. 

(a.) The broad scope of work covers the following: 

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 Owner Owner/RITES’s ’s review, approval and records. 

iv. Packing and transportation from the manufacturer’s works to site. 

v. Receipt, unloading, storage, preservation and conservation of equipment at 

site. 

vi. Fabrication, tion, pre pre-assembly, assembly, (if any), erection, testing and satisfactory operation 

of all the equipment including successful completion of facilities. 

vii. All associated civil, structural structural,electrical and C&I works. 

viii. Commissioning and completion of facilities and Performance Guarantee Tests. 

ix. Furnishing of mandatory spares and handing over to NALCO stores. 

x. Supply of commissioning spares 

xi. Reconciliation (if any) with custom authorities authorities. 

xii. Satisfactory conclusion of the contract. 

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

Specification shall also meet all the requirements as stated in other sections of bid 

documents which shall be considered as a part of this technical specification as bound 

herewith. 

(c.) The Contractor or 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 d quality desired. Other manufacturer’s products may also be considered 

Technical Specification Sec-2,:Intent :Intent of Specifications 

SECTION 2 

Page 1 of 17

provided sufficient information is furnished so as to enable the Owner Owner/consultant to 

determine that the products are equivalent or superior to those named. 

(f.) Bidder is requested tto 

o carefully examine and understand the specifications and seek 

clarifications, if required, to ensure that they have understood the specifications. Such 

clarifications should reach Owner Owner/consultant at least 15 days before the scheduled date of 

the opening of the bids. The Bidder’s offer should not carry any sections like clarifications, 

interpretations and/or assumptions. 

(g.) If the Bidder feels that, in his opinion, certain features brought out in his offer are superior 

to what has been specified, those may be highlighted separately. The Bidder may also 

make alternative offers provided such offers are superior in his opinion. In which case, 

adequate technical information, operating feedback, , etc. shall be enclosed with the offer, 

to enable the Owner/cons /consultant 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 

Owner/consultant to make an overall assessment. In any case, the base offer shall 

necessarily be in line with the bidding documents/ specifications. Under no circumstances 

the equipment / system specification in Technical Specification shall be brought out as 

alternative offer. 

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

shall be clearly defined by the Bidder in “Deviation to NIT Document” irrespective of the 

fact that such deviations/ variations may be standard practice or a possible interpretation 

of the specification by the Bidder. Except for those deviations/ variations covered under 

Deviation Schedules, which are accepted by the Owner before the award of the Contract, it 

will be the responsibility of the Bidder to fully meet the intent and the requirements of the 

specification within the quoted price. No other deviation whatsoever from this 

specification, except for the declared deviati deviations ons submitted by the Bidder with his proposal 

under “Deviations to NIT Document Document” ” shall be considered. Bids not complying with this 

requirement shall be treated as non non-responsive responsive and hence liable for rejection. The 

interpretation of the Owner Owner/consultant in respect of the scope, details and services to be 

performed by the Bidder shall be binding unless specifically clarified otherwise by the 

Owner/RITES in writing before the Award of the Contract. 

(i.) Before submitting his bid, the Bidder should inspect an and d 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 Owner. The contractor shall, prior to commencement of design work, carry 

out the Geo-technical technical investigation in the area proposed for development of wagon tippler 

and conveyor system package. The number of bore holes shall be decided by the 

contractor to ensure adequate data to carry out the design and guaranteeing the 


Page 2 of 17

installation. The cost of such Geo Geo-technical technical investigation is deemed to be included in the 

bid submitted by the contractor. 

(j.) The sizes of various buildings/conveyor galleries indicated in the tender drawings and the 

parameters of equipment indicated in various sections of technical specifications are the 

minimum requirements of the Owner. Any increase in these sizes or the parameters, if 

required to meet the system/maintenance/operational requirement shall be supplie supplied by 

the contractor without any extra cost implication to the Owner. 

(k.) 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, nt, 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 ntractor at his own cost to the satisfaction of the Owner. The contractor shall also 

take all necessary safety measures, at his own cost, to avoid any harm or injury to his 

workers and staff from the equipment and facilities of the power plant. 

(l.) 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 Owner in this regard. Further, contractor shall plan and 

coordinate all his activities considering restrictions, if any, on free access to his work areas 

due to the rail traffic. 

(m.) After award of work and, before finalising his layout especially the layout / l llevels 

of 

conveyors, cable / pipe routes routes/transmission lines 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 suit suitably ably modify his layout / levels 

to prevent dislocation of existing facilities and any cost / time implication arising out of 

such modifications shall be to his account. Contractor shall also be responsible to 

determine and obtain the necessary details at ssite 

ite as required for interfacing and 

interconnection with the existing system / facilities. 

(n) If during the execution of works it is found that there is interference with the existing 

facilities / structures, the contractor shall revise his design / deta detailed iled 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 an any y 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 Owner, the same shall be done by 

the contractor at no extra cost or ttime 

ime implication to the Owner. All such changes will be as 

per drawings and work plan approved by the Owner. 


Page 3 of 17

Equipment and services covered under WAGON TIPPLER AND CONVEYOR SYSTEM PACKAGE 

are described in the subsequent sections: 

1.2 In addition to the specifications cifications of equipment / system indicated in various sections as above 

and General Technical Requirement and Erection Conditions of Contract attached of the 

Specification shall also form part of this Technical specification. 

1.3 TENDER DRAWINGS 

1.3.1 The drawings listed elsewhere, form part of the specification and shall supplement the 

requirements specified herein. The scope and terminal points for the equipment to be 

furnished under this package shall be as identified in these drawings and read in co 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. 

1.3.2 In case of any conflicts / contradiction among various vol volumes umes / sections / annexures / 

chapters / appendices / tender drawings of bid documents, the same shall be referred to the 

Owner for clarifications whose decision shall be final and binding. No extra claims shall be 

allowed on this account. 

2.0 BRIEF DESCRIPTION IPTION OF PROJECT 

NALCO intends to augment the coal handling facilities at its Captive Power Plant by an 

additional annual volume of 2.0 Million tonnes. 

For this purpose, it intends to install a wagon tippler and connecting conveyor System to 

receive the above quantum of coal through rail mode. The wagon tippler system shall be 

suitable for handling all prevailing wagons in coal circuits such as BOX / BOX BOX-N / BOXNHA / 

BOX N.MKDII. 

The facility provided shall be suitable to accommodate locomotives of maxi maximum 140 T 

weight passing through the platform at a maximum speed of 8kmph. 

The Wagon Tippler System shall have an in built weighing mechanism (load cell type) below 

the platform for weighment of wagons prior to and after each tippling cycle to record the 

exact quantity of coal unloaded from each wagon. 

Coal received at the tippler hopper would be transported by belt conveyors and integrated 

to existing system for feeding the existing and the new stockpiles under development. 

2.1 BRIEF DESCRIPTION OF PRO PROPOSED POSED WAGON TIPPLER AND CONVEYOR PACKAGE 

(i) Indian Railway rakes consisting of Box Box-N N wagons shall transport coal to the power plant. 

These Box-N N wagons are proposed to be unloaded in underground RCC hopper by means of 

a Rota side Wagon Tippler Tippler/Rotary Wagon Tippler. . Wagon tippler hopper shall have a holding 

capacity of minimum 2 wagons loads of coal coal. One Rota side wagon tippler tippler/Rotary 


Page 4 of 17

WagonTippler(WT-1) 1) is to be utilised for unloading of IR coal rake. A Side arm charger is 

envisaged for placement of loaded wagon on the tippler table & retrieval of empty wagon 

from the tippler table after tippling. Clear access shall be provided for movement of pay 

loaders on the hopper side of Wagon tippler. Wagon tippler hopper grating is to be 

positioned and designed d accordingly. 

(ii) Apron feeder is proposed under the Wagon tippler for extracting coal from the Wagon 

tippler hopper and feed into the apron feeder which in turn discharges crushed coal on to 

the proposed receiving conveyor RC RC-1. Conveyor RC-1 will transfer sfer the coal to conveyor RC RC-2 

at the new transfer tower TP TP-1. Conveyor RC-2 2 shall feed coal on to existing Conveyor BC BC- 

103/BC-115 115 at the existing junction house (JH (JH-1). 1). The rated capacity of all the conveyors in 

this package shall be 1200 TPH. 

(iii) The existing CHP control and monitoring system is PLC based. It is proposed to provide 

an independent PLC based control for smooth, efficient & trouble free operations of Wagon 

Tippler and conveyor system package. The control and monitoring system for belt con conveyors 

covered under this Package shall be integrated with the existing control system such that the 

operation of existing CHP is not hampered. Necessary interlocks and software changes in the 

existing PLC logic are also envisaged in this package. 

3.0 SCOPE OF WORK 

3.1.1 The scope of Wagon Tippler and Conveyor System 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, engineer engineering, ing, 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 du during ring storage, construction, erection, 

including erection supervision, testing, inspection, commissioning and handing over to 

Owner and Guarantee testing including all associated electrical, civil & structural works as 

specified, unless specifically exclude excluded as per Section-Terminal Terminal Points & Exclusions. 

3.1.2 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 in this document. The general description of the proposed system and 

the broad scope of f work under the specification shall include but not be limited to as 

detailed below. 

3.1.3 An underground RCC Wagon Tippler Hopper, machinery hatches with wagon tippler hopper, 

associated underground tunnel, transfer point and pent house complete with ci civil, structural 

and electrical works for Wagon Tippler hopper and machinery hatches, steel grating over 

hopper portion, removable chequered plate covers over openings in machinery hatches for 

handling underground equipment, equipment handling facilities fo for r apron feeder feederinside 


Page 5 of 17

elow wagon tippler hopper including the structural steel shed with E.O.T crane over the 

WT-1 1 and other equipment/systems such as Dust Suppression system, ventilation system, 

drainage system etc. as specified elsewhere in the specifica specification. tion. However, the track work is 

excluded from Contractor’s scope however rails over tippler table and the track for Side Arm 

Charger are included in Contractor’s scope. 

3.1.4 One (1) no. Rotaside Wagon Tippler Tippler/Rotary Wagon Tippler complete with clamping 

arrangements, all structural members, tippler platform, tippling mechanism, tippler drive 

along with necessary controls, associated electricals, civil / structural works and accessories. 

3.1.5 Side arm charger associated with the Wagon Tippler complete with travel rails, drive 

equipment along with necessary controls, associated electricals, civil/structural works & 

accessories. 

3.1.6 One (1) no. Apron feeder complete with drives, all mechanical, electrical accessories & 

supporting g structure etc. 

3.1.7 Receiving Belt Conveyors RC RC-1 1 complete with conveyor supporting structures, short 

supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units, 

pulleys, idlers, gravity take ups, take up structure upt upto o ground level, take take-up platforms at 

intermediate level, internal and external belt cleaners, pull chord switches, belt sway and 

zero speed switches, electro electro-hydraulic hydraulic thruster brakes, all electricals etc. including RCC 

tunnel for receiving Conveyor RC RC-1 and nd underground tunnel portion upto pent house of 

Conveyor RC-1 1 with all civil, structural and architectural works for conveyor gallery, gallery 

supporting trestles and their associated foundations. 

3.1.8 A new pent house along with over ground structures structures, for conveyor Rc-1 

complete with all 

civil structural, architectural and electrical works including chutes, monorails, hoists/chain 

pulley blocks, hoist maintenance platforms, RCC/steel floors, external staircases, hand rails 

etc. 

3.1.9 A transfer point TP-1 1 complete with civil, structural and electrical works and associated 

foundations for transfer of coal from conveyor RC RC-1 to conveyor RC-2. 

3.1.10 Complete chute work along with chute plug switches and actuator operated flap gates in all 

Transfer points, nts, maintenance platforms along with suitable approach. 

3.1.11 Adequate number of ventilation equipment for ventilating the wagon tippler hopper, 

underground conv. RC-1 1 upto Pent House, complete with all mechanical, electrical, civil and 

structural works. 

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

mechanical, electrical, accessories, civil and structural works. 


Page 6 of 17

3.1.13 Air conditioning of Wagon Tippler control room room, PLC room and battery room room, complete with 

all electrical, civil & structural works etc. 

3.1.14 Exhaust fans for all toilets complete with electrical, civil & structural works etc. Exhaust fans 

along with required ducting shall also be provided for all underground structures/Transfer 

Points. 

3.1.15 Minimum of four (4) Nos. sump pumps in Wagon Tippler house complete with motors, local 

control panel, level switches, individual discharge piping with fittings and valves to nearest 

plant drain etc. 

3.1.16 A complete dust suppression system for contr control ol of fugitive dust at Wagon tippler, apron 

feeder, transfer points, complete with enclosed pump houses, water tanks, pumps, drives, 

hoisting arrangements, piping, valves etc. electrical, accessories, civil and structural works as 

briefly specified below: 

a) Plain water dust suppression through fogging nozzles for control of dust during Wagon 

Tippler operation. 

b) Dry fog type dust suppression system at all Transfer Points both at discharge and 

loading points including all electrical and accessories. 

c) Compressor units, Pump houses & water tanks for dust suppression, service water and 

cooling water system. 

3.1.17 Cooling water system for scoop coupling, Service water system for Wagon Tippler Package 

System shall be taken from nearest header located at new track ho hopper pper area. 

3.1.18 An E.O.T crane for installation & maintenance of equipment in wagon tippler complex 

complete with all electrical and control including the covered structural steel shed. 

3.1.19 Monorails and electrically operated hoist blocks as well aas 

s hand operated chain pulley blocks 

for servicing/installation/easy replacement of drive machinery, different types of pulleys for 

all conveyors, GTU and other equipment. 

3.1.20All All buildings in contractor’s scope shall be complete with all electrical, civ civil, structural, 

architectural works, cable trenches, fire safety walls, foundation / fencing / earthing earthingfor all 

equipments, structures, transformers etc. . All cables / duct banks, trenches, cable trestles 

shall be complete with associated civil/ structural wwork 

ork and necessary civil foundations. 

3.1.21 Drainage of Wagon Tippler hoppers, tunnels, conveyor galleries, TPs, upto nearest existing 

CHP drain including all civil & structural works. 

3.1.22 All equipment/fittings, supporting structure, along with inser insert t plates, bolts, accessories, MS 

sleeves, base plates, grouting as may be required and proper alignment etc. 

3.1.23 A complete set of all special tools and tackles, which are necessary or convenient for 

erection, commissioning and overhauling of any equipment, covered under the scope. 


Page 7 of 17

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

3.1.25 Preservative shop coating, final painting of all structures and equipment under the scope. 

3.1.26 (a) Adequate fire alarm & detection of coal conveyor gallery area, Junction unction houses, Wagon 

tippler area, Electrical switch gear rooms, Co Control ntrol rooms, Battery rooms, Transformer 

rooms, cable spreader rooms etc. consisting of heat detectors detectors(both (both ceiling mounted & 

Canopy mounted type), smoke detectors, LHS cables, manual call points, fire alarm panels at 

main control room of Wagon Tippler, rep repeater eater panel at CISF Fire control room near CPP 

main gate etc shall be considered. Fire alarm & de detection ction system shall be of Intelligent 

Addressable type of Notifire/Siemens make. 

(b) b) The successful bidder is to obtain necessary approval from TAC for the complete Fire 

protection System of Wagon Tippler Package. 

(c) c) Underground pipes will be M.S heavy duty with coating wrapping by 4mm thick coal tat 

tape conforming to IS15337 (latest version). Over ground pipes shall be of he heavy duty GI 

pipes with fittings etc. Suitable number of water actuated deluge valves shall be provided 

for the hydrant system. Hydrant line will be tapped suitably from the existing hydrant net 

work. 

(d) d) The coal conveyors shall also be provided with MVW (Medium Velocity Water) Spray 

System which h will be operating automatically for protection of conveyors. 

3.2 Electrical System / Equipment 

3.2.1 Unless specifically excluded, contractor’s scope of work shall include all electrical wor works as 

required for putting into successful operation of the Wagon Tipplers & Associated Conveyors 

covered under this specification. 

3.2.2 LT SWITCHGEAR 

415V Switchgear/motor control centers distribution boards, AC & DC fuse boards, local 

emergency stop push button stations for all drives and local motor starters as required for 

plant and equipment. 

3.2.3 MOTORS 

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

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

3.2.4 CABLES 

HT & LT Power cables, control cables, Instrumentation cables and any special cables required 

for connection between equipment / devices in Contractor’s scope and also cables between 

Owner’s equipment and Contractor's equipment. 

3.2.5 CABLING, EARTHING AND LIGHTNING PROTECTION 


Page 8 of 17

(a) All cabling with cable accessories, cable trays with supporting structure, terminations and 

jointing kits, trenches, overhead trestle, duct banks etc. as required for the cables to be 

supplied by the Contractor. 

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

scope along with its interconnection to the nearest Owner’s earth grid at two points. 

3.2.6 ILLUMINATION SYSTEM 

Complete illumination system as required for complete internal and external lighting of 

associated plant, equipment and buildings covered under Contractor’s scope including 2 

Nos. of Lighting Masts for area lighting in W.T. area. 

3.2.7 CONTROL SYSTEM 

An independent Control desk, PLC panels, II/O 

/O racks, UPS, battery & battery chargers etc. for 

the control of Wagon Tipplers and other equipment. 

One (1) No. control building to be located near WT WT-1 1 . This building shall have two floors i.e. 

ground & first floors. The first floor of control room shall house PLC panels, control desks for 

operation of WT-1. 1. One office room (5m x 5m) at the first floor. There shall be a projected 

viewing balcony at a suitable location to have clear view of the Wagon Tipp Tipplers during 

operation. The ground floor shall house the MCC, DBS, Battery DBS etc. 

3.3 CIVIL WORKS 

3.3.1 The work to be performed under this specification consists of providing all labor, materials, 

construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental 

items not shown or specified, but reasonably implied or necessary for successful completion 

of the work including Contractor’s supervision and in strict accordance with the drawings 

and specifications. The nature of work shall generally involve earthwork in excavation 

including very deep underground excavation, de de-watering, watering, shoring and strutting, sheet 

piling, back filling around completed structures and plinth protection, area paving, disposal 

of surplus excavated materials, aterials, 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,, Aluminum industrial troughed sheets sheets, anchor bolts, R. C. C. trenches with covers, 

drainage, damp proofing, water proofing and other ancillary items. Supply of cement, 

reinforcement steel, structural steel sections ,MS rounds, chequered plates, flats etc will be 

within the scope of the bidder bidder. 

3.3.2 The work shall have to be carried out both below and above ground level and shall be 

involving, basements, equipme equipment nt foundations, grounding, slabs, beams, columns, footings, 

rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer 


Page 9 of 17

galleries, trestles, penthouses, Wagon tippler hopper, underground tunnels, transfer points, 

finishes, hes, complete architectural aspects, drainage and all other civil, architectural and 

structural works associated with the complete Wagon Tippler and conveyor system 

Package. 

3.3.3 Scope of work shall also include dismantling and modifications of the exi existing 

structures/facilities, which may be required to facilitate, inter connection between the 

existing and the new structures or facilities and making good the dismantled/modified 

structures. 

4.0 TERMINAL POINTS 

Terminal point for Wagon Tippler and conveyor system commences from wagon tippler 

complex upto feeding points at conveyors BC BC-103 & BC-115, 115, in Junction House (JH (JH-1) 

including the modification necessary to the Junction Houseand and interconnection with the 

existing system. Within these terminal points, all equipment and services, civil, structural 

and architectural works, electrical distribution, piping network etc. as required for wagon 

tippler and conveyor system package will be furnished and erected by the co contractor unless 

specifically excluded. 

4.1 Contractor's Scope responsibilities shall include but not be limited to the following: 

4.1.1 Wherever Contractor is permitted by Owner to take support from any of the Owner’s 

Structures, the Contractor shall ensure that no damage is done, to the Owner’s Structures 

including Painting thereof. In case of any damage to the Owners Structure and/or Painting, 

then the Contractor shall rectify the same to the complete satisfaction of the Owner. 

4.1.2 The contractor shall carry out the redesign of JH JH-1 1 and shall ensure that the proposed 

modifications are adequate to support the discharge point of the conveyor RC RC-2 as well. 

4.1.3 Regarding erection of transfer point on existing junction house house-1, 1, contractor shall ensur ensure 

that opening on existing building and erection of conveyor chutes/skirts & platform are done 

in a manner to minimize shut down of existing conv. BC BC-103 & BC-115. 115. As work is to be 

executed in operating project, extra care must be taken by the Contractor. 

4.1.4 Water supply connections for dust suppression, service water system & cooling water shall 

be provided by the Owner, details of which are given elsewhere in the specification. Further 

network of piping including all compressors, pumps, tanks, necessa necessary ry accessories, supports 

and fittings etc. for distribution of water for dust suppression and service water system in all 

transfer points, control rooms, MCC rooms, toilets, Machinery hatches of the Wagon tippler 

etc. shall be under the scope of the contra contractor. 

4.1.5 Road lighting in wagon tippler area, for the roads, is included in the scope of Contractor. 

4.2 EXCLUSIONS 


Page 10 of 17

4.2.1 Supply, laying and fixing of rail track for the inhaul and out haul siding is excluded fr from the 

scope of this Contract. However, supply, laying and fixing of rail over Wagon Tippler table 

and for side arm charger is included in the scope of this Contract. Contract.The The approaches of wagon 

tippler where track is to be laid on concrete base( to the extent required) equired) and aligning with 

the inhaul/outhaul haul/outhaul track junctions is also included in the scope of this contract the cost of 

which is deemed to be included in the quoted rate of relevant items items. 

5.0 SYSTEM DESIGN BASIS 

5.1 The rated capacity of the Conveyors shall be 1200 TPH. . The design capacity of the conveyors 

shall be 1320 TPH. . The mechanical and structural / civil system shall be designed for 1320 

TPH capacity and round the clock operation with both the streams operatin operating simultaneously. 

5.2 Following shall be considered while designing the Conveyors : 

a. The Coal delivered to the power station shall be of size 300 mm & below. However 

occasionally coal of higher lump size may also be encountered. 

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

between 6% to 10%. However for design purposes, moisture content of 10% shall be 

considered. 

c. The coal “as received” shall contain varying percentage of fines. Coal with such fines may 

tend to form orm adhesive lumps, particularly during monsoon when surface moisture is at its 

maximum value. 

d. The sizing and selection of the vital equipment viz. apron feeder covered under the system 

shall be based on the above characteristic of coal and operating cond conditions. itions. Contractor shall 

ensure that equipment/ system efficiency shall not be effected particularly during monsoon 

when surface moisture is at its maximum value. 

5.3 For the purpose of volumetric computation, the bulk density of the coal shall be taken a aas 

800 kg/m3. Therefore for calculation of belt conveyor capacity, for their drives & drive 

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

bulk density shall be considered. For all other purposes viz. for stresses/ load on structures, 

loading on Apron Feeder tables, sizing of actuators for flap gates, calculations of plugged 

chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3. 

5.4 Coal Flow paths 

5.4.1 For the purpose of conducting guarantee test coal, the following flow path would be 

assessed. 


Page 11 of 17

Apron feeder will feed coal unloaded at WT WT-1 to Conveyor RC-1. 1. Coal on RC RC-1 will be 

transferred to RC-2 2 through Transfer point feeding on to existing Conveyors (either BC BC-103 

or BC-115) in JH-1. 

5.4.2 Contractor shall also demonstrate that all intermediate equipments can perform as per 

specification and design requirement during PG Test. 

5.4.3 Performance and Guarantee tests have been elaborated elsewhere in the specification. 

6.0 ENGINEERING NG SCHEDULES 

6.1 Within one month of acceptance of Award Letter, Contractor shall submit, for review and 

approval, detailed engineering schedules, based on Master Network (as per requirement of 

bid documents), to the Owner / Consultant, showing the logic & duration of activities in the 

following areas : 

a) Detailed engineering, including submission and approval of quality plans and PG test 

procedure. 

b) Inputs required from Owner for smooth and timely execution of contract. 

6.2 The Contractor shall submit within 30 days of letter of award a master list of drawings 

incorporating the scheduled dates of submissions. The schedule date of submissions should 

match with the manufacturing and erection programme submitted in the detailed Master 

Network Schedule. The list shall be updated every month reflecting the additions / deletions 

during the period. 

6.3 The network schedule shall be updated at a frequency mutually agreed upon for the 

purposes of progress monitoring. However, for the purpose of identification of Contractor's 

Contractual Liability the agreed Master Network shall only be applicable. 

7.0 GUARANTEE AND LIQUIDATED DAMAGES 

7.1 Guarantee 

The Bidder shall guarantee that equipment offered shall meet the rating, performance and 

functional requirement sti stipulated pulated for various equipment covered in this specification. The 

Bidder shall also furnish a declaration in the manner prescribed and included in the Bid 

Proposal Sheets and other Schedules for certain guaranteed parameters which shall attract 

levy of liquidated uidated damages for shortfall in performance. 

7.2 Performance Requirement 

Guaranteed parameters of the major equipments shall be as follows: 

7.2.1 Flow Path Capacity 

Flow path capacity including the intermediate equipment for conveyor streams to be teste tested 

for 1200 TPH 


Page 12 of 17

7.2.2 Equipment Capacity 

Capacity of individual equipment shall be tested separately: 

(i) Each Wagon Tippler : 20 tips/hour (Guaranteed) 

(ii) Each Apron feeder : 1200 TPH (Guaranteed) 

7.2.3 Contractor shall also demonstrate that all intermediate equipments viz. Gates, Dust 

suppression, Ventilation System etc. can perform as per specification and design 

requirement. 

7.2.4 Performance and guarantee requirement of various other equipments have been elaborated 

elsewhere. 

8.0 PERFORMANCE & GUARANTEE TEST PROCEDURE 

In accordance with GTR the plant shall be subjected to performance and Guarantee Tests on 

successful completion of trial operations. Further, the performance and Guarantee Tests 

shall be conducted as per the guideline procedure indicated elsewhere. However, detailed 

procedure shall be submitted by vendor as per the guidelines for Owner Owner/RITES's approval. 

The P&G Test procedure shall be submitted by the bidder. 

8.1 Liquidated Damages for Shortfall in Performance 

Should the results s of the performance and guarantee tests show that the equipments / 

system have failed to meet the guaranteed parameters, the Contractor shall carry out 

modifications, if considered necessary, within 90 days of the notification by Owner. 

If the equipment fails ails to meet the guarantee parameters at the end of the above specified 

period of 90 days, Owner may at his discretion, reject the equipment or accept it after 

assessing the liquidated damages at rates specified herein, to be payable by the Contractor. 

8.2 The following equipments/streams shall be subjected to performance and guarantee test in 

line with the specification to prove the performance guarantee for all intermediate 

equipment. 

Liquidated Damages towards shortfall in guaranteed performance shall be imposed as % of 

the order value limiting to 5% against following parameters. 

Sl. 

No. 

Equipment 

1 Wagon Tippler 

2 Apron Feeder 

3 Conveyors (R1 & R2) 


Guaranteed 

parameter 

Short fall LD amount to be 

imposed 

20 Tips /Hour By One tip per hour 1% of order value 

By two tips per Hour 2% of order value 

Beyond two tips per hour Rejected 

1200TPH By 0.5% 1% of order value 

By 1.0% 1.5 1.5% of order value 

Beyond 1.0% Rejected 

1200TPH By 0.5% 1% of order value 

By 1.0% 1’5 1’5% of order value 

Beyond 1.0% Rejected 

Page 13 of 17

The LD shall be assessed on the basis of conveyor equipment having the poorest 

performance. 

9.0 COMMISSIONING (SYSTEM TRIAL OPERATION) 

Duration of the trial operation of the he complete equipment shall be 30 continuous days with 

available no of loaded rakes during the period or as to be mutually agreed agreed. 

10.0 TYPE TESTS AND TYPE TEST CHARGES 

10.1 All equipment / systems to be supplied shall conform to type tests as per re relevant standards 

and proven type. 

10.2 The Bidder / Contractor shall furnish the reports of all the type tests carried out within five 

years of the date of bid opening as per specification and relevant standards for all 

components / equipments / systems. These reports should be for the tests conducted on 

identical / similar components / equipments / systems to those offered / proposed to be 

supplied under this contract. 

10.3 In case contractor is not able to submit report of type test(s) conducted in last five years, or 

in case type test report(s) are not found to be meeting the specification / relevant standard 

requirements, then all such tests shall be conducted under this contract by the Contractor 

free of cost to Owner, and reports shall be submitted ffor 

approval. 

10.4 All acceptance and routine tests as per relevant standard and specification shall be carried 

out. Charges for these shall be deemed to be included in the bid price. 

11.0 SPARES 

11.1 GENERAL 

The Contractor shall include in his scope of supply all the necessary Mandatory spares, start 

up and commissioning spares and recommended spares and indicates these in the relevant 

schedules of the Bid Form and Price Schedules. The general requirements pertaining to the 

supply of these spares have bbeen 

described in the following paras. 

11.2 MANDATORY SPARES 

11.2.1 The list of mandatory spares considered essential by the Owner Owner/RITES /RITES is included in this 

specification. The Bidder shall indicate the prices for each and every item (except for items 

not applicable to the Bidders design) in th the e ‘Schedule of mandatory 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 hi him. m. However during execution if 

such spares are found to be applicable, the Contractor shall supply them without extra cost 

to the Owner. The Bidder shall furnish the population per unit of each item in the relevant 


Page 14 of 17

Schedules. Whenever the quantity is menti mentioned oned in “sets” the Bidder has to give the item 

details and prices of each item. 

11.2.2 Whenever the quantity is indicated as a percentage, it shall mean percentage of total 

population of that item in the Package, 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 tthe 

he total requirement of the item 

for a unit, module or the station or 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 be bearings arings 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. 

11.2.3 The Owner reserves the right to buy any or all the mandatory spare parts. 

11.2.4 The prices of mandatory spares indicated by the Bidder in the Price Schedules shall be used 

for bid evaluation purposes. 

11.2.5 All mandatory spares shall be delivered at site at least two mmonths 

onths before scheduled date of 

initial operation. However, spares shall not be dispatched before dispatch of corresponding 

main equipments. 

11.2.6 Wherever quantity is specified both as a percentage and a value, the Contractor has to 

supply the higher quantity uuntil 

and unless specified otherwise. 

12.0 RECOMMENDED SPARES 

12.1 In addition to the spare parts mentioned above, the contractor shall also provide a list of 

recommended spares for 1 year 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 Volume, and should be independent of 

the list of the mandatory spares. The Owner 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. However, the spares shall not be 

dispatched before the dispatch of the main equipment. 

12.2 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 2 months from 

the last date of providing such justification to the sati satisfaction sfaction of the Owner. 


Page 15 of 17

13.0 START-UP UP & COMMISSIONING SPARES 

Start-up up and commissioning spares are those spares which may be required during the startup 

and commissioning of the equipment/system. All spares used till the plant is handed over 

to the Owner 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 Purchase Purchaser. 

14.0 COMMON REQUIREMENTS 

14.1 The Contractor shall include in his scope of supply all the necessary Man Mandatory spares, start 

up and commissioning spares and recommended spares and indicate 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. 

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

mandatory and recommended) under normal operating conditions before replacement is 

necessary. 

14.3 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 necess necessary. 

14.4 All the spares (both recommended and mandatory) shall be manufactured along with the 

main equipment components as a continuous operation as per same specification and 

quality plan. 

14.5 The contractor will provide Owner with cross cross-sectional drawings, wings, catalogues, assembly 

drawings and other relevant documents so as to enable the Owner to identify and finalise 

order for recommended spares. 

14.6 Each spare 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 urposes of identification. 

14.7 All cases, containers or other packages are to be opened for such examination as may be 

considered necessary by the Owner. 

14.8 The contractor will provide the Owner with all the addresses and particulars of his sub 

suppliers ers while placing the order on vendors for items/components/equipments covered 


Page 16 of 17

under the contract and will further ensure with his vendors that the Owner, if so desires, will 

have the right to place order for spares directly on them on mutually agreed term terms based on 

offers of such Contractors. 

14.9 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. 

14.10 In addition to the recomm recommended ended spares listed by the contractor, if the Owner 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 onths for consideration by the Owner and placement of order for additional 

spares if the Owner so desires. 

14.11 The Contractor shall guarantee the long term availability of spares to the Owner 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 unde under the 

Contract, he shall give the Owner at least 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. contractors. Further, in case of discontinuance of manu manufacture facture of any spares by the 

Contractor and/or his sub contractors, Contractor will provide the Owner, two years in 

advance, with full manufacturing drawings, material specifications and technical information 

including information on alternative equivalent makes required by the Owner for the 

purpose of manufacture/procurement of such items. 

14.12 In case of equipment supplied with grease/lubricants from imported origin, the supplier shall 

clearly indicate the indigenous equivalent of the grease/lubricant aand 

nd source of supply so as 

to enable the Owner to procure these items from indigenous sources. 


Page 17 of 17

1.1. GENERAL 

Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders 

SECTION 3 

(SPECIAL STIPULATIONS TO BIDDERS) 

1.1.1 This Technical Specification shall be read in conjunction with Commercial, General Condition 

of Contract and other project requirement mentioned in this specification. 

1.1.2 The Bidder shall quote for complete scope of work as covered in this specification. 

1.1.3 This Technical Specification is for turnkey supply of the plant & equipment and related 

structures including execution of structural steel works and civil works as specified in 

subsequent chapters, along with necessary modification, as detailed in the Scope of Work 

and Technical Specification. 

1.1.4 Instructions to Bidders idders / Special Instruction specified in other chapters shall be read in 

conjunction with stipulation stated in this chapter. 

1.1.5 The Bidder shall submit the drawings / documents, technical data / information as 

mentioned in various sections and annexure without which the Bid shall be considered as 

incomplete and may not be considered further. 

1.1.6 The Bidder shall submit along with the bid a work schedule in the form of a bar chart 

indicating the commencement and completion dates of each acti activity vity such as preparation of 

design, approval of design & drawings, preparation & approval of fabrication drawings, 

procurement of steel and other material, ordering of bought out items, their delivery to 

shop, major shop activities like fabrication of stru structures/ ctures/ manufacture of equipment, 

assembly, shop testing, inspection, shop painting &&dispatch 

to the site, schedule of erection, 

final painting after erection at site, testing and commissioning of Plant and Equipment, 

without which the bid may not be consi considered. 

1.1.7 The Bidder shall clearly indicate the clause wise compliance to the specification. Non 

compliance with this and generalized statements like. "The equipment shall be 

manufactured as per IS standard / our specification etc" may result in reje rejection of the Bid. 

The deviation, if any, shall be clearly specified clause clause-wise wise in the format enclosed with this 

technical specification. In absence of deviation indicated, it will be presumed that the Bidder 

has no deviations. 

1.1.8 One copy of the Tender er document and drawings shall be duly signed by the Bidder as a 

token of acceptance of all clauses / parameters / data mentioned therein and returned along 

with the Bid without which the Bid is liable to be rejected. In case the Bidder intends to 

change any ny data / parameter given in Technical Specifications the same shall be clearly 

mentioned in the deviation list, with reasons thereof. 

Page 1 of 11

1.1.9 If the Bidder feels that any information/ data described in the technical specification needs 

to be modified, he shall indicate the same specifically and submit an alternative proposal, on 

the basis of the design data, that he considers suitable and capable of meeting the 

requirement of this specification. 

1.1.10 All the materials used and equipment supplied shal shall l be new and the best of their kind and 

shall comply with the statutory requirements of the Govt. of Orissa, Govt. of India and the 

latest revision of the Indian Standards/ Indian Electricity Rules. Where the equipment/ 

material supplied is not according tto 

o Indian Standards or regulations to which the equipment 

/ material conform, the Bidder shall submit relevant document along with the Bid. 

1.1.11 The Bidder shall visit the plant / site, and satisfy himself fully about the existing plant /site 

conditions s etc. The successful Bidder shall bear full responsibility for inferences and 

conclusions as to the nature and conditions under which the work is to be executed, 

including effect of climate, rainfall etc. Failure to do so shall not absolve the Bidder of h hhis 

responsibilities about the proper execution of the job. No claim for extra payments due to 

any special site conditions and ignorance about the site conditions shall be considered after 

acceptance of his Bid. For the site visit, the Bidder shall contact the Purchaser and take prior 

appointment from them. 

1.1.12 The drawings of the existing coal handling plant, available with the Purchaser, can be made 

available to the successful Bidder for reference. However, for the areas of the plant for 

which drawings s are not available, the Bidder shall make site measurements and work 

accordingly. 

1.1.13 The Bidder as far as practicable ensure that major equipments are brought to site in pre 

assembled condition to minimize site work and to achieve an early commissi commissioning of the 

equipment after delivery. Site welding shall be avoided as far as possible. The Successful 

Bidder before proceeding with design details shall satisfy himself about the site condition so 

as to avoid any difficulty in erection arising out of des design. 

1.1.14 The equipment shall be inspected during different stages of its manufacture (starting from 

raw material till the completion of manufacture) by the Purchaser / his authorized 

representative at the Bidder's or his sub Successful Bidder's works as per the inspection 

procedure mutually agreed between the Purchaser or his authorized representative and the 

successful Bidder. Inspection shall be regarded as a check up and shall be in no way binding 

on the Purchaser. However, general terms and condit conditions ions of inspection and testing is 

indicated in the subsequent chapter of this specification. 

1.1.15 Documents of all electrical and mechanical equipment supplied with equipment shall be put 

up for inspection along with the equipment. After inspection, aan 

n endorsement would be 

made in the inspection certificate about the availability of the documents. 


Page 2 of 11

1.1.16 The offer shall be complete in all respects and any additional equipment, accessories, 

auxiliaries, services, work etc. which are not specifically mentioned in the specification but 

are required for smooth and trouble free operation and to achieve performance required to 

be guaranteed in terms of the Bid Document, shall be included by the Bidder in the offer. 

1.1.17 The make of all bought out items shall be as per” List of preferred makes” of supplies and 

equipment mentioned in tender document. 

1.1.18 Metric systems & English language shall only be used throughout the Bid and in the 

drawings. 

1.1.19 The Bidder shall satisfy himself about his ability for completing the work as per the time 

schedule before submitting his offer. In case the Bidder is unable to adhere to the schedule 

indicated in this specification, the Bidder need not submit their offer against this Bid Bid. 

1.1.20 A complete list of exclusions from Bidder's scope of work shall be clearly indicated in the Bid. 

1.1.21 In case of any contradiction between Instructions to Bidder and Technical Specifications, 

stipulation in the Technical Specification shall prevail. 

1.1.22 The Bidder has to carry out the work is such a manner that it does not affect the plant 

operations. If other Contractors are also engaged at the same work site for other jobs, the 

Bidder shall work in co-ordination ordination with them such that tthe 

he work of other Contractor is not 

affected. For integration of new facilities & the existing one, shutdowns period in phases, as 

per the schedule mutually agreed between “Purchaser” and successful Bidder would be 

provided. Hence, Bidder shall indicate in their offer, the stages at which the shut downs are 

required and their respective duration. 

1.1.23 All parts of equipment requiring replacement or inspection or lubrication shall be so 

arranged/ assembled that they are easily accessible without the need of dismantling of other 

equipment or structures. All electrical cables shall be so laid that they are not liable to be 

damaged and can be easily inspected and maintained and when necessary any damaged 

cable can be accessed & replaced individually. 

1.1.24 All equipment shall be complete with adequate safety devices wherever a potential hazard 

to personnel exists. Provision for safe access of personnel working to and around equipment 

for operation and maintenance, shall be provided. 

1.1.25 The Bidder shall train the Purchaser’s personnel in all disciplines of the operation & 

maintenance of the plant & equipment being provided by them under the contract. 

1.1.26 Standardization of components and assemblies shall be carried out to the maximu maximum possible 

extent to ensure interchangeability/as well as to minimize inventory levels. 


Page 3 of 11

1.1.27 Bidders shall furnish drive ratings of all equipments including conveyors along with the offer. 

Conveyor profiles enclosed with this specification are indicat indicative only. 

1.1.28 The Bidder shall include in his scope of supply, a complete set of new and unused special 

tools and tackles required for operation and maintenance of the plant and equipment. The 

list of tools & tackles considered in the bid shall also be submitted. 

1.1.29 The Bidder shall include in his scope, the requirement of initial fill of oils, lubricants, grease, 

and all other consumables required for start start- up, testing, commissioning and performance 

guarantee uarantee tests of the unit/equipment. A list of such consumables shall also be furnished by 

the successful Bidder for Purchaser’s use. 

1.1.30 The Bidder shall include in his scope the supply of spares required for successful 

commissioning of plant & equ equipment. ipment. The list of commissioning spares considered in the bid 

shall also be furnished along with the bid. 

1.1.31 The Bidder shall quote separately for the spares required for the normal operation and 

maintenance of the plant and equipment for a period of 24 months to be reckoned from the 

date of taking over of the plant and equipment. A list of the spare parts shall also be 

furnished along with item wise price. 

1.1.32 The successful Bidder shall not offload the contract or part thereof to any subcont subcontractor 

without written permission of the purchaser. In the event of subletting of any part of the 

work with due permission by the purchaser, the fact that such permission has been 

accorded shall not absolve the successful Bidder from any of his obligations and liabilities 

under the contract. 

1.1.33 Subject to availability and at the request of the successful Bidder, water for construction 

purpose will be made available by the Purchaser at one mutually agreed point at site. The 

successful Bidder shall mak make e his own arrangement for any further distribution at his own 

cost. Water supply shall be free of cost and shall be provided as specified under clause no. 

54.13 b) of the GCC. 

1.1.34 Power Supply 

Subject to availability and at the request of the succes successful sful Bidder, Electric Power will be 

made available at one point only at a distance not more than 500 meters away from the 

Contractor’s premises. The power will be supplied at 400/440 Volt and shall be metered and 

charged at the rate as specified in the GCC GCC. . The successful Bidder should have sufficient 

number & capacity of DG sets to meet the emergency power requirements in the event of 

failure in power supply. 

1.1.35 Civil and structural steel works 


Page 4 of 11

The supply of conveyor galleries, trestles, Junction ttowers, 

owers, buildings & civil work are in the 

scope of this tender including the Design of Civil & Structural works , shall be within the 

scope of successful bidder. 

1.1.36 Fire hydrant system 

The Bidder shall include in his scope the extension & rerouting of fire hydrant system to the 

wagon tippler & conveyor system. The hydrant line should be laid as per IS specification. 

1.1.37 Exclusions: : Following items are excluded from the scope of work 

1. Railway track system. 

1.2 ERECTION 

1.2.1 The successful l Bidder shall be responsible and perform the following with respect to the 

erection of the Plant and supplies. 

1.2.2 The scope of work of the successful Bidder shall be complete erection of the Plant and 

Equipment etc. as specified in the Technical Spe Specification. cification. The Bidder shall make all 

arrangements to deliver the equipment at their site stores by wagons / truck / trailers, build 

his own stores (covered, uncovered and air air-conditioned, conditioned, if necessary) for the proper storage 

of equipment, maintain the st stores ores and all related documents and records, transport the 

equipment to site for erection purpose and take an Erection Erection- cum- Storage insurance policy 

covering all the risks including third party liability for all supplies as well as human life. All 

security arrangements also shall be made by the successful Bidder. Space only for stores and 

site office shall be made available to the Bidder by the Purchaser. 

1.2.3 The successful Bidder shall take the equipment from their site stores and transport the same 

to erection site. 

1.2.4 The successful Bidder shall unpack and do visual checking against physical damages to the 

equipment / cases, cleaning of equipment before start of erection. Damage / shortage if any, 

will be reported to the Purchaser / consultant and shall be rectified / replaced expeditiously, 

free of charge to Purchaser so as not to upset the erection and commissioning schedule. 

Delay on account of settlement of insurance claims by the successful Bidder shall not be 

considered an excuse for delay in completion. 

1.2.5 The successful Bidder shall lay and maintain properly all the temporary supply lines in the 

erection site for temporary power and water required for storage and erection purposes 

from a single point to be provided by the Purchaser. Drinking water shall also be made 

available at one central point at site. The successful Bidder shall make his own arrangement 

for any further distribution. 

1.2.6 The successful Bidder shall arrange all necessary construct construction ion machinery/ equipment, tools 

& tackles, instruments, compressors, small hand tools, welding equipment, all 

commissioning instruments, erection & service bolts, nuts, jigs and fixtures, winches, 


Page 5 of 11

alignment tools, precision levels etc., Crane/ hoists and oother 

ther equipment which may be 

required for carrying out the erection work efficiently within the time schedule provided 

herein the specification. Unless otherwise specified, the above construction materials shall 

be the property of the successful Bidder. How However ever Purchaser's prior permission shall be 

required for removal of these construction materials from the site. Successful Bidder shall 

ensure that proper documentation is maintained for such items, which are required to be 

carried back by successful Bidder after the completion of work. 

1.2.7 The successful Bidder shall provide all temporary ladders, scaffolding materials, platforms, 

supports and other necessary facilities required for handling, erection, testing and visual 

inspection of supplies at the ppoint 

oint of installation and shall also provide necessary packing 

plates, wedges, shims, levelling screws etc. required for erection of equipment and 

technological structures. 

1.2.8 The successful Bidder shall provide erection consumables like oxygen and acetylene gas, 

welding rods, solder lugs, oil, grease, kerosene, cotton waste, etc. required for erection of 

equipment and technological structures. 

1.2.9 The successful Bidder sh shall all erect and maintain his own site offices, main stores and site 

temporary stores as required for the work and arrange for maintaining in neat manner of 

the area placed at the Successful Bidder's disposal. 

1.2.10 The successful Bidder shall provide suf sufficient ficient fencing, notice boards and lights to protect and 

warn others as may be considered necessary by the purchaser / consultant. All materials 

used for providing these facilities shall be properties of the successful Bidder. 

1.2.11 The equipment and technological echnological structures will be erected as per the instructions of the 

suppliers & under the supervision of the supervisory staffs to be deployed by the successful 

Bidder at site and only with the approval of Purchaser / Consultant. The successful Bidder 

shall use pre-assembly assembly and mechanisation to the maximum extent in order to fulfill erection 

& construction targets. 

1.2.12 The Successful Bidder shall align, level, couple and securely fix all equipment, appurtenances 

and accessories in accordance with ddrawings 

rawings and / or instructions of Purchaser/ Consultant. 

1.2.13 Laying and termination of cables, bus bars, bus ducts, lightening protection and earthing 

shall be done by the Successful Bidder. 

1.2.14 The successful Bidder shall be responsible for prot protection ection and / or diversion of all existing 

underground and over ground services, wherever required. The terms and conditions for 

protection / diversion of services not shown on drawing / indicated in the specifications shall 

be mutually agreed. 


Page 6 of 11

1.2.15 Installation stallation and connection of all piping and fittings within the scope of work shall be 

responsibility of the successful Bidder. 

1.2.16 The successful Bidder shall be responsible for checking the correctness of erection of 

mechanical equipment, technolog technological ical structures and auxiliary systems, electrical equipment 

etc. as per the specification. 

1.2.17 The successful bidder has to carry out the work in such a manner that it does not affect the 

operation of other plant/ shop. If other Contractors are also eengaged 

ngaged in the same work site 

for other jobs the bidder shall work with them in a co co-ordinated ordinated manner. 

1.2.18 The successful Bidder shall be responsible for the management of erection work with proper 

and adequate supervision for ensuring progress of ere erection ction work and quality of 

workmanship. 

1.2.19 The successful Bidder shall deploy required number of supervisory, skilled, unskilled and 

auxiliary labour as required for the erection work: as per detail mobilisation schedule (to be 

furnished with Bid by successful Bidder) and comply with such reasonabl reasonable instructions of the 

Purchaser / Consultant in the interest of satisfactory progress and completion of the work 

according to the schedule. The successful Bidder shall work in 3 shifts per day basis for 

meeting the completion target, if required within the contract price. 

1.2.20 The successful Bidder shall organise the work in a manner that other work at site is not 

impeded and the workmen therein not endangered and shall arrange temporary access at 

site, if required for the erection work. 

1.2.21 Successful essful Bidder shall return to the Purchaser all crates, packing cases and packing 

materials excess commissioning spares, oil and lubricants at a place designated by the 

Purchaser. 

1.2.22 The successful Bidder shall conduct all necessary tests / checks dduring 

uring erection. 

1.2.23 The successful Bidder shall attend to the rectification of erection defects, if any, 

expeditiously. The successful Bidder shall arrange all testing instruments for such testing at 

site. 

1.2.24 The successful Bidder shall carry out final painting of the Plant & Equipment and 

technological Structures etc. erected as per the instructions stipulated in the Technical 

Specification. 

1.2.25 The successful Bidder shall be responsible for total commissioning of the Plant and 

equipment including cold trial run and demonstration of Performance Guarantee Test. The 

Purchaser's supervisory and skilled operating personnel shall, however, be available to work 

under the guidance and supervision of the Bidder. Necessary raw materials, auxiliari auxiliaries, 


Page 7 of 11

utilities, electricity and operating personnel shall be made available by the Purchaser 

covering 3 shifts operation as per the programme agreed to in advance. 

1.2.26 The Successful Bidder shall supervise running of the Plant for satisfactory, reliabl reliable and 

regular operation and performance after its successful commissioning for establishing 

performance guarantees. 

1.2.27 Electrical energy and construction water shall be supplied by Purchaser to the successful 

Bidder during erection, at one point. 

1.2.28 All safety measures required to be adopted as per the Statutory Regulations & the Safety 

Rules of the Plant shall be strictly followed by the successful Bidder during the execution of 

the Contract. The successful Bidder shall depute safety engineer engineers s for strictly compliance of 

safety rules & regulations. 

1.2.29 The successful Bidder shall intimate the Plant authorities in writing well in advance about 

the requirement of shut down of any of the existing units / facilities for inter connection / 

incorporation orporation of additional facilities. The shut down period shall be mutually discussed and 

finalised. The work to be undertaken during the shutdown period shall be planned 

meticulously to reduce the shut down period to the minimum. 

1.2.30 The successful Bidder shall comply with all statutory Rules, Regulations with respect to the 

employment of labour at site. 

1.2.31 The successful Bidder shall carry out any and all such works, as may be required, to build a 

Plant complete in all respect as per the Technical Specification and achieve the Performance 

Guarantees and other parameters as given in the subsequent chapter of this specification. 

1.2.32 Any loss of plant and equipment due to imprudence, negligence and / or inequitable 

treatment and handling shall be replaced by the Successful Bidder / his sub sub-contractor at his 

own cost. 

1.3 PAINTING 

All parts of the equipment ipment shall be thoroughly cleaned of loose mill scales, rust or foreign 

matters. 

All parts excepting motors, resistors, gears etc. shall be painted at shop and at site with two 

coats of epoxy zinc based on zinc dust. 

Interior of all gear housing shall be painted with oil resistant paint. All machine pads, 

bearings surface or structures or housing shall be painted with white lead. All parts, 

inaccessible after assembly, shall be painted and assembled while the paint is wet. 


Page 8 of 11

After erection, the damaged portion of the painted surface shall be retouched and an 

intermediate coat / final coat of PVC copolymer alkyd resin with micaceaus iron oxide (MIO) 

shall be applied. The colour shall be as per the choice of the Purchaser. 

The subsequent one final coat of paint of PVC copolymer alkyd with weather resistant 

pigment (approved by the Purchaser) and glossy finish shall be applied. 

The details of the dry film thickness (DFT) of the different coats shall be as follows: 

a) Primary coat : 30 –40 micron per coat 

b) Intermediate coat : 70 –80 micron per coat 

c) Final coat 

: 40 –50 micron per coat 

The painting scheme & colour code shall be approved by the Purchaser. The successful 

Bidder shall refer to Section 8 for further detail of f painting scheme & colour codes. 

1.4 OPERATING / PERFORMANCE PARAMETERS 

All the equipment covered in this specification shall fulfill the operating and performance 

requirement covered under this Technical Specification and indicated in the approved 

drawings. 

The successful Bidder shall study the specification and satisfy himself thoroughly regarding 

the workability and suitability of the equipment offered by him. He shall take full 

responsibility for the guaranteed and satisfactory operation of the eequipment 

quipment as regards to 

its performance and smooth and reliable working. 

1.5 PRELIMINARY ACCEPTANCE 

After completing the erection of a unit or agreed portion thereof, the successful Bidder shall 

give a notice in writing stating that the job is complete in all respects and ready for 

preliminary acceptance. The job shall be visually inspected by representa representatives of the 

Successful Bidder and Purchaser / Consultant to ascertain whether supply, fabrication and 

erection are as per contract drawings and Technical Specification. All observed defects, 

deficiencies and omissions shall be noted down. If the defects, deficiencies and omissions 

are not major in the opinion of the Purchaser / Consultant, the successful Bidder shall be 

issued a preliminary acceptance certificate mentioning the defects, deficiencies and 

omissions. The noted defects, deficiencies and omissi omissions ons shall be made good by the 

successful Bidder within a period of 3 to 4 weeks. 

1.6 FINAL ACCEPTANCE 

Before commencement of final acceptance test of the building or unit, the successful Bidder 

shall make available required numbers of complete sets of ordinary prints of drawings, 

required numbers of set of DOD list for the drawings and one set of reproducible film of all 


Page 9 of 11

drawings, all representing As As-Built Built condition (i.e. all additions and alterations done during 

fabrication and erection shall be incorp incorporated in the drawings). 

The successful Bidder shall attend to all defects, deficiencies and omissions noted down 

during preliminary acceptance and after rectifying or making good the above in all respects, 

shall inform 10 days in advance the Purchaser / Consultant for conducting final acceptance. 

During Final Acceptance all defects, deficiencies and omissions noted earlier shall be 

checked. The successful Bidder shall also make good any defect, deficiency or omission not 

notified during earlier prelimina preliminary ry acceptance, but pointed out during final acceptance. Final 

Acceptance certificate shall be issued by the Purchaser after all defects, deficiencies and 

omissions noted under preliminary or final acceptance have been rectified. 


1.7.1 The broad turnkey scope of work shall be as per the following: 

• Design, manufacture, inspection, shop & primary coat of paint & supply of complete 

plant & equipment, fabrication (shop & site) of building structures & technological 

structures, civil construction materials, power distribution, electrics, instrumentation & 

automation, illumination, all utilities & services, in in-plant plant road networks, drainage 

systems, landscaping, fire detection & alarm system, fire fighting pump house, as 

required, for complete mplete & trouble free operation of Coal Handling System in an 

integrated manner. 

• Basic engineering, detail engineering and reference category of drawings, operating 

software and documents, in requisite copies, for approval of NALCO/ RITES. Further, the 

Tenderer nderer will furnish final basic & detail engineering drawings, manufacturing drawings 

of fast wearing items and non non-standard standard items, as built drawings, erection 

drawings/documents, operating software, operation and maintenance manuals in soft 

editable format. 

• Receipt of material, loading / unloading, storage, civil construction, complete erection, 

testing, commissioning, handing over of Wagon Tippler Complex to Purchaser, 

demonstration of performance guarantee and post commissioning services . Preparation 

and nd approval of erection survey / alignment schemes, grouting clearances, painting 

clearances, testing of welds, pressure testing protocols and other related site protocols. 

• Deputation of representatives of equipment suppliers and technology suppliers to site 

for supervision of erection, testing and commissioning. 

• Applying final finish coat of paint as per approved procedure & shades before handing 

over, first fill of lubricant & oil, special tools & tackles, mobile equipment, handling & 

hoisting equipment t etc. 


Page 10 of 11

• Supply of all commissioning spares. A list of such commissioning spares shall be 

indicated separately separately. Tenderer shall quote separately for one year recommended spares 

with the main offer. 

• Progress reporting as per agreed formats, providing documen documentary tary evidence of purchase 

orders on sub vendors with addresses of contact persons, attending all site progress 

review / engineering review meetings at NALCO, Angul or at RITES, Gurgaon / 

Bhubaneswar, opening an equipped site office with coordinator oversee overseeing all activities. 

• Arrangement of all erection equipment viz. cranes, hoists, winches, etc, and safety 

appliances as required for erection of plant & equipment. Appointment of safety officer 

by the contractor shall be included. 

• Specialized training of Purchaser’s personnel for operation, maintenance, for smooth 

handing over the plant. 

• Testing and cold trial run of systems/ sub - systems and integrated testing shall be 

carried out by the successful Tenderer on continuous basis for complete Coal Handling 

System along with associated facilities followed by commissioning. On successful 

commissioning of the various sub sub-systems systems of the Wagon Tippler complex, PG test of the 

entire Tippler House shall be carried out as elaborated in the relevant chapter. 

• Receiving g delivery of items at site, their proper storage, and handling at site, watch and 

ward services, removal of debris to a location specified by the Purchaser etc. Site shall 

be handed over to the Purchaser in clean and orderly manner to the satisfaction of the 

site engineers after commissioning of the project. 

• Getting Purchaser’s/ consultant’s approval for the drawings prepared by the successful 

Tenderer, obtaining required approval from statutory authorities, providing adequate 

personnel, equipment, tools & tackles for timely completion of the project. 

• For detailed scope of work and design parameters on various subsystems & facilities, the 

Tender Specification shall be referred to. 

1.7.2 This is a turnkey project for Installation of Wagon Tippler and convey conveyor or system and all the 

facilities required for proper functioning of the wagon tippler and achieving the rated 

capacity shall be deemed to be covered in the tender specification, unless specifically 

excluded from the Tenderer’s scope. 


Page 11 of 11

1.0 SYSTEM PARAMETERS, OPERATION & CONTROL PHILOSOPHY 

1.1 The specifications as brought out in various Sub Sub-sections sections for mechanical equipment shall be 

applicable for the proposed wagon tippler and conveyor system 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. 

2.0 PARAMETERS 

2. 1 Conveyor System 

i. Rated Capacity (Guaranteed) : 1200 TPH 

ii. Design capacity : 1320 TPH 

iii. Belt width : 1200 MM 

iv. Belt speed : 3.5 m/sec. (approx.) 

2.1.1 Belting and Pulleys 

Belts of conveyors shall be provided with latest belt weighing system to measure/record the 

quantum of coal falling on the belt and being carried by the conve conveyor yor system. The weighing system 

shall have adequate no of load cell., digitizer and intelligent terminal with printer facility for 

computerized zed print out of the weight. 

(a) Belt ratings with appropriate ratings shall be selected. 

(b) Minimum number of plies for belting shall be four (4) if possible, can be standardized 

with the type of belting available with NALCO. 

(c) For Pulley, following minimum parameters shall be adopted: 

(1.) Shell thickness : 16 mm (Min.) 

(2.) End disc plate thickness : 24 mm(Min.) 

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

(4.) Diameter for all drive pulleys shall be minimum 800 mm. Di Diameter of all other 

pulleys shall be minimum 630 mm 

The contractor shall obtain confirmation from belt manufacturers regarding the adequacy of 

the pulley diameters. 

2.1.2 Wagon Tipplers 

(a) No. required: 1 (One) 

(b) Guaranteed tips per hour per tippler: 20 

2.1.3 Side Arm charger 

(a) Nos. required :1 (one) 

(b) Guaranteed haulage : 60 fully loaded coal wagons (Box –N) 

2.1.4 Apron Feeder 

(a) No. required : One (1) 

SECTION 4 

Technical Specification:Sec-4,System System Parameters, Operation & Control Philosophy 

Page 1 of 64

(b) Guaranteed (rated) capacity: 1200 TPH Apron Feeder 

2.1.5 E.O.T Crane 

(a) No. of unit : One (1) 

(b) Guaranteed (rated) capacity (Main/Aux.) : 25 T /5 T 

2.1.7 Dust Control System 

The parameters for the dust control system specified hereinafter are intended for 

Contractor’s guidance only. Contractor shall provide adequately sized and effective dust 

control system, the performance of which shall 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 ssystem 

ystem shall not be less 

than that specified below. 

(a.) Area Dust Suppression System at Wagon Tippler 

(1) Location 

: Wagon Tippler Top 

(2) Capacity of each nozzle : 2.0 lpm at 2.5 kg/ cm 

(3) Nozzle spacing. 

All nozzles to operate simultaneously in each wagon tippler area. 

2 

(3) Nozzle spacing. : 500 mm 

simultaneously in each wagon tippler area. 

(b) Dust Suppression System for other areas 

(1) Operation 

: Water sprayed with fogging nozzle 

(2) Location of spray : All coal loading and discharge point on the 

conveyor 

(3) Capacity / Pressure : 2.0 lpm / 2.5 kg/cm 2 Water sprayed with fogging nozzle 

: All coal loading and discharge point on the 

inlet of spray head 

2.1.8 Service Water System 

Service water connections are to be provided in conveyor galleries & tunnels at 50 meter 

interval and one (1) no. on each floor of Transfer Point. 

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

(b.) Minimum discharge Pressure at tap point : 2 kg/sq.cm 

(c.) No of pumps : 2 nos. 

(d) No. of valves operated : 6 nos. simultaneously 

2.1.9 Ventilation System 

A Mechanical Ventilation System 

2.1.10 Chutes 

• For Underground Areas a Minimum of 15 supply air changes and minimum 7 exhaust 

air changes per hour. 

• For other Areas a Minimum of 10 supply air changes per hour. 

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

C. Air Conditioning System : 

• Adequate number of air changes to Maint Maintain ain uniform temp. & humidity. 


Page 2 of 64

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

2.1.11 Hoists 

Suitable hoists as specified elsewhere shall be provided for erection & servicing of all major 

equipment. The equipment to be covered shall include (but not limit to) all conveyor drive 

units, all pulleys, Apron feeder, sump pumps, various DS/service water/potable water pumps, 

gravity take up units, removal of equipment from tunnels, lifting of belt drum at all tr transfer 

houses. 

2.1.12 All other equipment under the scope shall be suitable to the system capacities parameters 

as specified above. 

3.0 OPERATION AND CONTROLS 

3.1 This section is intended to cover design, engineering manufacture, supply, erection, tes testing 

and commissioning of the complete control and instrument panel/desk with annunciation 

panel, etc. as specified hereinafter complete in all respects, required for the system. 

3.2 General Requirements 

The instruments and controls to be furnished and er erected ected under this specification are as 

required for safe and satisfactory operation of the plant & equipment under Wagon Tippler 

and Conveyor System Package, as outlined under mechanical section and as specified 

elsewhere in the specification. For the equip equipment ment and materials procured by the Contractor 

from his sub-vendors, 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 subvendors and supply instrumentation and control to ensure suitability of the 

system. 

3.2.1 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 Engineers (IEEE) 

• Instrument society of America (ISA) 

• National Electrical Code (NEC) 

• National Electrical Manufacturers Association (NEMA) 

• Bureau of Indian Standards (BIS) 

• Conveyor Equipment Manufacturers Ass Association (CEMA) 


Page 3 of 64

• Guideline for wagon tipplers issued by RDSO – G33 (Rev. 1) of May 2010 with latest 

amendments if any. 

3.2.2 This Sub-section section shall be read in conjunction with Electrical Sub Sub-sections. sections. 

3.3 Construction and Design 

3.3.1 Construction 

Control desks/panels and annunciation system shall be provided as per the requirement of 

electrical Section. Annunciation’s, indications, electrical meters and instrumentation shall be 

provided as specified. Ammeters shall be provided on control desk for a aall 

motors rated 30 

kW and above and for all equipment. 

3.3.2 Design 

The Contractor shall provide a comprehensive control indication and annunciation scheme 

for the plant & equipment under wagon tippler and conveyor system package and integrate 

the same with the existing control & monitoring scheme of the CHP. Contractor shall furnish 

a block diagram and write write-up up on the scheme proposed. The final scheme will be approved by 

the Owner/RITES and the Contractor shall be required to execute the approved scheme scheme. In 

general, interlocking shall be achieved through feed feed-back back signals from field equipment. A 

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 disp display ace of Control 

desk. 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 co considers nsiders 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 Owner. 

4.0 OPERATION AND CONTROL PHILOSOPHY 

4.1 The Wagon Tippler control room sh shall all be located by the side of Wagon Tippler to 

accommodate control & monitoring equipment of wagon tipplers. It shall also have a battery 

room. 

4.2 The existing coal handling system is being controlled from the following control points. The 

existing control ol philosophy of the coal handling plant is being described below for the 

contractor to understand the existing system and suitably plan integration of the controls 

and interlocks of the proposed control system of the wagon tippler package with the existin existing 

system. 

4.2.1 Owner’s Existing Coal Handling Plant Control Room 

Operation of the CHP equipment is being controlled from the Owner’s CHP control room. 

(a.) Conveyors, feeders, flap gates, hydraulic couplings etc. 

(b.) Complete Dust Suppression system & sservice 

water system. 

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

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


Page 4 of 64

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

(f.) Belt weigher (ON/OFF co control with indication) 

4.2.2 Local Control Panels 

Local control stations for following equipment shall be provided for 

(a) All conveyors 

(b) All gates 

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

(d) Wagon Tippler 

(e) Apron feeder 

(f) Sump Pump 

(g) ) Dust suppression system for wagon unloading 

(h) ) Hydraulic scoop coupling, if any. 

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. Necessary controls, indications and annunciation’s for all the above equipment shall also 

be provided at main CHP Control Room. 

4.2.3 In addition to the remote control of various equipments, local stop push butto button stations 

shall be provided for all equipment. 

4.3 SYSTEM OPERATION 

4.3.1 Typical Operation philosophy of the plant, in general, as elaborated below is for the 

information of the contractor to facilitate development of the control & monitoring scheme 

of wagon tippler and conveyor system package and integration with the existing control & 

monitoring system of existing CHP. 

(a.) Coal flow path selection shall be done from Owner’s existing control desk to select 

conveying paths. 

(b.) The coal handling system oper operator ator will select any one of the paths from the main control 

desk. The flow stream path is then selected by positioning different flap gates at desired 

positions. Once the system is in the operation, the gates can not be moved from their 

positions and path. Flap gates which do not fform 

rm the stream in which coal flow is taking 

place, can be operated at any time. 

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

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

rom Owner’s existing 

control desk. 

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” 


Page 5 of 64

is activated, all conveyors will also stop sequent sequentially ially (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 control desk. The operator will also stop the conveyor 

system, , by pressing "System stop" or individual “Stop” push buttons/command from control 

desk in the reverse sequence. System Start and System Stop PB’s and located on the 

Owner’s Control Desk. 

4.3.2 Conveyor System 

(a) Normally the operation of the apron feeder and the reclaim conveyor shall be controlled 

from main control room for evacuating coal from tippler hopper. 

(b) The 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 wagon tippler. 

(c) Each conveyor shall be protected against damage to the edge of the belt due to excessive 

sideways movement by providing 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. 

(d) All the conveyors shall be protected from roll back due to power failur failure by providing 

mechanical / or electrical locking system. 

(e) The starting sequence of the conveyors shall follow a direction opposite to that of flow of 

material. The details of Coal flow diagram of the existing stage stage-I I CHP shall be furnished to 

the successful bidder. 

(f) 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. 

(g) Pull-cord cord switches shall be provided along the length of each belt conveyor, which shall 

enable the respective conveyor to be stopped immediately. Each pull operated chord switch 

and belt sway switch shall be tagged and shall be identifiable in the main control room. 

(h) Siren shall be provided to fore fore-warn personnel sonnel working nearby when starting any conveyor. 

(i) Interlocking of various conveyors shall be achieved with Flap Gate, limit switches and zero 

speed switches. 

(j) Motors shall start only when the brake/rail clamp if if-provided, provided, is in “open” condition. This 

signal al shall be obtained from limit switch provided for that purpose. 


Page 6 of 64

(k) 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, to prevent 

jamming of gate. 

(l) Where ever scoop type coupling provided for HT motors, the coasting time of respective 

conveyor, thruster brake, actuator selection and the chute size shall be so selected such that 

there is no spillage of coal from any downstream conveyors. 

4.3.3 Interlocking 

a) The following conveyors / equipment are considered under interlock scheme : :- 

(1.) All conveyors 

(2.) All gates 

(3.) Wagon tippler 

(4.) Apron Feeder 

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 have local push button stations each consist of : 

(1.) Pos - I, Pos - II & stop button for flap gate 

(2.) Emergency stop push button (Red) for other equipment 

d) Belt scale is 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. Necessary input contact 

shall be made available lable to the Contractor in the Owner’s main control room. 

g) Interlock for H.T. Motor : H.T. motors used will continue to run on no load by 

disengaging the fluid coupling in case of failure of any process interlock. The H.T. 

motors will however be tripped in case of any motor fault like O/L, high motor winding 

temperature etc. In addition, in case of normal stop command, after running of the 

system, motors will stop. 

h) The following are the various safety interlocks for the conveyors and other equipment. 

This list st 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). Underspeed 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 


Page 7 of 64

Wagon Tippler 

a). Motor O/L - not tripped 

b). Local E-Stop PB - reset 

c). Stop PB in main CHP control room - reset 

d). All Limit Switches – reset 

e). All limit switches – not tripped 

Apron Feeder 

a). Motor O/L - not tripped. 

b). Local stop PB - reset. 

Flap Gates 

a). End of travel vel limit switches - reset. 

b). Torque limit switches - reset. 

c). Local stop - reset. 

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

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

4.3.5 Status indications in Mimic. 

Following individual status indications shall be provided in mimic with individual ON/ OFF 

/TRIP indications on HMI of PLC. 

(a.) Conveyor 'ON' 

(b.) Flap Gate/Rack and Pinion position. 

(c.) Belt scale flow rate indicati 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.) Wagon Tippler ‘ON' 

(h.) Apron Feeder ‘ON' 

(i.) .) DS/ SW/ VentON (System wise) 

Further Mimic lamps and Controls for HT and LT Breakers shall be provided on the control 

desk. 

4.3.6 Annunication System: 

The Control desk shall be provided with adequate number of facia type annunciation 

windows for the following audio audio-visual visual fault annunciation purposes. Wherever group 

annunciation is provided, alarm status of individual equipment shall be provided on mimic. 


Page 8 of 64

All audio visual annunciation of following parameters should be incorporated in the HMI of 

PLC. 

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

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

(c) Bus under voltage for each LT MCC 

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

(i) Buchholz alarm 

(ii) Winding/oil temperature high alarm 

(iii) Oil level low alarm 

(iv) Buchholz trip 

(v) 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) LT motor overload tripped (Group). 

(k) ) Belt sway switch operated (Group) 

(l) ) Pull cord switch operated (Group) 

(m) ) Zero speed switch operated. (Group) 

(n) ) Chute plugged (Group) 

(o) Wagon rake arrival. 

(p) ) Wagon Tippler tripped (group) 

(q) Apron feeder. 

(r)Dust Dust suppression/service water system faults and trips (system wise) 

(s) ) Water level low in tanks (group) 

(t) ) Oil temperature of fluid coupling high 

(u) 20% spare windows 

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 also 

start tart 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 cl 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, pre pressing ssing 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 conv conveyors eyors / equipment will start slow 


Page 9 of 64

linking while the faulty conveyor / equipment will be fast blinking. Start command shall not 

be initiated unless reset button in pressed after clearance offault. 

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

Condition 

Status 

Normal : Ann. Window : Off. 

Status indication : Steady glow 

Buzzer 

: Off. 

Fault : Ann. Window : Blinking. 

Status indication : Fast blinking 

Buzzer 

: Sounding. 

Press Accept PB. 

Ann. Window : Steady glow. 

Status indication : Fast blinking 

Buzzer 

: Off. 

Press Reset PB (When fault is cleared): 

Ann. Window : Off. 

Status indication : i) Steady blinking (if on selected path) 

ii) Off (if not on selected path) 

Buzzer. 

: Off. 

4.3.7 Dust Suppression System 

(a.) Conveyors / Equipment 

1. It shall be possible to spray the water on to coal stream only when corresponding 

conveyors/equipment’s are running with material at spray application points. 

2. If a running pump trips stand stand-by pump shall start automatically. lly. 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 high-high level in tank. 

6. All the controls shall be through control desk. 

(b.) Wagon unloading 

1. System shall be operated from local control panel. 

2. Dust suppression system shall be provided to cover the WT Hopper. 

3. Pumps shall be started manually or from control panel. . If any of the pump/pumps trips, 

stand-by 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. 


Page 10 of 64

(i) Motor electrical protection operated (Group) 

(ii) Discharge water pressure low (Group) 

(iii) Water level low in tank (Individual) 

6. Following individual indications shall be provided at local control panel. 

(i.) Motor ON/OFF/TRIP 

(ii.) Discharge pressure healthy 

(iii.) Water level high in tank. 

4.3.8 Sump Pumps 

(a) Sump Pumps shall start and stop by the level switches in the sump automatically. 

Further manual override start / stop push button shall be provided locally on ground 

level. 

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

(c) If the sump level continues to be high even after the first pump is under operation 

second pump shall ll 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. 

4.3.9 Wagon Tippler 

Wagon Tippler shall be controlled from the local control panel suitably placed. Require Requirement 

of operation as described elsewhere in the specification 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. 

4.3.10 Flap Gates 

All flap gates shall be motorised and remote controlled from the main control desk. Their 

position shall be indicated on the mimic of main control room. 

4.3.11 Service water and Cooling Wa Water 

(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 er pressure low 

(3.) Water level low in tank 

(4.) Water level high in tank 

5.0 WAGON TIPPLER 

GENERAL 

Rotaside / Rotary wagon tippler shall be furnished complete with all structural members, 

tippler platform, tipping mechanism, tippler drive motors, brakes, couplings, shafting and all 


Page 11 of 64

automatic controls for positioning, tipping and discharging the entire ccontents 

ontents of the wagons 

into the hopper. 

5.1 Wagon Unloading System 

5.1.1 The rake comprising of specified maximum maximum60number number of wagons shall be pushed into the 

reach of in-haul haul equipment by a locomotive. Further placing of wagons over tippler 

platforms and carrying aw away ay the empty wagons shall be accomplished with the help of a side 

arm charger under scope of bidder. 

5.1.2 Wagon unloading equipment shall be suitable to handle any type of wagons being used by 

Indian Railways for transportation of coal. Thus side arm charger aand 

nd wagon tippler shall be 

suitable to handle all standard broad gauge (1676 mm) wagons of RDSO design used by 

Indian Railways conforming to latest revision of IS: 10095. 

5.1.3 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. 

5.1.4 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. 

5.1.5 The bidder shall obtain all statutory approvals from the relevant Railway authorit authorities, before 

the wagon tippler complex is put into operation. Any statutory payment charges, to be made 

to the concerned authorities shall be to Bidder’s account. It is the responsibility of the 

Contractor to carry out any modifications as required by the RRailway 

ailway authorities, at no extra 

cost to the Owner. 

5.2 Wagon Tippler Hopper 

5.2.1 The wagon tippler hopper shall be of RCC construction and adequately sized to 

accommodate the coal load for atleast two (2) nos. 8 wheeled wagons of RDSO design used 

by Indian ian 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 sh 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 sto stock ck from the hopper. 

5.2.2 Steel gratings of mesh size 30 300 mm x 300 mm over wagon tippler hopper shall be provided. 

The gratings shall be built of minimum 200 mm x 36 mm thick flats. The hopper and gratings 

shall be designed for movement of ffront 

end loader/bulldozer over them. Bull Bull-dozer weight 

shall be considered as about 35 T. 


Page 12 of 64

5.3 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, shal shall l 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 Engineer shall be final and bindi binding. 

5.4 DESIGN REQUIREMENT 

Keeping in view Technical guideline issued by RDSO (Research & design services organization 

)G 33 Rev.01 issued on May’10 & effective from Dec’10, the specification of wagon tippler 

along with apron feeder to be designed as under: 

a) Wagon tippler capacity : 25 Tips per Hour 

b) Load handling capacity of wagon tippler : 140 Ton 

5.4.1 The wagon tippler shall be suitable to unloa unload a coal wagon. 

5.4.2 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. 

5.4.3 The tippler shall be suitable for continuous operation, 24 hours a day, round the clock. 

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

Railway’s “Research, Design and Standards Organisation, (RDSO) - G 33 Rev.1 ” 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. 

5.4.5 The wagon tippler shall be suitably counter balanced at each stage of operation so as to 

require minimum driving power. 

5.5 WAGON TIPPLER WEIGHING SYSTEM 

5.5.1 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 ti tippler 


Page 13 of 64

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 th 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, wago wagon n no., time, date etc. the weighbridge 

shall be chosen to accommodate all types of wagons as per RDSO guidelines to move coal. 

The weighbridge shall be supported on minimum 4 nos. compression type load cells 

mounted on free motion structural unit assembly. 

Alternatively, in-motion motion weigh scales in both in in-haul and out-haul haul tracks shall be provided 

for the purpose. The load cells shall be suitable for dusty environmental conditions. The 

calibration of the weigh bridge shall be the scope of the bidder. The bbidder 

idder shall co co-ordinate 

with statutory authority to get the necessary stamping & other requirements. 

6.0 CONSTRUCTION REQUIREMENT 

6.1 Cradle 

6.1.1 The cradle shall consist of a pair of heavy welded steel plate sections reinforced with 

stiffeners and connected cted by side bearer beams pivotally attached, each section being fitted 

with a massive trunion shaft carried in bronze bushed cast steel bearings on each side, 

bolted to steel pedestal carried on concrete pedestals. Circumferential driving rack shall be 

rigidly gidly bolted to the peripheries of the sectors. The sectors shall be made of cast steel. 

Necessary features of safety against coming down of wagon tippler in the event of failure of 

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

indicated in the bid. 

6.2 Rail Table 

6.2.1 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. 

6.3 Feeders and Clamps 

6.3.1 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. 

6.4 Spill Plate 

6.4.1 Fixed to the cradle of the tippler shall be a plain steel spill plate for deflecting material into 

the tippler hopper. 

6.5 Driving Gear 


Page 14 of 64

6.5.1 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 hydr hydraulic 

motors using gear boxes as applicable. Suitable oil coolers shall be provided for hydraulic 

power pack. Suitable dust protective cover shall be provided. 

6.6 Brake 

6.6.1 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. 

6.7 Limit Switches 

6.7.1 Limit switches of suitable type which can be readily adjusted to give the desired tippling 

angle shall be provided. An emergency over tip lim limit it switch operated by a striker on the 

tippler trunnion shaft shall be furnished. 

6.8 Ballast 

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

requirement. 

6.9 Lubrication 

6.9.1 All bearings shall be properly lubricated. Grease nipples and reservoirs shall be furnished 

where necessary. 

6.10 Guards 

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

6.10.2 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. 

7.0 DATA SHEET 

7.1 GENERAL 

Wagon Type 

: All types of wagons in coal transport used by Indian 

Railways to move coal (as per latest test RDSO guidelines) 

Moving Profile 

: As per IR norms. 

No. of tips (guaranteed) : 20 per hour. 

Designed : 25 Tips per Hour 

Rail Gauge 

: 1676 mm. 

Weigh bridge 

: Load cell type 

Duty 

: Continuous 24 hrs. 

7.2 DESIGN & CONSTRUCTION 


Page 15 of 64

A. Wagon Tippler Hopper 

Construction 

: RCC Construction. 

Size 

: To accommodate atleast 2 nos. 8 wheeled wagons wagons. 

No. of openings : One (1) 

Angle of repose of coal for 

wagon tippler hopper sizing : 37° 

Lining 

Steel Grating 

: 50 mm thick guniting. 

(i) Mesh size : 300 mm x 300 mm 

(ii) Grating Section : 200 mm x 36 mm thick flats. 

B Wagon Tippler 

Type 

: Rotaside / Rotary type (As per latest RDSO guidelines) 

Tipping angle : The Wagon Tippler shall be suitable to unload Coa Coal wagons. 

The angle of tippling shall conform to RDSO GG-33 

(Rev – 1) 

Technical pamphlet for requirement of tippler installation 

for approval by RDSO. 

Duty Requirement : Continuous operation 

Counter balancing : Suitable to keep power requirement at minimum. 

Cradle 

: Heavy welded steel plate construction trunion mounted. 

Driving Gear 

(i) Racks 

: Cast steel rack sections bolted to end sectors. 

(ii) Pinion 

: Multiple pinions meshing with rack. 

8.0 SIDE ARM CHARGER 

8.1 GENERAL 

Rail Table 

: Rolled steel joists with ith steel rails mounted on it. 

Drive 

: Hydraulic motors. 

Brake 

: Electro hydraulic thruster operated. 

Clamping 

: Hydraulically operated 

Top & side stops : Self aligning type made of resilient material. 

8.1.1 Side Arm Charger shall be furnished complete with travel rails, drive equipments and 

associated accessories. 

8.1.2 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 c ccharger. 


Page 16 of 64

8.2 CODES & STANDARDS 

The design, manufacture, inspection and testing of Side Arm Charger shall comply with all 

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

equipment is to be installed and all nor norms stipulated by RDSO- G 33 Rev.1. The Side Arm 

Charger 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 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 Engineer shall be final and binding. 


8.3.1 A single module of side arm charger shall be used for inhaul and outhaul operations. Thus, 

side arm charger shall be used for indexing forward the rake of 60 nos loaded wagons, 

placing decoupled wagons on the tippler table and out hauli hauling ng the empty wagons. 

8.3.2 The rake of 60 loaded wagons will be brought by locomotive and placed on the retipping 

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 wwagon, 

agon, pull the rake of 60 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 de-coupled. Now the 

leading wagon will be placed centra centrally lly 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 de-coupled coupled from the loaded wagon. Adequate 

clearance between tippler table aand 

nd empty wagon shall be ensured. The side arm charger 

will stop at the end of its strokes, the arm will be swung vertically vertically-up up and the machine will 

move towards in-haul 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. 

8.4 TECHNICAL REQUIREMENTS 

8.4.0 CONSTRUCTION REQUIREMENT 

8.4.1 The Side Arm Charger shall be suitable to handle handle60 number of loaded wagons wagons. The pusher 

arm shall be vertically rotatable arm mounted on a carriage running back and forth parallel 

to the train track. 

8.4.2 The arm shall be raised to clear the movement of wwagons 

agons 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. 


Page 17 of 64

8.4.3 The arm shall be raised and lowered by means of hydraulic cylinder mounted on the 

carriage. iage. Suitable means shall be provided to prevent damage to the arms should the arm be 

accidentally lowered into the side of wagon. 

8.4.4 The arm shall be of robust construction either of cast steel or of heavy duty fabricated steel 

for the required duty. 

8.4.5 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. 

8.4.6 The carriage frame shall be a suitable fabrication assembly of large proportions massive 

enough in strength and rigidity for the required duty. 

8.5 Travel Carriage Drive System 

8.5.1 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. 

8.5.2 The rating of the drive equipment and its characteristics shall match with indexing forces 

required quired to be exerted in varying amounts depending upon train dynamics and to suit 

haulage of 60 wagon loaded rake. 

8.5.3 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 positioned arm to the 

foundation. The wheels/rollers shall be of forged steel and shall run on the rails supported 

over the RCC pedestal. 

8.5.4 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 mal-operation. 

9.0 DATA SHEETS 

9.1 GENERAL 

Quantity 

No. of wagons to be handled By 

: 1 (One) no 

each side arm charger at a time : 60 

No. of tips by wagon tippler 

: 25 per Hour (designed) 

: 20 (min.) per hour (guaranteed) 

9.2 DESIGN & CONSTRUCTION REQUIREMENTS 

Arm : Robust construction either of cast steel or heavy duty fabricated 

steel. 

Arm Drive : Hydraulic cylinder 


Page 18 of 64

Carriage Frame 

Travel Carriage drive 

: Single fabrication assembly. 

Motor : Hydraulic 

Travel brake : Integral part of hydraulic motor 

Bearings for sheaves : Anti friction bearings. 

10.0 APRON FEEDER 

10.1 GENERAL 

Apron feeders complete with all accessories shall be furnished for wagon tippler hoppers as 

specified. 


The design, manufacture, inspection and testing of apron feeders shall comply with all the 


equipment is to be installed. The apron feeders shall conform to the latest edition of the 

standards and codes. Other internationally acceptable standards/codes, which ensure equal 

or higher performance e 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 of 

the Engineer eer shall be final and binding. 

10.3 DESIGN REQUIRMENTS 

Apron feeders shall be of robust construction & designed for handling ROM coal as specified 

and without any choking particularly during rainy season when coal is sticking. A drible 

conveyor shall be provided for proper clean up. The pan and chain shall be of proven design 

and shall be with adequate factor of safety. 


The frame shall be manufactured from rolled steel section welded and bolted together to 

form a rigid structure. cture. 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 thickn 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 bbe 

e provided for the tensioning of the chain chain. 

Complete dribble belt system consisting of head pulley, tail pulley, drive, motor, stringers, 

deck plates etc. shall be provided. 


Page 19 of 64


Capacity (TPH) : 1500 MTPH ( Design) 

1200 MTPH ( Rated ) 

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 

11.0 No sizer or crusher is required. 

12.0 DRIVE EQUIPMENT 

GENERAL 

Suitable Drive Chain Equipment’s like electric motors, gearboxes (where applicable), fluid 

couplings (where applicable), flexible couplings and other accessories shall be provided for 

all the belt conveyor systems, wagon tippler tippler, , side arm charger, apron feeders, various 

pumps of dust suppression 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 ffor 

or individual equipment’s shall be taken into consideration while 

designing the associated drive chain equipment’s. 

12.1 CODES AND STANDARDS 

The design, manufacture, inspection and testing of Drive Equipment shall comply with all 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 standards/codes, whic 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 specif specification, ication, the decision of 

the Owner shall be final and binding. 

IS:3688 : Dimensions for shaft ends 

IS:3681: General plan for spur & helical gears 

IS:7403 : Code of practice for selection of standard worm and helical gear boxes 

12.2 DESIGN AND CONSTRUCTION REQUIREMENTS 

12.2.1 GEAR BOXES 

12.2.2 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces. 

12.2.3 The gearboxes shall be designed for 24 hours continuous duty and gear boxes shall have 

appropriate thermal rating. 


Page 20 of 64

12.2.4 The e 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. Ab Above 40 kW drive 

rating, all gearboxes shall be helical or bevel helical type only. 

12.2.5 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. 

12.3 COUPLINGS 

12.3.1 Flexible / Rigid Couplings 

Approved type of 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. Geared type flexible coupling shall be used on 

low speed side ide for all conveyors and other drive chains where gear box is provided. Other 

couplings in the drive chains shall be either rigid or flexible type, depending upon the 

requirement of equipment design and shall be finalized during detailed engineering. 

12.3.2 Fluid Couplings 

Fluid couplings shall be provided in all the drive machinery for wagon tipplers & associated 

belt conveyor systems if the actual power requirement at motor output shaft is more than 

40 kW. The fluid coupling for LT motors shall be of tr traction action 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. 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 shall necessarily 

be provided for circulating the fluid coupling oil through oil cooler. Independent 

arrangement for forced cooling wat water er supply using 2X100% capacity pumps 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 eptable levels. Suitable pressure indicators and flow indicators shall be 

provided in the cooling water lines along with all all-relevant relevant valves, strainers 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 n nnormal 

operation 

shall result in scoop tube re re-positioning 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 act actuator uator for scoop type fluid coupling 

shall be made taking into consideration the coasting time of downstream and upstream 

conveyors and the engagement/disengagement time achievable. The scoop tube operation 

must be such so to ensure quick draining out of oi oil l from the operating circuit, by providing a 

double speed motor. 


Page 21 of 64

12.4 DATA SHEET: DRIVE EQUIPMENT 

GENERAL 

12.4.1 Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for 

Electric Motors 

a) For conveyors of belt conveyor systems and belt for In line magnetic separator: 

*120% 120% of actual power at drive motor output shaft at specified design capacity 

b) WT, SAC, apron feeders: *110% 110% of actual power requirement at drive motor output 

shaft at guaranteed (rated) capacity. 

c) Mono-rail rail hoists (travel and hoisting), various pumps of DS systems, service water 

systems, cooling water system, potable water system and sump pumps: *110% of 

actual power requirement at drive motor output shaft at guaranteed (rated) 

capacity. 

d) Ventilation Fans: *110% 110% of actual power requirement at drive motor output shaft at 

guaranteed (rated) capacity. In case of belt drive, the efficiency of transmission shall 

be considered as 95%. 

*The The actual power at drive motor output shaf shaft t shall be calculated after considering all the 

losses of down the line equipment’s of the drive train. 

1.0 Drive Equipment Rating 

a) For Conveyors : 120% of actual design requirement 

b) Other Equipment 1 x 100 % duty: 120% of actual design requirement 

c) ) Other Equipment 2 x 50 % duty: 110 % of actual design requirement 

2.0 DESIGN & CONSTRUCTION REQUIREMENT 

2.1.0 Gear Box 

2.1.1 Type 

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

(b) Above 40 KW: Helical / bevel helical wwithout 

cooling coil 

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

recommendations 

2.1.3 Ambient temperature for Thermal rating: 50 

2.1.4 Mounting: On Machined/Ground Surfaces 

2.1.5 Output Rating: 

a) For belt conveyor systems 

requirement at drive pulley shaft at design capacity} 

b) For other equipment 

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. 

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

C Minimum 

2.1.4 Mounting: On Machined/Ground Surfaces 

a) For belt conveyor systems @ Service factor X {1.2 times the actual power 

requirement at drive pulley shaft at design capacity} 

b) For other equipment @ Service factor X {1.2 times the actual power requirement 

of the driven equipment } 

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 

2.2.0 Flexible Couplings: 

2.2.1 Type: Geared capacity. 

2.2.2 Rating: Not less than han motor rating. 


Page 22 of 64

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 rating 

13.0 EOT CRANE 

13.1 GENERAL 

An E. O. T. crane complete with all accessories shall be furnished for maintenance at wagon 

tippler house. 

The design, manufacture, supply erection and commissioning of EOT crane complying with 

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

equipment is to be installed. The EOT crane shall conform to the latest edition of the 

standards and codes. Other internationally acceptable standards/codes, which insure equal 

or higher performance than those specified, shall also be accept accepted. ed. Nothing in this 

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


the Engineer shall be final and binding. 

13.2 DESIGN REQUIREMENTS EQUIREMENTS AND CONSTRUCTION REQUIREMENTS 

The crane shall be generally of box type double girder construction and shall designed for 

appropriate class of duty in accordance with BSS: 466/1960 and or IS:3177 to meet the 

installation and maintenance of wag wagon on tippler and the associated equipment. 

The bridge should comprise of two main girders with two out riggers and the end carriage 

built up from mild steel channel with adequate diaphragms or stiffing plates. Each bridge 

girder shall be fabricated and dis dispatched without any spliced joints. 

Box Girder & End carriage joints shall preferably have fit bolts. For all bolted joints the holes 

are to be drilled and reamed and bolts are to be force fitted. 

Hand railing shall be fitted on both sides of the end carriages and throughout the length of 

the platform (height of 1.1m) parallel to girder. Size of the hand rail shall be not less than 25 

mm bore heavy gauge steel pipe. The vertical pipes shall have flanges at the bottom for 

proper support. Suitable hand rrailing 

ailing should be provided on Cross Travel Trolley also. 

All Rotating parts & Overhang parts shall be provided with suitable guard. 

The end carriages shall be of approved design, with L type Brackets of substantial 

construction and ample stiffness built up of mild steel sections securely welded. 

The end carriages of the crane are to be mounted on double flanged wheels of approved 

diameter in accordance with IS: 3177. Number of wheels on each side of the crane shall be 2 


Page 23 of 64

Nos (Total 4 Nos in the Crane ffor 

or Long Travel motion) The Wheel shall be of forged steel 

having composition as Cr 55 Mn 75 (EN 9) hardened to 300 300-350 350 BHN with minimum depth 

10mm confirming SAE 1055 / IS 1570 & shall be fitted with roller bearings with dust proof 

seals. For lubrication, Grease nipples shall be provided at convenient points. 

Twin drive system to be adopted for Long Travel of E. O. T. in the bay. 

One wheel in each carriage is to be driven by forged steel gears through a motor mounted 

on or adjacent to the carriage. 

Long travel mechanism shall be provided with, a thruster brake on each individual drive of 

the track wheels. These brakes shall be such that it can be operated from both the control 

desk as well as remote control. The brakes shall be of post type with hing hinged shoes, lined 

with good quality reinforced bonded brake lining and suitable for easy of adjustment of the 

wear on lining. 

An independent additional mech. / electrical operating brake are to be provided with LT 

motion to stop the crane immediately in ca case of power failure. 


13.3.0 CAPACITY AND LEADING DIMENSION 

13.3.1 Safe Working Load: Main Hoist - 25T 

13.3.2 Safe Working Load: Aux. Hoist - 5T 

13.3.3 Duty as per I.S.3177 (Latest Amendment) 

13.3.4 SPEED OF MECHANISMS: 

(a) Main hoist Hoisting / Lowering - 6 M/Min 

(b) Aux. Hoist Hoisting / Lowering - 8 M/Min 

(c) Cross Traverse (CT) Forward/ reverse - 10 M/Min 

(d) Long Travel (LT) Left / Right - 30 M/Min 

13.3.5 (a) Normal Span: Actual span & other dimensions as required as per structural steel 

shed of wagon tippler shall be evaluated by the bidder and confirmed in the bid. 

13.3.6 (b) RailCenter to Center: Bidder to confirm 

13.3.7 Gantry Rail heights above floor level: Bidder to confirm 

13.3.8 Hook lift above flo floor or level to be provided: Bidder to confirm depending upon actual 

site condition 

13.3.9 Type of Hook - Shank type 

13.3.10 Available head height above rail top: to be confirmed by Bidder 

13.3.11 Available side clearance from gantry rail center: Bidder to confirm 

13.3.12 Location 

Wagon tippler shed, Bay Length & Width: Bidder to confirm 

13.3.13 Electric power supply - 415 Volt, 3 Phase, 50 HZ A.C. Supply 

13.3.14 Gantry rail size - Bidder to confirm. 


Page 24 of 64

14.0 MONORAILS AND HOISTS 

14.1 GENERAL 

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 Owner. For this purpose Contractor shall provide monorails and hoist 

blocks with cross travel facility. 

14.1.1 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 al 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 


the Owner/RITES shall be final and binding. 

14.2 DESIGN REQUIREMENTS 

• 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 gener general al engineering purposes 

• IS:210 : Cast Iron Castings 

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

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

travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both 

travel and lift. For hoists for GTU’s and bend pulleys clause no. 1.02.18 shall be referred to. 

All monorails coming out of the buildings shall be provi provided ded with electric hoist blocks, 

irrespective of load and lift. Minimum 3 meter length of Cantilever shall be provided in 

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

building sidewalls and any other facilities be beneath neath the floor upto ground level. 

14.2.2 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 Owner Owner/RITES at the 

time of detailed engineering. Us Use e of single hoist shall be avoided for handling more than one 

equipment. 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 e 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 


Page 25 of 64

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. 

14.2.3 Monorails shall be extended outside the building to handle the equipment to g gground 

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. 

14.2.4 Electrically operated monogirder typ type e 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. 

14.2.5 The electric hoist shall be de designed signed and constructed in accordance with the latest revision of 

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

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

motors. Motors shall be as per technical re requirements quirements discussed elsewhere. However the 

motors shall be suitable for 150 starts per hour at 40% CDF. 

14.2.7 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. 

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

driven through motor. 

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

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

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

14.2.10 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. 

14.2.11 All running shafts and wheels shall be fitted with roller bearings with a rated life not less 

than 20 years based on eq equivalent running time as per IS:3938. 

14.2.12 An electromechanical brake shall provided for hoisting as well as cross travel. Brake lining 

shall be of asbestos. 


Page 26 of 64

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

14.2.14All chain n 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 for bottom look. 

14.2.15 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 disturb disturbing other equipment. 

14.2.16 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 load loads in all working positions. 

14.2.17 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. 

14.2.18 Hoist for Gravity Take up arrangement and bend pulley. 

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

arrangement shall be provided: 

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

Further minimum four (4) nos. manually operated chain pulley blocks of adequate capacity 

shall also be provided for the entire coal handling plant for handling bend pulleys. 

(2) For handling take-up 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 take-up 

pulley only of conveyors. 

(3) For handling take-up up weight, a separate mmanual 

anual 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. 


14.3.1 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 mai maintenance. ntenance. Each rope shall have not more than 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 nd it should not be caught between the gear wheel. 

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


Page 27 of 64

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

on antifriction iction bearings and shall be easily removable for repair/replacement. 

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

IS:8610. 

14.3.5 All gears and bearings shall be lubricated by grease. All lubricating po points ints shall be grouped 

together in easily accessible position. 

14.3.6 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. 

14.3.7 All parts requiring replacement/inspection/lubrication shall be accessible without need for 

dismantling of other parts/structures. 

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

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

floor level stating safe working load. 

14.3.10 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. 

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

standing man. 

14.3.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 1.5m) with 

ladder shall be provided for each hoist. 

14.3.13 Each inline magnetic separator shall have in independent dependent motorised hoist for its handling / 

maintenance purpose. Each suspended magnet shall also be provided with a dedicated 

electric hoist. 

14.4 DATA SHEET : MONORAILS AND HOISTS 

1.0 GENERAL 

1.1 Functional Requirement : To transfer equipment’s to maintenance a aarea 

or outside 

the building. 

2.0 DESIGN & CONSTRUCTION REQUIREMENT 

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 out-side the 

buildings: Motor driven for both travel & lift. 

(ii) Other hoists including the hoists for handling takeup pulley and takeup 

weight: Manual for both travel & lift. 

2.1.2 Maximum trolley travel speed for electric hoists: 15m/min 


Page 28 of 64

2.1.3 Maximum Hoisting speed for electric hoists: 6 m/min 

2.1.4 Drive Motors: SQIM, Separate for travel & lift 

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

2.1.6 Wire Rope 

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

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

2.1.7 Bearing 

(i) Type: Ball/Roller bearing 

(ii) Life: 20 years 

2.1.8 Brake: Electro Mechanical type with asbestos lining. 

2.1.9 Load Hook: Swiveling type forged circular shank section. 

2.1.10 Duty: Class –2 

2.2.0 Monorail location/layout 

2.2.1 Cross section I beam 

2.2.2 Distance between CC/L 

/L of monorail & C.G. of equipment to be lifted Maximum 500 

mm 

2.2.3 Power Cables Support Festoon type arrangement 

2.3.0 Manual Hoists 

2.3.1 Maximum manual effort for operation. 30 Kg 

15.0 CHUTES AND HOPPERS 

15.1 GENERAL 

Chutes & Hoppers, flap gates and 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. 

15.1.1 CODES AND STANDARDS 

The design, gn, manufacture, inspection and testing of Chutes & Hoppers shall comply with all 

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

equipment is to be installed. The chutes, hoppers shall conform to the latest editio edition of the 

following standards and codes. Other internationally acceptable standards/codes, which 

ensure equal or higher performance than those specified, shall also be accepted. Nothing in 

this specification shall be construed to relieve the,contractor of tthe 

he required statutory 


the Owner/RITES 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. 

15.2 DESIGN AND CONSTRUCTION 

15.2.1 Chutes, Hoppers 

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


Page 29 of 64

15.2.3 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without 

any accumulation anywhere. 

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

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

15.2.5 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 ute 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. 

15.2.6 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL or equivalent material. 

However, Contractor ntractor to submit test certificates stating composition of material and 

mechanical properties of these wear resistant steel to the Owner during detail engineering. 

Long chutes guiding flow from considerable height shall be provided with impact plates 

wherever ever change in direction of flow takes place. Hinged inspection doors (generously sized) 

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. 

Maximum distance between two inspection doors in a chute shall be 2 mtrs. For s ssealing 

of 

inspection doors labyrinth type arrangement (with rubber inserted in grooves) to be 

provided. In addition to positive locking arrangement, mounting bolts, to tighten the door 

further against rubber shall also be provided. 

15.2.7 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 non-striking striking surface i.e. the covers oof 

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 fl 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 TISCR TISCRAL AL 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, the constitu constituent ent plates used shall be in one piece. No welds in between 

shall be allowed. In the zones of direct impact due to Coal trajectory, wear resistant backing 

plate with stiffners shall be provided in coal flow chutes. Similar backing plates & stiffening 

arrangement ement shall also be provided on the chute surfaces having direct coal fall. 


Page 30 of 64

15.2.8 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 suit suitable 

access to them. Further, serrated rubber seal shall also be provided at the very inlet of head 

chute to minimise dust nuisance. 

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

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

hinged with positive locking facility. 

15.3. Skirt Boards 

15.3.1 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable 

‘Skirt Plates’ of minimum 3.0 meters length shall be provided at each feeding point of 

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

beltswhere coal of appreciable lump size (250 mm) is being conveyed 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 holdi holding ng 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. 

15.4 Flap Gates 

15.4.1 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. 

15.4.2 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 r rrated 

load 

and thrust. The equipment shall be shop tested to prove this requirement. 

15.4.3 The motor rating for the actuator shall be so selected as to provide sufficient thrust for 

operation of the flop gates against the moving weight of coal and/or fla flap p gate. The flap gate 

travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight. 

15.4.4 Lever arm shall be provided between actuator and flap gate shaft for obtaining required 

thrust. The linkage mechanism proposed shall be indicated in the Bid. 

15.4.5 The actuators shall be capable of preventing any over travel. Suitable travel dependent limit 

switches controlling the travel of the flop gates on either direction shall be furnished. These 


Page 31 of 64

shall be placed internal to the drive unit and shall be completely dust dust-proof. The limit 

switches shall be capable of adjustments to vary the total length of travel of the gates. 

15.4.6 Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip 

off the e actuator motor in case of excessive thrust due to jamming of the gates during its 

travel in either direction. The same shall also be integral to the drive unit and shall be dust 

proof. 

15.4.7 Provision for alternative manual operation shall also be mad made e using declutchable 

handwheel. The diameter of handwheel 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. 

15.4.8 All the two way chutes, one way of which is leading towards the future conveyor, shall be 

provided with blind flange and flap gate with a provision to mount an actuator in future. 

15.4.9 The Contractor shall furnish calculations for selection of actuator for each location for 

approval of Owner/RITES /RITES. 

15.4.10 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 sh shall all rest on a suitable 

projected surface from chute to prevent leakage of coal dust through the available clearance 

between chute and flap gate. 

15.4.11 Maximum feasible counterweights shall be provided for better utilisation of system. 

However, for calculation lation of thrust required, the benefit of counterweight shall not be taken 

into considerations. 

15.4.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. 

Suitable provision for re--greasing 

shall be provided. 

15.4.13 For standardisation 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 co component mponent wise shall be 

completely interchangeable for all locations. 

15.4.14 The material of shaft shall be EN EN-8 8 or equivalent. The diameter of the shaft shall be suitable 

for motor stalled condition and associated twisting. 

15.4.15 Approach/maintenance platforms complete with the chequered plate floor, hand rails, 

ladders etc. shall be provided for all flap gates. 

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


Page 32 of 64

15.4.17 On both faces of flap gate main plate, 20mm thick TISCRAL liner pla plate te or equivalent material 

shall be provided. 

15.5 DATA SHEET : CHUTES AND HOPPERS 

1.0 GENERAL 

1.1 Coal Parameters As specified elsewhere 

2.0 DESIGN & CONSTRUCTION 

2.1.0 Chutes & Hoppers 

2.1.1 MinimumValley Angle: 60 degrees 

2.1.2 Material : 

(a) Chute work 

Sliding zones & adjacent sides : 20 mm thk. TISCRAL / equivalent 

No striking/ Non sliding zones : 10 mm thk MS 

Chute with valley angle 80 degree and above : All four sides of 20 mm thk. 

TISCRAL/equivalent material 

In the zone of magnetic field of ILMS (chute above floor level) : SS-304 304 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 Size of Chutes 

: Minimum 1200mm X 1000mm (inside both way ways) 

2.1.4 Inspection Doors 

2.1.5 Chute Construction 

:Hinged & leak proof construction (min. size 35 x 45 cm) 

(a) Corners: One face of removable bolted flange connection 

(b) Joints Bolted: flange joints of dust tight construction 

(c) Bolt size: Min. MM-16 

(d) Bolts spacing: Not more than 125 mm C/C 

(e) Fixing Arrangement: Bolts with plain spring washers 

2.2.0 Skirt Boards 

2.2.1 Length : Min. 3 m for each feeding point 

2.2.2 Height : Not less than 750 mm 

2.2.3 Width : 2/3 of belt width 

Side plate : Min. 10 thk TISCRAL/equivalent 

Top cover : 6 mm thk M.S. 

2.3.0 Flap Gate 

2.3.1 Type: Linear actuator operated, 2 position 

2.3.2 Travel: 60 to 70 deg. (with limit switches on both sides). 

2.3.3 Automatic operation 

(i) Drive: Dust tight motor driven wit 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. 


Page 33 of 64

2.3.4 Manual Operation 

(a) 

(b) 

2.3.5 Flap gate shaft 

(i) Diameter: minimum 130 mm 

(ii) Material: EN-8 

16.0 DUST CONTROL AND MISCELLANEOUS SYSTEM 

16.1 GENERAL 

INTENT OF SPECIFICATION 

16.1.1 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 Wagon Tippler Package. 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/Owner's and shall coordinate his work 

with the work of other Contractors. 

16. 1.2 Dust Control System 

The dust control system to be furnished under this specification is required for control of 

fugitive dust emissions from dust generation points such as transfer points, feeders etc. Dust 

control is achieved by dust suppression sys system. tem. 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 Owner Owner/RITES approved guidelines or any 

internationally recognized hygienic SStandards/Codes. 

tandards/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 he 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. Water scheme dust suppression 

shall be provided as indicated in tender drawings. Clarified water shall be used for Service 

water system, Plain water dust suppression system shall be used for all receipt and discharge 

points in Transfer. 

16.1.3 Miscellaneous Systems 

Maximum effort : Convenient for single 

operator by declutchable hand wheel regardless 

of electrical power. 

Minimum Handwheel : Diameter 500 mm 

Service water system, p otable water system, cooling water system & sump pumps shall be 

provided as specified elsewhere in this specification and as indicated in tender drawings. 

16.2 Scope 

16.2.1 Plain Water Dust Suppression System 

Complete with water supply system, piping, sp spray ray heads, pumps, drive motors with canopy 

(wherever required), couplings with enclosure, electricals, supporting structures, 


Page 34 of 64

approach/maintenance platforms, handling for equipment, civil and structural works and 

necessary accessories shall be provided for WT hopper top & all transfer points, etc. 

16.2.2 Sump Pump 

4x100% sump pumps alongwith level switches and piping up to nearest Owner'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. Sealing pumps with valves, 

piping fittings and other accessories for sealing of sump pumps shall be provided. 

16.2.3 Service Water System 

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. 

16.2.4 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, ints, jointing material etc. as required. 

(3) Instrument tapping connections, stubs. 

(4) Gate, 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 embedments 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 shall be routed/supported on concrete 

pedestal and conveyor galleries. Whereever the layout does not permit the pipes to be 

routed over ground, the same shall be buried in conformity to the relevant standards & 

shall be provided with necessary protective coating as per relevant standards. 

(9) Painting, anti-corrosive corrosive coatings etc. inside and outside pipe pipes s as necessary. 

(10) Welding electrodes and welding rods. 

(11) The area around storage tanks strainers, two valves etc. (located out side pump house) 

shall be paved with drains. 

16.3 Terminal Points 

Owner shall provide supply of water for dust suppression system, service water, potable 

water at one terminal point as elaborated elsewhere. Beyond the terminal point, the 

complete pipe work along with associated valves, specialities, instruments, fittings and 


Page 35 of 64

supports, pumps, tanks, etc. as required for the satisfactory operation of dust control, 

service water & potable water systems shall be furnished by the Contractor. 

16.4 Codes and Standards 

The design, manufacture, inspection and testing of Dust Co Control ntrol & Miscellaneous Systems 

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

locality where the equipment is to be installed. The Dust Control & Miscellaneous Systems 

shall conform to the latest edition of the following standards and codes. Other 

internationally acceptable standards/codes, which ensure equal or higher performance than 

those specified, shall also be accepted. Nothing in this specification shall be construed to 

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

standard and this specification, the decision of the Owner Owner/RITES shall be final and binding. 

• IS:778 : Gun Metal gate, globe & check valves for general purpose. 

• IS:780 :Sluice valves for water work works purposes (50 to 300 mm) 

• 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. 

• ANSI B 31.1:Code for pressure piping. 

• Hydraulic institute Standards of U.S.A. 


Plain Water Dust Suppression 

16.5.1 At specified locations dust suppression system shall be provided which comprises spray 

nozzles discharging plain water in a fine spray to capture air borne dust particles and direct 

them into the main in coal flow. Water shall be discharged via a pipe work system through 

spray heads at the dust suppression zones. 

16.5.2 Water shall be drawn from the water storage tank by 2x100% electric motor driven pumps 

and discharged into tank from where 2x100% dut duty y electric motor driven pumps shall 

discharge the water via a pipe network system through spray heads at the dust suppression 

zones. Solenoid valves shall be provided for open/close control of water line to each spray 

head. Each spray head shall consist of minimum 4 nos. nozzles. Spray heads shall be 

provided at coal loading and receipt zone. Pressure at inlet to spray head shall not be less 

than 2.5 Kg/sq.cm(g). 

16.5.3 The dust suppression system over the WT hopper shall have a canopy on which fogging 

nozzles zzles are fixed at specified distance. Each nozzle header shall be provided with adequate 

number of spray nozzles spaced at 500 mm interval so that the entire length & width of the 

wagon tippler hopper are covered by a grid of nozzles. Further, the water s sspray 

shall be of 


Page 36 of 64

fogging type with a minimum pressure of 2.5 kg/sq.cm(g) at spray nozzle inlet. It should be 

possible to operate any number of zones simultaneously. The operation of wagon tippler 

dust suppression system shall be automatic so that the foggi fogging ng water spray shall get 

activated only when the tippling is in operation. 

16.5.4 Each spray head shall have a provision for installing a pressure gauge whenever required. 

Further, pressure gauges shall be provided at least at two locations. 


Sump pumps shall be vertical centrifugal type with separate discharge pipe and shall be 

capable of developing required head at rated capacity for continuous operation. Sump 

pumps shall be suitable for handling coal slurry & sludge. Head capacit capacity y curve of the pump 

shall be rising type up to the shut off condition. Sump pumps alongwith level switches & 

piping upto nearest Owner's drain (max upto 50.0 mtrs. from outside the building) shall be 

provided at all locations wherever natural drainage is nnot 

ot possible. Further sump pumps 

alongwith drain pits shall be provided at other locations also, if required, during detailed 

engineering stage. The capacity of each pump shall not be less than 50 cub. M/hr. 

Continuous motor rating (name plate rating) at 50 deg. C. for sump pump shall have at least 

10% margin above the maximum load demand of the equipment in the entire operating 

range (including run out condition of pumps in case of parallel operation). The maximum 

load demand shall include the drive losses in the transmission system. Size of the sump pit 

shall not be less than 2.0 meters x 2.0 meters x 2.5 meters. One no. of settling pit, of 

adequate size, before the sump pit shall also be provided so that water without heavy coal 

particles goes into sump pu pump mp pit. High and low level switches shall be provided in the sump 

pump pit. 

16.5.6 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. 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 distributio distribution n system shall be designed considering the water 

scheme and water requirement indicated in tender drawings. 


16.6.1 Water Supply Pumps 

16.6.1.1 Water supply pumps shall be provided as required. 

16.6.1.2 The pumps shall be complete with drive motors, baseplate and other accessories. The 

constructional features of the pump shall be as follows: 


Page 37 of 64

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 h hhardened 

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 acking 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 leak leakage age 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 cum cum/hr. 

16.6.1.3 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. 

16.6.1.4 All rotating parts of the pumps shall be statically and dynamically balanced. 

16.6.1.5 The motor shall be rated for continuo continuous us 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. 

16.6.1.6 Design duty point of pump shall match with the average value oof 

f maximum and minimum 

flow rates of the pump in the stable operation zone. 


Page 38 of 64

16.6.1.7 Materials of construction of pump components shall be as stated in data data-sheet to this 

section. 


16.6.2.1 The column pipe shall serve as a housing for the line shaft and bearing and support for 

bowl (casing). The line shaft bearing shall be supported from the pump column pipe. 

Individual sections of column pipe shall be coupled by flanged joints. The flange outside 

diameter shall not exceed the bowl outside diameter. 

16.6.2.2 Casing shall house the impeller and shall be hydraulically designed to minimize radial 

thrust. Further suitable sealing arrangement shall be provided to prevent the leakage of 

pumped liquid into the column pipe. 

16.6.2.3 The impeller shall be semi open or open (non clogging) as per standard design of the 

Manufacturer. All rotating parts including the impeller shall be statically and dynamically 

balanced. Impeller shall be securely fastened to the impeller shaft with keys taper 

bushings or locknuts and shall be specifically designed to pass large solids or unscreened 

liquids. The clearances between stationary and moving part shall be such as to allow 

sustained performance without excessive maintenance. 

16.6.2.4 The discharge pipe ipe should be terminated above the base plate or mounting channel. 

Type of end connection shall be as specified in data sheets. No support shall be provided 

for the bottom elbow (near pump bowl) to facilitate easy removal of line pump from top 

without the necessary to go down to the sump for removal of bottom support, if 

provided. 

16.6.2.5 The design of the bunt shaft shall also take into consideration the critical speed of the 

shall which shall be minimum 20% higher than any operating or run away speed. 

16.6.2.6 Individual sections of the shaft shall be interchangeable. 

16.6.2.7 The type of couplings for the line shaft shall be such to prevent loosening during reserve 

rotation. 

16.6.2.8 Line shaft bearings shall be water lubricated. Line shaft bearin bearings gs shall be spaced not more 

than 1.5 meters apart. For lubrication purpose clarified water shall be used. 

16.6.2.9 For meeting the sealing/lubricating water requirement, Contractor to provide seal water 

pumps (2x100% capacity). 

16.6.2.10 Replaceable shaft aft sleeves shall be furnished. The shaft sleeve shall be securely locked to 

shaft to prevent loosening while in operation. 

16.6.2.11 Replaceable type wear rings shall be provided for casing and/or impellers wherever 

applicable. 

16.6.2.12 For the following accessories shall be provided for sump pumps 


Page 39 of 64

(i) Base plates together with foundation bolts and nuts. The base plate shall 

accommodate the discharge pipe, which is to be terminated above the floor level. 

(ii) Motor stool. 

(iii) Non-return return valves and gate vvalves 

alves on pump discharge lines (unless otherwise 

specifically excluded). 

(iv) Lifting lugs, eye bolts etc. 

(v) Pre-lubricating lubricating tank with accessories (if necessary). 

(vi) Sleeves and inserts to be embedded in concrete. 

(vii) Coupling guard, if necessary 

16.6.2.13 The pump shaft shall be connected to motor shaft by a heavy duty rigid/flexible coupling 

or the pump shall be VV-belt 

driven. 

16.6.3 PIPING, FITTINGS, VALVES AND SPECIALTIES 

16.6.3.1 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 galvanized piping shall be joined by screwed connec connections. tions. Minimum pipe 

diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall 

be 32 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 ports shall be capable of carrying the sum of all concurrently acting 

loads. They shall be designed to provide the required supporting effects and allow pipe 

line movements as necessary. All guides, anchors, braces, dampers, expansion joints and 

structural steel to be attached to the building/structure, trenches etc. shall be provided. 

The type of hangers and components for all piping shall be selected and approval 

obtained from the Owner Owner/RITES. 

(f) All piping shall be routed on ground on concrete pedestals and at road crossings, these 

shall be laid through hume pipes. 

16.6.3.2 Valves and Specialties 

(a) Valves & Specialties shall be used to start, stop or regulate the flow. All valves/specialities 

below 50 mm size (for isolation purpose) 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. 


Page 40 of 64

(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above 50 NB 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: 

i. Hand wheel 

ii. Position indicator 

iii. By-pass pass valve and spur gear reductio reduction unit for larger valves. 

iv. 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 stainless steel 

16.6.4 Special cleaning, protection and painting 

16.6.4.1 Piping & Fittings 

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

brushing. 

(b) For over ground exposed steel pipes, one shop and one site coat of red oxide zinc p pphosphate 

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 du duty ty bitumastic paint shall be applied on 

the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen 


Page 41 of 64

impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty 

bitumastic paint. 

16.7 DATA SHEET : DUST CONTROL & MISCELLANEOUS SYSTEM 

1.0 GENERAL 

1.1 Dust Control: Plain water dust suppression 

1.2 Miscellaneous systems: Service water system, Potable water system, Cooling water 

system & Sump pumps. 


2.1 Dust Suppression 

2.1.1 Operation: ration: Water sprayed through nozzles. 

2.1.2 Pumps: 2x100% for water 

2.1.3 Spray Head 

(i) Minimum No. of nozzles per spray head: 4 (Four) 

(ii) Pressure at inlet: Minimum 2.5 kg/sq. cm 

2.2.0 Plain Water Dust Suppression 

2.2.1 Pumps: 2x100% electric motor driven 

2.2.2 Minimum Pressure at inlet of spray nozzles: 2.5 kg/sq. cm 

2.2.3 Nozzle spacing on WT Top: 500 mm 

2.2.4 Nozzles: Fogging type 

2.2.5 Flow from each nozzle: 2.0 Lpm 

2.3.0 Sumps Pumps 

(i) Type: 2x100% electric motor driven 

(ii) Capacity: 50 cub.m/hr minimum with 10% margin 

(iii) Head: 20% margin on computed head 

2.3.1 Drain Pits: Minimum 2x2x2.5 mts. and 1 No. settling pit for slurry & high/low level 

switches in drain pit. 

2.3.2 Piping: To nearest plant drain 

2.4.0 Service ice Water System 

2.4.1 Water connections 

(a) Conveyor Galleries and tunnels: every 50 m 

(b) Transfer points: Min. 1 no. at every floor 

2.4.2 Connection details: 1 No. 32 NB globe valve & quick coupling 

2.4.3 Hose pipes with hose reel: One in each building of 25 mtr. Length with nozzle 


Page 42 of 64

3.0 CONSTRUCTION REQUIREMENTS 

3.1 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 AISI-416 hardened. 

(g) Gland packing: Impregnated Teflon 


3.2.1 Type: Vertical, centrifugal, single st stage, age, semi open or open (non clogging) type impeller. 

3.2.2 Duty: Intermittent. However, to be designed for contineous operation. 

3.2.3 Fluid to be Pumped: Sludge/Coal slurry 

3.2.4 Suction Condition: Submerged 

3.2.5 Pump speed (maximum): 1000 RPM 

3.2.6 Type of coupling between pump and motor: Directly driven through flexible or rigid 

coupling/V-Belt 

3.2.7 Location of pump thrust bearing: In motor stool 

3.2.8 Materials 

(a) Casing: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.) 

(b) Impeller: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.) 

(c) Impeller: Shaft Stainless steel 

(d) Line Shaft: EN-8 8 to BS; 970 

(e) Column pipe and discharge pipe: Fabricated steel to IS: 226 (min. 6mm thick). 

(f) Shaft sleeve: Hardened stainless steel to 400 BHN 

(g) Base Plate: Steel to IS: 226 up to 20mm thickness and IS: 2062 over 20mm thickness. 

3.2.9 Accessories Provided with the Pump 

i. Lubrication and sealing water system: Yes 

ii. Common base plate for Pumps and Motor and Motor stool: Yes 

iii. Anchor Bolts, nuts, sleeves and inserts (which will be embedded in concrete): Yes 

iv. Coupling, guards lifting lug, eye bolt, positioning Dove: Yes 


Page 43 of 64

3.3.0 Pipings & Fittings 

3.3.1 Joints 

(i) Pipe to pipe 

Pipe size < 50 NB: Socket welding/screwed Butt 

Pipe size > 65 NB: welding 

(ii) Pipe to valves 

Pipe size ≤ 50 0 NB: Screwed 

Pipe size ≥ 65 NB: Flanged 

3.3.2 Isolation of flow: Plug / Gate / Sluice valves 

3.3.3 Regulation of flow: Globe Valve 

3.3.4 Valves 

i. Size > 65 NB: Bolted bonnet outside screw rising type. 

ii. Size < 50 NB: Union bonnet with screwed ends for Globe valves & screwed 

ends for plug valves. 

3.3.5 Materials for Pipework 

(a) For sizes 200 NB and Larger: ERW carbon steel pipes to API API-5LGr.B minimum 

thick 6.35 mm or plate fabricated and welded pipes to IS:3589, Class Class-2. 

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

Class). 

(c) For sizes upto 50 NB: ERW carbon steel galvanized pipes to IS:1239 (Part (Part-I) Heavy 

class. 

3.3.6 Materials for Valves & Specialities 

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

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

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

iii. Seating surfaces and rings: 13% chromium steel 

iv. Hinge pin for non return valves: Stainless steel type AISI AISI--316 

v. Stem for gate and globe valves: 13% chromium steel 

vi. Back seat bush: 13% chromium steel 

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

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

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

(c) Duplex Strainer 

(i) Body: MS fabricated 

(ii) Strainer: Stainless steel type element AISI-316 

(d) 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 


Page 44 of 64

(iii) Bourdon : AISI 316 SS 

(iv) Block : AISI 316 SS 

(v) Movement : AISI 316 SS 

(vi) 

Case and Bezel : Die cast Alum. Weather proof case stove 

enameled block with screwed type inner bezel of ABS plastic 

and glycerin filled. 

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

(viii) Type of contact : Adjustable throughout the range. 

(ix) Degree of protection : IP. 65 

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

(i) Type 

: 2/2 way Diaphragm type pilot operated 

(ii) Diaphragm : molded synthetic rubber 

(iii) Body 

: Forged brass / SS 

(iv) Pressure : 0.5 to 20 kg/cm2 

(v) Protection : Class IP 65 

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

(i) Body 

: Forged steel 

(ii) Extension Rod/wire : SS-304 

(iii) Sleeve and Sleeve pipe: SS 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 

(g) Level Switch 

(i) Type : Displacer operated magnetic type 

(ii) Displacer: SS – 316 

(iii) Wire rope: SS – 316 

(iii) Spring Housing Spring and sleeve pipe: SS – 316 

(iv) Cover: Cast Aluminum 

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

(vi)Type of Contact: Adjustable throughout the range. 

(viii)Protection: class IP – 65 

(h) Level gauges 

(i) Type: Float type mechanical gauge wit with arrow scale 

(ii) Accuracy: (+/--) 

1% of full scale range 

(iii) Material of construction 

(a) Float & Guide wire: 316 SS 

(b) Elbows: Suitable grade of SS 

(c) Housing: Mild Steel 

(d) Cable fastener: SS 304 

(i) Nozzles 


Page 45 of 64

(j) Y Strainer 

17.0 VENTILATION SYSTEMS 

17.1 GENERAL 

17.1.1 INTENT OF SPECIFICATION 

(i) Type: Fogging, non non-clogging type 

(ii) Material: Stainless Steel 

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

(a) Body: SS 304 

(b) Plug: SS 304 

(c) Filter Element: SS 316, 60 mesh 

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 plant & equipment of 

Wagon tippler package. 

17.1.1.1 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. 

17.2 GENERAL DESCRIPTION 

17.2.1 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 ided 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. 

17.2.2 Pressurised Ventilation System 

The pressurised ventilation system having adequate nos. of supply and exhaust air fans with 

washable metallic pre filters, HDPE fine filters, and exhaust fans with self closing flaps, 

ducting along with 3 phas phase e 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 onsidering 20 air changes per hour to maintain these areas pressurized slightly 

above atmospheric pressure to prevent ingress of dust from outside. 

17.2.3 Air Conditioning System 

Air conditioning system shall be furnished for control room area of Wagon tippler control 

building, it shall be designed considering the equipment heat loads, solar heat loads, heat 


Page 46 of 64

17.3 SCOPE 

gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and 

relative humidity within the air conditioned areas. 

17.3.1 Mechanical Ventilation System 

The ventilation system generally consisting of adequate number of supply and exhaust air 

fans, air filters, ducting along with 3 phase AC motor drives, electricals, supporting 

structures, approach/maintenance platforms, civil and structural works and necessary 

accessories shall be furnished for ventilating the WT hopper, underground portion of 

transfer points, underground conveyor tunnel tunnels s and pent houses. Exhaust fans shall be 

provided for Toilets & Battery rooms. 

17.3.2 Pressurised Mechanical Ventilation System 

The ventilation system generally consisting of adequate number of supply and exhaust fans, 

metallic pre filters, HDPE fine fi filters, lters, 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. 

17.3.3 Air Conditioning ioning System 

17.3.4 2x100% capacity air conditioning units shall be provided for Wagon Tippler Control Room. 

17.3.5 Supply and return air distribution ducting complete with insulation, of resin bonded mineral 

wool equivalent of density at least 24 Kg/m Kg/m³ ³ 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. 

17.3.6 Air cooled PAC shall be provided provided. 

17.3.7 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear 

surrounding. 

17.4 Codes & Standards 

The design, manufacture, inspection and testing of Ventilation & A/C System shall comply 

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

the equipment is to be installed. The Ventilation & A/C System shall conform to the latest 

edition of the following standards and codes. Other internationally acceptable 

standards/codes, which eensure 

nsure 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, ion, the decision of the Owner Owner/RITES shall be final and binding. 

• IS:3588 : Specification for electrical axial flow fans. 


Page 47 of 64

• IS:2312 :Propeller type AC Ventilation fans 

• IS:3963 :Specification for roof roof-extractor units 

• IS:4894 :Centrifugal Fans 

• IS:655 :Specification ation 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 surfa surfaces. 

• IS:4671:Expanded polystyrene for thermal insulation purpose. 

• IS:8148 :Packaged Air conditioners. 


17.5.1 Roof Ventilators & Accessories 

17.5.2 Roof ventilators & accessories shall be provided as required. Impeller shall be axial flow 

type. 

17.5.3 Design duty point of the fan shall match with the average value of maximum and minimum 

flow rates of the fan in stable operation zone. 

17.5.4 The speed of the roof ventilators shall not exceed 960 rpm for ventilators with impeller 

diameter above 450 mm & 1440 rpm for ventilators with impeller diameter 450 mm and 

less. The first critical speed of rotating assembly shall be at least 25% above operating speed. 

17.5.5 Motor shall be totally enclosed type suitable for vertical mounting mounting. . Motors shall comply with 

the companion electrical specifications. 

17.5.6 Axial Fans 

17.5.7 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. 

17.5.8 Impellers shall be axial flow low type single piece. 

17.5.9 Centrifugal Fans 

17.5.10 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. 

17.5.11 Fans shall be manufactured vibration free in operation and shall be designed to limit noise 

level within limits specified in Data Sheet. 

17.5.12 The motor shall be rated for continuous operation and conform to companion electrical 

specification. However, motor rating shall not be less than the m mmax. 

power demand 

throughout the entire range of operation of fan. 


Page 48 of 64

17.5.13 All fan mountings shall have adequate arrangement for vibration isolation. 

17.5.14 The reverse flow through non non-working working fan shall be prevented by dampers. The dampers 

shall be made out of 18 SWG MS sheets. 

17.5.15 Design duty point of the fans shall match with the average value of maximum and minimum 

flow rate of the fan in the stable oper operation zone. 

17.5.16 Filters 

17.5.16.1 Metallic Filters 

Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be 

2 m/sec. 

17.5.16.2 HDPE Filters 

HDPE filters should have an efficiency of 90% down to 5 microns. Vel Velocity ocity across the filter 

shall be limited to 2.5 m/sec. 

17.5.17 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99.9% down 

to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm 

w.c. 

17.5.18 Packaged Air-Conditioning Conditioning Unit 

PAC units shall be provided as required. 

17.5.19 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. 

17.5.20 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled 

condenser (outdoor air) section. Heavy gauge steel cabinet factory finished with two coats of 

epoxy paint of approved colour, shall be used to house components of PAC. 

17.5.21 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 connecting refrigerant circuits shall comprise of multiple cylinder hermetic 

compressor(s) and motor(s) with all necessary isolation valves, suction gas controlled 

thermal expansion valves, with adjustable set point, sight glass, copper tubing and pipeline 

ancillaries. The condenser coils shall be air cooled by propeller type fans complete with 

safety guards. The condensing coils shall be suitably arranged to avoid radiant heat pick pick-up 

from solar sources. 


Page 49 of 64

17.5.22 Condenser capacity control shall be provided by means of variable speed fans and ‘head 

pressure’ sensing. 

17.5.23 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 anti-vibration vibration mounts. The fan/motor drive shall be capable of 

capacity adjustment by pulley changes within +15% of design duty. 

17.5.24 High efficiency filters shall be pprovided 

rovided in the main supply air duct and in the fresh air 

connection to return air duct. 

17.6 Construction Requirements 

17.6.1 General construction details of various equipment under Contractor’s scope shall be as 

elaborated in subsequent clauses below. 

17.6.2 Roof Ventilators and accessories 

Roof ventilators and accessories shall be provided as required. 

17.6.3 Impeller shall be axial flow type, cast in one piece finished all over and carefully dynamically 

balanced after final assembly. All impellers shall consist of high efficiency aerofoil blades. 

Impellers shall be mounted directly on the motor shaft. 

17.6.4 Casing shall be of heavy gauge construction and shall be properly reinforced for rigidity. 

Access door with suitable locking arrang arrangement shall be provided. 

17.6.5 Hood shall be of hinged type providing easy access to motor and impeller. It will also protect 

them from rain and any other contingencies. Weather Weather-proof proof lockable type disconnect switch 

shall be provided such that the hoods can be opened only when the disconnect switch is in 

‘OFF’ positions. On larger sizes of roof ventilators, hoods shall be of split construction. 15 

mm mesh galvanised bird screen shall be provided. The hoods will have low pressure drop 

across it. 

17.6.6 Suitable uitable arrangement shall be provided for mounting the roof ventilators such that ingress 

of rainwater into the building will be avoided completely. 

17.6.7 Axial Flow Fans 

Axial flow fans shall be provided as required. 

17.6.8 Impellers shall be axial fl flow ow 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. 

17.6.9 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. 


Page 50 of 64

17.6.10 Rain protection cowls will be de designed signed to suit wall exhausters/supply fans for protecting 

fans/motors from rain. It will be provided with bird screen. 

17.6.11 Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or 

M.S. 

17.6.12 Motor shall be of totally otally enclosed type complying with the companion electrical 

specification. Suitable rain/sun shade for motors shall also be provided. 

17.6.13 Centrifugal Fan 

Centrifugal fans shall be provided as required. 

17.6.14 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. 

17.6.15 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 ve 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. 

17.6.16 The bearings shall be self self-aligning heavy-duty duty ball or roller bearings. They shall be 

adequately supported. They shall be easily accessible and lubricated properly from outside. 

17.6.17 Filters 

17.6.18 Metallic Filters 

Metallic allic cleanable filters shall consist of VV-fold 

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. 

17.6.19 HDPE Filters 

HDPE filters shall all be provided as required. This shall be constructed of HDPE fabric with 

continuous water spraying on it from a header for keeping it clean. 

17.6.20 High efficiency filter (for A/C purpose) 


Page 51 of 64

The media of the filter shall be made from either special synthetic non 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. 

17.6.21 Package A/C Unit 

17.6.22 .22 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 shall be provided for wall mounting. The casing shall be fitted with all necessary 

coil drains and service connections/ 

entries. 

17. . 6.23 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 prewir prewired to unit mounted 

control/power terminal boxes. 

17.6.24 Ventilation and Air Conditioning system ducting 

17.6.25 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/cm2. 

17.7 DATA SHEET : VENTILATION SYSTEM 

1.0 GENERAL 

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

1.1.1 No. of air changes per hour 

(a) For overground building: Not less than 10 supply air changes & 7 Exhaust air 

changes 

(b) For underground areas: Not less than 15 supply air changes & 7 Exhaust air changes 

1.1.2 Equipment 

(1) Underground tunnel: Centrifugal fans/Axial Fans 

(2) All other places: Axial fans, roof ventilators 

1.2.0 Pressurised ventilati ventilation on system: To provide clean air to all MCC / Switchgear buildings 

1.2.1 No. of air changes per hour: Not less than 20 


Page 52 of 64

1.2.2 Equipment: Centrifugal fans/Axial Fans and exhaust air fan 

1.3.0 Air-conditioning conditioning system As specified 

1.3.1 Temperature to be maintained : 24 ± 1 deg. C 

1.3.2 Humidity to be maintained : 50 ± 5% relative humidity 

1.3.3 Fresh Air intake : More than 1.5 air changes per hour. 

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

and window AC 

1.4.0 Outside Ambient Conditions 

(i) Summer: As per weather data given in project synopsis. 

(ii) Monsoon: - Do – 

(iii) Winter: - Do 

2.0.0 DESIGN & CONSTRUCTION 

2.1.0 Roof Ventilators 

2.1.1 Capacity: 10% more of actual requirement 

2.1.2 Head: 20% more of actual requirement 

2.1.3 Speed 

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

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

(c) Critical speed: 25% above operating speed. 

2.2.0 Axial Fans 

2.2.1 Capacity: 10% more of actual requirement 

2.2.2 Head: 20% more of actual requirement 

2.2.3 Speed 

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

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

(c) Critical speed: 25% above operating speed. 

2.3.0 Centrifugal Fans 

2.3.1 Capacity: 10% more of actu actual requirement 

2.3.2 Head: 20% more than actual requirement 

2.3.3 Speed: Max. 1500 rpm 

2.3.4 Outdoor temperature: 50 deg.C. 

2.3.5 Rating: Continuous 

2.4.0 Packaged Air-Conditioning Conditioning Unit 

2.4.1 Type: Roof top mounting 

2.4.2 Service/application: Continuous, round the clock. 

2.4.3 Capacity 

(i) TR: Suitable 

(ii) CFM: Suitable 

2.4.4 Type of compressor: Multiple cylinder hermetic compressor. 


Page 53 of 64

2.4.5 Condenser: Air cooled type 

2.4.6 Fan: Forward curved centrifugal fan 

2.4.7 Filter: High efficiency filter 

2.4.8 Cooling Coil 

(a) Type: Direct Expansion 

(b) Material: Copper 

(c) Fins: Aluminum mechanically bonded. 

2.4.9 Refrigerant: Piping Copper 

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

2.5.0 Filters 

2.5.1. Metallic Filters 

(1) Max. air velocity: 2m/sec. 

2.5.2 HDPE filters 

(1) Efficiency: 90% down to 5 microns 

(2) Max. velocity: 2.5 m/sec. 

(3) Testing: As per BS 2831 / Sqv. 

2.5.3 High Efficiency Filter 

(1) Efficiency: 99.9% down to 5 microns. 

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

(3) Testing: As per BS 2831 / Sqv. 

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

2.6.1 Density: 24 kg/cub.m 

2.6.2 Thermal conductivity: 0.49 mw/cm deg.C 

18.0 DESIGN OF CONVEYOR GALLERIES AND JUNCTION HOUSES 

18.1 Design Considerations 

a) The general parameters for conveyor galleries shall conform to the provision of IS : 11592 11592- 

1985 unless specified otherwise in Technical Specifications. The structures shall be designed 

so as to meet functional requirem requirements ents and shall provide space for operation, maintenance 

and removal of machinery and give the workers good and safe environment. 

b) Gallery floors shall be of chequered plates supported on steel beams. 

c) Steps shall be provided with (rise not exceeding 130 mmm 

m along the walkways if the gallery 

slope exceeds 12°. . In case the slope of gallery is between 66° 

to 12°, , suitable ribs (without any 

sharp edges) shall be provided on floor at 250 to 300 mm intervals. 

d) Roof and side walls of conveyor galleries shall be covered with Aluminium industrial 

troughed sheets. . with a provision of gap of 300 mm below roof and 150 mm from top of 

floor level on the side wall for ventilation. 

e) Adequate provision for natural light in inside side conveyor gallery shall be made through side walls 

by providing translucent sheets (FRP sheets as per IS: 12866 12866-1989). 1989). Every sixth sheet on side 

wall shall be FRP sheet and shall be staggered on opposite wall. 


Page 54 of 64

f) Roof slopes of conveyor galleries shall bbe 

1:5 (1 vertical, 5 Horizontal). 

g) The level of underside of the base plate of gallery supporting trestles shall be 300 mm above 

the average ground level of the surrounding area. 

h) Protective hand railing shall be provided along gallery walkways, open platf platform, stairways, 

landings, edges of walkways when the gallery is not enclosed, and around erection openings, 

if any, to ensure safety of operating personnel. 

i) Conveyor galleries longer than 150 m shall be provided with expansion joints with twin 

trestles/supports. pports. Each expansion block shall have fixed support/rigid trestle with adequate 

arrangement (provision of top chord and bottom chord bracing to gallery girder etc.) for 

transferring the transverse and longitudinal forces to the foundation. 

j) Gallery girders rs near junction house shall be preferably supported on trestle located as close 

to the junction house as possible, with part of gallery girder between junction house and 

trestle cantilevered from the trestle. Supporting gallery girders on junction house s sshall 

be 

generally avoided. 

k) The underside of the belt conveyor shall be fully covered with 3 mm sheet in case of 

conveyors located within the boundaries of the plant area. including the gallery crossing the 

roads / railway lines / areas of public gathering gatherings. 

l) When conveyor gallery crosses above or below H.T cables, a minimum clear distance of 1.0 

m between the structural elements/cladding and HT cables shall be maintained. 

m) When the conveyor bridge passes over plant roads, clearance between the road surface and 

the lowest points of the bridges shall not be less than 8.0 m or the height needed for the 

passage of the largest individual components of the plant equipment, whichever is the 

larger. 

n) The junction house shall be designed to suit the functional requirement. Number of floors, 

height of building etc. shall be decided accordingly. 

o) In general the junction house shall be designed as framed structures on shorter span side 

and vertically braced on longer side to achieve stability. 

p) Floor of junction houses ouses shall be of RCC slab / Chequered plate supported on steel beams, 

unless required otherwise from technological suitable lugs. 

q) Roof and side covering of junction houses shall be with Aluminium industrial troughed 

sheets as specified. Roof slope shall be 1: 5 ( 1 Vertical : 5 Horizontal). 


Page 55 of 64

) Suitable access staircase with safety hand railing shall be provided to all floors of junction 

houses. 

s) Wall sheeting shall generally start from the lowest working floor and extend up to roof level 

with louvers at each h floor level to ensure adequate natural ventilation. 

t) Monorails for maintenance hoists shall be provided for maintenance and repair of various 

equipments located on the floors. 

18.2 Components of structures 

a) Gallery Trusses and Roof 

Gallery truss shall be of latticed type construction. The trusses shall be adequately braced at 

top and bottom chord level to transfer the horizontal wind forces to end portals. 

b) Stringer Beam 

These beams shall be suitably spaced to support the conveyor stringer supports and shall 

transfer load to gallery. Walkways on either side of the conveyor shall also be supported on 

these stringer beams. 

c) Supporting Trestles 

Intermediate trestles shall be two legged and shall deliver loads from gallery trusses to the 

foundations. In addition, four legged trestles shall be provided which will act as fixed support 

to transmit all longitudinal forces between expansion block, in addition to other forces. 

d) Junction Houses 

i) Floors - Floor beam layout shall be arranged to suit equipment llayout 

ayout as well as equipment 

anchoring system. 

ii) Columns - In addition to loads from floor and roof, columns shall be designed to transmit 

horizontal load due to belt tension/snapping of belts to the foundation. 

e) Belt Tensioning Device 

Suitable structures shall be provided to accommodate belt belt-tensioning tensioning device which may be 

located either under the conveyor gallery or in the junction house itself. 

f) Wall Structures 

(i) Wall runners with necessary sag rods shall be provided to support wall sheeting in 

conveyor galleries and junction houses. 

(ii) Walls shall be provided with louvers and translucent sheeting at appropriate levels, 

to provide natural ventilation and lighting. 

g) Access stairs, walkways, platforms, ladders, hand railing etc. 


Page 56 of 64

(i) Wherever possible, access shall be provided by means of stairs. 

(ii) All walkways and stairs leading to working platforms shall have minimum 800 mm width 

of walkways/flight of stair. 

(iii) All other walkways and stairs leading to areas for maintenance purpose, or due to 

restriction iction of space, shall have a minimum width of 800 mm of walkway/flight of stair, 

unless required otherwise. 

(iv) Staircases shall be generally designed with slope of approximate 37.5 37.5° with the 

horizontal. (In no case the slope shall exceed 40 ° with the horizo horizontal). Intermediate 

landings shall be provided wherever required such that vertical rise of each flight does 

not exceed 3000mm. Risers in one flight shall be equally spaced. 

(v) Walkway floors and stair treads shall be designed with chequered plate (or non non-slip 

type plates). Ribbed floor/treads may be provided wherever the possibility of 

accumulation of dust exists, taking care that such provisions do not crate a nuisance to 

the operating personnel on the shop floor. 

(vi) Rise of treads in staircases shall not excee exceed 200 mm. 

(vii) A minimum headroom of 2200 mm shall be provided over operating platforms, visitor's 

galleries, or other areas with possibility of public gathering. In all other platforms, 

walkways and stairs, minimum headroom of 2000 mm shall be provided. Only i iin 

special 

cases, local headroom of 1800 mm may be allowed (i.e. at intersection with structural 

members etc.). 

(viii) Cat ladders shall be provided for access, wherever provision of staircase is impractical 

due to limitations of space, or the access is required vvery 

ery infrequently. 

(ix) Wherever the height of cat ladder exceeds 4.0 m, safety cage shall be provided. 

Intermediate landing shall be provided to cat ladders such that vertical height of single 

rise does not exceed 8.0 m. 

(x) Cat ladders shall be designed with follo following provisions: 

i. Width of rung = 500 mm 

ii. Minimum rise of rung = 250 mm; Maximum rise of rung = 300 mm 

iii. Minimum clearance from rung of ladder to back of cage (in case of caged 

ladders) = 700 mm 

iv. Minimum clearance from the centre of cage all round = 350 mm 

v. Slope of cat--ladders: 

I. For normal cat cat-ladders, ladders, slope shall be within the range of 75 75°-90° with the 

horizontal. 

II. For ship-type type ladders (i.e cat cat-ladders ladders with short side handrails) the slope shall be 

within the range of 65 65°-75° with the horizontal. 

(xi) All walkways, platforms and stairs shall be provided with safety handrails. All handrails 

shall be constructed with steel tubes / angles for posts, top and middle rail and 

plates/sheets for toe plates. In case of stairs, the toe guards need not be provided. 

(xii) The he vertical height of hand hand-railings railings on walkways and stairs shall be minimum 1000 mm 

above floor level. 

(xiii) Hand-railing railing along edge of roof and gutters shall have a minimum height of 600 mm 

over top edge of gutters/sheets. In such hand railings toe guards need not be provided. 

(Only top handrail and midrail shall be provided). 


Page 57 of 64

18.3 ADDITIONAL DESIGN CRITERIA 

a) Design of steel structures shall be done in accordance with IS:800 IS:800-1984. 1984. 

b) In absence of specified dynamic factor to be considered for the load from the belt 

conveyor, a dynamic factor of not less than 1.3 shall be considered for the design of 

floor beams and gallery girders. 

c) Gallery trusses and stringers as well as floor be beams ams of junction house shall be checked 

for obviating occurrence of resonance and shall be designed such that the ratio of 

applied frequency to natural frequency shall not lie within the range 0.7 to 1.5. 

d) As far as possible gallery structure shall be mmade 

ade independent of junction houses. A 

trestle shall be planned close to the junction house to avoid gallery span resting on the 

junction house. 

e) The contractor after the award of work shall submit design criteria to owner / 

consultant for approval befo before submission of design drawings. 

f) The design drawings shall be submitted in complete for a unit along with design 

calculations both in hard copy and soft copy. Design shall be done using STAAD. 

g) The effective ratio of utility of all main sections shall be limited to 0.85 

h) Structural schematic general arrangement with plans at various levels, elevations along 

each row and axes, sections, considered loads and load diagrams with location etc. and 

Structural design drawings with BOQ and Table of me members mbers containing design forces shall 

be submitted for Owner’s/Consultant’s approval. However the approval shall be limited 

to checking of overall dimensions, general stability of system, effective load transfer and 

deflection limits etc. The approval shall not relieve the contractor of his responsibility of 

correctness in design, adequacy of connections, accuracy etc. 

i) Submission of Stability certificate for all the steel structures is under the scope of the 

contractor. 

18.4 Description of loads and loading codes 

a) Unless specified otherwise hereinafter, all the live loads shall be considered in 

accordance with IS: 875 (Part (Part-2) -1987. 

b) Wind loads shall be considered in accordance with IS: 875 (Part (Part-3)-1987. 1987. 

c) Seismic loads shall be considered in accorda accordance nce with IS:1893(part1) 

IS:1893(part1)-2002 and 

1893(part 4)-2005 

d) Live loads from conveyor on the gallery floor shall be as per conveyor suppliers load 

data. 

e) While designing the fixed support/rigid trestles in an expansion block of conveyor 

gallery the following loads (in addition to wind load) shall be considered. 


Page 58 of 64

(i) Forces due to difference in frictional resistance of top and return idle rollers of 

conveyor. 

(ii) Forces due to inertia of rollers at the time of starting of conveyor belt. 

(iii) Break down load caused by snapping of bbelt 

elt (in case of multiple conveyors, 

snapping of one belt at a time) shall be considered. 

(iv) Special loads if any 

f) Gallery girders and floor shall be designed for the following live loads,inclusive of 

spillage loads on floors. 

i) Walkway/Supporting beams for floor - 4.0 KN/m² 

ii Under the conveyor belt - 0.75 KN/m² 

iii) Gallery girder, for floor load of - 3.0 KN/m² 

g) Dust load on roof of junction house and conveyor galleries shall be considered as 

follows: 

i. For building and structures located at a distance of 300m from the dust 

producing units - 0.5 KN/m² 

ii. At a distance of 300 m to 800 m from the dust producing unit - 0.25 KN/m² 

h) As per technological requirements, provision of supporting the following, and load 

arising thereof shall be considered in the design of conveyor gallery. 

i) Ventilation duct. 

ii) Electrical cables/cable racks. 

iii) Fire Fighting equipment. 

i) Junction house floors shall be designed for the following loads: 

i) Live load on floor - 5.0 KN/m² 

ii) Tension from conveyor belt 

ii) Load due e to equipment located on floor. 

iv) Load due to jamming of chutes. 

v) Erection loads anywhere on the floor. 

j) Combination of loads 

The various loads specified shall be combined in accordance with clause 8.0 of IS: 875 

(Part-5)-1987 1987 to give the most severe loading condition for design of structures. 

k) Stress enhancements 

Permissible limits of stress may be increased, wherever permissible, in accordance with 

IS:800-1984. 

18.5 Limiting deflection 

a. The deflection shall be limited in various elements of structures in accordance with 

clause 3.13 IS: 800-1984. 1984. 

b. In addition following limitation in deflection shall be observed in design: 


Page 59 of 64

i) Gallery Trusses 

Span / 400 

ii) Top of End portal of gallery truss H / 325 where H =Height of portal above beams 

iii) Traverse deflection of top of Trestle H/1000 where H = Height of trestle above foundation 

18.6 FABRICATION OF STEEL STRUCTURES 

18.6.1 Drawings 

The Contractor shall prepare fabrication drawings, erection drawings, bill of materials, 

drawing office despatch lists / shipping documents, schedule of bolts and nuts and as built 

drawings. All drawing work shall be in metric system and all writing work shall be in English. 

The work shall be carried out as described in General Technical Specifications for s sstructural 

works. 

18.6.2 Material of Construction 

18.6.2.1All steel and other materials used for steelwork and in association with steelwork shall 

conform to appropriate Indian standards. Only tested materials shall be used unless written 

authority is obtained for the use of untested materials for certain secondary structural 

members. 

Unless otherwise specified in the drawings 

i. All rolled sections and plates upto 20 mm thk. Shall conform to Grade Grade-E250 & quality 

A of IS: 2062-2006 2006 and shall generally be of tested quality. 

ii. Plates above 20 mm thk. and plated structures subjected to dynamic loading shall 

conform to Grade Grade-E 250 & quality B as per IS: 2062-2006. 

iii. For High Tensile steel requirements, material conforming to IS: 8500 or SAIL SAIL- MA 

(HYA or HYB) shall be used. 

18.6.2.2 Steel sheets shall conform to IS: 1079. 

18.6.2.3 Steel tubes for structural purpose shall conform to IS: 1161 (of Grade Yst 240) 

18.6.2.4 Corrugated Galvanised Sheets shall conform to IS: 277 with appropriate Zinc coating for 

the selected thickness of sheet on roof and sides. (1.0mm thk for roof and 0.8mm thk for 

sides) 

18.6.2.5 Aluminium industrial troughed sheets conforming to IS: 1254 shall be used as follows: 

i) On roof - 0.91mm thick ii) On side walls - 0.71mm thick 

18.6.2.6 Translucent sheets shall be fibre glass reinforced polyester sheets of matching profile as 

per IS: 12866. 

18.6.2.7 Colour coated sheets shall be as per appropriate standard. 

18.6.2.8 Gutters shall be of copper bearing steel conforming to Grade "A" as per IS:2062. 

18.6.2.9 Rails shall conform to IS: 3443. 

18.6.2.10 All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364 (for precision and 

semi precision hexagonal bolts) of property class 6.4unless otherwise specified. Washers 

shall conform to IS: 6610 


Page 60 of 64

18.6.2.11 All tapered washer shall be as per IS: 55372 

372 for channels, and IS: 5374 for Joists. Spring 

washers shall conform to IS: 3063. 

18.6.2.12 All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG bolts shall 

conform to IS: 4000. Nuts and washers for HSFG bolts shall be as per IS: 66 6623 & IS:6649 

respectively. 

18.6.2.13 Covered electrodes for arc welding shall conform to IS:814 IS:814–2004. 2004. Electrode to be used 

for submerged arc welding shall conform specification IS: 7280 7280-1974. 

Alternatively 

Covered electrodes for arc welding shall confirm to AWS Specifications and shall be as 

follows. 

- E 6013 for all fillet welds of IS 2062 steel dr E250 , quality A & B 

- E 7018 for all fillet welds of SAIL SAIL-MA 350 HYA steel 

- E 7018 for all but welds including site welds irrespective of the quality of ste steel.Viz. IS 

2062 gr E250 , quality A , B or SAILMA SAILMA-350 HYA steel. 

18.6.2.14 Certified mill test reports of materials used in the work shall be made available for 

inspection by the Owner / Consultant upon request. 

18.6.3 Fabrication 

18.6.3.1 Fabrication of all structural steelwork shall be in accordance with IS:800 or their equivalent 

foreign national standard of the country of origin of supply unless otherwise specified, and 

in conformity with various clauses of the Technical Specification. 

18.6.3.2 Wherever herever practicable and wherever perfect matching of parts is required at site, members 

shall be shop assembled before despatch to minimise site work. Parts not completely 

assembled in the shop shall be secured, to the extent possible, to prevent damage du during 

despatch. 

18.6.3.3 ERECTION OF STEEL STRUCTURES 

18.6.3.3.1 Scope 

The scope of work under erection includes in addition to provision of erection and transport 

equipments, tools and tackles, consumables, materials, labour and supervision, the 

following: 

a) Storing and stacking at site of erection of all fabricated structural components/ 

units/assemblies till the time of erection. 

b) Transportation of structures at site. 

c) Receiving at site of structures including site handling /movement, unloading, storing and 

stacking at site of erection of technological structures such as bunkers and the related 

structures 

d) All minor rectification / modification such as : 


Page 61 of 64

i) Removal of bends, kinks, twists, etc. for parts damaged during transportation and 

handling; 

ii) Cutting chipping, filing, grinding, etc., if required, for preparation and finishing of site 

connections; 

iii) Reaming for use of next higher size bolt for holes which do not register or which are 

damaged. 

iv) Welding of connections in place of boltin bolting g for which holes are either not drilled at all or 

wrongly drilled during fabrication. 

e) Other rectification work such as 

i) Re-fabrication fabrication of parts, damaged beyond repair during transportation and handling or 

incorrectly fabricated. 

ii) Fabrication of parts s omitted during fabrication by oversight or subsequently found 

necessary. 

iii) Plug-welding and re-drilling drilling of holes which do not register and which cannot be reamed 

for use of next higher size bolt. 

f) Fabrication of minor items/missing items or such import important ant items as directed by the Owner / 

Consultant. 

g) Assembly at site of steel structural components wherever required including temporary 

supports and staging. 

h) Making arrangements for and providing all facilities for conducting ultrasonic X XX-ray 

or 

gamma ray tests on welds; getting the tests conducted by reputed testing laboratories, 

making available test films/ graphs,reports and interpretation. 

i) Rectifying at site, damaged portions of shop primer by cleaning and touchup paint. 

j) Erection of structures including making connections by bolts/high strength friction grip bolts 

/ welding. 

k) Alignment of all structures true to line, level plumb and dimensions within specified limits of 

tolerances as per IS :12843 “Tolerance for Erection of Steel Structures”. 

l) Application of second coat of primer paint and two coats of finishing paint at site after 

erection. 

m) Grouting of all column bases after proper alignment of columns and only after obtaining 

clearance from Owner / Consultant. 

n) Conducting preliminary acceptance and final aacceptance 

tests. 

o) Preparation of as built drawings, preparing of sketches/drawings to suit 

field engineering decisions, availability of material, convenience of fabrication, 

transportation and erection and changes during fabrication and erection. 

All such works are subject to approval by the Owner / Consultant. 

18.6.4 PAINTING OF BUILDING STEEL STRUCTURES 

18.6.4.1All steel structural work shall be painted as follows unless otherwise stated in the drawing / 

Technical Specification. 


Page 62 of 64

18.6.4.2 Surface preparation 

The steel surface which is to be painted shall be cleaned of dirt and grease, and the heavier 

layers of rust shall be removed by chipping prior to actual surface preparation to a specified 

grade. 

Following are the type and standards of surface preparation to be followed based on the 

requirement of a particular painting system or as specified in the design drawings. 

Manual/Power tool cleaning : :- Manual/Power tool cleaning shall be done as per Grade St St-2 or 

St-3 3 of Swedish Standard Instit Institution ution SIS 05 5900 or cl.6.2.1.1 & 6.2.1.2 of IS : 1477 - 1987 (Part 

- 1). 

Grade St-2 :- Thorough scraping and wire brushing, machine brushing, grinding etc. This grade 

of preparation shall remove loose mill scale, rust cleaner or with clean compressed air or clean 

brush. After preparation, the surface should have a faint metallic sheen. The appearance shall 

correspond to the prints designated St St-2. 2. If no grade of surface preparation is specified, St St-2 

grade of preparation as per Swedish Standard shall be followed. 

18.6.4.3 Paint System 

(i) Surface preparation : :- St-2 

(ii) Primer paint:- Two coats of zinc phosphate in phenolic alkyd medium 

(35microns/coat). 

(iii) Finishing paint:- Two coats of synthetic enamel (25 microns/coat) conforming to IS : 

2932 - 1974. 

All paints shall be of approved and shade as per Purchaser / Consultant's requirements. 

18.6.4.4 Paint and Painting 

Manufacture of paints, mixing of paints, etc. shall be generally according to the relevant IS 

codes of practice. 

Generally compatibility between primer intermediate and finishing paint shall be certified by 

the paint manufacturer supplying the paints. 

Guarantee period shall commerce from the date of completion of finishing coat of paint on 

entire structures. The guarantee period shall be indicated depending on the type of surface 

preparation and system of painting. To fulfill this obligations, the Contractor may obtain 

from the painting manufacturer, guarantee for the performance of paint/painted surfaces. 

Application of paint shall be by spraying or brushing as per IS : 486-1983 1983 and IS : 487 487-1985 

and in uniform layers of 50% overlapping strokes by skilled painters. Painting shall not be 

done when the temperature is less than 5 degree C or more than 45 degree C and relative 

humidity is more than 85 85% % unless manufacturer's recommendations permit. Also painting 


Page 63 of 64

shall not be done in foggy weather. During application, paint agitation must be provided 

where such agitation is recommended by the manufacturer. 

Painting shall be applied at painting manufactu manufacturer's rer's recommended rates. The number of 

coats shall be such that minimum dry film thickness specified is achieved. The dry film 

thickness (DFT) of painted surfaces shall be checked with ELCOMETER or measuring gauges 

to ensure specified DFT. 

All structures shall receive one coats of primer paint at shop after fabrication before 

despatch after surface preparation has been done as per requirements. 

Unless otherwise specified all structures after erection shall be given one coat of primer and 

two coats of finishing shing paint of approved colour and quality. The under coat shall have 

different tint to distinguish the same from the finishing coat. 

The proposed make, quality and shade of paint shall have the approval of Purchaser / 

Consultant. 


Page 64 of 64

1.0 INTRODUCTION 

This part covers technical requirements which will form an integral part of the Contract. The 

following provisions shall supplement all the detailed technical requirements brought out in 

the Technical Specifications and the Technical Data Sheets. 

2.0 BRAND NAME 

Whenever a material or article is specified or described by the name of a particular b bbrand, 

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. 

3.0 COMPLETENESS OF FACILITIES 

3.1 Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in 

the specification. Each of the plant shal shall l 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. 

3.2 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 & maintenan 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 compon components/ ents/ parts of similar 

standard equipment provided, shall be interchangeable with one another. 


4.1 In addition to the codes and standards specifically mentioned in the relevant technical 

specifications for the equipment / plant / sy system, stem, all equipment parts, systems and works 

covered under this specification shall comply with all currently applicable statutory 

regulations and safety codes, including the following: 

a. Bureau of Indian Standards (BIS) 

b. Indian electricity act 

c. Indian electricity city 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 

Technical Specifications: Sec-5,General Techn chnical Requirements 

SECTION 5 

Page 1 of 27

i. Pollution n 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. Guideline for wagon tippler – G33 Rev.01 of May 2010. 

m. Any other statutory codes / standards / regulations, as may be applicable. 

4.2 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), pening), of the codes and standards given below shall also apply: 

(a.) Japanese Industrial Standards (JIS) 

(b.) American National Standards Institute (ANSI) 

(c.) American Society of Testing and Materials (ASTM) 

(d.) American Society of Mechanical Engineers (ASME) 

(e.) American Petroleum Institute (API) 

(f.) Standards of the Hydraulic Institute, U.S.A. 

(g.) International Organisation for Standardization (ISO) 

(h.) Tubular Exchanger Manufacturer's Association (TEMA) 

(i.) American Welding Society (AWS) 

(j.) National Electrical Manufacturers Association (NEMA) 

(k.) National Fire Protection Association (NFPA) 

(l.) International Electro Electro-Technical Commission (IEC) 

(m.) Expansion Joint Manufacturers Association (EJMA) 

(n.) Heat Exchange Institute (HEI) 

4.3 In the e 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. 

4.4 In case of any change in codes, standards & regulations betwee between n 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 no notice tice of the Employer such changes and 

advise Employer of the resulting effect. 

4.5 EQUIPMENT FUNCTIONAL GUARANTEE 

The functional guarantees of the equipment and the system under the scope of the Contract 

is given elsewhere in the technical specification. These guarantees shall supplement the 

general provisions covered under General Conditions of Contract. 

4.6 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS 

4.6.1 Design of Facilities 

All the e 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 appropria appropriate 


Page 2 of 27

equipments to provide the best co co-ordinated 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 tha 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. 

4.7 DOCUMENTS, DATA AND DRAWINGS TO BE FURN FURNISHED ISHED BY CONTRACTOR 

4.7.1 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. The Contractor sh shall all furnish engineering data/drgs. in accordance with the 

schedule of information as specified in Technical Specification and data sheet. 

4.7.2 The number of copies/prints/CD 

copies/prints/CD-ROMs/manuals ROMs/manuals to be furnished for various types of 

documents is given in Section 5. . Distribution schedule shall be informed to successful 

Contractor. 

4.7.3 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 : 

4.8 INSTRUCTION MANUALS 

The Contractor shall submit to the Employer, Instruction Manuals for all the equipments 

covered under the Contract. The Instruction manuals shall contain full details required for 

erection, commissioning, operation and maintenance of each equipment. The ma manual shall 

be specifically compiled for this project. The Instruction Manuals shall comprise of the 

following. 

4.8.1 Erection Manuals 

The erection manuals shall be submitted prior to the commencement of erection activities 

of particular equipment/system 

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. 


Page 3 of 27

i) Procedure for initial checking after erection. 

j) Procedure for testing and acceptance norms. 

k) Procedure / Check list ffor 

pre-commissioning activities. 

l) Procedure / Check list for commissioning of the system. 

m) Safety precautions to be followed in electrical supply distribution during erection 

4.8.2 Operation & Maintenance Manuals 

i. The operating and maintenance ins instructions tructions together with drawings (other than shop 

drawings) of the equipment, as completed, shall be in sufficient detail to enable the 

Employer to operate, maintain, dismantle, reassemble and adjust all parts of the 

equipment. They shall give a step by st step ep procedure for all operations likely to be carried 

out during the life of the plant / equipment including, operation, maintenance, 

dismantling and repair including periodical activities wherever required. Each manual 

shall also include a complete set of drawings of the equipment. 

ii. If after the commissioning and initial operation of the plant, the manuals require any 

modification / additions / changes, the same shall be incorporated and the updated final 

instruction manuals shall be submitted to the Emp Employer for records. 

iii. A separate section of the manual shall be for each size/ type of equipment and shall 

contain a detailed description of construction and operation, together with all relevant 

pamphlets and drawings. 

iv. The manuals shall include the following: 

a) List of spare parts along with their drawing and catalogues and procedure for 

ordering spares. 

b) Lubrication Schedule including charts showing lubrication checking, testing and 

replacement procedure to be carried daily, weekly, monthly & at longer intervals to 

ensure trouble free operation. 

c) Where applicable, fault location charts shall be included to facilitate finding the 

cause of mal-operation operation or break down. 

v. Detailed specifications for all the consumables including lubricant oils, greases, che chemicals 

etc. system/equipment/assembly/subassembly - wise required for the complete plant. 

vi. On completion of erection, a complete list of bearings / equipment giving their location, 

and identification marks etc. shall also be furnished to the Employer indicating lubrication 

method for each type/category of bearing. 

4.8.3 Project Completion Report 

The Contractor shall submit a Project Completion Report at the time of handing over the 

plant. 

4.8.4 DRAWINGS 

(a.) All documents submitted by the Contractor for Employer's review shall be in electronic 

form (soft copies) along with the number of hard copies. The soft copies to be supplied 

shall be either in CDs, or through direct transfer via EE-mail, 

mail, etc. depending upon the 

nature/volume/size of the document. The drawings submitted for approval could be in 

the Image form. 


Page 4 of 27

(b.) Final copies of the approved drawings shall be submitted in vector form on CDROM 

along with the requisite number of hard copies. 

(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 arrangeme 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 ach drawing submitted by the Contractor (including those of sub sub-vendors) vendors) 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, th the 

name of the Project, drawing number and revisions. If standard catalogue pages are 

submitted the applicable items shall be indicated therein. All titles, notings, markings 

and writings on the drawing shall be in English. All the dimensions should be in m mmetric 

units. 

(f.) The drawings submitted by the Contractor (or their sub sub-vendors) vendors) shall bear Employer’s 

drawing number in addition to contractor’s (their sub sub-vendor’s) vendor’s) own drawing number. 

Employer’s drawing numbering system shall be made available to the succe 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 ppurpose 

urpose 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/ awings/ 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 resp responsibilities onsibilities 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 Employe Employer. 


Page 5 of 27

(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, system, once they are approved by the Employer. However, if some changes are 

necessitated in the design of the equipment/ system at a later date, the Contractor may 

do so, but such changes shall promptly be brought to the notice of the Employer 

indicating the reasons for the change and get the revised drawing approved again in 

strict conformance to the provisions of the Technical Specification. 

(l.) Drawings shall include all installations and detailed piping and wiring drawings. 

(m.) Assessing & anticipating the rrequirement 

equirement 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 suita 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 su submitted bmitted without proper endorsement 

for checking by the Contractor, the same shall not be reviewed and returned to the 

Contractor for re-submission. submission. The contractor shall make a visit to site to see the existing 

facilities and understand the layout completel completely y 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, g, 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. 

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 

owner/RITES /RITES’s agreement. 


Page 6 of 27

(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 change changes s desired. When changes are required, drawings 

shall be re-submitted 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 informat 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 revisio 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 owner / consultant for consideration. In all such cases 

vendor shall necessarily enclose explanations along with the revised drawing (taking 

care of balance comments) to avoid any delay and/or duplication in review work. 

• It is responsibility of the Vendor to get all the drawings approved in the Category I 

& IV (as the case may be) and complete engineering activities within the agreed 

schedule. Any delay arising out of submission and modification of drawings shall 

not alter the contract ontract completion schedule. Vendor shall not make any changes in 

the portions of the drawing other than those commented upon. If changes are 

required to be made in the portions already approved, the vendor shall resubmit 

the drawing identifying the change changes for owner/RITES’s ’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 ccomments 

omments 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 s 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. 


Page 7 of 27

(v.) After final acceptance of individual equipment / system bby 

y the Employer, the 

Contractor will update all original drawings and documents for the equipment / system 

to “as built” conditions. 

4.8.5 ENGINEERING INFORMATION SUBMISSION SCHEDULE 

Prior to the award of Contract, a Detailed Engineering Information Submi Submission Schedule shall 

be tied up with the Employer. For this, the Contractor shall furnish a detailed list of 

engineering information along with the proposed submission schedule. This list would be a 

comprehensive one including all engineering data / drawin drawings gs / information for all bought out 

items and manufactured items. The information shall be categorised into the following 

parts. 

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 month wise. The schedule should allow 

adequate time for proper review and incorporation of changes/ modifications, if any, to 

meet the contract without affect affecting ing the equipment delivery schedule and overall project 

schedule. The early submission of drawings and data is as important as the manufacture and 

delivery of equipment and hardware and this shall be duly considered while determining the 

overall performance e and progress. 

4.9 ENGINEERING COORDINATION PROCEDURE 

Identification of Principal Engineering Coordinators 

4.9.1 The following principal coordinators will be identified by respective organisations at time of 

award of contract 

RITES’ COORDINATORS 

RITES- Engineering Coordinators 

Name : 

Designation : 

Address : 

a) Postal : 

b) Telegraphic : 

TELEX : 

FAX : TELEPHONE : 

EMPLOYER’S COORDINATORS 

NALCO- Engineering Coordinators (NALCO EC) 

Name : 

Designation : 

Address : 

a) Postal : 


TELEX : 


Page 8 of 27


NALCO- SITE CO-ORDINATOR ORDINATOR (NALCO SC) 

Name : 

Designation : 

Address : 

a) Postal : 


TELEX : 


VENDOR ENGINEERING CO CO-ORDINATOR (VENDOR EC) 

Name : 

Designation : 

Address : 

a) Postal : 


TELEX : 


4.9.2 All engineering correspondence shall be in the name of above coordinators on behalf of the 

respective organisations. 

4.9.3 Vendors Drawings 

(a) The contractor shall furnish, discuss and finalise with the Employer, the engineering 

information ion 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 sha shall ll be furnished along with the tender. Further drive list shall be 

submitted to the RITES’s 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 s sstrictly 

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 


Page 9 of 27

y the Engineer shall not relieve the contractor of any of his responsibilities or liabilities 

under the contract. 

4.9.4 Erection Drawings 

(a) Contractor shall furnish erection drawings for the guidance of his/ RITES’s site staff at 

least 4 weeks before scheduled commencement of erection or the first shipment, 

whichever r 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 ch 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 CLAUSE NO. 

4.9.5 ENGINEERING PROGRESS AND EXCEPTION RREPORT 

A report giving the status of each engineering information including the list of 

drawings/engineering information which remains unapproved for more than one (1) 

weeks after the date of first submission Drawings which were not submitted as per 

agreed schedule. 

4.9.6 TECHNICAL CO-ORDINATION ORDINATION MEETING 

(a) The Contractor shall be called upon to organise and attend monthly Design/ Technical 

Co-ordination ordination Meetings (TCMs) with the owner/owner’s representatives and other 

Contractors of the Employer during the period of contract. The Contractor shall attend 

such meetings at his own cost as and when required and fully co co-operate with such 

persons and agencies involved during the discussions. 

(b) 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 practica 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 Co-ordination ordination Meeting (s) 

wherein best efforts shall be made by both sides to ensure the ap approval proval of the drawing. 

(c) The Contractor shall ensure availability of the concerned experts / consultants/ 

personnel who are empowered to take necessary decisions during these meetings. 

(d) Should any drawing remain unapproved for more than one (1) ) weeks after it’s first 

submission, this shall be brought out in the monthly Engineering Progress and Exception 

Report with reasons thereof. 

(e) Any delays arising out of failure by the Contractor to incorporate Employer’s comments 

and resubmit the same during the TCM sh shall all be considered as a default and in no case 

shall entitle the Contractor to alter the Contract completion date. 


Page 10 of 27

4.9.7 DESIGN IMPROVEMENTS 

The Employer/RITES 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 g 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. 

4.9.8 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 support the unit and its drive assembly, shall bbe 

e of a neat design with 

pads for anchoring the units. 

4.9.9 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. 

4.9.10 LUBRICANTS, SERVO FLUIDS AND CHEMICALS 

(a) The Contractor’s scope includes all the first fill of consumables such as oils, lubricants 

including grease, servo fluids, gases and essential chemicals etc. Consumption of all thes these 

consumables during the initial operation and final filling after the initial operation shall also 

be included in the scope of the Contractor. 

(b) The variety of lubricants shall be kept to a minimum possible. Detailed specifications for the 

lubricating oil, grease, gases, servo fluids, control fluids, chemicals etc. required for the 

complete plant covered herein shall be furnished. On completion of erection, a complete list 

of bearings/ equipment giving their location and identification marks shall be furnis furnished to 

the Employer along with lubrication requirements. 

4.9.11 Lubrication 

Equipment shall be lubricated by systems designed for continuous operation. Lubricant level 

indicators shall be furnished and marked to indicate proper levels under both standsti standstill and 

operating conditions. 

4.9.12 Material of Construction 

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. 

4.9.13 RATING PLATES, NAME PLATES & LABELS 


Page 11 of 27

Each main and auxiliary item of plant including instruments shall have permanently attached 

to it in a conspicuous position, a rating plate oof 

non-corrosive 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. 

Each item of plant t shall be provided with nameplate or label designating the service of the 

particular equipment. 

Such nameplates or labels shall be of white non hygroscopic material with engraved black 

lettering or alternately, in the case of indoor circuit breakers, st starters, arters, 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. 

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.. 

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 

4.9.14 TOOLS AND TACKLES 

The Contractor shall supply with the equipment one complete set of all special tools and 

tackles and other instruments required for the erection, assembly, ddisassembly 

isassembly and proper 

maintenance of the plant and equipment and systems (including software). These special 

tools will also include special material handling equipment, jigs and fixtures for maintenance 

and calibration / readjustment, checking and measure measurement ment aids etc. A list of such tools and 

tackles shall be submitted by the Contractor alongwith the offer. 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 ssent 

ent 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 f reputed make acceptable to the Employer. 

4.9.15 Welding 

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. 

4.9.16 COLOUR CODE FOR ALL EQUIPMENTS/ SERVICES 

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. 

4.10 PROTECTION AND PRESERVATIVE SHOP COATING 


Page 12 of 27

4.10.1 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 over ground environment as the case 

may be. 

4.10.2 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 ffor 

or 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 finish-painted painted after installation or require corrosion protection 

until installation, shall be shop painted with atleast two coats of primer. Transformers and 

other electrical equipments if included shall be shop finished with one or more coats of 

primer and two coats of high grade resistance enamel. The finished colors shall be as per 

manufacturer’s ufacturer’s standards, to be selected and specified by the Employer at a later date. 

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 ap 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 Empl Employer. 

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. 

All piping shall be cleaned after shop assembly. 

Painting for Civil structures shall be done as per relevant part of technical specification 

4.11 QUALITY ASSURANCE PROGRAMME 

The Contractor shall adopt suitable quality assurance programme to ensure that the 

equipment and services under the scope of co contract ntract whether manufactured or performed 

within the Contractor’s works or at his sub sub-contractor’s 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 Contracto Contractor r 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 IS/ISO- 9001.A quality assurance programme of the contractor shall 

generally cover r the following: 


Page 13 of 27

(a) His organisation structure for the management and implementation of the proposed 

quality assurance programme 

(b) Quality System Manual 

(c) Design Control System 

(d) Documentation and Data Control System 

(e) Qualification data for Contractor’s key personnel. 

(f) The procedure for purchase of materials, parts, components and selection of subcontractor’s 

services including vendor analysis, source inspection, incoming raw raw-material 

inspection, verification of materials purchased etc. 

(g) System for shop manufa manufacturing cturing and site erection controls including process, fabrication 

and assembly. 

(h) Control of non-conforming 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. 

4.12 GENERAL REQUIREMENTS - QUALITY ASSURANCE 

4.12.1 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 Progr Programme. amme. 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 Contractor and will be submitted to Employer for approval. 

Schedule of finalisation ation of such quality plans will be finalised before award. Monthly 

progress reports on MQP/FQP submission/approval shall be furnished on enclosed format 

No. QS-01-QAI-P-02/F1. 

4.12.2 Manufacturing Quality Plan will detail out for all the components and e eequipment, 

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 supplier's Quality Control Organisation 

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 EE-mail 

in 

addition to hard copy, for review and approval. After approval the same shall be submitted 

in compiled form on CD-ROM. 


Page 14 of 27

4.12.3 Field Quality Plans will detail out for all the equipment, the quality practices and procedures 

etc. tc. 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. 

4.12.4 The Contractor shall also furnish copies of the reference documents/plant 

standards/acceptance ndards/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 proce 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 justif justification ication for approval and 

dispositioning. 

4.12.5 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 Em Employer’s ployer’s Project Manager/Authorised representative and 

duly authorised for despatch by issuance of Material Despatch Clearance Certificate (MDCC). 

4.12.6 All material used for equipment manufacture including casting and forging etc. shall be of 

tested quality lity 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 emperature chart. Tests shall be carried out as per applicable material standards and/or 

agreed details. 

4.12.7 The contractor shall submit to the Employer Field Welding Schedule for field welding 

activities in the enclosed format No.: QS QS-01-QAI-P-02/F3. The field welding schedule shall be 

submitted to the Employer along with all supporting documents, like welding procedures, 

heat treatment procedures, NDT procedures etc. at least ninety days before schedule start 

of erection work at site. 

4.12.8 All welding and brazing shall be carried out as per procedure drawn and qualified in 

accordance with requirements of ASME Section IX/BS IX/BS-4870 4870 or other International equivalent 

standard acceptable to the Employer. All welding/brazing procedures shall be submitte submitted to 

the Employer or its authorized representative for approval prior to carrying out the 

welding/brazing. 

4.12.9 All brazers, welders and welding operators employed on any part of the contract either in 

Contractor’s/sub-contractor’s contractor’s works or at site or eelsewhere 

lsewhere shall be qualified as per ASME 

Section-IX or BS-4871 4871 or other equivalent International Standards acceptable to the 

Employer. 


Page 15 of 27

4.12.10 Welding procedure qualification & Welder qualification test results shall be furnished to the 

Employer for approval. al. However, where required by the Employer, tests shall be conducted 

in presence of Employer/authorised representative. 

4.12.11 Unless otherwise proven and specifically agreed with the Employer, welding of dissimilar 

materials and high alloy materials sh shall be carried out at shop only. 

4.12.12No welding shall be carried out on cast iron components for repair. 

4.12.13 All the heat treatment results shall be recorded on time temperature charts and verified 

with recommended regimes. 

4.12.14 All non-destructive tive examination shall be performed in accordance with written procedures 

as per International Standards, The NDT operator shall be qualified as per SNT SNT-TC-IA (of the 

American Society of non non-destructive destructive examination). NDT shall be recorded in a report, whic which 

includes details of methods and equipment used, result/evaluation, job data and 

identification of personnel employed and details of correlation of the test report with the 

job. All Bar stock / forgings of diameter equal to or greater than 50mm shall be u uultrasonically 

tested. In general all plates of thickness equal to or greater than 40mm and for pressure 

parts, pates of thickness equal to or greater than 25mm shall be ultrasonically tested unless 

as specified otherwise in respective equipment specificati specification. 

4.12.15The Contractor shall list out all major items/ equipment/ components to be manufactured in 

house as well as procured from sub sub-contractors. All the subcontractor proposed by the 

Contractor for procurement of major bought out items including castings, forging, semifinished 

and finished components/equipment etc., list of which shall be drawn up by the 

Contractor and finalised with the Employer, shall be subject to Employer's approval. The 

contractor’s proposal shall include vendor’s facilities established at the respective works, the 

process capability, process stabilization, QC systems followed, experience list, etc. along with 

his own technical evaluation ation for identified sub sub-contractors contractors enclosed and shall be submitted 

to the Employer for approval within the period agreed at the time of pre pre-awards discussion 

and identified in "DR" category prior to any procurement. Monthly progress reports on sub- 

contractor ctor detail submission / approval shall be furnished. Such vendor approval shall not 

relieve the contractor from any obligation, duty or responsibility under the contract. 

4.12.16For 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 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. Suc Such h 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 sub-contractor. contractor. Within three weeks of 

the release of the purchase ord orders ers /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 


Page 16 of 27

the monthly basis by the Cont Contractor ractor along with a report of the Purchase Order placed so far 

for the contract. ** 

4.12.17Employer reserves the right to carry out quality audit and quality surveillance of the systems 

and procedures of the Contractor’s or their sub sub-contractor’s contractor’s quality management and 

control activities. The contractor shall provide all necessary assistance to enable the 

Employer carry out such audit and surveillance. 

4.12.18The contractor shall carry out an inspection and testing programme during manufacture in 

his work and that of his sub sub-contractor’s 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 ll 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 pla plan. 

4.12.19Quality 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 sat satisfaction isfaction 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. 

4.12.20 For or all spares and replacement items, the quality requirements as agreed for the main 

equipment supply shall be applicable. 

4.12.21 Repair/rectification procedures to be adopted to make the job acceptable shall be subject to 

the approval of the Employer/ authorised representative. 

4.13 QA DOCUMENTATION PACKAGE 

The Contractor shall be required to submit the QA Documentation in two hard copies and 

two CD ROMs. 

4.13.1 Each QA Documentation shall have a project specific Cover Sheet bearing name & 

identification ation 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 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 CD-Rom Rom may be issued not later than three weeks. 

4.13.2 Typical contents of QA Documentation is as below: below:- 

(a) Quality Plan 

(b) Material mill test reports on components as specified by the specification and approved 

Quality Plans. 


Page 17 of 27

(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 ructive 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 (Time- temperature Chart) 

(f) All the accepted Non Non-conformance conformance Reports (Major/Minor) / deviation, including 

complete technical details / repair procedure). 

(g) Inspection reports duly signed by the Inspector of the Employer and Contractor for the 

agreed Customer Hold Points. 

(h) Certificate te of Conformance (COC) wherever applicable. 

(i) MDCC 

4.13.3 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. 

4.13.4 Before despatch / commissioning of any equipment, the Supplier shall make sure that the 

corresponding quality document or in the case of protracted phased deliveries, t tthe 

applicable section of the quality document file is completed. The supplier will then notify the 

Inspector regarding the readiness of the quality document (or applicable section) for review. 

If the result of the review carried out by the Inspector is sat satisfactory, isfactory, the Inspector shall 

stamp the quality document (or applicable section) for release. If the quality document is 

unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing to 

finalize the quality document (or applicab applicable le section) by time compatible with the 

requirements as per contract documents. When it is done, the quality document (or 

applicable section) is stamped by the Inspector. If a decision is made despatch, whereas all 

outstanding actions cannot be readily cle cleared ared for the release of the quality document by 

that time. The supplier shall immediately, upon shipment of the equipment, send a copy of 

the quality document Review Status signed by the Supplier Representative to the Inspector 

and notify of the committed date for the completion of all outstanding actions & submission. 

The Inspector shall stamp the quality document for applicable section when it is effectively 

completed. The submission of QA documentation package shall not be later than 3 weeks 

after the despatch spatch of equipment. 

4.13.5 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 tthe 

he 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. 

4.14 Project Manager’s Supervision 


Page 18 of 27

4.14.1 To eliminate delays and avoid dispu disputes tes 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 GCC, the Contractor shall proceed to 

comply with the Project Manager's decision. 

4.14.2 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. 

4.15 INSPECTION, TESTING AND INSPECTION CERTIFICATES 

(a) The word ‘Inspector’ shall mean the Proj Project ect Manager and/or his authorized 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. 

(b) The Project Manager or his duly aut authorised horised 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 wo works rks 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 remises or works. 

(c) 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 Man Manager/Inspector, ager/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 mmay 

ay 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. 

(d) The Project Manager or Inspector shall within fifteen (15) da days ys 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 


Page 19 of 27

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 th the contract. 

(e) When the factory tests have been completed at the Contractor’s or sub 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 Co Contractor ntractor 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. 

(f) In all cases where here the contract provides for tests whether at the premises or works of the 

Contractor or any sub-contractor, contractor, the Contractor, except where otherwise specified shall 

provide free of charge such items as labour, material, electricity, fuel, water, stores, 

apparatus pparatus 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 er/Inspector or to his authorised representative to accomplish testing. 

(g) 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 th the 

agreed Quality Assurance Programme forming a part of the contract. 

(h) To facilitate advance planning of inspection, the Contractor shall furnish quarterly inspection 

programme indicating schedule dates of inspection at Customer Hold Point and final 

inspection ion stages. Updated quarterly inspection plans will be made for each three 

consecutive months and shall be furnished before beginning of each calendar month. 

(i) 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 NALCO. Wherever asked 

specifically, ically, the contractor shall re re-calibrate calibrate the measuring/test equipment in the presence 

of Project Manager / Inspector. 

4.16 PRE-COMMISSIONING COMMISSIONING AND COMMISSIONING FACILITIES 

(a) As soon as the facilities or part thereof has been completed operationally and 

structurally cturally and before start start-up, 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 ceptability for initial pre pre-commissioning commissioning tests, commissioning and start start-up at Site. The 

list of pre-commissioning commissioning tests to be performed shall be as mutually agreed and 


Page 20 of 27

included in the Contractor’s quality assurance programme as well as those included 

elsewhere where in the Technical Specifications. 

(b) The Contractor’s pre pre-commissioning/ commissioning/start-up up engineers, specially 

identified as far as possible, shall be responsible for carrying out all the pre- 

commissioning tests at Site. On completion of inspectio inspection, n, checking and after the precommissioning 

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 sub-systems and supporting equipment uipment 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 truction completion schedule. Each equipment/system, as it is completed in 

construction and turned over to RITES/Employer's Employer's commissioning (startup) 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/RITES. 

(e) On completion of all pre pre-commissioning commissioning 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 Operat Operation' ion' of the complete facility as an integral unit shall be 30 

continuous days with available wagon loads or as to be mutually agreed agreed. 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 operat operation ion with any load shall be counted. 

(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 de details tails of the various observations 

during trial operation shall also include the dates of start and finish of the Trial 

Operation and shall be signed by the representatives of both the parties. The report 

shall have sheets, recording all the details of inte interruptions rruptions 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 en enable able the latter to accord permission to 

carry out the Guarantee tests on the facilities. However, minor defects which do not 


Page 21 of 27

endanger the safe operation of the equipment, shall not be considered as reasons for 

with- holding the aforesaid permission 

(i) Contractor ctor 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: 

a) Experience of the Commissioning Engineers. 

b) Role and responsibilities sponsibilities of the Commissioning Organisation members. 

c) Expected duration of posting of the above Commissioning Engineers at site. 

4.17 GUARANTEE TESTS 

(a) The final tests as to the guarantees shall be conducted at Site, by the Contractor. The 

Contractor's Commissioning and start start-up 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 cost. The bidder should 

particularly note that suitable and necessary method and arrangement for the PG test 

for 1200TPH of the new conveyor integrating into 800 TPH of existing conveyor system 

has to be made by him/them acceptable to owner/RITES at no extra cost. 

(d) The guarantee figures and design/performance parameters of the equipment shall be 

proved by the Contractor during these Guarantee Tests/ and or during the 'Trial 

operation' as detai detailed led 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 ccost 

ost for modifications including labour, materials and the cost of 

additional testing to prove that the equipment meets the guarantees, shall be borne by 

the Contractor. 

(e) The specific tests to be conducted on equipment have been brought out in the technical 

specification. 

4.18 Test Codes 

The provisions outlined in the ASME Performance Test Codes shall be used as a guide for all 

the above test procedures unless otherwise specified in the technical specifications. 

4.19 TAKING OVER 

Upon successful completio completion n of Initial Operations and all the tests conducted to the 

Employer's satisfaction, the Employer shall issue to the Contractor a Taking over Certificate 


Page 22 of 27

as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably 

be with held ld 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 ations which otherwise survive, by the terms and conditions of the Contract after 

issuance of such certificate. 

4.20 TRAINING OF EMPLOYER'S PERSONNEL 

The scope of service under training of Employer’s engineers (min. 3 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 wagon tippler system in a manner accepta acceptable 

to the Employer: 

The scope of services under training shall also necessarily include training of Employer's 

personnel. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & operation etc. and 

shall include all the related areas like Des Design ign 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 vis visits its and visits to manufacturer's works, exposure to 

various kinds of problems which may be encountered in fabrication, manufacturing, 

erection, welding etc. The training module prepared by the contractor, shall be submitted 

for the Employer’s approval, pri prior to imparting training. 

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 (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. 

Training schedule shall be finalised based on the Contractor's proposal within two (2) 

months prior to commissioning. 

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 Co Contractor. 

4.21 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION 

In addition to the requirements given in Erection Conditions of Contract (ECC) the following 

shall also cover: 

1. Working platforms should be fenced and shall have means of access. 

2. Ladders in accordance ccordance 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. 

4.22 NOISE LEVEL 


Page 23 of 27

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. 

4.23 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 t ttill 

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 eensured 

nsured 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 pre-assembly 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. 

4.24 ELECTRICAL ENCLOSURE 

All electrical equipments and devices, including insulation, heating and ventilation devices 

shall be designed for am ambient temperature (50 0 All electrical equipments and devices, including insulation, heating and ventilation devices 

C) and a maximum relative humidity (75%). 

4.25 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. 

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. ale. All scales and charts shall be calibrated and printed in Metric Units as follows: 

a) Temperature - Degree centigrade (deg C) 

b) Pressure - Kilograms per square centimetre (Kg/cm2). Pressure instrument shall 

have the unit suffixed with 'a' to indicate absolu absolute te 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. 


Page 24 of 27

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 plugin 

connection at rear. 

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 bette better. 

4.26 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 electrica electrical l noise shall be hardened to 

eliminate possible problems. Any additional equipment, services required for effectively 

eliminating the noise problems shall be included in the proposal. The equipment shall be 

protected against ESD as per IEC IEC-801- 2. Radio Frequency equency interference (RFI) and Electro 

Magnetic Interference (EMI) protection against hardware damage and control system mal- 

operations/errors shall be provided for all systems. 

4.27 TAPPING POINTS FOR MEASUREMENTS 

Tapping points shall include probes, wwherever 

herever 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 intima intimated ted 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 thermo well Pressure 

test pockets 

4.28 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 uivalents of the same. 

4.29 JUNCTION BOXES 

The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates shall be 

removable type and made of 3 mm thick sheet steel. The boxes shall be provided with 

detachable cover or hinged door with captive screws. Top of the box shall be arran 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 IP--55 

as per IS: 2147. 

Adequate spacing shall be provided to terminate the external cables 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 


Page 25 of 27

shall be done. In case of junction box for powe power r cable, the box shall be rated for maximum 

current carrying capacity. Terminal blocks shall be of one piece, klippon RSF RSF-1 or ELMEX 

CSLT-1 1 type with insulating barriers. 

The bidder shall supply the following. 

S. NO. DESCRIPTION NO OF PRINTS (SETS) NO. OF CDROMs 

OF MANUALS 

(SETS) 

1. Drawings "FOR APPROVAL" 4 1 CD 

2. Drawings "FOR INFORMATION" 4 1 CD 

3. Drawings "FINAL DRAWING" 10 2 CD-ROMs ROMs 

4. Drawings "AS BUILT " 

10 2 CD-ROMs ROMs 

5. DATASHEETS,DESIGN 

CALCULATIONS, etc. and Other type of documents 

i) For Approval 

4 

1 CD 

ii) FINAL 

10 

2 CD-ROMs - 

iii) Analysis reports of equipments/ 

piping/ / structures components/ 

systems employing software 

packages as detailed in the specifications 

a) Input 

4 2CD ROMS 

b) Output 

4 2CD ROMS 

c) Drawings/ Sketches 4 2CD ROMS 

6. Erection manual "DRAFT" 

7. Erection manual nual "FINAL" 2CD ROMS 

8 Operation & Maintenance manual "DRAFT" 

9 Operation & Maintenance manual "FINAL" 2CD ROMS 

10 Plant Hand Book "DRAFT" 

11 Plant Hand Book "FINAL" 2CD ROMS 

12 Commissioning and Performance Procedure manual "DRAFT" 

13 Commissioning and Performance Procedure manual "FINAL" 2CD ROMS 

14 Performance and Functional 

GURANTEES TEST REPORT 

4 2 CD 

15 Progress Reports 

4 2 CD 

16 Project completion report 10 2CD ROMS 

17 QA programme including Organisation for 

implementation and QA system manual 

(with revision-servicing) 

18 Vendor details in respect of proposed 

vendors including contractor’s evaluation 

report. 


1 

1 

Page 26 of 27

19 Manufacturing QPs, Field QPs, Field 

welding g schedules and their reference 

documents like test procedures, WPS, 

(i) For review/comment 

3 

(ii) For final approval 

floppies 

4 

20 Welding Manual, Heat Treatment Manuals, 

Storage & preservation manuals 

Draft 

- 

Final 

4 sets 

21 Monthly Vendor Approval 

and QP approval status 

2 

22 QA Documentation Package for items / 

equipment manufactured and dispatched to site 2 

23 QA Documentation Package for field activities 

on equipment / systems at site 2 


1 set 

4 sets 

2 CD ROMS 

1 CD 

1 CD 

2 CD ROMS 

2 CD ROMS 

Page 27 of 27

ELECTRICS FOR WAGON TIPPLER SYSTEM 

1.0 SPECIAL INSTRUCTIONS TO BIDDERS 

1.1 Inspection of site by Bidder 

Bidder shall inspect the site and examine and obtain all information required and satisfy 

himself regarding all matters such as access to site, communication, transport, right of way, 

the availability of local labour, availability and rates of materials, local working conditions, 

extreme weather conditions, uncertainty of weather, obstructions and hindrances that m mmay 

arise, etc, which may affect the work or cost thereof, before the submission of his tender. 

Ignorance of site conditions shall not be accepted as basis for any claim for compensation. 

The submission of tender by Bidder will be construed as evidence tha that t such an examination 

was made and any later claims / disputes in regard to price quoted shall not be entertained 

or considered. 

Bidder shall also indicate in his bid all the major assumptions including major design 

assumptions / criteria made by him on which the bid is based. 

1.2 Compliance with Specification 

All equipment and accessories covered under this specification shall conform to the 

“Technical Specifications” given in this document. 

In case alternative type of equipment is offered, all technical particulars of equipment 

offered, number of such equipment supplied in India, reference list of installations where 

such equipment is in operation as per qualifying requirements, type test cer certificates of their 

collaborators, type test certificates of indigenously made equipment, extent of import 

content and availability of spares indigenously, along with any other data for considering the 

alternative equipment shall be furnished with the offer offer. . The Purchaser, however, reserves 

the right to accept or reject the proposal without assigning any reason. 

All equipment shall be suitable for voltage/frequency variations and other data given in 

Electrical System Design. 

The contractor shall be responsible for satisfactory working of system with guaranteed 

parameters. All the major equipment shall be installed, tested and commissioned under 

supervision of representative of manufacturer of respective equipment. 

1.3 Standards and Regulations 

Technical Specification:Sec-6, Electrical 

SECTION 6 

Page 1 of 97

The design, manufacture, performance, testing and installation (including earthing and other 

essential provisions) of equipment and accessories covered under this specification shall, in 

general, comply with the latest issue of the follow following: 

• Applicable Standards and Codes of Practices published by Bureau of Indian 

Standards. 

• Central Board of Irrigation and Power 

• Indian Electricity Act, 2003 

• Central Electricity Authority 

• Indian Electricity Rules 

• Equipment specific statutory regulations 

• Indian Factory Act 

Equipment complying with other recognized Standards such as IEC, BS, VDE, DIN etc. will also 

be considered if it ensures performance equivalent to or superior to Indian Standards. 

Equipment and nd accessories for which Indian Standards are not available, shall be designed, 

manufactured and tested in accordance with the latest issues of recognized Standards such as 

IEC, BS, VDE, DIN etc. 

In case of conflict between applicable Standards referred to in this part and technical 

specifications, the Technical Specifications shall govern to the extent of such difference. 

1.4 Make & Interchangeability 

This specification is issued for procurement of specified equipment and system preferably 

from indigenous suppliers who may make use of imported systems / sub sub-systems systems / equipment 

/ parts and who have valid collaboration agreement with reputed foreign suppl suppliers with 

experience in design and supply of similar systems as specified. The Bidder shall furnish 

division list of supplies from foreign and Indian sources indicating the name of the agency or 

make against the respective items. It shall be the responsibi responsibility lity of the successful Bidder to 

arrange the import license for the imported items offered and to co co-ordinate ordinate the supply of 

equipment from foreign and Indian sources and execute the contract within the agreed time 

schedule. 

The make of major equipment sh shall all be limited to preferred makes indicated under ‘List of 

preferred makes'. Makes of all other equipment and accessories are subject to prior approval 

by the Purchaser/RITES. 

Similar equipment and components shall be of same make; equipment of same type and 

rating shall be interchangeable. 

The Purchaser has the option of selecting the manufacturer of electrical equipment, 

instruments and controls and any other specialized items in the interest of standardization and 

the successful Bidder shall have to supply equipment of particular make, if so required. 


Page 2 of 97

1.5 Safety 

All equipment shall be complete with approved safety devices wherever a potential hazard 

exists and with provision for safe access of personnel to and around equipment for 

operational and maintenance enance functions. 

The design shall include not only those usually furnished with elements of machinery but also 

the additional covers, staircases, ladders, etc which are necessary for safe operation of the 

plant. All danger and caution notice boards shal shall l be in Hindi, English and Oriya. 

The Contractor must take sufficient care in moving his construction plants and equipment 

from one place to another so that those may not cause any damage to the property of the 

Purchaser particularly to the overhead and underground cables and other service lines. 

When the work is carried out at night or in the obscure day light, adequate arrangements for 

flood lighting in the working area shall be made by the Bidde Bidder. 

The safely postures/regulations for the prevention of accidents shall be displayed by the 

Bidder at appropriate places. Notices and warning signs shall be displayed for all sources of 

dangers. 

All electrical drives and equipment must be equipped with safety devices. The safety 

provisions shall conform to the recognized standards, safety codes and statutory regulations. 

All safety measures as required to be adopted as per the statutory regulati regulations and the safety 

rules of the plant shall be strictly followed by the Contractor during the execution of the 

Contract. 

Adequate number of first aid boxes as defined in the State Factory Rules shall be provided and 

maintained at all the work sites. 

1.6 Coding/Numbering ding/Numbering Scheme 

A coding scheme for identifying the drawings, plant and equipment, structures, spares and 

shipping documents shall be adopted by the contractor in a sequential manner. 

1.7 Contractor's License 

The contractor shall possess a valid an and d competent contractor's license of specified voltage 

issued by the electrical licensing authorities of the Govt. of Orissa for carrying out electrical 

installation work of the type and magnitude covered in this document, in the state of Orissa. 

The contractor ctor shall also be required to obtain labour license from Statutory Authority. 


Page 3 of 97

Copy of the license shall be made available to the Purchaser/consultant for verifications during 

the execution of contract. 

All linemen, wiremen, electricians, supervisors aand 

nd engineers engaged by the Bidder or his 

sub-Bidder Bidder shall possess necessary valid license issued by the statutory authority and the same 

shall be submitted for verification, if called for. 

1.8 Compliance with rules, regulations, and obtaining statutory appr approval 

All equipment/materials shall be installed in accordance with the requirements of relevant 

standards, Indian electricity Rules, Indian Electricity Act, 2003 and also the Factory Act. It is the 

responsibility of the Bidder to see that the electrical install installation ation supplied and erected by him 

shall be to the entire satisfaction of Chief Electrical Inspector, Central Electricity Authority or 

any other statutory body having jurisdiction in the area and also to the Purchaser/ consultant. 

The responsibility for obtaining btaining all statutory approvals for the installation to be carried out 

rests entirely with the contractor. It shall be the responsibility of the contractor to prepare and 

submit all necessary drawings, calculations, test certificates and relevant details (other than 

those given by the Purchaser/consultant) to the Electrical Inspector and obtain prior approval 

for commencing the work and for the complete installation work done. The inspection fee for 

statutory approvals shall be borne by the bidder. 

2.0 SCOPE AND BRIEF DESCRIPTION OF WORK AND ELECTRICAL SYSTEM DESIGN CRITERIA 

2.1 General 

The scope of work includes the basic engineering, detailed design engineering, manufacture or 

procurement of electrical equipment, shop testing, packing, transportation, loading, delivery 

at site, unloading, storage at site, handling, erection, pre pre-commissioning commissioning tests and 

commissioning of all equipment/system including preliminary acceptance test, performance 

guarantee and post commissioning services, inclu including ding insurance cover during transit, storage, 

erection and commissioning. The job shall be done on turnkey basis. Scope of Bidder shall also 

include the following: 

• Supply of commissioning spares 

• Supply of mandatory spares required for one year normal O&M 

• Supply of special tools and tackles for the equipment/systems supplied 

2.2 Bidder shall provide complete design inputs in form of assignment indicating complete 

requirements of civil building to accommodate comfortably an electrical substation consistin consisting 

of electrical equipment under his scope as well as the equipment under scope of the 

Purchaser, if any meeting all the required statutory clearances. The building shall be finalized 

and constructed by the bidder 

Bidder shall also provide the following ddesign 

esign inputs for detailed design and engineering of 

civil and structural works i.e. foundations, room, etc. The same shall be taken into 

consideration while designing the civil buildings by the bidder: 


Page 4 of 97

• Static and dynamic loading of the equipment 

• Clearances, , approach, safety exits required 

Clearances from all the four sides of the walls shall be maintained, wherever applicable in the 

electrical premises while considering the design inputs. 

The civil buildings for the complete WTP substation (including sw switchgear itchgear room, battery room, 

transformer rooms, etc), dust suppression MCC room, electric room for WTP, Apron feeder feeder, 

etc shall be under the scope of work. Electrical sub-station station will be installed in the out door 

near the wagon tippler station. 

2.3 Bidder er shall also take into consideration of various aspects like clearances, approach, roads, 

safety exits, cable trenches, transmission lines, foundations, floor opening, inserts, 

underground GI pipes, office premises, etc while finalizing the designing of c ccivil 

installations 

and building within battery limit of the package. 

2.4 Scope cope of the Bidder starts from tapping 33KV source including supply of 33KV/415KV 

transformers and corresponding switchboards, bus ducts and down below all the electrical 

equipments etc. 

For WT System Bidder shall include complete electrics including all the equipment/services on 

turnkey basis as per requirement irrespective of the same as s specified in the specification or 

not. Separate set of suitable rated 33/0.44 kV transformers, ormers, dedicated MCC for WT System 

machine, PLC, UPS with sealed maintenance free batteries, VVVF drive control system, 

junction boxes, other equipment, etc shall be included for smooth operation of wagon tippler 

system. 

Air conditioning of control room to be done with suitable capacity by air cooled packaged AC AC. 

For other LT drives and mechanism, Bidder shall include dedicated MCCs consisting of required 

number and capacity of outgoing feeders. 

For dry fog type dust sup suppression pression systems of transfer points in junction houses, Bidder shall 

include a dedicated MCC in pump cum compressor house. 

For miscellaneous and non non-critical critical loads like power socket cabinets, ventilation, AC power 

requirement of 33KV switchboard / 415V PPCC 

CC / transformer marshalling boxes, etc, Bidder 

shall include a dedicated PDB. 

For illumination of WT System (Wagon Tippler, Apron feeder) including conveyors and 

substation, dust suppression room and adjoining areas / sub areas, Bidder shall consider a 

dedicated LDB and sufficient number of SLDBs. SLDB shall be timer control. Two numbers 

flood light high mast towers 30m high eachshall shall be included for illumination of WT Area with 

metal Halide lide Lamps. Illumination of street light and conveyor gallery shall be with LED lamps 

within a radius of 500m of wagon tippler tippler. 


Page 5 of 97

A separate room shall be provided adjacent to WT control room to house the Dust suppression 

MCC, Pumps, compressors etc for the DS System by the Bidder. Bidder shall furnish the 

complete requirements quirements including size, cable trenches/opening, etc. The pressurized ventilation 

shall be provided by the Bidder in this Dust Suppression Room. 

The number of MCCs / DBs shall be provided as per requirement by the bidder. 

Following shall also be inclu included in the Bidder’s scope: 

• Pressurized ventilation system for the switchgearroom 

switchgearroom. 

• Pressurized ventilation system for the Dust Suppression cum MCC room. 

• Air conditioning of battery and battery charger rooms. 

• Exhaust fan in the transformer rooms. 

The bidder r shall supply the PLC for safe operation of WT System. Necessary integration with 

existing PLC of new coal yard will be scope of tender tenderer. . Design and installation of electrics shall 

ensure operation of complete integrated electrics of the various drives/m drives/mechanism without 

any constraint during maintenance. 

Bidder shall also consider sufficient numbers of local auxiliary PDBs to cater miscellaneous 

loads of WT System. These PDBs shall be located at various places and exact locations shall be 

finalized during g detailed engineering. 

HT Power cables and LT power/control cables shall be laid in different cable trays. LT power 

cables and LT control cables shall also be laid in different trays. 24V DC cables shall be laid 

entirely in different dedicated trays. 

Cable trays in single tier or in multitier shall be installed in vertical arrangement everywhere to 

avert coal accumulation and space reduction. Cable trays shall be supplied by the bidder. 

Power supply of all voltage levels including 415V AC or 220V DC, 24V DC etc, shall be arranged 

by Bidder himself by providing suitable systems. 24V DC supply shall be through screened 

cable to be supplied by the Bidder. 

Only at receiving point of 33KV, control supply of 415V AC and 220V DC shall be made 

available by the he purchaser purchaser. 

Following HT cabling shall also be included by the Bidder apart from the above: 

1. ACSR conductor for O/H transmission of 33kv line. 

2. Cabling required for underground track/road crossings of33 kV System including intake 

pump well feeder and ashpond feeder feeder. 

Standard power and control cables (Trailing Cables) of required sizes in adequate quantum 

shall be supplied and terminated by the Bidder. Hence, complete HT & LT trailing cables for 

Wagon Tippler, etc tc shall be supplied and laid by the bidder. 

Cables used for 24 VDC supply for PLC system shall be laid separately from 230 V AC control 

cables. 


Page 6 of 97

All cables Power cable, Control Cable, Trailing Cable, instrumentation cables, signal cables, 

screened cables, es, special cables, fibre optic cables shall be supplied, laid and terminated by the 

Bidder as per actual site requirement. 

Cabling shall include laying and termination at both ends, cable trays and cable accessories for 

the cables to be laid by the Bidd Bidder. 

Bidder shall consider all required cables for cable engineering, preparation of cable schedule, 

terminal plans, cable support structure layout, cable layout drawings, etc. All cable trays, 

accessories, termination kits, glands, lugs, clamps including clamps, etc shall be included in the 

scope for all the cables (to be supplied by the Successful Bidder) interconnecting both side 

equipment or one side equipment of the Bidder’s scope. 

All drives shall be controlled and monitored at existing WT SYSTEM control room from the PLC. 

Bidder shall include PLC and all the interfacing/ interconnecting cabling and cable trays. All 

Cables required for this interfacing, shall be supplied and laid by the Bidder. Copper power 

cables, if required by the bidder, shall also be under scope of supply and laying of the bidder. 

Ampere meters for all conveyor belts are to be installed at the control room for monitoring 

the current of each drive. 

Bidder shall consider numeric PLC and type of Inputs / Outputs (I/Os) required for WT system 

for smooth and trouble free operation of various drives / mechanism from the WT SYSTEM 

control room. Sufficient number of I/Os in PLC extension shall be considered as per act actual 

requirement. Exact number and type of I/Os shall be decided during detailed engineering 

based on approved schemes. 

Bidder shall also consider sufficient number of I/Os in PLC control and monitoring for electrical 

power distribution system for the electrical power distribution system starting from 33KV till 

the down most voltage level. 

New PLC of WT shall be interfaced with existing PLC of Coal Handling Plant for operation of BC 

– 115 and BC – 103. 

The earthing system shall be provided for compl complete ete WT SYSTEM plant. The new earthing 

system shall be connected to the existing earthing system. 

Bidder shall also consider earthing of following equipment: 


• 33kv substation equipments. 

• WT LT distribution transformers – Neutral as well as body earthing 

• 415 5 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room 

• Control panel for power distribution equipment at existing WT control room 

• LT busducts 

• Charger panels, DCDB, etc at WT substation in switchgear cum MCC room 

• Underground eart mat. 

Page 7 of 97

Bidder shall consider earthing ring mains at each electrical premise and connect the electrical 

equipment with the rings. The earthing ring mains shall be connected with underground 

earthing mats to be provided by the bidder made of 2x40mm dia solid MS rod. Adequate 

number of risers shall be made available for connection with his earthing ring main. For 

transformer neutral earthing, bidder shall consider dedicated plate earthing. 

Lightning protection shall be provided by the bidder for complete WT SYSTEM including tall 

installations covered under the battery limit. 

Bidder shall also include complete illumination of the premises under the battery limit and all 

the above electrical premises coming at WT SYSTEM substation and adjoining areas. 

Air-conditioning, conditioning, ventilation and exhaust fans for various rooms / premises of WT SYSTEM 

along with their complete electrics shall be under scope of the Bidder. The battery and battery 

charger room shall be air- conditioned. Switchgear cum MCC room of WT substation shall have 

pressurized ventilation. Transformer rooms of the WT substation shall have exhaust fans fans. 

All interconnection for power, control and instrumentation/signal amongst equipmen equipment 

supplied by the Bidder shall be under Bidder's scope of work. Similar interconnections 

including power, control and signal between Purchaser's equipment and Bidder's equipment 

shall be done by the Bidder. All the cable terminations at both ends, cable tr trays and cable 

accessories shall be under Bidder's scope. 

2.5 Electrical system design criteria 

a) General 

The design, manufacture, assembly and testing as well as performance of the equipment shall 

conform to the relevant IS : specifications (latest revision) and other relevant standards. In 

case IS specifications is not available in respect of certain items, the Bidder may base his 

proposals on IEC/BS/VDE/DIN recommendations or other reputed national or international 

standards subject to the approval of the Purchaser Purchaser/RITES. . All equipment supplied and all work 

done including system design and detailed engineering shall also comply with the statutory 

requirements of the Government of India and the Government of Orissa. 

b) Climatic Conditions 

Electrical Equipment selection and derating shall generally be based on ambient temperature 

of 50 o Electrical Equipment selection and derating shall generally be based on ambient temperature 

C. The equipment offered shall be suitable for smooth, efficient and trouble free service 

in the climate prevailing at Angul. 

c) Standard Voltage levels 


Page 8 of 97

Following power utilization standard voltage levels shall be adopted for various systems: 

1. Station supply 

3. Power supply to PLC extension 240 V, 1 phase, 2 wire, 50 Hz, A.C. (from UPS) 

4. DC control supply 

220 V, 2 wire, unearthed 

5. Plant illumination 

6. 

7. 

Welding socket / power 415 V, 3 phase, 50 Hz, A.C. outlets 

receptacles 

240 V, 1 phase, 2 wire, 50 Hz, A.C. outlets 

Special socket outlets for 24 V, 1 phase, 2 wire, 50 Hz, A.C. through suitable 

portable lamps 

transformers 

8. Sockets for electrical tools, etc 240 V, 1 phase, 2 wire, 50 Hz, with one point earthed 

9 Emergency illumination 220 V DC 

d) Permissible variations 

The system / unit / plant / equipment shall be designed suitably for following variation in 

voltage and frequency; 

Permissible variation with rated performance and control 

effectiveness maintained 

Permissible variation for control and regulation equipment with 

rated performance and control quality maintained 

Permissible voltage dip at HT switchgear bus during starting of 

motor 

- 15 % - 

Permissible voltage dip at MCC bus during starting of LT motors - 15 % - 

e) Symmetrical short circuit ratings 

The short circuit ratings of all the equipment like MCCs, motors, PDBs / LDBs, cables, power 

socket & lighting cabinets, etc shall be selected keeping in view the fault level capacities of the 

Purchaser’s electrical equipment. 

The three phase symmetrical short circuit rating at 33 kV level shall be 25 25kA. The three phase 

symmetrical short circuit rating at 415 V level shall be 50kA. 

The rated short circuit withstand duration for 33 KV shall be 3 sec, whereas for 415 V system, 

it shall be 1.0 sec. 

f) Criteria for selection of voltage levels ffor 

drive motors 


33 kV, 3 phase, 3 wire, unearthed system 

415 V, 3 phase, 4 wire, solidly earthed 

240 V, 1 phase, 2 wire, 50 Hz, A.C. 

Voltage Frequency 

+/-10% 10% +/-5% 

+/- 10 % +/-5% 

Page 9 of 97

All AC squirrel cage induction motors shall be fed at 415V V from switchboard through air circuit 

breakers with numeric type compreh comprehensive motor protection relays via power contactor and 

overload relay. 

g) System Earthing 

33kV system is unearthed, , 415V system is solidly earthed. 

2.6 ELECTRICAL SYSTEM REQUIREMENTS 

Minimum number of spare feeders in each of the MCC / PDB / LDB / SLDB shall be 10% subject 

to minimum one no. of each type and rating in each section. The rating a aand 

type of spare 

feeder shall be decided during detailed engineering stage. 

Sizes and requirement of various power and control cables shall be decided and intimated to 

the Purchaser well in advance to suit the approved scheme/to achieve scheme requiremen requirement. 

Space heater power supply to the motors shall be fed from the MCC through same cubicle by 

415/240 V transformers. Space heaters shall be interlocked with motor main power supply. 

Bidder to submit a system wise drive list indicating required process in interlocks, permissive 

conditions etc. with places and mode of control, control system philosophy with provision of 

various control, indication, measuring devices at various places. The Purchaser Purchaser/RITES shall 

approve this based on above approved philosophy an and d Bidder shall have to provide all 

equipment / materials and prepare a control scheme/logic diagram which shall be utilized for 

designing the motor feeders at 33 kV switchboard and 415 V MCC at Bidder’s end. 

Above-mentioned mentioned control philosophy and interlocking logic shall be prepared as per the 

technological requirement. 

Suitable electrics for all the material handling equipment like hoist, etc shall be provided for 

handling the various drives and mechanism. 

Warning hooter shall be of brushless type Siren and AC single phase. 

All actuators shall be of geared motors. 

Complete 24 V system, wherever required, shall be provided by the bidder. 

24 V and 230 V AC shall be taken through separate cables. Screene Screened d cables shall be supplied 

and used for 24 V power supply. 

All the indication lamps shall be LED based with LVGP (Low Voltage Glow Protection) up to 100 

V. 

All the hoist control panel shall be located at workable height and platform shall be provided 

for r each hoist at one point for maintenance purpose. 


Page 10 of 97

Ammeter for Wagon Tippler, Apron feede feeder and Conveyors etc. shall also be provided in 

Control Pane for monitoring of currents. 

3.0 PERFORMANCE REQUIREMENT AND GUARANTEE 

The PG test shall be conducted for overall system of wagon tippler including electrical system 

and equipments as mentioned elsewhere. 

4.0 TECHNICAL SPECIFICATION 

4.1 CONTROL & PROTECTION SYSTEM AND LAYOUT CONTROL PHILOSOPHY 

The control, monitoring, interlocking, annunciation and metering functions of various 

drives/mechanism shall be performed through PLC at WT SYSTEM control room. All the drives 

shall also be operated from local control stations for emergency stop as well as for decoupled 

trial run of motors. 

Following interlocks ks / alarm, etc shall be provided for various drives/mechanism of cooling 

water system: 

• When conveyor will trip, Apron feeder will trip. 

• When apron feeder trips, Wagon tippler will trip. 

• When any of the running drive trips, the standby drive shall start automatically. 

• When any of the running conveyor trips, the preceding/succeeding conveyor shall trip 

automatically. 

• A conveyor shall take start only when it’s preceding conveyor starts 

• Auto-Tripping Tripping of conveyor drives through various mechanism like pull chord, belt sway 

switch, etc 

The above interlocks/alarms and control philosophy are minimum and indicative. The detailed 

requirements for the above shall be finalized during detailed en engineering. 

Bidder shall furnish details of control, monitoring, interlocking, protection, annunciation and 

metering system for all drive. Bidder shall use state of art technology while fulfilling the 

functional requirement of all the equipment for smooth and trouble free operation through 

PLC. 

Various transducers (4-20 20 mA range) as per requirement shall be provided to facilitate control 

and monitoring from PLC. Required transducers and wirings to hook up all analog and digital 

inputs / outputs to / from PLC shall be included in the scope. 

Interlocking arrangement shall also be furnished to take care of all the approved logic 

schemes. Bidder shall provide necessary wiring, control and required items to achieve the 

approved logic / scheme. Selecting loca local l / remote switch of local control station in local 

position shall carry out local mode operation of the drives for test/trial etc. Permissive 


Page 11 of 97

conditions for start and tripping of various drives shall be provided as per approved logic 

diagrams. 

A dedicated ed hardwired control panel / desk shall also be provided by the bidder at WT control 

room to control and monitor electrical power distribution system. 

Controls of all equipments of wagon tippler including conveyor’s all interlocks shall be PLC 

based. The PLC system shall be latest version having dual redundant processor with HMI based 

control station. There shall be two HMI control system with one operating station and other 

an engineering station. The system shall be designed with 10% extra input/output pprovision. 

Input/output of PLC(analog & digital) shall have at least 10% extra channel wired up to TB TBs in 

the panels. A portable programming station (Laptop) with all the ladder logic/ 

programming/software shall be provided for engineering and troubleshooti 

troubleshooting functions. The 

system shall be capable of communicating with the existing PLC system of the CHP(The 

existing PLC is of GE Fanuc make make- Model 90-30,CPU-370). 370). The vendor shall be responsible for 

communicating and displaying the important parameters of wago wagon n tippler PLC system to the 

existing CHP PLC through optical fibre cable. All electrical power distribution system shall be 

controled and monitored through PLC. 

PROTECTION SYSTEM 

Protections for the different electrical equipment are enlisted below: 

For Protection of LT T motor motor, comprehensive omprehensive numeric motor protection shall be provided in the 

switchboard. 

Laying of control and power cables including supply and laying of signal cables from motors to 

switchboard shall be in the scope of Bidder. 

Comprehensive ensive numeric motor protection including but not limited to the following: 

• Instantaneous over current protection 

• Differential protection (for rating above 1000 kW) 

• Instantaneous time over current protection in two phases and definite time delayed over 

current urrent alarm on the third phase 

• Negative phase sequence protection 

• Thermal overload taking -ve and +ve phase sequence into account 

• Earth fault 

• Locked rotor protection 

• Winding temp monitoring and alarm for rating beyond 1000 kW 

• Under voltage protectio protection 

Microprocessor based numeric motor protection relay shall also have following facilities: 

• Communication facility with open protocol like IEC/Modbus. 

• Relay should store last five fault records (minimum) with date and time stamping. 

• Relay should have no. o. of start menu for start inhibition. 

• Relay should have facility for displaying three phase and neutral current 


Page 12 of 97

• Relay should have heavy duty tripping contact which will be used for breaker tripping 

• Battery backup facilities 

The Motor Protection Relays shall also have the following additional features: 

• Fault recording facility 

• Password protection 

• Local/remote communication facility with open protocol 

• Minimum 4 nos. BI and 4 nos. BO 

Protection of LT motor (less than 75 kW) 

Motors below 75 kW shall be fed from MCC through MCCB with power contactor and overload 

relay. 

Motors of 5 kW and above but below 75 kW, shall have fed through MCCBs (for short circuit 

protection), numeric motor protection relay like MPR MPR-300 300 or equivalen equivalent (for overload and 

other motor protection) and power contactors. 

For motor below 5 kW, MPCBs may be considered in place of MCCBs. 

Single phasing protection shall also be provided in the MCC modules. 

METERING 

Following metering shall be provided in various MCC/DBs; 

415 V MCC 

1. 415 V INCOMER (EACH) • AMMETER (DIGITAL TYPE) 

• VOLTMETER 

• kWH METER 

2. BUS COUPLER 

• AMMETER 

3. OUTGOING 

• AMMETER (DIGITAL TYPE) 

MOTOR FEEDER (EACH) 

PDB 

1. 415 V INCOMER COMER (EACH) • AMMETER (DIGITAL TYPE) 

• VOLTMETER 2. OUTGOING (EACH) 

• AMMETER (DIGITAL TYPE) 

4.2 LT MOTOR CONTROL CENTRE (LT MCC) 

Constructional Features 

Fully drawout type with modules having service, test and isolated positions. Floor mounting, 

free standing with base channel 50 mm high for fixing on the inserts on the floor. MCC shall be 

single front, totally enclosed, dust and vermin proof. 

All the module of the MCCs shall be spacious to facilitate maintenance of equipment inside the 

module. Pollution degree applicable shall be pollution degree 4 as per IS IS-13947 13947 (Pt (Pt-I), 1993. 


Page 13 of 97

Incomer and bus coupler panels 

MCC incomers and bus couplers shall have Air circuit breakers. Incomers and bus couplers 

shall be rated for at least 125% of maximum de demand mand taking into account the spare feeders 

and shall be suitable for the specified fault level. 

Incomers and bus coupler shall be electrically interlocked to prevent parallel operation. 

However, a definite delay defeat Interlock switch shall be provided to facilitate parallel 

operation. Auto changeover facility shall also be provided between the two incomers and bus 

coupler. 

Feeder Modules 

Feeders for motors of 75 kW and above shall be fully drawout type air circuit breakers (ACBs) 

with numeric type comprehensive mprehensive motor protection relays. Other motor feeders shall be 

consisting of MCCB, contactor, overload relay as main power components to ensure type 2 

protection. The short circuit release of MCCBs shall be suitably selected to the applications 

concerned. 

At least 10% spare feeders (minimum one spare feeder of each type and rating bus sectionwise) 

shall be provided. Ammeters with selector switches shall be provided for all continuous / 

intermittent running motors beyond 15 kW rated drives. 

Busbars and d terminations 

Busbars and connection shall be of high conductivity aluminium/aluminium alloy of suitable 

hardness and purity complying with as per IS IS-5082-1981. 1981. Busbars shall be insulated by colour 

coded heat shrinkable sleeves. 

Busbars shall be rated for the nominal current rating of incoming breaker and for the full 

short-circuit circuit rating. Earth bus shall run throughout the length of MCC at bottom . 

Control bus shall be provided in the bus bar chamber isolated with main bus in all the MCCs. 

Similarly power and control terminations shall be in separate chambers in the MCCs. Cable 

alley y shall have sufficient space for maintenance and minimum width of cable all alley shall be 

300 mm. Shrouding/isolation shall be provided for outgoing power terminations in th the cable 

alleys. ys. Modules of MCCs shall be spacious for easy maintenance of the various equipment 

inside. 

Short circuit strength 

Rated short time withstand current shall not be less than 50 kA for 1 second. Rated peak 

withstand current not less than 2.1 times the specified short circuit level. 

Air circuit breaker (ACB) 


Page 14 of 97

Air break, drawout type conforming to IS 13947 (1993) and sy symmetrical mmetrical breaking capacity not 

less than 50 kA for 1 second shall be provided. Service short circuit breaking capacity (Ics) shall 

be 100% of rated ultimate short circuit breaking capacity (Icu). Performance category of the 

MCC shall be B. ACB used for in incomer comer & bus coupler should have numerical feeder protection 

relay. 

Motor operated mechanism shall be applicable with air circuit breakers. Spring charged stored 

energy mechanism shall be there to ensure high speed closing and tripping independent of the 

operating perating forces. Electrical anti pumping and trip free feature shall also be provided. Spring 

charging universal motor suitable for rated control voltage (220 DC). The closing coil and trip 

coil shall be suitable to DC operation. 

Closing and tripping of ACB shall be by closing coil (operating range 85% to 110% of rated 

voltage) and tripping by trip coil (operating range 70% to 110% of rated voltage) respectively. 

Built-in in direct acting type microprocessor based numerical releases for short circuit, over 

current and earth fault shall be provided. 

Auto changeover shall be done through under voltage relays and check synchronization relay 

with time delay. All the relays shall be microprocessor based numerical relays. 

Motor protection moulded case circuit breaker (MCCB) 

The characteristic shall match the motor duty application. Rated ultimate short circuit 

breaking capacity (Icu) shall be 50 kA. Ratings selected shall be at least 125% of the full load 

current of the motor. otor. For small rating drives such as valves, Siemens 3UV13 type (or 

equivalent) or motor protection circuit breaker (MPCB) shall be used. Utilisation category shall 

be A. 

Magnetic contactors 

Pick up shall be positively at voltage between 85% to 110% of rated value. For frequently 

reversing drives, AC 3 rating selected shall be 50% higher than full load current of the motor at 

the specified duty cycle shall be provided. For reversible drives, mechanically as well as 

electrically interlocked contactors sh shall be used. 

Thermal overload relay 

Thermal overload relay shall be triple pole, ambient temperature compensated, inverse time 

lag, hand reset type, bimetallic with adjustable setting and built in single phase protection. The 

relay shall be able to withstand prospective short circuit circuit-current without damage or injurious 

heating till the motor protection MCCB clears the fault. Tripping indication and reset push 

button operable from outside shall be provided. 

Push Buttons / Indicating Lamps / Indicating instruments 


Page 15 of 97

Push buttons shall be spring ng return, push to actuate type and their contacts shall be suitable to 

carry and break 240 V AC, 10 A and 220 V DC, 1 A. Indicating lamps shall be LED LVGP (Low 

Voltage Glow Protection up to 100V) type. Standard colours shall be applicable for push 

buttons s and for indicating lamps. Indicating instruments shall be flush mounting, square dial 

with 900 scale with zero adjusting device for external operation. Accuracy class shall be 1.0 or 

better. KWh meter shall also be provided with incomers. 

MCC shall have e run / start, stop, tripped, and ready to start push button cum indication lamp 

for motor feeders. 

Current transformers 

The thermal and dynamic stability current for CTs and CT ratio shall be as per requirement. 

Protection and measuring current transf transformer ormer shall be bar primary/ window type with 1A 

secondary. Burden of CTs shall be as required by the associated measuring equipment. 

Potential transformers 

Potential transformers shall be provided on incomers as well as on buses and shall be in same 

circuit rcuit breaker cubicle. 415 V side of PTs shall have fuses. Accuracy class 1.0 shall be used. VA 

burden shall be selected based on meters and relays connected with the PT. 

Control transformer 

Control transformers shall be dry type 415V/240V, primary taps at +2.5 %, +5 % and shall be 

mounted in drawout trolley if outgoing feeders are in drawout execution. Control supply shall 

have supervision facility, alarm shall be provided for non availabilit availability y of any one of the control 

supply. Automatic/manual changeover facility shall also be provided. Auto Auto-changeover shall be 

blocked if power supply to respective section is not available. 

For capacity consideration of control transformers, each shall be ca capable pable to meet 100 % load 

including spare feeders and 10 % cushion for future and 15 VA for each module for remote 

aux. relays and indication lamps. Separate DC and AC control (3 ph & neutral) copper busbars 

shall be considered for each MCC. From AC contro control l bus, motor space heater supply shall be 

tapped with suitable control and interlocking arrangement. 

220V DC Control supply 

220V DC supply is required for electrically controlled ACBs. For two sections, two DC buses 

shall be there. In bus coupler panel, manual switch shall be there for changeover of one supply 

to other section. Non-availability availability of DC supply shall be annunciated in MCC or nearby control 

room. 

Internal Control Wiring and external Terminations 


Page 16 of 97

Internal control wiring shall be by 1100V V grade PVC insulated, single core stranded copper 

conductor of minimum cross section 2.5 sq.mm. for CTs and space heater circuits and 1.5 

sq.mm for other circuits. For CT secondary wiring, disconnecting type terminal blocks (CAD 

type) shall be considered. . 

For external terminations, , DIN rail mounting type bakelite type terminal blocks shall be used 

complete with insulated barriers, stud type terminals, washers, nuts and lock nuts and 

identification strips. Power and control terminals segregated. 

Other accessories 

Following items shall be provided for the MCCs under the scope of the Bidder: 

Breaker lifting/handling trolley (for ACBs) : 1 No. per MCC Room 

Breaker racking handle (for ACBs) : 4 Nos. per MCC Room 

Panel key (if applicable) 

: 5 Nos. per MCC Room 

Selection of power components & wiring for continuous duty cage motor drives is given below: 

Motor 

Rating 

at S1 

Duty 

(KW ) 

Up to 

3.7 

5.5 

7.5 

Minimu 

m 

rating 

of 

MCCB 

* 

* 

* 

11 * 

15 * 

18.5 * 

22 * 

30 * 

37 * 

45 * 

55 * 

75 * 

90 * 

110 * 

125 * 

135 * 

160 * 


Minimum 

rating of 

contactor 

(AMPS) AC3 

duty 

25 

40 

40 

Minimum size for internal 

power connections 

Copper 

wire 

(sq.mm) 

Aluminium flat 

(mm x mm )** 

*Minimum rating of MCCB shall be selected to achieve type ‘2' protection. 

4 

4 

6 

40 6 - 

63 10 - 

- 

- 

- 

Minimum size of 

power cable 

Aluminium 

(sq.mm) 

4x 2.5(copper) 

4x 2.5(copper) 

4 x 6 

4 x 16 

4 x 16 

63 16 12 x 2 3.5 x 35 

63 16 12 x 2 3.5 x 35 

100 25 12 x 2 3.5 x 70 

100 35 15 x 3 3.5 x 70 

160 50 15 x 3 3.5 x 95 

160 70 20 x 3 3.5 x 120 

200 95 20 x 5 3.5 x 185 

400 20 x 5 3.5 x 185 

400 30 x 5 2(3.5 x 120) 

400 40 x 5 2(3.5 x 120) 

400 40 x 5 2(3.5 x 120) 

400 40 x 5 2(3.5 x 185) 

Page 17 of 97

** Copper flat of equivalent size can be used instead of aluminium flat. 

NOTES : Overload relay shall be selected based on actual full load current and starting time. 

GENERAL TECHNICAL PARTICULARS OF MCC 

GENERAL 

1. System 

: 415V, 3 phase, 4 wire, 50 Hz. Solidly earthed neutral 

2. Type 

: Indoor type, cubicle construction, free standing 

3. Pollution degree : 4 

4. Creepage distance : As per IS-13947 (1993), Part-I 

5. Enclosure 

: IP54 

6. Mounting 

: I/C & B/C in single tier and O/G in multi-tier tier arrangement 

execution 

7. Neutral earthing : Effectively earthed 

8. Control supply : 240V AC / 220 DC for ACB 

9. Short time rating : 50 kA for 1 sec 

10. Autochangeover required? :Yes 

11. Delay drop off required? uired? :Yes 

12. Control supply 

AIR CIRCUIT BREAKER 

: 220 V DC for ACB, 240V AC/220 DC for spring charge motor and 

240 V AC for MCCB, etc. 

1. Service 

2. Type 

3. Insulation level : 6 kV (1.2x50 micro Sec) Impulse withsta 

4. Utilization Category 

5. Operating mechanism 

I. Closing 

II. Opening 

III. Latching 

6. Auxiliary Voltage 

I. Closing 

II. Tripping 

CURRENT TRANSFORMERS 

1. Type 

: Resin cast, window type 

2. Rated voltage : 415 V +10% 

3. C.T. secondary 

4. Accuracy 

: 1 Amp rating 

i. Protection : 5P10 or better for protection 

ii. Metering : Class - 1 


: Indoor 

: Air – break 

: 6 kV (1.2x50 micro Sec) Impulse withstand 

: B 

: Stored energy type 

: Motor wound spring operated 

: Shunt trip coil 

: Mechanically and electrically trip free arrangement 

: DC (85% - 110%) 

: DC (70% - 110%) 

III. Spring charging : 240V + 10% AC or DC motor 

IV. Space heater & Lamp : 240V + 10% AC 50 Hz 

7. No. of poles of C.B : 3 

Page 18 of 97

POTENTIAL TRANSFORMERS 

1. Type 

2. Primary/secondary 

: Cast Resin 

voltage ratio 

415V : 

3 

110V 

3 

3. Method of connection :Star/Star connection 

4. Rated voltage : 1.2 continuous, 1.9 for 30 Sec factor 

5. Class of insulation : Class E or better 

CONTROL TRANSFORMER 

1. Type 

2. Voltage ratio 

3. Rated burden 

4. Quantity 

MOULDED CASE CIRCUIT BREAKER 

1. Type : Air break (Motor duty) 

2. Rated service : 415 V +/ +/- 10% voltage 

3. Utilization Category : A 

4. Protection 

: Type `2 to the contactor 

CONTACTORS 

1. No. poles : 3 

2. Rated service : 415 V + 10% voltage 

3. Control circuit : 240V +10% 1ph, 50Hz +5% 

4. Utilisation category 

5. Limits of operation 

: AC23A for uni uni-directional motors 

i. Closing (pick-up) : 85% to 110% 

ii. Dropout : Shall not be higher than 75% 

RELAYS/RELEASE 

1. Relay type 

2. Release type 

THERMAL OVERLOAD RELAYS 

1. Type : Ambient temperature compensated bimetal operated hand reset type (direct or 

C.T. operated) 

2. Hand resetting 

: To be provided at the front of the panel feature 

3. Single phasing protection : Built in 

4.3 CABLE AND CABLE ACCESSORIES 

TYPES OF CABLES 


: Dry cast resin, class B or better 

: 415V/240V 

: As per requirement (Minimum 1.5 kVA) 

: 2 nos. per board and minimum capacity shall be 1 kVA 

: Numeric 

: Microprocessor based. 

Page 19 of 97

All cables viz.power power and control cables, trailing cables, signal, instrumentation, screened, fire 

optics, copper power cables and special purpose cables required for applications concerned 

and for satisfactory operation of the all the drives at Wagon Tippler plant shall be in the scope 

of the Bidder. All power cables cables(XLPE) should be FRLS (Fire Retardant low sulphur) type (inner 

& outer sheath) and shall have round armouring armouring. 

Bidder shall include all the cable accessories in his scope of supply aas 

s well as installation as per 

actual requirement at site. 

Trailing Cables 

All the trailing cables shall be 4 core XLPE. The cable for application in 33 KV supply system 

shall conform to IS:7098(Part (Part-2) 2) 1985 and for low and medium voltage including 1100v shall 

conform to IS: 7098(part I) ),1988. 

HT trailing cables shall be 33 KV (UE) heavy duty power cable 4 core, flexible. The detailed 

specification for the HT trailing cables required shall be fu furnished rnished by the Bidder along with the 

tender. 

1.1 kV grade flexible trailing cable shall be of heavy duty type having tinned annealed high 

conductivity flexible copper conductors, butyl rubber or ethylene propylene (EPR) insulation 

and CSP or PCP sheathing. The conductor shall conform to IS:8130 - 1984 and insulation and 

sheathing shall be as per IS:6380 - 1984. For high temperature zone and side side-arm-charger the 

insulation shall be of silicone rubber. 

For all the cabling, Bidder shall include layi laying ng including all the GI prefabricated cable trays/hot 

dip galvanized perforated trays and other cable accessories like cable termination/jointing kits, 

glands, cable identification tags, connectors, ferrules, clamps, etc 

HT Cable End Termination & Straight through jointing kits 

All high voltage cable terminations shall meet the test procedures and requirements stipulated 

in IEEE 48-1990 as class-I I termination. 

Heat shrinkable type of cable termination and joints shall be used for HT cables in i iindoor 

and 

outdoor applications as specified. 

The stress control and grading wherever necessary shall be by means of semi conducting heat 

shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces 

shall be achieved by using ng hot melted sealants or adhesives. 


Page 20 of 97

Where such sealants or adhesives shall be exposed to high electrical stress, same shall be track 

resistant type. 

Straight through joints and end sealing termination kits of 33 KV (UE) grade cross cross-linked 

polyethylene cables shall be of well tried out design compatible for XLPE insulation. The 

joints/ends sealing kits shall be of heat shrinkable type and shall be complete with stress 

grading material, protective and lug sealing sleeves, self tightening earthing clamp, slide angle 

sleeve etc. Outdoor termination shall have necessary skirting over protective sleeving to 

increase the creepage distance and the sleeves shall ensure total protection against ingress of 

moisture. Straight through joints shall feature moisture pproof 

roof environmental seal, mechanical 

protection and impact resistance envelope around the joined cables. 

The end termination and straight through joints shall conform to the relevant standards. The 

complete termination / joint kits shall be of reliable and field proven design having been fully 

type tested and relevant type test reports shall be furnished. 

In addition the termination and joint shall be tested for various accelerated aging tests such as 

thermal aging, weathering etc. to have long and troubl trouble e free service. Necessary type test 

certificates for aging tests shall also be furnished. 

Following type of cable termination and joints shall be used for HT cables in indoor and 

outdoor applications: 

1. Tapex type 

2. Heat shrinkable type 

3. Pre moulded push on type 

Tapex type system 

The stress grading material shall be wrapped around the cable core, over lapping the edge of 

the outer conducting layer. The tape layer shall fuse together to form a compact rubber body 

around the stress grading ng material and cable core and thereby exert an active pressure on 

cable. This system shall be used for straight through joint only. 

Heat Shrinkable type system 

The stress control and grading wherever necessary shall be by means of semi semi-conducting heat 

shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces 

shall be achieved by using hot melted sealants or adhesives. 

Where such sealents or adhesives shall be exposed to high electrical stress, same shall be track 

resistant type. 

Pre-moulded moulded Push On type system 


Page 21 of 97

Premoulded refers to moulded Ethylene Propylene Diene monomer rubber components. 

Sealing between the pre-moulded 

moulded push on material and cable surface shall be achieved by 

semi conducting pad which has cold fflow 

properties. 

Cable trays 

All the cable trays shall be prefabricated hot dip galvanised sheet steel trays. 

Prefabricated GI ladder type / perforated type cable racks/trays shall be used for laying of 

cables in cable trenches, cable spreader floors, cable cellers, through piping and while routing 

cables along technological structures etc. The factory made system of cable trays shall be 

complete in all respects with all standard accessories like reducers, bends, tees, risers etc. and 

shall be suitable for bolted type assembly at site so as to avoid any welding. 

The GI ladder type factory fabricated cable trays mmade 

ade from 2.5 mm thick hot welded steel 

sheets grade ‘o’ shall be provided as per IS : 2062. Hot dip galvanizing of 86 micron thick as per 

IS-2629, IS-4759 and IS- 209. Trays shall be of standard length of 3 M / 2.5 M with max 

deflection not exceeding 1/400 of span with sufficient load bearing capacity. 

Sheet steel thickness shall be minimum 2.5 mm. Rung hall be provided at every 250 mm. At 

one meter interval two rungs shall be provided side by side to facilitate clamping. Beside, 

Bidder shall also provide suitable pre pre-fabricated fabricated bends of cable trays at all the bending points 

as per actual site requirement. 

Horizontal tees and 900 bends shall be provided for each size of cable trays as per actual 

requirement at site. 

Lugs/connectors 

Cable termination shall hall be made with aluminium / tinned copper crimped type solderless lugs 

of approved make for all aluminium conductor and stud type terminals. The lugs shall be 

tinned copper compression type. 

Glands 

Cable glands to be supplied shall be nickel plated br brass ass double compression type. Glands for 

classified hazardous areas shall be certified by CMRS and approved by CCE, Nagpur. 

Cable glands for terminating PVC insulated armoured/unarmoured cables (as applicable) shall 

be made of brass and shall be of double compression type with necessary provision for armour 

earthing. 

Cable clamps 

All cables shall be clamped with GI (minimum size of 25x3mm) / Al (minimum size of 25x4) 

clamps and single core cables shall be clamped with trefoil clamps made of non non-magnetic 

materials. 


Page 22 of 97

Specifications for miscellaneous materials 

Cable identification 

Cable tags shall be of 2 mm thick, 20 mm wide aluminium strap of suitable length to contain 

cable number as per cable schedule. 

Ferrules 

Ferrules shall be approved interlocked type & size to suit core size mentioned and shall be 

employed to designate the various cores of control cable by the terminal numbers to which 

the cores are connected, for ease in identification and maintenance. 

LT BUS DUCTS 

Electrical design 

Bus duct shall be suitable for 33KV/415 415 V, 3 phase, 50 Hz. neutral solidly grounded system and 

shall be covered with canopy if required to be installed outdoors outdoors. . Rated short time withstand 

current not less than the system short circuit level specified for 1 sec for 415V. Rated peak 

withstand current not less than 2.1 times the system short circuit level. 

Rated continuous current shall be as per requirement while in enclosure and at specified 

ambient temperature with maximum tempe temperature rature of bus bars limited to 85 85˚C. Neutral bus in 

LT with rating not less than half the rating of phase bus. 

The bus duct shall be rectangular, non non-segregated segregated phase, totally enclosed type. 

Insulation level 

Rate insulation voltage, one minute PF withstan withstand d voltage & impulse withstand voltage shall be 

as specified in technical particulars. 

Clearance in air (minimum) 

Clearance shall meet the minimum requirement specified in the technical particulars. 

Short circuit strength 

Rated short time withstand current not less than the system short circuit level specified for 1 

sec for 415V. 

Rated peak withstand current not less than 2.1 times the system short circuit level. 

Rate current 

Rated continuous current as specified while in enclosure and at specified ambient 

temperature with maximum temperature of bus bars limited to 85 85˚C. 

Neutral bus in LT with rating not less than half the rating of phase bus. 

Type test certificates 

Tenderer shall have type test certificates for similar bus ducts (same voltage level and same or 

higher current rating/fault level) 


Page 23 of 97

Construction details 

Degree of protection for enclosure IP 52 or better for indoor installation. 

Enclosure material: : The minimum thickness shall be 2.5 mm. Tender shall include enclosure 

with the thickness required red for the shape and mechanical/ electrical strength point of view. 

Aluminium enclosure shall be provided for rating equal or more than 3000A. MS enclosure 

may be provided for LT bus ducts of rating less than 3000A. Provision shall also be provided 

for draining moisture. 

Maximum temperature of enclosure under rated operating conditions limited to 70 70˚C. Rubber 

bellows shall be provided at transformer end to take care of vibration. 

GI supporting structures, wherever required, shall be provided with necessary hardwares. In 

horizontal run of more than 10 mtr of bus ducts expansion joint with copper flexibles shall be 

provided at every 10 mtr interval. 

Maximum temperature of enclosure under rated operating conditions limited to 70 70˚C. 

Bolted covers with gaskets sshall 

hall be provided for easy inspection and access to insulators and 

bus bar joints. 

Gasketted (Neoprene) connections shall be provided between adjacent sections of metallic 

enclosure. 

Tinned copper flexible shall be considered for connection of bus ducts at transformer end as 

well as PCC end. 

Rubber bellows at transformer end shall be provided to take care of vibration. 

Seal off bushing and frames complete with bolts. 

Provision shall be provided for draining the moisture. 

Provision shall be provided for mounting the bus ducts on brackets. 

The bus duct shall include straight run, 90 degree bend, Phase crossover chamber, 

transformer end chamber, tinned copper flexible, wall frame assembly, rubber bellows and 

other accessories as per the requirements.] 

Busbars rs and connections. 

Bus bar material shall be EC grade aluminium alloy equivalent to E91E WP conforming to IS 

5082-1981. 

Final operating temperature of both bus bars and joints under continuous operation in 

enclosure limited to 85˚C ˚C by thermometer method. While designing the bus duct, site 

condition and solar radiation shall be taken care of. 

Bus bar arrangement shall be as per IS 5578 5578-1991. 1991. Phase identification shall be by colour at 

ends and at regular intervals. Busbar joints shall be of bolted type, cad cadmium mium plated with zinc 

bichromated high tensile steel bolts, nuts and spring washers and coated with oxide inhibiting 

grease prior to jointing. 

Copper flexible busbars shall be tinned. Copper flexible connections shall be provided for 

termination on equipment as well as on expansion joints. 

Bimetallic joints /strips shall be provided for jointing between dissimilar metals (if required). 

Bus bar support insulators of non non-hygroscopic hygroscopic material having impact and di di-electrical 

strength with an anti-trackin tracking contour. 

Bus duct of 3000 A and above rating shall be interleaved type. 

Bus conductor shall be given a coat of black mat point. 

Protective earthing 

Double earthing shall be provided for enclosure of bus ducts. 


Page 24 of 97

Two numbers 50 x 6 mm GI flat earth buses sshall 

hall be provided running separately throughout 

the length of the bus duct, positively connected to the enclosure body of the bus ducts. 

Provision shall be there at each end of bus duct for terminating external earth conductor. 

Surface treatment 

Two Coats of synthetic enamel paint for indoor application shall be provided. Various standard 

procedures shall be followed in this regard for a quality work. 

Shade of paint 

Interior 

Exterior 

Technical particulars of LT busducts 

Applicable standard : IS - 8623 

Rated system voltage & frequency : 415V, 50 Hz 

Maximum ambient temperature : 50˚C 

System earthing 

System short circuit level(kA rms) : 50 KA 

Maximum voltage at which bus duct can operate 

continuously 

: 500 V 

Location of bus duct : Indoor 

Type of bus duct 

Material of main busbar : Aluminium Alloy 

Rated continuous current : As specified 

Earth bus material 

Bus duct support structure required :` To be provided 

Rated continuous current : As specified 

Rated short time withstand capacity : 50 kA 

Rated short time withstand duration : 1 sec 


: Black/white/light yellow 

: As per technical particulars 

: Solidly grounded 

: Non Phase segregated 

: Aluminium 

Page 25 of 97

Insulation level 

Insulation class 

1 minute dry power frequency withstand : 2.5 kV 

1 minute wet power frequency withstand : 2.5 kV 

Support insulator 

Type 

: Non: hygroscopic SMC 

Maximum distance between supports 

Clearance 

: 

moulded/FRP 

To be worked out based on 

short circuit calculation. 

Phase to Phase 

Phase to earth 

Enclosure 

Material 

: AI (for >/= 3000 A) / MS 

(For < 3000A) 

Degree of protection (Minimum ) : IP52 – Indoor 

IP55-Outdoor Outdoor 

Thickness of material : 2.5 mm (minimum) 

Accessories 

Sea- Off bushing with wall frame (for wall crossing) : Only wall frame required 

Silica gel breather 

Space heaters 

Maximum temp allowed at max. ambient temp : 

Bus conductor 

Bus enclosure and support structure : 70˚C 


: 1.1 kV 

: 

: 25.4m 

: 19.0m 

: Required 

: Required 

: 85˚C 

Page 26 of 97

Paint shade 

Phase crossover chamber/section : 

Exterior: Approved 

One set in one of the bus 

duct portion of each 

PCC/board. 

ERECTION, INSTALLATION ACCESSORIES 

All erection & installation accessories required for erection/installation of equipment are 

included in the scope of the tenderer. 

All the accessories and other erection materials required to complete the erection job in all 

respect shall be considered as part of the tenderer’s scope. 

Safety insulating mats of minimum thickness of 2 to 3 mm and of suitable voltage grade in 

front of all the PCCs/board and control panels shall be provided by the tenderer. 

4.4 ELECTRIC MOTORS 

General 

All motors shall generally conform to IS 325 and CBIP publication No. 140. Motors shall run 

continuously at rated output with + 5 % variation in frequency and + 10 % variation in voltage 

and + 10 % combined ned variation of frequency and voltage (absolute sum). Motor shall not stall 

due to momentary drop in voltage up to 70 % of rated value and shall run satisfactorily for five 

minutes at a supply voltage of 75 % of rated value. 

The limiting value of voltage at rated frequency under which motor will successfully start and 

accelerate to rated speed with load shall be assumed to be a constant value of 80 % rated 

voltage throughout the starting period. 

All motors shall be supplied with foundation bolts (if app applicable), licable), drain holes with plugs. 

Motors shall be designed for 50oC ambient temperature. 

Motors supplied shall be complete with required double compression cable glands, crimp type 

cable lugs and first filling of lubrication, name plate, etc. Lifting fac facility ility to be provided for all HT 

motors and big size LT motors. Guards shall be provided to prevent accidental touch for 

couplings and for free shaft ends shall be provided. 

Degree of protection for motor and bearings shall be IP IP-55 55 for indoor and IP55 wit with rain 

canopy and weather proof construction for outdoor. Motor shall be suitable to withstand at 

least three successive starts from system cold condition and two starts from hot condition at 

normal system voltage and frequency. 

The drive motor shall have e at least 15 % margin over the maximum power requirement of the 

driven equipment after considering all losses, de de-rating rating due to temperature and specific site 

and operating conditions. 


: Interior: 

yellow 

Black/white/light 

Page 27 of 97

The motor may be subjected to sudden application of 150% rated voltag voltage e during bus transfer, 

due to phase difference between the incoming voltage and motor residual voltage. 

Motor handling facility and canopy 

Handling facility and space shall be provided for all the LT motors. Mono rail shall be provided 

and shall be extended up to open maintenance space for each of the LLT 

motors. Canopies 

made of GI sheet of minimum thickness of 2 mm shall be provided to each of the LT motors 

located outdoor. 

All motors, in general, including conveyor motors shall be 4 pole construction, hence speed of 

maximum 1500 rpm. However, motors for travel drives of yard machines shall be of 6 pole 

construction, hence speed of 1000 rpm rpm. 

LOW VOLTAGE INDUCTION MOTORS 

Frame sizes shall be as per IEC. Casing feet shall be integral with the motor body. For motor of 

rating up to 5 kW, ball bearings shall be used for both DE & NDE end. For ratings above 5 kW 

the DE end shall be provided with ball/roller bearing and NDE end shall be provided with ball 

bearing. Bearings shall be suitable for running of motor in either direction. Motors 110 kW and 

above shall be provided with bear bearing ing temperature indicators. Explosion proof/increased safety 

design for explosion hazardous areas as per requirement. 

Terminal box shall be of suitable dimension to receive aluminium cables and shall be rotatable 

by 4x90 o 

Terminal box shall be of suitable dimension to receive aluminium cables and shall be rotatable 

Cooling of motors shall be of TTEFC 

EFC (IC0141) design. Ventilation shall be effective irrespective of 

direction of rotation. 

Motors shall be dynamically balanced. Vibration intensity shall be limited as per IS 12075 

(1987). Continuous noise level should not exceed 75 dBA at a distance of 1.0 m from motor 

body. 

Starting current shall be less than or equal to six times the rated current with IS tolerance. 

Motors shall have class ' F' insulation with temperature limited to class ‘B’. Permissible 

temperature shall be limited to 120oC in case of class 'B' insulation and 130 

insulation as measured by resistance method. Class H insulation shall be considered in specific 

cases. Limiting temperature shall also be limited to 130 deg C in case of Class H insulation as 

measured by y resistance method. 

o C in case of class F 

insulation as measured by resistance method. Class H insulation shall be considered in specific 

cases. Limiting temperature shall also be limited to 130 deg C in case of Class H insulation as 

Space heaters shall be provided for all motors rated above 30kW. Adequate handling space 

shall be provided for all the big LT motors. 

HIGH VOLTAGE MOTORS 


Page 28 of 97

Degree of protection for motor and bearings shall be IP IP-55 55 for indoor use aand 

IP-55 with 

removable rain canopy for outdoor use. 

Vibration monitor with contacts shall be provided at the DE end of motor bearing for motors 

of ratings 1000 kW and above. On line vibration measurements shall be provided for larger 

and critical motors. 

All motors shall be provided with Bearing (DE & NDE) temperature detectors and 6 nos. stator 

winding temperature detectors, RTDs for monitoring alarm and trip conditions. Temperature 

shall be displayed on VDU's. RTD's shall be of PT100 type and suitable for digital scanner or 

PLC input requirement. 

Digital igital type bearing temperature indicator for all motors shall be provided for local 

measurement with adjustable alarm contacts. 

Each terminal box shall have fault withstand capacity equal to at least rated short circuit level 

of the system voltage for 00.25 

.25 sec and shall have pressure relief device. Terminal boxes shall 

be suitable for termination of FRLS, XLPE cables with cable end seals. Separate terminal boxes 

shall be provided for space heaters, RTDs for winding/ bearings temperatures, vibration 

monitors etc. 

All terminal boxes shall be provided with two earthing studs for termination of protective 

earth conductor. Box covers shall be provided with handle to facilitate easy removal. 

Low kW range machines may be of TEFC (IC0141) design. For higher rrating, 

ating, type of cooling 

shall be CACA (IC0151). General accessories like flow switches, space heater, terminal boxes, 

drain plug, dowel pipe cable lugs, glands clamp etc. shall be provided. 

Vibration intensity shall be limited to values as stipulated in tthe 

he IS. Motor shall be designed to 

withstand the vibration produced by the driven equipment. Continuous noise level should not 

exceed 75 dBA at a distance of 1.0 m from the motor body. 

Electrical design shall be same as in case of low voltage induction mot motors ors except the following: 

All motors shall have class F insulation but with total permissible temperature limited to 1300C 

(as measured by resistance method). Starting current of the drives shall be limited to six times 

of full load current. 

Motors of rating 1000 kW and above shall be provided with differential protection. Matching 

CT and cabling up to switchgear shall be provided by the Bidder. 

Motors shall be capable of withstanding locked rotor current at 110 % rated voltage for at 

least 2.5 sec (for or motors having staring time up to 20 sec) or 5 sec (for motors having staring 

time more than 20 sec) longer up to than starting time under rated load condition at 80 % 

voltage. If above condition is not possible then, centrifugal type speed switch to be provided 


Page 29 of 97

which has to be connected to the motor protection relay. Speed switch shall be capable to 

withstand 120 % of the overspeed in either direction. 

Insulation of motors shall be designed conforming to IEC 34 34-15/ 15/ 1990. Gland plate for single 

core cable shall be non-magnetic magnetic type. 

All motors shall have individual dedicated handling and lifting facilities preferably by dedicated 

electric hoist. 

4.5 POWER DISTRIBUTION BOARD /AUXILIARY POWER DISTRIBUTION BOARD 

POWER DISTRIBUTION BOARD 

PDB shall be suitable for 415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec) indoor 

type. 

Board shall be single front, metal clad, front matched, dust and vermin proof, draw draw-out 

(incomer & bus coupler) / fixed (outgoing), fully compartmental 

compartmentalized ized and extensible on both 

sides, IP54 type enclosure. 

Shall have isolated busbar chamber for main busbar at the top, running throughout the length 

of the board. Chamber shall have removable cover. 

Busbars shall have same cross section throughout the length . Rating of the neutral busbar 

shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the 

length of the panel. 

Shall have Moulded case circuit breaker (MCCB) triple pole, air break type with independent 

manual quick make and quick break type. MCCB shall be capable of breaking rated current at 

0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system. 

Generally PDB will have following feeder arrangement. However, details of feeders e.g no. 

type and capacity, etc shall be finalized during detailed engineering: 

Incomer : ACB of 630A (or as per requirement) 

Outgoings : MCCBs of 400/250/125A/63A/16A (or as per requirement) 

Number and capacity of PDB given in the enclosed Single Line Diagram is minimum and 

indicative. Bidder shall provide as per actual load requirement and same shall be finalized 

during detailed engineering. 

AUXILIARY POWER DISTRIBUTION BOARD 

Aux. PDBs shall be suitable for 415V, 3 phase, 4 wire wire, , 250A, 50 kA (short time rating for 1 sec.) 

indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof, 

non-drawout, drawout, fully compartmentalized and extensible on both sides, IP54 type enclosure. 


Page 30 of 97

The other technical particula particulars rs of aux. PDBs shall be similar to PDB. The tentative feeder 

arrangement shall be as follows. However, details of feeders e.g no. type and capacity, etc 

shall be finalized during detailed engineering: 

Incomer : MCCB of 250A (or as per requirement) 

Outgoings : MCCBs of 125A/63A/16A (or as per requirement) 

4.6 33 KV ON-LOAD LOAD ISOLATOR WITH EARTH SWITCH 

Technical features 

• Triple pole air break, fault make load break type. 

• Independent manual, quick make, quick break type 

• Mechanical trip device 

• Mechanical “ON”- “OFF” indicator 

• Suitable to connect cables on incoming and outgoing side. 

• Shall have 3 NO and 3 NC aux. contacts. 

• Earthing switch shall be provided on transformer side having rating same as that of main 

switch. 

• Totally enclosed, floor mounted, outdo outdoor kiosk type with IP-55 55 protection along with a 

canopy 

• Shall have padlocking facility 

• Panel door shall be mechanically interlocked so that isolator cannot be closed on open 

position of door and door cannot be opened on close position of isolator. 

• Earthing switch shall be interlocked with isolator blades to prevent simultaneous closing of 

both. 

• Isolator shall be interlocked with Purchasers upstream breaker. 

Technical particulars 

1. System voltage 

2. System earthing 

3. Type 

4. Nos. of poles 

5. Continuous current 

6. carrying capacity 

7. S/c withstand capacity : 25KA for 3 sec/43.7 kA for 3 sec. 

8. Pf withstand voltage : 75/20 kV 

9. Impulse withstand voltage 

10. Termination 

11. Incomer 

12. Outgoing 

4.7 HT/LT TRANSFORMERS (OIL OIL IMMERSED TYPE) 

4.7.1 Design 

Design shall be generally as per IS 1886. Transformer shall be suitable for rated frequency 50 

Hz, -5%, 5%, +5%. Insulation level shall be designed according to the voltages specified below: 

Description 


:33kV 

: Resistance earthed 

: Air break, fault make & load break type 

: Three 

: As per requirement 

withstand voltage : 170/60 kV 

: To accept cables of required size 

: To accept cables of required size 

33/.415 kV 

Page 31 of 97

Capacity 

Nominal voltage (kV) 33 

Max system voltage (kV) 35 

Power frequency withstand voltage (kV) 75 

System earthing 

No. of phases 

Frequency 

Impulse test withstand voltage (kV) 170 

Short time current rating (for all current 25 kA for 3 sec 

carrying parts) 

Fault level (3 phase symmetrical) 25kA 

Type of Cooling 

Connection HV winding DELTA 

Connection LV winding STAR 

Connection Symbol 

HT/LT transformers shall be of the latest design, oil immersed type as per IS : 1886 and testing 

as per IS 2026 part I. . All dry type air natural transformers shall be suitable for indoor use line 

up with power control centre as unit type. 

Bidder shall ensure that manufacturer shall have his own in in-house house core cutting facilities on 

CNC machines. 

Special care shall be taken ken to make enclosed equipment proof against entry of rats, lizards and 

other creeping reptiles which may create electrical short short- circuits inside live equipment. The 

design of each transformer shall be such that the risk of accidental short short-circuits due to 

reptiles or vermin shall be obviated. 

The transformer shall be of cast resin type. The tap changing arrangement shall be of 

removable link type. 

Each transformer shall be suitable for operation at full rated power on all tappings without 

exceeding the temperature rise of 800C over the ambient of 50 

shall be F. 

o Each transformer shall be suitable for operation at full rated power on all tappings without 

C. Minimum class of Insulation 

The transformers shall be designed to be capable of withstanding, without injury, the thermal 

and mechanical effects of short short-circuits between phases or between n phase and earth at the 

terminals of any winding with full voltage applied across the other winding. All transformers 

shall be capable of withstanding specified through fault current for minimum of 2 seconds as 

per IS: 2026 (Part-1). 

The transformers shall all be designed to suppress harmonic currents, especially the third and 

fifth, so as to eliminate distortion in the wave form and consequent additional insulation 


Low resistance earthed 

3 

50 Hz 

ONAN 

Dyn 11 

Page 32 of 97

stress, noise on communication system and undesirable circulating currents between the 

neutrals ls at different transformer stations. 

The Transformers shall operate with minimum noise and vibration. The cores, protective 

housings and other structural parts shall be properly constructed and windings properly 

braced so that the mechanical vibrations are kept to the minimum, thus reducing the noise. To 

this effect, the laminations shall also be bonded together with appropriate resin. The core core-coil 

assembly shall also be fixed in such a manner that no shifting or deformations occur during 

shipment or installation. 

Each transformer shall be designed for minimum no no-load load and load losses within the economic 

limit. 

All electrical connections and contacts shall be of ample section for carrying the rated current 

without excessive heating. 

All mechanism shall all be of stainless steel, brass, gunmetal or other suitable material to prevent 

sticking due to rust or correction. If any temporary fitting is fixed to the protective housing of 

the transformer for transporting / handling purpose, these shall be identica identical as well as 

instructions and illustrated drawings shall be furnished to facilitate their removal at site after 

erection. 

4.7.2 Core 

The framework, clamping arrangement and general structure of the cores of each transformer 

shall be of robust construction and shall be capable of withstanding any shock to which they 

may be subjected during transport, installation and operation. The assembled core shall be 

securely clamped on the limbs and the yoke to build up a rigid structure. The clamping 

pressure sure shall be uniform over the whole of the core and so adjusted as to minimize noise and 

vibration in the core when the transformer is in operation. The framework and the core bolts 

shall be effectively insulated from the core so as to reduce the eddy eddy-currents rents to the minimum. 

The magnetic circuit shall be built of high quality, low loss, non non-ageing. ageing. Cold rolled, grain 

oriented, silicon steel laminations (CRGO Prime Grade) having excellent magnetic properties 

and specially suitable as core material. Lamina Laminations tions shall be insulated from each other with 

material having high inter inter-lamination lamination insulation resistance and rust inhibiting property and 

also capable of withstanding stress and mechanical vibration. 

Necessary cooling ducts shall be provided for heat dis dissipation sipation from the core so that the 

anticipated maximum hot spot temperature in the core shall not be injurious to any material 

used in the core assembly. 

The core-clamping clamping frame shall be provided with lifting eyes having ample strength to lift the 

complete te core and winding assembly. 

Suitable provision shall be made in the dry type transformers for effective core earthing. 


Page 33 of 97

4.7.3 Winding 

The coils used for transformer winding shall be made of insulated, continuous and smooth 

electrolytic copper conductors of high conductivity and of 99.9% purity. Similar coils shall be 

connected by accessible joints brazed or welded and finished smooth. No corona discharge 

shall result on the winding during induced voltage test as specified in applicable standard. 

The insulating materials for dry type transformers shall be of type not inferior to Class “F”. All 

insulating materials shall be of proven natu nature re and shall be suitable for the suitable for the 

limits indicated in the applicable standards as well as the maximum possible winding 

temperature and shall not deteriorate when the transformer is operated continuously at its 

specified rating at the specif specified ambient temperature. 

The inter-turn and inter-coil 

coil insulation shall be so designed that the dielectric stress is 

uniformly distributed throughout the winding under all operating conditions. 

The windings shall be dry cast resin type. 

The transformer er windings shall be designed for basic Impulse insulation level not lower than 

those specified above. 

4.7.4 Protective Housing for Dry type Transformer 

Dry type transformer shall be provided with suitable protective sheet steel housing, with 

minimum IP P 23 degree of protection for the enclosure. The housing shall have ventilation 

louvers provided with wire mesh screens and shall be supplied with suitable lifting lugs. Safety 

limit switches shall be provided and wired in such a way that the incoming supp supply may be 

disconnected whenever any one of the sides of the enclosures are opened with the 

transformer in energized condition. 

Sufficient precautions shall be taken so that doors are closed fully. Door locks shall be 

provided and keys shall be universal type. 

4.7.5 Off-Circuit Circuit Links 

The off-circuit circuit tapping links shall be provided on the HV side with appropriate register plate to 

show the link location. The links shall be provided with a separate door for access. The door 

shall be provided with appropriate safely limit switches which will trip the transformer HV / LV 

sides in open condition. 

4.7.6 Cooling 

The cooling system for or dry type transformers shall have Air Air-Natural Natural (AN) cooling. 

4.7.7 Neutral Bushing Current Transformers 


Page 34 of 97

CTs for back up earth fault (51N) as well as for restricted earth fault (64) shall be provided on 

the neutral end. 

Neutral bushing CT shall be re removable movable at site without opening transformer tank cover/active 

part. Secondary leads of 4 sq.mm shall be brought to a weatherproof terminal box and from 

there to the marshalling box. 

Neutral bushing CTs of suitable ratio, class and adequate burden shall be provided by the 

Bidder to cater to the requirement of all standard protection associated with the transformer 

of this capacity. CTs for REF shall be PS class. 

4.7.8 Marshalling Box 

Enclosure mounted marshalling box to be supplied with all controls instruments, protection, 

accessories & fitting as required for the transformer and its associated ancillaries. The box 

shall be made of 2 mm sheet steel with IP 54 degree of protection. 

Sheet heet steel marshalling box of dust dust-proof proof design shall be provided to accommodate 

temperature measurement as well as control system, as may be necessary. The box shall be 

mounted on the transformer enclosure and shall be provided with internal lighting, spa space 

heater and thermostat with their controls accessible from outside. 

The box shall be provided with suitable hinged steel doors at the front and all equipment shall 

be so placed as to accessible from the front. Provision shall be made for padlocking the doors. 

Suitable glazed windows shall be provided at appropriate positions to give an unrestricted 

view of the temperature indicators etc, without opening the door. 

All initiating tiating “contacts” of shall be wired up to the terminal block in the box. All control wiring 

shall be with 1.1kV grade stranded PVC insulated armoured copper cable of 2.5 sq.mm. 

Terminal blocks shall have 20% spare capacity. 

The external connections betw between een the apparatus on the transformer and the marshalling box 

shall be done with suitable heat resisting copper conductor cables of core size not less than 

2.5 sq. mm. The cables required to connect the marshalling box and transformer accessories 

shall be adequately dequately protected against mechanical damage. There shall be no joints or tappings 

between two terminations of any cable. Not more than two terminations shall be made at any 

one terminal. All terminations at various devices and terminal blocks shall be pr provided with 

plastic ferrules having engraved numbers. All terminals and links shall be so arranged as to 

facilitate easy checking and testing of relays, instruments etc. Provision shall be made for 

termination of power cables as well as multi multi-core control cables in the marshalling box. 

The control circuit terminal blocks provided for external cable connections shall be provided 

with screw type terminals and shall be complete with terminal screws, links, cable carries etc, 

Each terminal block shall have 20 20% % spare terminals and all wiring shall be such that it is easily 

identifiable and accessible for maintenance. 


Page 35 of 97

All devices, wires and terminal blocks within the marshalling box shall be clearly identified by 

symbols corresponding to those used on relevant schematic or wiring diagrams. 

Enclosure class of marshalling box shall be IP IP-55. 

Terminal Arrangement HV/LV terminals shall be suitable for cables considered. 

4.7.9 Transformer Fittings & accessories 

Each transformer shall be fitted with all standa standard rd and special fittings and accessories and shall 

include but not be limited to the following: 

• Inspection covers. 

• Off circuit links in the primary for voltage variations. 

• Rating, diagram and tap connection plates. 

• Terminal marking plate 

• Two nos. earthing g terminals with lugs. 

• Winding temperature detectors with microprocessor based Temperature scanners with 

digital read out and requisite set of remote signaling contact for alarming/tripping 

operation. 

• Under carriage with bi bi-directional directional rollers with locking and bolting devices. 

• Marshalling box complete with all instruments, accessories and fittings as required for the 

transformer. 

• Off load tap changers with position indicators and padlocking faciliy 

• Neutral eutral bushing CTs with terminal arrangement 

• HV cable box with disconnecting chamber and supporting arrangement 

• LV side flanges suitable to receive busducts 

• Jacking pads 

• Haulage lugs 

• Flat base, foundation bolts and clamps and other accessories as requ required ired 

4.7.10 Details of Fittings 

Requisite number of Resistance type temperature detectors shall beprovided with solid state 

type temperature signaliser for dry type transformer. The temperature signaliser shall be 

provided with two sets of contacts, on one e for alarm and the other for circuit circuit-breaker trip. The 

signaliser shall be provided with digital read out for the temperature being measured and for 

the zone where the current measurement. 

Two nos. earthing terminals of adequate mechanical and electrical capacity shall be provided. 

Separate earthing terminals shall also be provided on the enclosure, marshaling box and 

terminal boxes. 

Rating and diagram plates shall be provided as per adopt adopted ed standards for each transformer. 

Lifting lugs and hauling holes as required shall be provided for the transformer as well as for 

the enclosure. 


Page 36 of 97

Suitable under-carriage carriage fitted with flat rollers shall be provided. The rollers shall have 

adequate mechanical ical strength and shall be so designed that the transformer shall roll without 

undue effort after it has remained immobile for a long period. The edges of rollers shall be 

duly rounded off to permit skidding of transformer on flat surface. 

4.7.11 Technical Particulars of HT Transformers (33KV/ (33KV/440V) 

1.0 General 

1.1 Make 

1.2 Type 

1.3 Service 

1.4 Duty 

: Continuous 

1.5 Degree of Protection : IP:55 

1.6 Reference Standard : IS/IEC Equiv 

2.0 Rating 

2.1 Rated output 

2.2 Quantity 

2.3 Type of cooling 

2.4 Rated voltage Volt : 

H. V. 

: 33kv 

L. V. 

2.5 No. of phases 

2.6 Rated Frequency Hz : 50 

2.7 Vector group reference : Dyn11 

2.8 Connection 

H. V. 

L. V. 

LVn 

2.9 Insulation 

H. V. 

L. V. 

2.10 Insulation level kVp/kV 

H. V. 

L. V. 

3.0 Temperature 

3.1 Reference ambient temp. : 50 0 C 

3.2 Temp. rise over reference ambient 

a) Top Oil measured by : 50 0 C Thermometer 

b) In winding by 

4.0 Tappings 

4.1 Type 

4.2 Taps 

4.3 Taps provided on HV winding : Yes 

5.0 Method of earthing : Neutral Grounding Resistor 


: Reputed Make 

: Two winding 

: Outdoor 

: As per load calculation 

: 2 nos 

: ONAN 

: 440V 

: 3 

: Delta 

: Star 

: Grounded through NGR 

: Uniform 

: Uniform 

: 75/28 

: 40/10 

: 

: 55 0 C Resistance 

: Off circuit Tap Changer (OCTC) 

: ±10% in steps of 2.5% 

Page 37 of 97

6.0 Neutral grounding Resistor 

6.1 Rated current 

6.2 Application 

6.3 Service 

6.4 Resistor material & connection : Punched stainless steel grid element type 

6.5 Maximum allowable 

over ambient 50 0 allowable temperature rise 

C 

6.6 Enclosure degree of protection : IP - 55 

7.0 System Fault Level 

7.1 H. V. 

7.2 L. V. 

8.0 Conductor material : Electrolytic grade copper 

9.0 Creepage distance mm/KV : 3lmm/kV 

10.0 Terminal connections 

10.1 H. V. 

10.2 L. V. 

11.0 Marshalling box Degree of protection : IP:55 

Power frequency to withstand voltage of 33 KV system should be 75KV.Impulse KV.Impulse test voltage 

should be 170KV for system voltage of 33 KV. 

4.7.12 Technical Particulars of Dry type transformers (LT) 

1. Rated capacity 

2. Cooling 

3. Duty 

4. Voltage ratio (HV/LV) 

5. Impedance 

6. Winding connection 

7. Vector group 

8. Termination 

9. Tap changer 

10.Range of tap changer 

11. Short circuit level 

12. Earthing system (33 kV) 

13. Earthing system (415 V) 

14. Bushing CTs 

15. Ratio of neutral bushing CTs 

16. Impulse test withstand voltage (HT/LT) 

17. Power frequency rated short duration 

18. Temp. rise above 50 0 C 

19. Overload capacity 

20. Auxiliary supply voltage 


: Less than 100A for 10 seconds 

: Grounding through Resistor 

: Outdoor 

: As per Standards 

: 25kA 

: 50kA 

: Segregated phase bus duct/Cable 

: Segregated phase bus duct/Cable 

: As per requirement 

: AN 

: Indoor 

: 33/0.440kV 

: As per IS 

: Delta/star 

: Dyn11 

: HV : 33KV cable 

LV : Cable 

: OFTC 

: +5% in 5 steps @2.5% 

: 25 kA (33kV) for 3 sec 

: Low Resistance earthed 

kV) : Low Resistance earthed 

13. Earthing system (415 V) : Solidly earthed 

: On neutral 

al bushing CTs : As required for Standby E/F Restricted E/F 

16. Impulse test withstand voltage (HT/LT) : As per IS/IEC 

17. Power frequency rated short duration : As per IS/IEC withstand voltage (HT/LT) 

: 80 0 : As required for Standby E/F Restricted E/F 

: As per IS/IEC withstand voltage (HT/LT) 

C 

: As per ANSI standard 

20. Auxiliary supply voltage : 240V AC 

Page 38 of 97

21. Suitable for parallel operation : Yes 

4.8 VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVE 

Basic design particulars 

All VVVF Converters shall have Digital Control Technology with vector less control. VVVF shall 

communicate to basic automation system. 

Type of connection 

• Three phase frequency converters with rectification and inversion i.e. variable voltage and 

variable frequency output with current source / voltage source (PWM) inverters. 

• Line reactors for harmonic and noise suppression 

• Suitable for 415 V , 3 phase ,50 Hz , 4wire neutral earthed system 

Overload capacity 

• 150% of the rated current for 1 minutes followi following ng 100% load & to meet the drive overload 

capacity. 

• Efficiency more than 95% at full load 

• Suitable to withstand vibrations more than 0.59. 

• Output frequency : 5-50 Hz (Constant torque) 

50-100 Hz (Constant power) 

• Ramp rate: Linear acceleration and dec deceleration eleration adjustable independently. 

Power components 

The main power components of the VVVF equipment shall have the following incoming AC 

side: 

• Matching input power transformer / reactor 

• AC line surge suppression network. 

• ACB/MCCB 

• Line contactors 

Converter –Inverter Inverter Equipment 

• Thyristor converter bridge for AC/DC 

• DC link circuit with reactor/capacitor 

• Inverter bridge for DC/AC 

• PLC to take care of interlocking and sequencing etc. 

• Mimic panel where drive is HT 

Load side 

• Filter network 

• Step-up up transformer, as required 

• Isolator and over over-load relay for each motor. 

By-pass Arrangement 


Page 39 of 97

• By-pass pass arrangement shall be provided to operate the motor in case of failure in 

frequency converter. 

Thyristor converter 

• Minimum ratings of thyristor cells 

• PIV rating : 2.5 times the peak value of line voltage 

• dv/dt rating : 200V/microsecond for voltage control and 

1000V/microsecond for inverter control. 

• di/dt rating : 100A/ microsecond. 

Protective features 

• AC line surge suppression net network 

• Under voltage in supply network 

• Phase sequence protection and monitoring 

• RC snubber network across each thyristor cell 

• Thyristor fuse failure 

• Under voltage in Dc line 

• Over voltage in Dc line 

• Over speed monitor 

• Over load 

• Earth fault 

• Instantaneous over current 

• Transformer fault 

• Cooling fan failure – Stall monitor for motor Alarms 

Above condition shall be annunciated. Following warning signals shall also be provided as 

minimum in addition to above. 

• Motor fault (winding / bearing te temperature, vibration) as applicable 

• Loss of frequency command 

• Meters, Switches, Lamps 

Following shall be provided as minimum meters: 

• Input volt meter and ammeter with selector switches 

• Output voltmeter and ammeter with selector switches. 

• Output frequency ncy meter 

• Selector switches, pushbuttons, and lamps as required. 

• kW meter for drive ratings above 200 kW Regulation and controls 

Control facilities shall include following but not limited to: 

• Reference speed setter 

• Ramp generator 

• Speed feed back 

• Current feed back 

• Trigger module 

• Pulse transformers 

• Logic control module 


Page 40 of 97

• Sequence module 

• Zero speed/over speed monitor as applicable 

• V/f control 

• Current limiter 

• Counter current/ regenerative braking unit as applicable 

• active electronic components used shall be of industrial grade hermetically sealed 

• Regulated power supply for reference setting: 

Voltage variation of (+/-) ) 0.1 % with an input variation of +10% - 15% 

Steady state regulation of (+/ (+/-)0.25% % guaranteed against 100 to 200 % load disturbance and + 

3%, -6% 6% input supply frequency variation. 

• Facility to accept speed reference from computer/ programmable controller 

Construction features 

• Floor mounted, free standing 

• Dust and vermin proof 

• Sheet steel clad 

• Minimum 2.5 mm thick for panels. 

• Minimum 2.0 mm thick for doors and side covers. 

• Suitable to withstand vibrations to be encountered in steel plant application. 

• Cubicles with illumination lamps, door switches, space heaters and adequate sockets 

for soldering. 

• All control blocks plug –in-type with necessary test sockets. 

• Units shall be self contained and serviceable. 

Enclosure and Ventilation 

• Enclosure conforming to IP IP-52 or more with weather proof enclosures 

• Units shall be provided with cooling fans and louvers at the bottom sides. All louvers shall 

have fine mesh behind them. 

• Ventilation through individual ventilation ducts, from bottom not acceptable. 

4.9 RELAY PANELS 

Relay panels (RP) housing aux. contactors, timers, relays, etc. shall be provided for equipment 

control, sequential control, monitoring, safety alarm signals, annunciation signals, interlocking 

of drives ,signal exchange, interface with future system etc. shall be provided. Constructional 

features of R.P. shall be similar to MCC. At least 10 % spare auxiliary contactors, timers &relays 

shall be provided in the relay panel whose contacts and coils shall be wired up to terminals. terminals.10 

% spare terminals shall als also be provided. 10 % of auxiliary contactors, timer and relays shall be 

provided as spares which will be wired upto terminals. 

4.10 PROGRAMMABLE LOGIC CONTROLLERS (PLC) 

Power supply system 


Page 41 of 97

Input power supply shall be fed through UPS system. However, PLC shall be capable of 

withstanding power supply from electrical feeder. Alternate source of power supply 

arrangement or second UPS shall be provided to take care of the situation when the original 

UPS fails. 

Built-in in power supply units 

• Suitable for the e power supply system as specified above. 

• Independent units for the following: 

• CPU and associated electronic units 

i) sensing the status of input devices 

ii) driving outputs if outputs are relays 

iii) Insulation level 2.5 kV for 1 minute. 

• Protection against t surge protection & short circuit 

• Electronic over current protection with feedback feature. 

Central processor unit 

• Modular and plug-in in type 

• 32 bit microprocessor based 

• Scan time 2 m sec per one K Words of instructions or better 

• Provision to latch desired outputs. 

• The processor shall have in in-built built provision for examining input conditions, compare, 

compute, logical, conversion from/ to BCD, bit manipulation, block memory manipulation, 

diagnostic, shift, sequencing, conditional jumping, subroutine instructions. 

• In-built built PID instruction shall be preferred over separate PID hardware Module. 

• Timer & counter modules shall be provided wherever required. 

Memory units 

Modular and plug-in type 

• Word length 32 bit as per CPU 

• Expandable in blocks of 4K Words 

• Minimum size 16K Words 

• EPROM/ RAM with battery back back-up 

• Back-up up battery shall be as follows: 

i) Rechargeable Ni-Cd Cd batteries with necessary charging circuit, Lithium or any other 

internationally acceptable type. 

ii) Able to retain memory for a minimum of 1 year with no power applied to the controller. 

Input units 

• High density (32/16 Channels), modular and plug plug-in type 

• Insulation level of 1.5 kV 

• Input interrogation voltage 24V DC 

• Discrete input units shall l have the following: 

i) Filter to take care of contact bounce 

ii) Opto-isolation isolation to isolate the input device from the controller 


Page 42 of 97

iii) LED status indication iv) BCD input units suitable for four digit input 

• Analog input units shall be as follows: 

i) Suitable for 4-20 20 mA / 00-10V 

/ +/-10V inputs 

ii) With necessary A/D converter 

• Pulse/ frequency input module shall have range up to 50 kHz. For very high frequency 

applications, the range shall be up to 1 MHz. 

Output units 

• High Density (32/16 Channel), modular and plug plug-in type 

• Discrete output units shall be as follows: 

i) Opto-isolated isolated outputs with insulation level of 1.5 kV 

ii) Rated for 24V DC, 2A 

• Power devices like contactor or odd voltage actuating device shall b bbe 

actuated through 

relays 

• LED status indication 

• BCD output units shall be as follows: 

i) Suitable for four digit output 

ii) Rated to drive seven segment LED displays 

iii) With insulation level of 1.5 kV 

• Analog outputs shall be as follows 

i) Suitable for 4-20mA/ 20mA/ 00-10V/ 

+/-10V 10V outputs capable of driving Digital / Analog Panel 

Meters 

ii) With necessary D/A converters 

iii) With insulation level of 1.5 kV 

iv) Any special requirement to control field devices shall be met by using separate 

interface modules 

PC based programming unit: 

• PC used for Programming Terminal shall be commercial grade and latest available in the 

Suitable for developing programs in ladder diagram/ block diagram or statement form 

• With facility for loading the program from floppy 

• The terminal shall be capable of developing multiple programs offline without connecting to 

the programmable controller. 

Self diagnostic features 

• Parity errors, cycle errors and under voltage 

• Failure in central processor unit, memory and power sup supply. 

• Indication of type of failure 

• Automatic turning OFF of all outputs or optionally holding of all outputs in their last state on 

failure detection. 

Additional features 

• Fully pre-programmed 

• Connection of field devices with input units throu through ordinary multi-core 

copper control 

cables of 1.5 sq. mm size, upto a length of 500 m. 


Page 43 of 97

• Connection of remote input/ output units to programmable controller through remote I/O 

units, wherever substantial saving in cabling is envisaged. 

• Serial interface, ce, RS232C and better shall be provided 

• High speed communication among PLC and operator consoles/ display units shall be 

provided through ethernet 

• Latest appropriate model of HP Inkjet Printer to get hard copy of the program dump/ data 

logging / alarm m logging / event logging / data trending etc. [Printer covered also under 

“Programming Unit”. Only one printer shall be supplied.] 

Special features 

• Switch to disable all outputs of the controller during start start-up/ up/ debugging 

• Fuse failure indication for outputs Mounted spares 

• Min of 30 % of I/O modules used of each input & output type (with at least one module of 

each type) shall be offered as unused spare for each I/O rack. Minimum of 30% I/O rack 

slots shall be kept reserved rved for future expansion. 

• 30 % spare memory capacity shall be provided 

Constructional features 

• Unitised construction 

• Floor mounted, free standing and indoor type 

• Bottom cable entry 

• Sheet steel clad 

• Dust and vermin proof 

• Suitable to withstand vibrations as per application 

• All modules plug-in in type 

Enclosure 

• Conforming to IP-42 42 class 

• Conforming to IP-54 54 class for remote I/O cubicles located in shops/ bays. 

Miscellaneous 

• Programmable controllers, even if housed in air air-conditioned enclosure, shall be suitable for 

normal industrial environment and ambient temperature upto 50 

air filter shall be provided at the top of each PLC panel for proper air circulation. 

0 ditioned enclosure, shall be suitable for 

C. A suitable fan with inlet 

air filter shall be provided at the top of each PLC panel for proper air circulation. 

• Dual redundant processor shall be envisaged. Redundancy shall be provided in such a way 

that in case of failure of the main processor, the standby shall takeover automatically. The 

changeover shall be bump less and the system shall be fail proof. Redundan Redundancy shall be 

provided for complete processor system including CPU, Memory, Power supply and 

Communication sub system. 

• Failure of a single processor shall not affect the system. 

• In case of failure of complete processor system, outputs shall take fail safe st state 

automatically. 

• It shall be possible to generate the first out alarm contact by the PLC in case where a group 

of parameters are likely to trip a system. 


Page 44 of 97

• The communication subsystem between PLC processor and I/O subsystem shall be dual 

redundant. 

• The communication munication subsystem between processor subsystem and PLC console shall be dual 

redundant, consisting of two separate communication interfaces and two buses, each one 

configured in redundant mode. 

• No hardwired alarm system is required. All the alarms are to be displayed in OWS of PLC 

with multi tone buzzer and with alarm history provision. 

• The software provided at the time of supply should be of latest version. 

• Necessary license to be provided along with the software. 

• The OS (Operator Station) desk and opera operator tor chair to be supplied by the bidder. 

4.11 UNINTERRUPTIBLE POWER SYSTEM (UPS) 

General System Description 

The required kVA, 50 Hz, single phase UPS system shall provide continuously operating 

uninterrupted power supply to critical AC loads such PLC PLC, , instrumentation, etc. 

The capacity of UPS shall be suitable to feed power requirement of the PLC which shall control 

and monitor all the drives/mechanism of proposed additional coal handling system. 

The UPS system shall include but not necessarily limited to the following equipment: 

• One 100% rated battery bank 

• One set of Float Charger (FC) and one set of Float cum Boost Charger (FCBC) complete 

with associated incoming AC switchgear. 

• Two nos. 100% capacity inverter banks. 

• One no. DC switchgear, cconnecting 

onnecting above and also inverter banks stated above 

• One no. 3 phase to 1 phase transformer and associated AC switchgear, 230V, 1 phase 

voltage stabilizer and backup source static switch. 

• One no. 240 V UPS ACDB 

• One no. four way manual bypass switch 

• Static switches 

• All inter connecting cables/wiring with connection accessories and other required items 

to make the system complete. 

Mode of Operation 

Normal Mode 

During the normal operation the UPS shall be used to provide power to the critical loa loads. The 

primary AC source shall be used to supply power to the rectifier charger. Two (2) no. chargers 

shall feed regulated DC power to their individual inverter banks and simultaneously float 

charge the backup batteries. 

Emergency Mode 


Page 45 of 97

Upon failure of primary AC source supplying three phase power to the battery chargers, the 

input power to the inverters shall be supplied from the back up batteries. When the AC power 

is restored, input power for the inverter and power for recharging the b bbattery 

shall 

automatically be supplied from the rectifier charger. The batteries shall supply the inverter 

whenever the chargers are unable to supply the sudden load demand or their response to the 

load change is slow. 

The output of the UPS shall feed al all l the essential loads through the ACDB. The connection 

from the UPS to ACDB shall be through a switch and fast acting semiconductor fuses, trip fuses 

and micro switch with alarm contacts. The feeders shall be designed by the bidder to suit the 

load requirements. 

Battery Charger 

Two (2) nos. each of 100% capacity, battery chargers shall be provided for each UPS system. 

These chargers shall be of static type and shall be provided with suitable transformer and full 

wave, SCR type rectifiers. Chargers shall share automatically the load during parallel operation 

of the inverter system and shall maintain output voltage within plus or minus one percent of 

the nominal value from no load to full load. 

Suitable ripple filtering circuits shall be provided to give a smooth DC output. The ripple 

content shall be limited to less than +5% on resistive load. 

The rectifier charger shall have float, equalising and boost charging facility as well as furnish 

the inverter input current. In the `Boost' mode, the ‘boost' ch chargers argers shall recharge the 

completely discharged battery to full capacity in eight (8) hours. 

In charger system, all the standard protection, metering and static annunciation shall be 

provided. 

Static Inverters 

The two (2) nos. 100% capacity, (IGBT) rrequired 

equired kVA inverters shall be static type consisting of 

SCR type inverter, static filters, integrated control modules including necessary oscillators, 

voltage regulators, current limiting and surge suppression networks. In addition, the inverters 

shall have ve features of soft start, wave shaping, transient recovery etc. Any other equipment 

required for normal operation of the inverter shall be included irrespective of whether 

specified or not. 

The output from the inverter shall be 240V AC, sine wave 1 phas phase. e. The output of the UPS shall 

be distributed to the essential loads through the AC switchgear. The connection from the UPS 

to the AC switchgear shall be through a switch and a quick acting fuse. The feeders shall be 

designed by the bidder to suit the load requirements. 


Page 46 of 97

Static Transfer Switches 

The static transfer switches shall use SCRs and other static devices, for automatic transfer of 

load from the Normal source to the Alternate source. The continuous capacity of each static 

switch shall be equal to the full load capacity of one inverter. Maximum transfer time including 

sensing shall not be more than 1/4 cycle. The transition shall be "make before break" in both 

directions. The static switch shall be provided with fuses in both `normal' and àlternat àlternate' 

power source. Provision for annunciation of failure of fuse or failure of alternate source shall 

be made. The switch shall be provided with surge suppression networks and shall also be rated 

to withstand transient voltages upto 150% of rated voltage. Th The e short time rating of the switch 

shall be 150% of the rated full load current for two (2) minutes. 

Three phase/single phase Transformer and voltage stabilizer 

The transformer connection shall preferably be of Le Blanc type with delta connected winding 

on the three phase side or of open delta connection type. Other alternatives shall also be 

considered, provided the connection has minimum unbalance on the primary side. The 

transformer shall be encapsulated in Class B insulation. The transformer shall be adequately 

rated for the duty involved. The actual value may be slightly increased to take care of any 

losses in the static voltage stabiliser. 

The voltage stabiliser shall employ silicon solid state circuitry and shall maintain the specified 

output voltage for 0 to 100% load, with maximum input voltage variation as specified specified. 

Manual Bypass 

Switch The manual bypass switch shall be a four (4) position swit switch. ch. It shall be used to isolate a 

static switch from its load and alternate power supply and to take it out of service without 

power interruption to the load. It shall be ‘make before break’ type contacts, so that power 

supply to the loads is continuous du during ring switch operations. It shall be capable of carrying rated 

continuous full load inverter current. 

Fault Diagonistic Unit 

Unit Fault diagonistic unit shall be provided to supervise UPS operation. Facility to take print 

out and recording of important pparameters 

arameters shall be provided. All the alarms shall be interfaced 

with DDCMIS. 

Battery 

DC battery shall be VRLA, sealed maintenance free type. Battery capacity should be 500Amp 

Hr with float charger of 110 Amps. Float cum boost charger should be 110Amps also. Battery 

shall be located in the battery room. Battery shall be suitable to maintain the power supply for 

at least 60 minutes (battery back time) in the event of mains failure. 


Page 47 of 97

Necessary distribution board for distribution of power from UPS output t tto 

individual 

consumers. 

Permissible variations for mains power supply system shall be as follows: 

Voltage 

: + 10 % , -15 % 

Frequency 

: As per IS 

Harmonic distortion 

: < 5% 

Output of the uninterruptable power supply system while delivering a load of its rated 

capacity (P.F of load shall not effect its output) shall have following variations; 

Voltage regulation 

:1% (For 0-100% load) 

Frequency 

: (+/-) 0.5% (For 0-100% load) 

Efficiency 

:Above 80% 

100% to 0% and 0% to 100% load : Volt dip +10% 

Enclosure and ventilation 

Enclosure conforming to IP IP-41 41 class. Units shall be provided with cooling fans and louvers at 

the bottom sides. Individual ventilation ducts for eac each h unit shall be provided. 

Distribution Board 

The DB shall have two buses, main and standby and shall be protected by semiconductor fuses 

with fuse monitoring device, bus healthy lamps, voltmeters and ammeters. Each load shall be 

fed by two independent feeders. Isolating and buscoupling switches shall be provided. 

The enclosure sheet steel thickness shall be 2.0 mm. with cold rolled sheets and 2.5 mm for 

hot rolled sheets and enclosure class protection shall be IP IP-54. 

TECHNICAL PARTICULARS 

1. Application : Uninterruptible Power supply for PLC aand 

nd other essential loads 

2. Capacity : 200 % of PLC load 

3. Degree of protection : IP 54 

4. Cable entry : Bottom 

5. Input Supply Voltage : 415V+/ 415V+/- 10%, 3 phase 4 wire, 50 Hz +/- 5% 

Batteries 

1. Type 

2. Application 

3. Number of cells in each bank in series 

4. Ambient temperature 

5. D.C. nominal system voltage 

6. Ampere hour capacity 

7. Charging method proposed 

8. Emergency load duration 


: VRLA, SMF 

: UPS System 

3. Number of cells in each bank in series : As per requirement 

: Min.temp. :5.0 deg.C Max.temp. :50 deg. C 

5. D.C. nominal system voltage : Suitable to inverter system 

: Bidder to furnish along with cal calculations 

7. Charging method proposed : . Float and boost 

8. Emergency load duration : 60 Minutes (battery back up time) 

Page 48 of 97

9. Continuous load/duration : As per requirement 

Battery chargers 

1. Number required 

: 2 nos. (1 FC + 1 FCBC) 

2. Type 

: Static 

3. Method of charging 

: Float and boost charge type 

4. DC system voltage 

: To suit the system 

5. Automatic voltage regulator required(AVR) : Yes 

6. Regulation with AVR 

: +/-1% 

7. Permissible harmonics at rated continuous load : +/ +/-2% 

8. D.C. load requirement 

a) Momentary : As per requirement 

c) Continuous : As per requirement 

b) Emergency : As per requirement 

9. Maximum time for boost charging : 8 Hours 

Inverters 

1. Type 

: Static 

2. Suitable for parallel oper : suitable for parallel operation 

3. Service 

: Indoor 

4. Output rating 

: As required 

5. Output Voltage 

: 240 V A.C. 

6. Phase 

: Single phase 

7. Frequency 

: 50 Hz 

8. Total harmonic content 

any single harmonic. 

: 5% RMS maximum not more than 3% distort distortion in 

9. Duty 

: Continuous. 

10. Overload capacity 

: 125% for 15 minute at 0.8 p.f 

11. Efficiency 

: Not less than 80% at rated load 

12. Cooling 

: Natural air cooled 

13. Synchronization with source : Yes 

Static transfer switch 

1. Capacity Continuous 

2. Type 

3. Voltage 

4. Frequency 

5. Transfer time 

Manual bypass switch 

1. Capacity Continuous 

2. Type 

3. No. of positions 

4. Short time rating 

5. Transfer 


: Make and carry F.L. current of inverter at 0.8 p.f. 

: Make before break 

: 240V, single phase 

: 50 Hz 

: 1/4 cycle maximum 

: Make and carry F.L. current of inverters at 0.8 p.f. 

: Make before break. 

: 4 

: Short time rating of the inverter for 1Sec & 150% of full load 

current for 2 minutes. 

: Manual. 

Page 49 of 97

4.12 RESISTORS AND RESISTANCE BOXES 

The resistors offered shall be arduous duty, industrial application, shock and vibration proof, 

unbreakable, rigid and rust proof punched chromium steel alloy grid and conforming to the 

requirements stipulated in IPSS 11-10-002-82 

82 "Specification for resistance boxes for power 

circuits" with latest amendments. Cast iron resistors shall not be acceptable. 

The resistors shall be assembled on high quality asbestos or mica insulated high tensile steel 

tie e rods and separated from one another by mica or asbestos washers in required numbers 

and rigidly supported to eliminate vibration, breakage, displacement or deformation. Tappings 

shall be provided with every resistance element indicating resistance value to enable 

adjustments, if required. Individual grids shall be TIG welded at the junctions and terminal taps 

shall be welded to grids, ensuring a consistent current path. 

The grids shall be assembled on heavy steel frames which shall be suitably stacked, housed 

and mounted in minimum 2.5 mm CRCA sheet steel enclosed cubicles with louvers along with 

wire mesh to ensure good ventilation and mounted on a base frame of ISMC 125 . The panel 

of resistor units shall be free standing, floor mounting type and provi provided ded with two numbers of 

grounding pads, tapped holes and bolts suitable for connection of grounding conductor of 

50x6 mm G.I flat. Enclosure shall be in single front execution. 

Individual banks shall be mounted on bracket welded to the frame, as such individual bank can 

be withdrawn out from enclosure without disturbing other banks. All resistor banks shall be 

provided with adequate lifting facility for handling during installation and over hauling. 

The terminals shall be brought out in the separate terminal box (IP-55) 55) on one side and 

marked with metallic tags for external connection with AYFY cables. 

The current carrying capacity of the resistor shall be so selected that the temperature shall not 

exceed 370 deg. C. 

4.13 PLANT ILLUMINATION SYSTEM 

The scope includes complete plant illumination system to achieve required illumination levels 

as per IS or as per CBIP guidelines. The scope shall cover the following illumination systems: 

• Normal AC lighting 

• DC Emergency light lighting. Maintenance lighting 

• Peripheral, road/street and area lighting within battery limit 

Illumination shall be provided in all the following premises: 

1. Switchgear room at WT substation 

2. Battery room at WT substation 

3. Transformer rooms 


Page 50 of 97

4. A/C & ventilation RRoom 

5. Peripheries of buildings 

6. Coal conveyor galleries 

7. Dust suppression MCC room 

8. Junction houses and transfer towers 

9. Wagon Tippler System 

10. Control room of WT 

11. MCC room for WT 

12. Roads/streets within battery limit 

13. Area/sub areas within battery limit 

14. Any other premise coming under the battery limit 

The illumination system shall include the following in required quantities: 

• Lighting DBs/ Sublighting DBs • Steel tubular poles 

• Light fittings with lamps • Switches 

• Lighting fixtures and accessories • Conduits & brackets 

• Cables and wiring • Hangers & clamps 

• Ceiling fans 

• JBs 

• Receptacles • Timers/photocell 

• For street light LED lamps preferable 

• High mast system should have Metal Halide Lamps 

All lighting in outdoor area such as ccWT 

areas, road/street and area lighting as well as 

peripheral lighting shall have auto ON/OFF facility with suitable 24 hrs timer. All the light 

fittings shall be dust and weather proof. 

Illumination levels envisaged for different areas will be as indicate indicated d below: 

S.N. Area 

1 Switchgear room 250 FTL AC normal lighting DC 

emergency lighting 

2. Battery room 100 FTL AC normal lighting DC 


3. Transformer room 200 FTL AC normal lighting 

4. MCC room 250 

lighting 

5. WT Control Room 250 FTL AC normal lighting DC 


6. Junction house 200 MH AC normal lighting 

7. Conveyor gallery 100 MH AC normal lighting 

8. Peripheral lighting 20 MH AC normal lighting 

9. Street / road / area lighting 20 SV AC normal lighting 


Lux Fitting type Remarks 

FTL AC normal lighting DC 

emergency 

Page 51 of 97

Lighting DBs of all the areas shall preferably be located inside the rooms like switchgear cum, 

control room, etc. 

Sufficient numbers of LDBs, SLDBs, lighting poles, 415/240 V switch socket outlets, ceiling fans 

with regulators, earthing pits, MCB controlled socket outlet, junction boxes, etc shall be 

considered under scope of the Bidder as per actual requirement. 

DC emergency lights shall be fed from separate DCELDB. Similarly, power receptacles shall be 

fed from dedicated Receptacles DB. DCELDB at WT SYSTEM substation shall be fed from 

Purchaser’s DCDB. Receptacle DB shall be fed from Bidder’s PDBs/aux. PDBs. 

Sufficient icient numbers of DCELDBs and Receptacles DBs shall be considered by the Bidder as per 

requirement. 

LIGHTING DISTRIBUTION BOARD (LDB) 

415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec.) indoor type. 

Board shall be single front, metal cl clad, ad, front matched, free standing, floor mounted, dust and 

vermin proof, non-draw-out, out, fully compartmentalized and extensible on both sides, IP54 type 

enclosure. Incomers shall be draw out type. LDBs shall have a series of panels of uniform 

height placed side de by side having front access for operation as well as cabling and access for 

maintenance of busbars. LDBs shall have two incomers and one bus coupler. 

Separate busbar compartments provided on the top shall have bolted covers in the front and 

rear. The main busbars shall have continuous current rating as required. The rating of the 

neutral busbar shall be 50 % of the phase busbars. The busbars shall be of aluminum alloy 

conforming to IS 5082. The busbar sizes shall be so selected that with the passage of rated 

current, the temperature rise over 500C ambient does not exceed 400C as measured by 

thermometer. 

Each cubicle shall have segregated feeder compartments arranged in tier formation with each 

compartment housing one feeder circuit with lockable hinge hinged d door having neoprene gasket all 

around. Modular construction shall be adopted to cater for different sizes of feeders. The 

cubicles shall have common horizontal busbar chamber at the top and vertical risers at the 

back. The cable compartment shall be pro provided vided on the side with cable entry arrangement from 

bottom. The busbar and cable compartments shall be provided with bolted cover plates. The 

rear cover shall be easily removable type construction. 

The LDBs shall conform to IS 8623 for factory built asse assemblies, mblies, IS 13947 for general 

requirement of switchgear and IS 5578 & IS 11353 – Guide for making and identification of 

conductors and apparatus terminals. 


Page 52 of 97

The LDBs shall be fabricated from CRCA sheets with 2 mm thickness for all members except 

the doors of the modules, the rear covers, the covers of cable chambers and busbar chambers 

which may be of 1.6 mm with adequate stiffeners to prevent buckling. Non Non-load bearing 

partition walls may be of 1.6 mm thick sheet steel. 

The cubicles shall be made up of bolted sheet steel members and side panels of pressed sheet 

steel with neoprene gasket at all joints and openings including doors. 

Bus bars shall have same cross cross-section section throughout the length. Rating of the neutral bus ba bar 

shall be 50% of the main bus bar. Earth bus bar shall run in bottom chamber throughout the 


The LDBs shall have necessary provision at either end for future extension by bolting 

additional section. 

The busbar shall be supported wi with high quality non-hygroscopic, hygroscopic, insulating, self extinguishing 

and fire retardant insulating material, of adequate mechanical strength so as to withstand, 

without damage, effects of available short short-circuit circuit current. The busbars shall also be properly 

spaced d of facilitate taking vertical connections to individual units. The connections to 

individual units shall be taken by taped busbars. The busbars shall be of uniform cross cross-section 

and the main busbars shall run throughout the length of the board. Similarly vertical droppers 

shall extend for the full height of the panel except the bottom chamber. The connection 

between busbars of different metals as well as their connection with the terminals of the 

equipment shall be made in such a way to prevent corrosion and local heating. 

Liberal space shall be provided for cabling and to accommodate any conventional type of cable 

glands for PVC insulated and PVC sheathed armoured aluminum conductor cables. 

The cables compartment shall have provision for clamping of ccables 

ables inside compartment on 

perforated sheet steel sections. 

The LDB shall have following meters in each of the two incoming feeders: 

• One no. digital type voltmeter with accuracy class of 1.0 

• One no. digital type ammeter with accuracy class of 1.0 

• One no. digital energy meters with accuracy class of 1.0 

Suitable CTs with accuracy class of 1.0 shall be provided in the incomer modules for the above 

metering. 

Moulded Case Circuit Breakers 

LDBs shall have moulded case circuit breaker triple pole, air break type with independent 


0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system and 

shall be current limiting type. All outgoin outgoing g feeders shall have earth fault protection. 


Page 53 of 97

The MCCBs shall be suitable for panel mounting and shall be fixed type. All live parts shall be 

enclosed in moulded case and all contacts shall be silver plated. The breakers shall be trip trip-free 

and with quick make & break operating mechanism. The MCCBs sha shall be provided with 

ambient temperature compensated bi bi-metal metal overload releases and a magnetic short short-circuit 

release with inverse time characteristic. Releases shall be either static or microprocessor 

based. 

The operating handle shall be included with mod module ule door such that the door can be opened 

only with the breaker in the “OFF” position. The MCCB handle after the breaker tripped due to 

a fault shall occupy an intermediate position. The breaker shall be capable of interrupting a full 

fault current corresponding onding to the fault level specified. 

MCCBs shall have a breaking capacity of 50kA at 415V. Current limiting MCCBs are not 

permitted. 

The LDB shall be consisting of following feeders: 

Incomer : 2 Nos. each of 600 A MCCB with over current and earth pprotection. 

Bus coupler : 1 No. of 600 A MCCB 

Outgoing : 125 A MCCB 

63 A MCCB – 10 Nos. 

SUB LIGHTING DISTRIBUTION BOARD (SLDB) 

415V, 3 phase, 4 wire, 125/63A (as applicable), indoor/outdoor type (as applicable) generally 

conforming to IS 13947 and IS 8623 as applicable. 

The SLDB shall comprise of one number of incoming TPN MCCB, three nos. of DP MCBs, and 

requisite number of outgoing SPN MCBs (as specified) and adequately rated bus bars. The 

SLDBs shall also have timer, contactors, A/M switch, etc as per requirement. The enclosure 

class of SLDB shall be IP 54. The terminals of MCCB shall be fully shrouded. The boards shall be 

of industrial, totally enclosed dust dust-proof, proof, wall mounted, sheet steel cubicle design. The 

thickness of the sheet steel shall be 2 mm. The boards shall have welded back and sides and 

gasketted hinged door at the front with door handle and suitable locking devices. For boards 

with incoming isolating switch the access to the operating handle shall be from the front of the 

cubicle without opening the front door. Operating knobs of outgoing MCBs shall be accessible 

only after opening the front door of the cubicle. Protective insulated cover plate shall be 

provided inside the cubicle to shroud all the live parts with only the operatin operating knobs of the 

MCBs protruding outside the cover plate. The boards shall also be dust dust-proof in door-open 

position. Adequate space shall be provided within the boards to facilitate termination of 

incoming and outgoing cables. The boards shall be factory wir wired ed and assembled. Where 

specifically called for, the boards shall be of special weather weather-proof proof design suitable for outdoor 

installation. 


Page 54 of 97

The miniature circuit-breakers breakers (MCBs) shall be heat resistant plastic moulded type generally 

designed, manufactured an and d tested as per IS 8828. Unless specified otherwise all MCBs shall 

be provided with quick break trip free mechanism and direct acting thermal overload and 

short-circuit circuit trip elements. The short short-circuit circuit breaking capacity of the MCBs shall not less than 9 

kA at 0.8 power factor. Single Single-phase phase MCBs which are not provided with built built-in phase barriers, 

and mounted adjacent to each other and connected to different phases, shall be provided 

with adequate insulated phase barriers, shall be selected from standard cur current rating. 

The TPN busbars shall have continuous current rating as required. The busbars shall be of 

copper and sizes shall be so selected that with the passage of rated current, the temperature 

rise over 500C ambient does not exceed 400C as measured by thermometer. The minimum 

size of busbars shall be 25 x 3 mm. The busbars shall be properly supported with high quality 

non-hygroscopic, hygroscopic, self extinguishing and fire retardant insulating material of adequate 

mechanical strength so as to withstand, without ddamage, 

amage, effects of available short circuit 

current. The busbars shall also be properly spaced to facilities mounting of MCBs and taking 

connections to individual units. 

Detachable cover plate shall be provided at top and bottom for cable glands suitable f ffor 

PVC 

insulated, PVC sheathed armoured aluminum conductor cables or for direct entry of conduit. 

Cable terminals shall be suitable for aluminum conductor cables and so arranged to enable 

connecting of each circuit without disturbing any other circuits. 

Identification labels, inscription plates, danger boards, etc shall also be provided as per 

requirement. Earthing arrangement and danger plates shall be as specified. 

SLDBs shall have automatic group switching arrangement for which timer of robust 

construction uction and suitable contactors shall be provided in each board. Bypass arrangement of 

timer in form of auto/manual switch shall also be provided in the SLDBs. The controller shall 

sense the outdoor light and shall switch “ON” through auxiliaries contacts w wwhen 

the sunlight 

falls bellow a present value. It shall remain in this position till dawn when it shall switch “OFF” 

when the sunlight remains a preset level. 

Suitably engraved identification labels and inscription plates shall be provided for each circu circuit. 

The same shall also be provided for the boards. 

One continuous G.I earth bus shall be provided in the bottom part of SLDB along the full length 

of the board with two bolted type earthing terminals to comply with the requirements of 

Indian Electricity Rules. Proper danger plates shall also be provided on each board. 

Each SLDB shall be provided with padlocking facility with sufficient number of keys. The 

following types of SLDBs shall be provided: 

SLDB, Type A (To be used for 2x40 W FTL light fittin fittings) 

Incomer : MCCB, 4 POLE, 63 A : 1 No. 


Page 55 of 97

Outgoing : MCB, DP (63 A) : 3 Nos. 

Outgoing : MCB, SPN (10 A) : 10 Nos./Phase (Total 30 Nos.) 

SLDB, Type B (To be used for 250 W HPSV/MH light fittings inside the building) 



Outgoing : MCB, SPN (16 A) : 6 Nos. per phase (Total 18 Nos.) 

SLDB, Type C (To be used for 250W/150W/70 W HPSV/MH light fittings outside building) 

Incomer : MCCB, 4 POLE, 63 A : 1 No No. 


Outgoing : MCB, SPN (20 A) : 5 Nos. per phase (Total 15 Nos.) 

SLDB, Type D (To be used for 250 W HPSV/MH street light fittings) 


Outgoing : MCB, TPN (63 A) : 8 Nos. 

Sufficient number of SLDBs of different types (A, B, C and D) shall be used as per requirement 

of different areas and sub sub-areas areas of the coal handling plant. Exact quantity of SLDBs of various 

types shall be finalized during detailed engineering. Bidder sha shall ll consider as per requirement 

subject to minimum one number of each type of SLDB. 

RECEPTACLE DISTRIBUTION BOARD 

Receptacles DB shall be suitable for 415V, 3 phase, 4 wire, 125 A, indoor type. 

Board shall be single front, metal clad, front matched, ddust 

ust and vermin proof, draw draw-out, fully 

compartmentalised and extensible on both sides, IP54 type enclosure. 

Shall have isolated busbar chamber for main busbar at the top, running through out the length 

of the board. Chamber shall have removable cover. 

Busbars usbars shall have same cross section through out the length . Rating of the neutral busbar 

shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the 


Shall have Moulded case circuit breaker (MCCB) tripl triple e pole, air break type with independent 


0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system. 

Generally all boards will have ffollowing 

feeder arrangement. 

Incomer : MCCB TPN of 125A : 1 Nos. 


Page 56 of 97

Outgoings : MCCB TPN of 32 A : 10 Nos. 

220V DC Emergency LDB (DCELDB) 

The DCELDB used for emergency lighting distribution shall be industrial heavy duty type 

suitable for 2-wire 220V DC operation, and shall have a DC double pole power contractor and 

requisite number of auxiliary contractors and timers and outgoing feeders protected with DP 

MCBs of suitable ratings. 

The incomer shall be of double pole load break design suitable ffor 

or operating on 220V DC. The 

enclosure shall be made of 2 mm thick sheet steel and shall have requisite number of cable 

glands and terminal strips for incoming and outgoing cables. The control circuit voltage shall 

be of 220V DC. 

The DCELDBs which feed aall 

ll the emergency lighting points shall be automatically switched on 

the event of power failure through a separate circuit which sense under voltage of normal AC 

supply at the specified location. These emergency lighting fittings shall glow for a preset tim time 

and shall be switched OFF automatically through a time relay in case the normal AC power 

supply is not restored within that time. 

Feeder configuration of DCELDB shall be as follows: 

Incomer : MCCB, DP (63 A) – 1 No. 

Outgoing : MCB, DP (10 A) – 16 Nos. 

Supply of battery, battery charger(FC & FCBC, DCDB for 220V DC system shall be in bidder’s 

scope. 

415 V switch outlets 

Switch socket outlets and plugs for 415 V, 33-phase 

phase circuits shall be of four four-pin (three pole and 

one earth), non-reversible reversible typ type enclosed in dust-proof proof 2 mm thick sheet steel enclosures. The 

socket outlets shall be provided with fuses and shall have isolating switch interlocking as per 

IS:4160 such that it can be switched ‘ON’ only when the plug has been inserted and plug can 

be provided rovided for the socket outlets. The isolating switches shall be of category AC 23 

conforming to IS 13947 (Part 3). The socket outlet shall be suitable for terminating aluminum 

conductor cables either directly or through GI pipe and shall be provided with c ccompression 

type lugs. The socket outlet shall be supplied with metal clad plug. The socket outlets and 

plugs shall have porcelain base and shall be of 32A rating. 

Weather-proof proof enclosure shall be used for outdoor installation. Inscription plate shall be 

provided indicating the voltage rating for the switch outlet. 

240 V switch socket outlets 

Socket outlet for 240 V supply shall be of 33-pin 

(two-pole pole and one earth) nonreversible, metal- 

clad, dust-proof, proof, industrial type suitable for horizontal insertion generally as per IS 1293. 240 V 


Page 57 of 97

socket outlets shall be controlled by rotary type switch mounted flush in the socket outlet box. 

Operating handle of the rotary switch shall be fixed in such a manner that it will not be 

possible either to insert or to with withdraw draw the plug without switching off the supply. All socket 

outlets shall be supplied with heavy duty type plug and cap with chain. The isolating switches 

shall be of industrial type of category AC 23. The isolator shall be housed in dust and vermin- 

proof sheet heet steel enclosure suitable for terminating aluminum conductor cables either directly 

by means of cable gland or through conduits. The current rating for the socket outlets shall be 

20 A. Wherever called for HRC fuses shall be incorporated in the socket outlet box. 

Inscription plate shall be provided indicating the voltage rating and feeder identifications for 

the switch socket outlet. 

MCB Controlled Socket Outlet 

The MCB controlled socket outlet shall be similar to the above switch socket outlet and 

provided with industrial type socket outlet with cover suitable for 240V, 20A single phase AC 

and controlled through single pole 20A MCB. 

Ceiling Fans and Regulators 

Ceiling fans regulators shall be designed, manufactured and tested as per IS:374. The fans shall 

have totally enclosed, capacitor start and run motors, suitable for operation on 240V, single 

phase, 50 Hz AC system. The electronic type regulator shall have ‘ON’ – ‘OFF’ position next to 

the lowest speed contact, shall be provided with necessary harmonic filters and shall be 

suitable for operation at 500C ambient temperature. 

Down rods required for installation of ceiling fans shall be included by the Bidde Bidder. 

Lighting Poles 

Steel tubular road lighting poles with single outreach shall be of swaged and welded 

construction conforming to IS:2713 IS:2713-1969 with latest amendments. 

The outer surface of pole above foundation shall be painted with two coats of red o ooxide 

zinc 

chromate primer paint as per IS:2713 and finished with two coats of synthetic enamel paint of 

approved shall not be less than 100 microns. 

The outer surface of the pole embedded in concrete foundation as well as the entire inner 

surface shall be e painted with two coats tar based general type black paint. 

The poles shall be provided complete with fixing arrangement for loop loop-in in and loop out box and 

lighting fittings. The Bidder shall submit a drawing indicating the general arrangement and the 

final l design and arrangement shall be subject to purchaser’s approval. 

The 415 loop-in loop-out out box shall be weather weather-proof, proof, dust tight, sheet steel enclosure suitable 

for outdoor installation. The box shall have hinged front with front locking device. 3 Nos. open 


Page 58 of 97

type terminals for taking looping connection of 4C x 16 sq.mm Al conductors. Conductor 

power cables and 2C x 2.5 sq.mm PVC copper wiring cable through rewirable fuse cutout to 

the control gear. The box shall be supplied complete with 63A terminal blo block, 5A rewirable 

fuses cutouts, brass / aluminum alloy cable gland, clamps, lugs, earthing terminals, danger 

plates and other required hardwares. 

Street lighting pole shall have a single outreach suitable to hold the street lighting fitting. 

Flood lighting ng pole shall have a cross bar on top of the pole and shall be suitable for fixing the 

flood light fitting. 

Earthing provision of lighting poles 

2 Nos. 8 SWG GI wire shall run throughout along with street light poles in loop in loop out 

arrangement. One number of earth pit shall be provided for every 5 nos. of lighting poles. Each 

earth pit shall be consisting of 40 NB GI pipe of 3 mtr length, funn funnel, el, salt, charcoal, cast iron 

cover, clamps, etc. 

Junction Box 

The 415/240V, TPN junction boxes shall be of fabricated from 2mm thick sheet steel suitable 

for mounting on wall / column. The box shall have suitable provision for entry and termination 

of aluminum conductor, PVC insulated cable supplied complete with terminal blocks, earthing 

terminal, wire support etc. The box shall be painted with anti anti-corrosive corrosive primer both inside and 

outside and furnish with two coats of approved colour paint. The junct junction boxes used 

outdoors shall be with suitable canopy arrangement. The junction boxes shall be suitable for 

terminating one (1) incoming cable and two outgoing cables. 

Lighting Fittings 

High Mast light fittings shall be with Metal Halide (MH) lamps).Al lamps).All other 

LED lamps. 

All lighting fittings and accessories shall be manufactured from best quality materials and shall 

be completed in all respect ready for installation at site. 

Unless otherwise stated lighting fittings shall have provision for 25 mm / 19 mm dia conduit 

(as applicable) entry for low low-bay bay fittings. Medium bay fittings shall have eyebolt suspension 

arrangement. 

Terminals off all fittings shall be suitable for connecting 2.5 sq mm flexible, copper conductor, 

PVC insulated ted and PVC sheathed cable for low low-bay bay fittings and 2.5 sq mm flexible copper 

conductor cable for high bay fittings. 

All the LED fittings and MH fittings shall be non non-integral integral type. Control gear boxes shall be 

mounted at man height for ease of maintenanc maintenance. 


fittings shall be with 

Page 59 of 97

High mast fittings (Non-integral integral type) : 2 nos 

Non-integral integral type asymmetrical beam flood light fittings with 2x400W MH lamps complete 

with control gear, accessories, etc suitable for installation on 30 M high lighting mast as per 

technical specification ion (Bajaj BGENF 22 or equivalent with MH lamps) shall be mounted on the 

lantern carriage of each of the high lighting mast. 

Lamps 

All lamps shall be of high lumen output and with long life. 

Incandescent Lamp 

All general service incandescent lamps shall be gas filled, clear finished and coiled coil type 

where possible. Incandescent lamp cap shall be of screwed type having GES/ES thread 

depending on the sizes of the lamp. 

Fluorescent Lamp 

All fluorescent lamps mps shall be of day day-light light type unless otherwise specified and shall be suitable 

for suitable for switch-start start with bi bi-pin type cap. 

Sodium vapour lamps shall be suitable for universal burning position. The elliptical outer bulb 

shall be coated inside the diffusing powder and shall have good colour appearance. The 

sodium vapour lamp shall be of screwed type E40/E27 base depending upon the wattage of 

the lamp. 

Ballast 

The ballast shall be of electronic type and well tried out design to give trouble trouble-free operations 

with long service life having provisions for suitable tappings in steps. 

Capacitor 

Capacitor shall consist of element wound from layers of higher purity aluminum foil and 

capacitor paper contained in aluminum cylindrical can. The capacitor sh shall be vacuum dried 

and impregnated. The can shall be hermetically sealed and terminals provided over porcelain 

insulations. The capacitor shall conform to IS 1569. 

Lamp Holder 

The lamp holders shall have spring loaded contacts for positive contact wit with pins so as to 

prevent the lamp from being extinguished due to vibration. The holder shall be such that the 

lamps can be removed easily whenever required for cleaning or replacement purposes. 

For fluorescent lamp, bi-pin pin lamp holder shall be provided. TThe 

he holder of incandescent lamps 

upto 200 W shall be of ES type. 


Page 60 of 97

The starter holders shall be of well tried tried-out out design and of robust construction with provisions 

for easy insertion and removal of the starter ensuring correct contacts by means of strong 

spring action. 

Push button for group switching of lights 

The push h buttons (one no. ON and one no. OFF) shall be mounted on cast iron box with 

2NO+2NC contacts and terminal block. 

Conduits and Conduit Fittings 

Surface conduit installation shall be carried out using hot dip / electro galvanised rigid steel 

seamed by welding, screwed type, designed, manufactured and tested in accordance with IS 

9537. The various conduit accessories like couplers, bends, elbows, reducers, saddles, clamps, 

lock nuts, junction boxes etc. shall conform to IS 3837 shall be supplied and erec erected as per 

requirement along with the conduits. 

Point wiring materials and Accessories 

The point wiring materials and accessories for lighting for installation, fan points, sockets etc. 

where specified shall include wiring cables, conduits and conduit fittings, wiring accessories 

inclusive of switches, sockets, fan regulators, switch boxes, junction boxes etc. 

Point wiring 

The wiring cables used in point wiring installation shall be 1100 volts grade PVC insulated 

single core flexible stranded copper conductor type confirming to IS:694. The size of 

conductors to be adopted shall be 2.5 sq.mm for lighting, fan and 5/15A socket outlet circuit 

and 2.5 sq.mm for 15A socket power circuits. 

Wiring Accessories 

The various electrical wiring accessories vi viz. z. Switch boxes, switches and sockets shall confrom 

to IS 5133, IS 3854 and IS respectively. The switch boxes shall preferably be of passed sheet 

steel cadmium coated and passivated or galvanised with knockouts at the top and the bottom 

for conduit entry. The surface mounted type boxes shall have necessary provisions for 

mounting on the wall. Earthing terminals shall be provided in the box. Junction boxes provided 

at intermediate points shall also be identical in construction to the switch boxes. The switch 

and junction boxes shall be of standard dimensions with adequate wiring space. The switches 

and sockets shall be made of superior quality engineering plastic with excellent dielectric 

properties. The switches shall be of piano key design and shall have ad adequately equately rated switch 

contacts. The switch contacts shall be silver tipped electrolytic grade copper. The switch plate 

forming part of the switch box cover shall be made of plastic material and shall be made with 


Page 61 of 97

number of slots in which the switches and ssockets 

ockets shall be assembled. The sockets shall be of 

three pin design with phase neutral and earth conducts. 

Earthing 

All electrical equipment shall be effectively earthed as to meet the requirements to Indian 

Electricity Rules and IS:3043 IS:3043. . Earthing conductors for individual equipment shall be of either 

galvanised mild steel flat or stranded/solid G.I. wire as specified. 

Earth pits for street/area lighting poles 

The earth pits shall be consisting of 40 NB GI pipe of 3 mtr length, funnel funnel, salt, charcoal, cast 

iron cover, clamps, etc. The Bidder shall include all civil work as per requirement. All 

accessories shall be included as per requirement. 

4.14 LIGHTING HIGH MAST WITH FLOOD LIGHT FITTINGS 

General 

a. High mast tower for floor ligh lighting ting shall be factory fabricated mild steel plates welded, 

polygon section, hot dip galvanized and provided in standard lengths. 

b. The structure shall be 30 meter high, well tried, proven design to withstand high wind 

speed of 180KM/ hr. 

c. The mast shall have ave a movable lantern carriage tower from the top of tower to bottom and 

vice-verse verse with the help of a motorised winch arrangement (with motor of minimum 2.2 

kW capacity) and shall be provided with suitable gears, pulleys and ropes. The reeling of 

ropes shall all be such that to prevent twisting & tangling. Means shall be provided for normal 

operation of the winch in case of failure/ non availability of power to the motors. Safety of 

lantern carriage in case of breakage of the rope shall be ensured by arresting free fall of the 

lantern carriage to the ground by providing Safety locking arrangements. 

d. All the carriage components shall be galvanised and mounted inside the tower. The tower 

shall be provided with a suitable man entry door at the bottom section to facilitate 

inspection and maintenance. The door shall be weather proof and provided with safet safety lock 

to prevent unauthorised access. 

e. The lantern carriage shall be symmetrical, robust construction housing the luminaire and 

control gear boxes. The cables to the luminaries shall be run inside the tubes of the lantern 

with junction boxes provided for branch off cables. 

f. Proper luminaries carriage ring support arms shall be provided for supporting the 

luminaries’ carriage ring when the latter is lowered for maintenance of luminaries. Lantern 

carriage ring should be in channel tube and with concealed wwiring 

iring the carriage should be 


Page 62 of 97

essentially have a 3 points suspensions system. The mobile luminaries carriage shall be 

evenly balanced Rubber Paddle Guide Ring shall be incorporated as a buffer arrangement 

between mobile luminaries carriage and mast shaft. TThis 

his is to prevent damage to mast 

surface during raising and lowering operation of mobile luminaries carriage. 

g. The winch shall be provided with a separate control panel housing the control for the winch 

drive motor and controls for switching the luminarie luminaries. s. It shall be complete with switch fuse 

units/MCCBs, starters, contactors, etc that may be necessary to the operation of the light 

tower. It shall be suitable for outdoor installation with IP IP-65 65 degree of protection. It shall 

be suitable for mounting on a suitable plinth adjacent to the high mast tower. 

h. The winch must be of robust design and completely self self-sustaining sustaining type without the need 

for brake -shoe, shoe, springs or clutches. It can be removed from the mast for maintenance if 

the need arises in the futu future re with the lower carriage on the top. The reduction gear of the 

winch shall be of endless worm gear, operating in oil bath. The minimum safe working limit 

of the winch shall not be less than 750 Kg. 

i. A minimum 6 turns of wire rope shall be on the drum whe when n the mobile luminaries ring is 

fully lowered to rest on the luminaries supporting arms. 

j. The winch is entirely self self- sustaining under all normal circumstances and it is not 

dependent on the brake or restraining device that uncontrolled or dangerous runaw runaway 

speed shall occur in the event of the total failure of this device. Slip test on winch is carried 

out by the manufacturer. Test certificate and report shall be submitted up, on request. 

k. The speed of the raising and lowering of lantern carriage ring sh shall all be at least 1.5 meter Per 

minute. 

l. The high mast shall be fitted with flexible standard G.I / S.S. hoisting wire ropes of 7 x 19 

construction with a minimum breaking strength of 1900 kgs. The combine lifting capacity of 

the hoisting wire ropes shall hhave 

ave a factor of safety not less than 5 times the safe working 

load (SWL) of the winch and shall be entirely suitable for the design application. 

m. A transition plate shall be incorporated to balance the carriage from below of the mast. 

n. Cable for lighting and winch control shall be as per approved scheme. The cables shall be 

clamped or rolled so that no twisting of cables happens while the winch is hoisted or 

lowered. Electrical cable shall be PVC coated round flexible cable suitable for small bending 

radius. One standard multi core flexible electrical cable with 4 sq mm conducting areas 

shall be provided for connecting of power supply to the light source and shall terminate at 

the stationary connecting board in the base compartments. 

o. The high mast shall be suitable for asymmetrical loading of with 16 nos. of 2 x 400 W MH 

luminaries mounted on the lantern carriage. The luminaries shall be grouped in individual 

240V RYB circuits fed through time switches. It shall be possible to switch t tthe 

lamp 

bypassing the timer. The timer shall be programmable digital/analogue quartz controlled, 


Page 63 of 97

high accuracy real time clock. It shall be set from 6 PM to 6 AM or any other intermediate 

time. The tendered shall indicate the controls offered by him clearl clearly y in the offer. 

p. The successful Bidder shall submit design and preliminary data for the design of foundation 

of the high mast tower indicating the requirements of embedded inserts etc. The 

foundation shall be designed and provided by the purchaser. Bidder to include foundation 

bolts etc which shall be embedded in the foundation. Grouting of the bolts shall be done by 

the Bidder. 

q. The high mast shall be provided with lightning protection with air air- termination and down- 

comers as per requirements of BIS and aviation warning lamps as per statutory and civil 

aviation requirements. All metallic portions of the high mast shall be effectively earthed 

and provided with two earth pits near the base. Effective earthing for luminaries shall be 

provided during normal ooperation 

and in lowered position. 

r. Mast structure is designed to withstand wind velocity conforming to IS 875 (Part (Part-III)-1987. 

Mast Design Criteria 

The high mast and the lowering system with the required number of floodlights and lamp 

controls gears etc. tc. In place shall be capable of withstanding a sustained basic wind speed of 

180 Km/ hrs. 

The design shall be in such a manner that it is capable of withstanding external forces exerted 

by wind pressure and should have a minimum wind load factor of 1.25 and material factor of 

1.15. Design life of mast shall be 25 years. 

CONSTRUCTIONAL FEATURES OF MAST 

The mast shaft shall be made with the best steel grade, in compliance with MS IS IS- 2062/BSEN 

10025 having adequate characteristics w.r.t. minimum yield strength, tensile strength and 

minimum elongation for thickness. 

The steel grade for accessories shall also be MS IS 2062 or equivalent, having adequate 

characteristics w.r.t. minimum yield strength, tensile strength and minimum elongation for 

thickness. 

Each mast section to be delivered to site shall have a minimum length of 10.7 Mtrs. The Mast 

sections shall have Single longitudinal weld from Bottom to Top. 

The base shall have a flange plate for high mast onto the concrete foundation by anchor bolts. 

The mast shall be fabricated and welded longitudinally to form a tapered section with 

telescopic friction on slip joints. All welding shall be to IS 816 / 82 having the following basic 

requirements. 


Page 64 of 97

The wall thickness of each section shall be designed to withstand the loads to which the high 

mast shall be subjected to, but shall not be less than 8 mm for base section and 6 mm for 

other sections and minimum base dia shall not be less than 530 mm. 

Connection between the various sections, shall be achieved by telescopic slip joints, the 

overlapping length being at least 1600mm slip joint assembly shall be perform at site. Shaft 

section shall not be joined by circumferential weld or bolting at site. 

The base plate shall be free from lamin lamination ation and shall be single flange constructed with holes 

jig drilled for anchor bolts passage. The bottom of the base mast section shall be securely 

welded to the base plate by complete penetration fillet welding. The welded connection of the 

base plate to the mast section shall fully develop the strength of the section. 

The base section shall be equipped with a hinged service door. The service door opening shall 

be complete with a close fitting weatherproof and equipped with a vandal resistant lock. The 

service ervice door shall not be smaller than 1400 mm x 300 mm the opening shall be reinforced by a 

thick steel door frame. 

Base plate of suitable dimensions and thickness, diameter, size and the placement of anchor 

bolts shall be determined by calculations. An Anchor chor bolts shall be of deformed steel 

reinforcement bars having the adequate characteristics w.r.t. tensile strength. 

Welding of two or more anchor rods of shorter lengths to achieve the design length shall not 

be permitted. No welding shall be allowed oon 

the anchor rod body. 

Adequate earthing and earthing terminal shall be provided within the access door area of each 

Mast. All high mast shall be hot dip galvanized, in accordance with IS 2629 / TR 7 Timer control 

panel shall be provided with overload and single phase preventor. Timer control panel shall 

be outdoor type. 

Motor capacity of the winch 

Motor shall be of hoist duty and of adequate capacity with 15 % minimum margin over 

mechanical power requirement. Minimum capacity of 2.2 kW shall be consi considered. 

4.15 EARTHING AND LIGHTNING PROTECTION 

EARTHING PROTECTION 

Bidder shall include complete earthing of WT substation, MCC rooms, Wagon tippler, 

apron feeder & conveyor drives etc. The underground earthing mats also 

shall be done by the Bidder. Risers shall be available at all the premises for 

interconnection of own earthing network. However, Bidder shall pprovide 

rovide complete separate 

earthing for transformer neutrals. 

Bidder shall include the following in each and every substation: 


Page 65 of 97

1. Earthing ring mains at WT substation and all the electrical rooms/premises 

2. Equipment earthing 

3. Transformer neutral earthing prov providing dedicated pits 

Bidder shall include complete earthing material including earthing strips, earth electrodes 

other accessories for treated earth pits, etc. and carry out earthing ring mains, earth pits, 

interconnections, equipment earthing, all assoc associated iated civil works, etc at all the ubstations. 

All the connections of earthing ring mains with available underground earthing grid of 

respective substation/premise shall be under scope of the Bidder. 

Separate dedicated treated earth pits shall be provid provided ed for transformer neutrals. Two nos. 

such earth pits shall be provided for each of the transformers. The treated earth pits shall be 

consisting of 3 mtr 65 NB GI pipes, funnels, clamps, 3 mtr long 40 mm MS rod electrodes, MS 

cover with lifting lugs, assoc associated civil works, etc. 

All the equipment located in the WT premises / sub sub-premises e.g. 33 KV switchboard, LT PCCs, 

busducts, transformer bodies, charger panels, DCDBs, LDBs, SLDBs, receptacles, control panels, 

MCCs, etc shall be connected by the Bidder with earthing ring mains at least two different 

points. 

Electronic earthing shall be considerd for PLC, etc 

Bidder shall also consider earthing of following equipment to be installed by the bidder. 

• 33kV kV WT switchboard at WT substation in switchgear cum MCC room 

• WT distribution transformers (2 nos.) – Neutral as well as body earthing 

• 415 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room 

• Control panel for power distribution equipment at existing WT control room 

• LT busducts (2 sets) 

• Charger panels, DCDB, etc at WT substation in switchgear cum MCC room 

Bidder shall consider earthing ring mains at each electrical premise and connect the electrical 

equipment with the rings. The earthing rring 

ing mains shall be connected with underground 

earthing mats (consisting of 2x40MM dia to be installed by the bidder. . For transformer neutral 

earthing, bidder shall consider dedicated plate earthing. 

Bidder shall include complete earthing material includin including g earth electrodes, risers, GI earthing 

strips, other accessories, etc. and carry out main earth grid mat, earthing ring mains, earth 

pits, risers, interconnections, equipment earthing, all associated civil works, etc within battery 

limit of the package. All ll the interconnections with other earthing systems of the plant and 

with existing systems shall be under scope of the Bidder. 

The Bidder shall obtain the actual soil resistivity of the plant area by carrying out soil resistivity 

tests and design the earthing thing system accordingly. 


Page 66 of 97

While designing the earthing system, Bidder shall note the following fault levels at 415 V bus 

shall be 50 kA. Plant earthing system shall be designed such that overall earthing resistance is 

less than 1(One) Ohm without interco interconnections. 

The materials shall be galvanized steel laid over the ground and mild steel buried inside the 

ground/concrete. 

Fault clearing time for sizing of earth conductors and for calculations of the maximum 

allowable step and touch potential shall be taken 1 sec. Maximum allowable temperature rise 

for steel bolted joints shall be taken as 3100C taking ambient temperature of 50 o C. 

The earthing system shall be generally designed on the basis of the following codes & 

standards: 

• IS 3043 Code of practices for safety and standards 

• IEEE 80 Guide for safety in AC substation grounding 

• Indian Electricity Rules 

Entire system shall be earthed so that the values of the step and contact potentials in case of 

faults are kept within safe permissible limit limits. 

Parts of all electrical equipment and machinery not intended to be alive shall have two 

separate and distinct earth connections each to conform to the stipulation of the Indian 

Electricity Rules. 

In case of HT system, E/F current will be made to flow through copper screen tape provided 

over inner sheathing. Screen will be connected to earth bus at both ends. In case of LT the TN TN- 

S system will be followed, i.e. neutral bus of the switchgear shall be connected to switchgear 

earth bus and then to DBs sha shall be through armouring of cable. 

Bidder shall submit the layout drawings of earthing network with supported calculations for 

approval of purchares/consultant. Taking approval of Electrical inspector/CEA and providing all 

inputs to them like data/drawing 

data/drawings are under scope of the Bidder. 

The materials shall be galvanized steel laid over the ground and mild steel buried inside the 

ground/concrete. 

Earthing of SLDBs, power receptacles, etc shall be connected with respective source LDBs 

through armouring of f cables. 

Earthing conductors run on walls/floors/cable and equipment structures etc. shall be 

supported at suitable intervals and painted with black oxide paint. 

The armour of cables and all conduits for cables shall also be connected to the earthing m mmains. 

A continuous earth strip shall run in each side of cable channel and in cable ducts/tray route. 

All joints in the branch connections except at earthing electrode shall be welded and painted 

black. At road/rail crossings earthing strips/rods shall be laid through conduits/concrete ducts. 


Page 67 of 97

The armour of cables and all conduits for cables shall also be connected to the earthing mains. 

A continuous earth strip shall run in each side of cable trenches. 

All joints in the run of the main earthing conductors will be welded or brazed type. Connection 

to equipment structure shall be bolted type. All welded jjoints 

oints shall be protected from 

corrosion by applying bitumen paint. 

Earthing system shall be distinct and separate from the lightning equipment earthing system. 

Earthing Conductors and Installation Accessories for Equipment Earthing System 

All electrical equipment installed by the successful Bidder as well as equipment installed by 

Purchaser shall be effectively earthed in conformity with relevant clauses of Indian Electricity 

Rules (1956) and in accordance with IS: 3043 to the complete sati satisfaction sfaction of the Chief 

Electrical Inspector to Government of Orissa State. All non non-current current carrying metallic conduit 

parts of various electrical equipment as well as cable armouring, metallic conduits, GI pipe, 

cable racks, trays, brackets, supporting struc structures tures etc. shall be effectively earthed. 

Main earth mat comprising 40 mm dia MS rods and earth electrodes and riser upto + 1.0 M 

level shall be supplied and installed by the ownr. All other equipment to complete the earthing 

of equipment installed by the Bidder shall be in the scope of the Bidder. The Bidder shall also 

connect his sub earth mat to the main earth mat provided by the Bidder. 

Conductor size adopted for earthing ring shall in no case be less than that of the earth 

continuity conductors conn connected ected to it. The size of conductors used for overground sub earth 

mat in switchgear rooms/ control rooms/ plant buildings/ areas shall be 65 mm x 8 mm 

galvanized mild steel strips. 50 mmx 6mm galvanized MS strips will be used for earth buses 

inside the buildings/ ldings/ floors/ platforms etc. and also for earth conductors laid along cable trays. 

For buildings having a number of floors, separate earthing ring shall be established in each 

floor and shall in turn be connected to the Purchaser’s earth mat. 

Separate earthing system shall in no case have cross cross-sectional sectional area less than 6 sq mm stranded 

GI wire. 

Size of earth conductors selected for system earthing and earthing of various equipments shall 

be as follows. 

Galvanized Iron flat conductor strips shall be used for neutral earthing. The minimum size of 

conductors for neutral earthing of various transformers shall be as given below unless a higher 

size is required from the viewpoint of higher available fault current. 

LV neutral of 33/0.440 kV, 1600 KVA tran transformers : 75mm x 10mm 

The minimum size of galvanized Iron flats for earthing of various equipment shall be as 

follows: 


Page 68 of 97

Ring mains 

LT PCCs/board 

Control Panels 

LT Busducts 

DC Distribution Board 

LDB 

SLDB 

Push button station 

Transformer bodies 

Cable tray (running earthing) 

LIGHTNING PROTECTION 

All buildings and d plant structures including switchgear building and junction houses shall be 

protected against atmospheric flash over and lightning strokes in such a manner as to 

eliminate any danger to the personnel employed therein. Stipulations of IS : 2309 - 1969 shall 

be followed. 

A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and steel 

structures crossing this cage ring shall be laid around plant as earthing device. This shall be 

separate from the electrical equipment earthing ri ring main. 

Design shall be as per the standard like IS 2309 (latest revision) and Indian Electricity Rules. 

All lightning arrestor earth leads of the plant shall be connected to this cage ring. 

Air termination network should cover all salient points of the structure. All metallic structures, 

ducts and the like above the roof of the structure shall be bonded to and form part of the air 

termination network. Vertical air termination points shall project at least 30 cm above the 

object on which it is fixed. 

Down conductors shall follow the most direct path possible between air termination and earth 

termination avoiding sharp bends. Down conductor shall have a testing point adjacent to the 

earth electrode. Each conductor shall have an independent earth termination. All earth 

terminations shall be interconnected. 

Earthing electrodes and grid for lightning protection will be distinct separate from the earthing 

system for earthing of electrical equipment and at no place will be connected to other 

earthing system. 

4.16 MISCELLANEOUS ELECTRICS 

SAFETY 


: 75mm x 10mm 

: 65mm x 8mm 

: 50mm x 6mm 

: 50mm x 6mm 

DC Distribution Board : 50mm x 6mm 

: 50mm x 6mm 

: 25mm x 3mm 

: 6 sq mm stranded 

: 50mm x 6mm 

Cable tray (running earthing) : 50mm x 6mm 

Page 69 of 97

All equipment shall be complete with approved safety devices wherever potential hazard to 

personnel exists and with provision for safe access of personnel to and around equipment for 

operational and maintenance functions. The design shall include all reaso reasonable precautions 

and provisions for the safety of operating and maintenance personnel. 

Special care shall be taken to make enclosed equipment proof against entry of rats, lizards and 

other creeping reptiles which may create electrical short short- circuits inside side live equipment. 

MINOR CIVIL WORKS 

Minor civil works associated with cabling, earthing, conduit installation, illumination systems, 

lighting poles, for buried cables, for erection of equipment supplied by the Bidder, foundation 

of lighting masts/poles, es, etc shall be included under scope of bidder. Similarly minor civil works 

like widening of floor openings / cable trenches, wall opening for cables, minor chipping, etc 

shall be included under scope of bidder. 

LOCAL CONTROL STATION 

Near all drives local cal control stations shall be provided. Local stations shall have Cast 

Aluminium body, dust and vermin proof, and structure mounting. Stat and stop push buttons 

shall be mounted on front hinged gasketted and lockable door. Local/remote selector switches 

shall all be provided on local control stations. Stop push button shall be lockable type. In addition, 

ammeters shall be provided on local control stations for HT drives. Suitable knockouts with 

glands shall be provided on the bottom or top cover for cable entry entry. . Terminals shall be suitable 

for 2 cores of 2.5 sq.mm conductors with 10% spare terminals. Enclosure shall be conforming 

to IP55 with proper rain canopy. 

ELECTRICS OF DUST SUPPRESSION SYSTEM 

Bidder shall include complete electrics of dust suppression systems coming in the scope within 

the battery limit. Bidder shall provide complete electrics including MCC, drives/mechanism, 

associated cabling & their termination, local DBs, all power and control ccessories, all related 

annunciations, etc. 

ELECTRICS OF AIR-CONDITIONING CONDITIONING AND VENTILATION SYSTEM 

Bidder shall include complete electrics of air air-conditioning conditioning system and ventilation system. 

Complete electrics for the following shall be included: 

• Ventilation system for the switchgear cum MCC room at WT SYSTEM substation 

• Exhaust fans for the two numbers transformer rooms at WT SYSTEM substation 

• Air-conditioning conditioning system for the battery and battery charger room at WT SYSTEM 

substation 

• Ventilation system stem for dust suppression MCC room 

WT SYSTEM ELECTRICS OF HOISTING AND HANDLING EQUIPMENT 


Page 70 of 97

Bidder shall include complete electrics of hoists coming in the scope within the battery limit. 

Bidder shall provide complete electrics including source feeders, associated cabling & their 

termination, local DBs, all power and control accessories, all rela related ted annunciations, etc. 

All the hoist control panel shall be located at workable height and platform shall be provided 

for each hoist at one point for maintenance purpose. 

33 KV OVERHEAD LINES 

In coming power supply to Wagon tippler, apron feeder, & conveyor system will be taken 

from 33KV Lean Slurry substation located near the 220KV switch yard with provision of 

lighting arrester, load brake switch, 33KV VCB, CT,PT relay and control panel housed in a 

suitable building comes under bidder’s scope. Layi Laying ng Power cable/Transmission line from 

the substation to wagon tippler area along with provision of transformer, switch gear system 

& panels will be the scope of the bidder. Approximate distance from the substation to the 

wagon tippler area will be 2.00 KKm. 

m. However, actual distance & Suitable route for laying of 

cable will be assessed by the party in consultation with NALCO. The transmission line(33 KV) 

where ever crossing roads shall be through double run underground cabling arrangement as 

per relevant regulations. gulations. 

The bidder shall also execute underground cabling and other necessary work for crossing 

railway track of the existing Intake Pump House and Ash pond 33KV overhead transmission 

lines with provision of DP,lighting arrester and associated switchge switchgear. 

Cost of power cable/transmission line shall be in scope of bidder. 

RS joist poles of size to 200 X 100 mm shall be erected by excavation of pit size 700 mm X 

700 mm to a depth of 1/5th of the pole. The pole shall be erected upright to the plumb. MS 

channel shall, be used for ‘V’ type cross arm of size 100 X 50 X 6.4 mm. The spacing between 

two extreme conductors shall be 1100 mm and the 3rd conductor shall be provided on the 

top of the mast. Suitable porcelain pin type insulators shall be used. A con continuous earth wire 

shall be provided for RS joist pole earthing and securely fastened to each pole and 

connected to earth, at 4 points in every 1.6 km, the spacing between the points, being as 

nearly equidistant as possible. Galvanized steel guard wire mes mesh h having breaking strength of 

635 kg shall be connected to earth at different points and shall be used in over head while 

crossing street/passage. Suitable lightening arrester shall be provided in the four pole 

structure. 

Suitable route for 33KV V overhead transmission line will be decided by the bidder in 

consultation/coordinating with NALCO to avoid any local/field interference. 

HT transformer of suitable capacity (33KV/0.44KV) KV) will be supplied by the bidder confirming to 

latest features. Supply y of associated switch gear and measuring equipments will be supplied 

by the bidder for the HT system. 


Page 71 of 97

Technical details of HT transformer and other switch gear will be submitted to NALCO / RITES 

for its approval. The conductor for 33KV line shall be of AACSR 

CSR (dog/Rabbit) type. 

The HT transformer (33KV/ (33KV/0.44KV) shall ll be located in the near the wagon tippler area. The 

switch gear will be designed in conformity to CEA norms having provision of LA, PT, CT, ISO etc. 

Fencing and development of switch gear will be the scope of the bidder. The switch gear will 

be located near wagon tippler area. 

Room size to be decided by the bidder to house all required equipments (HT & LT switch 

gears) at the ground floor. 

WT Control room and operating panel will be located aat 

t first floor of the building. 

Bidders are also advised to visit the site and assess the actual quantum of work to be done for 

this diversion and include accordingly. 

The operation of the WT SYSTEM plant shall be monitored and controlled from the proposed 

WT control rooms by means of VDU operator interface on a microprocessor based 

programmable logic controller (PLC). The system shall be envisaged for the purpose of initial 

operation, protection and interlock, data acquisition, close loop control, data a aarchiving, 

etc for 

fully automatic operation. The system shall be capable of monitoring and displaying the status 

of equipment, including the analog and digital signal displaying of status in the form of 

diagram, trend bar chart, overview, logs, etc with th the e help of CRT, keyboard, mouse and 

printers. 

Necessary hardware and software license of the proposed PLC shall be provided provided. PLC 

programme, ladder logic and control philosophy shall be submitted by the bidder for approval 

of NALCO/RITES. 

The preferred make of PLC shall be GE GE-FANUC make. 

33 kV Unit Vacuum Circuit Breaker 

33 kV indoor Vacuum Circuit Breaker shall conform to the following technical particulars: 

i) Type 

Indoor, Vacuum type, electrically operated, 

trip free type, panel mounted 

ii) Quantity 

iii) System Voltage 33 kV 

iv) Maximum system voltage 36 kV 

v) Continuous current As per requirement 

vi) Rated short time current rating 31.5 kA for 3 sec 

vii) Interrupting capacity at 36 kV 31.5kA 


Page 72 of 97

The VCB shall be indoor drawout type with numerical type over current (50+51), earth fault 

(51N) relay with timer for instantaneous overcurrent protection as we as master 

trip and trip circuit supervision relay. The VCB shall be capable of withstanding through fault 

current of 31.5kA for 3 sec. and shall be provided with remote closing and 

tripping facilities. Under voltage relay with timer shall be provided in line PT. 

transformer nsformer differential protection shall also be provided. PT shall be provided with protection 

core of 3P class and metering core of CL 0.5. CT shall be provided with protection core of 

5P20 class and metering core of CL 0.5. For transf transformer ormer differential protection PS class CT shall 

be considered. 

The closing coil of the breaker shall be suitable for operation between 85 to 110 percent 

of 220 V DC control power supply voltage available from batteries. 

The circuit breaker shall have redundant shunt trip device. The trip coil shall be designed 

to operate satisfactorily when the voltage at the terminals of the shunt trip coils is 

between 70 to 110 per cent of 220 V DC control power supply voltage available from 

batteries. VCB B shall be provided with dual trip coil. For actuation of trip coils, similar set of 

contacts shall be provided separately for each trip coil. Hence, necessary arrangement for 

duplication of contacts shall be done inside the pane panel l if multiple No. of similar contacts are not 

available. 

The circuit breaker shall be power operated with motor wound spring closing mechanism with 

electrical spring release coil. The motor shall be suitable for operation on 240 V AC single phase 

supply. Means shall however be provided for manual operation of the breaker under 

emergency or for testing and adjustments. 

The operating mechanism shall be anti pumping and trip free type. 

The spring operated perated mechanism shall be so designed that the spring gets automatically 

recharged immediately after closing. 

Imploding type surge suppressor and earthing truck with full capacity circuit breaker, three 

(3) Nos. single phase e PT, selector switch and test plugs shall be considered at the outgoing side of 

VCB. 

Both incoming and outgoing terminals of VCB shall be suitable for terminating 33 kV (E) 

grade XLPE insulated PVC sheathed, 3core, aluminium condu conductor cables. 

The circuit breaker shall be provided with necessary auxiliary switches for indication, 

control, interlocking, protection and alarm. Six spare auxiliary contacts, three (3) NC and 

three (3) NO shall be left eft free in the breaker. All the contacts shall be wired to the terminal 

block. 

Space heaters to prevent moisture condensation within the enclosure shall be provided in 

relay and control cubicle. Heaters shall be suitable for opera operation tion from 230 V, AC 50 Hz, single 

phase supply. 


Page 73 of 97

33kV Control and Relay Panel 

One (1) set of relay and control panels consisting of two (2) feeders and PT complete 

with mimic buses, instruments, controls, indication, alarm annunciation relays and 

alarm facia and protection relays as required for th the e 33 kV feeder for the proposed plant and 

as described below shall be provided. 

The mimic diagram shall provide single line representation of the 33 kV 

system. The control and relay panel shall be located inside the room for new 33 kV VCB 

panel. 

The relay and control panel shall be floor mounted type, having sheet steel of 2.5 mm 

thickness. A equipment shall be mounted such that removal and rreplacement 

eplacement may be 

accomplished individually without interruption of service to adjacent equipment. The relay and 

control panel shall have rear access. 

Test devices shall be provided for C.T. circuits. CTs shall not be open ci circuited rcuited during testing 

operation. 

Adequate illumination shall be provided inside each cubicle. CFL lamps suitable for 230 V, 

50 Hz, single phase supply shall be provided. 

Potential circuits for instrumentation aand 

nd for metering each shall be protected by 

suitable MPCB/MCB. 

Annunciator shall be suitable for 220 V DC operation. It shall have a single DC alarm common to 

all points. 

Space heaters to prevent moisture condensation wi within thin the enclosure shall be provided in 

relay and control cubicle. Heaters shall be suitable for operation from 230 V, AC 50 Hz, single 

phase supply. 

A relay shall be numerical type having communication port conforming commun communication 

protocol as per IEC61850 for direct interfacing with plant 

PLC/DCS/SCADA system. Numerical relay shall be capable to receive minimum adequate 

nos. inputs and output contacts. 

415-240 V AC Distribution Board (ACDB (ACDB) 

415 V, 3phase, 4wire ACDB shall be provided which will be fed from the secondary side of 

33/0.433kV auxiliary control transformer. The auxiliary transformers shall be 

tapped from before the incoming HT circuit breakers over HT load break isolator, HRC fuse 

and voltmeter. The distribution board shall be provided with two incoming feeders, each 

comprising one MCCB and one magnetic contactor connected to one comm common set of busbars. 

ACDB shall be floor mounted, totally enclosed, fully compartmentalised, multitier single 


Page 74 of 97

front design. The distribution board shall be suitable for cable entry from the bottom. 

Devices requiring operation sh shall all be located in between 450 mm and 1900 mm from the floor 

level . 

The ACDB shall have indicating voltmeter with selector switch, PT, MPCB & MCB at the line 

side of the distribution board. Ammeter with selector switch, CT, MPCB & MCB shall 

also be provided. These instruments shall be flush type located on the front door of the 

compartments. The sizes of ammeter and voltmeter shall be 96 mm x 96 mm. Phase 

indicating lamps shall be provided vided at the bus side of incomer. 

The ACDB shall be fabricated from minimum 2.0 mm thick CRCA sheet steel with load 

bearing members comprising 2.5 mm thick CRCA sheet steel. The degree of protection 

shall be IP:54. 

A the outgoing feeders shall be of MCCB/MCB unit. 

Power circuit isolation shall be possible without opening the front door and shall have 

provision for padlocking in OFF position with the door closed. ON/OFF indications 

shall be provided for a feeders by means of cluster LED lamps. 

The main phase busbars and tappings shall be made of aluminium having cross sectional 

areas to be substantiated during en engineering gineering but in no case the current density shall 

be more than 80 A/sq cm. The busbars shall be suitably supported on non hygroscopic 

moulded glass reinforced plastic insulators so as to be capable of withstand withstanding dynamic 

forces due to 50 kA through fault short circuit. All joints shall be coloured PVC taped. 

Temperature rise of busbars/joints while carrying the rated current shall not be more 

than 45°C over maximum ambie ambient nt temperature of 45°C when measured by thermometer. 

Tappings from the main busbars to individual feeder compartments shall be by means of 

insulated single core copper cables with stranded conductor for feeders upto 100 A ratings 

above which aluminium busbars shall be used. All copper to aluminium joints shall be 

provided with bimetallic nuts/bolts/washers. 

A continuous 50 mm x 10 mm aluminium earth bus shall be provided throughout the 

length gth of the panels and shall be located in a separate chamber at the bottom with 

removable front cover. Provision shall be kept for taking earth connections to external earth 

mat. PVC insulated (Green coloured) copper wires shal shall l be used to connect all noncurrent 

carrying metallic parts, doors, etc to the earth bus. 

All relays, instruments, meters, pushbuttons, switches and other devices of any feeder 

shall be located on the respective compartment only. 

All operating handles, control switches, pushbuttons, indicating lamps, instruments, meters 

etc shall be mounted on the front of the cubicles. 

220 V DC Control Battery Bank 

Battery bank shall consist st of plante type lead acid cells in transparent plastic containers 

with sufficient quantity of electrolyte, acid level indicating floats, intercell connectors, 

cell support insulators, cell number plates, properly ttreated 

reated and acid resistant painted 

wooden stand supported on porcelain insulators, terminal connectors for external 

connections etc. as required to make the installation complete in all respects. The wooden 


Page 75 of 97

stands shall be made of good quality teak wood suitably treated with two coats of 

linseed oil and three coats of antisulphuric acid paint. 

Inter row and intertier connectors for the batteries shall be made of copper coated 

with lead. The terminals of each cell shall be indelibly identified for polarity. The 

terminals of battery outgoing leads shall have provision for connecting lead coated 

copper bars which shall be suitably extended upto the room wall for termination of external 

aluminium conductor, XLPE insulated cables. Suitably terminals shall also be provided for takin taking 

external connections from cell by aluminium conductor XLPE insulated cables. 

The cells shall be delivered in dry and discharged condition. Sufficient quantity of electrolyte 

ready to fill condition shall be supplied for tthe 

he first filling of the batteries in nonreturnable 

airtight plastic/polypropylene containers. Ten (10) percent extra electrolyte shall also be 

provided. 

Complete battery maintenance equipment required for conven convenient and safe handling and 

preparation of electrolyte shall be supplied with the battery bank. These shall include 

but not be limited to items like syringe type hydrometer, 

mercury in glass thermometer calibrated 0 to 100 

and one thermometer, syringe, level testing tube, 150 mm dia glass funnel, spanners, centre 

zero cell testing voltmeters, PVC gl 

o ient and safe handling and 

preparation of electrolyte shall be supplied with the battery bank. These shall include 

but not be limited to items like syringe type hydrometer, 

C, wall mounted holder for one hydrometer 

and one thermometer, syringe, level testing tube, 150 mm dia glass funnel, spanners, centre 

zero cell testing voltmeters, PVC gloves, PVC jug, etc. 

Load Break Switch (LBS) 

Load break switch panel shall consist of the following: 

33 KV, 31.5 KA rated HT air break/load break switch suitably interlocked with earth switch shall be 

provided. It shall be with front operated spring as assisted sisted manual mechanism with 2 N/O and 2 N/C 

auxiliary contacts. It shall contain: 

ON/OFF indication lamp – 2 Nos. 

Suitably rated copper busbar – 1 set 

Space heater with thermo start and switch control 

Mechanical interlocks 

Provision of receiving incoming coming 33 KV XLPE cable at bottom. 

Ring Main Gear (RNG): 

The ring main gear shall be indoor type and shall consist of one No. 33 KV suitably rated, short 

rating 31.5 KA, load breaks switch with interlocked earth switch front operated spring assisted 

manual closing mechanism horizontal draw out, horizontal isolation VCB fitted with motor 

operated charging mechanism for controlling the outgoing supply. 

Rated voltage – 33 KV 

Rated Current- as per requirement 

Frequency – 50 Hz 

Cubicle – Floor mounted fr free standing dust and vermin proof. 


Page 76 of 97

Encl: IP-45 

Control voltage – 220 V DC 

BELT SWAY SWITCH 

The belt sway switch shall be shall be auto reset type and provided at both ends and at an 

interval of 50 mtrs (for conveyor length greater that 200 mtrs) on both sides of conveyors and 

also before and after belt weighing system on both sides. It shall be of auto reset type. 

The belt sway switch shall be industrial heavy duty type housed in dust and vermin proof box 

with degree of protection IP IP-54. 54. The switch shall be designed that conveyor does not come in 

direct contact with the switches and mechanism shall have strong rest spring to absorb high 

impact of loaded belt edge. 

The switch element shall be self rest type and shall have 2NO+2NC contacts each rated for 

10A, 240V AC. It shall be suitable for ambient temp. of 600C. Resetting spring mechanism, 

built in terminal box, actuating ctuating rollers, roller shafts, supporting frame, etc shall be provided as 

per requirement. Belt sway switch shall be J&N make. 

PULL CHORD SWITCH 

Pull chord switches shall be auto reset type industrial heavy duty enclosed in dust and vermin 

proof enclosure with degree of protection IP IP-65. 65. They shall be provided with following 

facilities; 

• Switch elements shall be 2NO+2NC each rated for 10A, 240V AC. 

• Automatic locking arrangement in the operated position with manually reset 

• Snap action type for posi positive operation of contacts 

• Number of position shall be 11-0-1 

• Separate compartment for built in terminal box 

• Suitable base plate Pull rope shall be stranded galvanized steel wire with at least 1 

mm thick PVC cover and having overall diameter of 6mm to 7m 7mm. m. 

Pull rope switch shall be placed at an interval of 25 mtr on both sides of conveyor with 

minimum of one pair for conveyor length less than 25 mtr. 

ZERO SPEED SWITCH 

The unit shall be provided with MS flags, sensing probes, monitoring unit and inte interconnecting 

special cables. The unit shall be of multi speed range with setting facility and shall be provided 

with output contacts (2NO+2NC) with facility for initial bypass adjustable time delay, nuisance 

tripping delay and analog/digital speed display. 4-20mA 20mA isolated DC signal shall be applicable 

for external metering. Sensing probe shall be provided with metallic enclosure of degree of 

protection IP-67 67 and LED lamp for visual indication of correct functioning of sensing probe. 


Page 77 of 97

PASSIVE FIRE PROTECTION 

Fire protection for cables at entry/exit points of the wall shall be provided with proper sealing 

by fire sealing material. The fire sealing compound shall be rated for minimum 2 Hours. Fire 

retardant painting shall also be provided on cables for 2 Mtrs on both sides of the wall/floor 

crossing. 

ERECTION & INSTALLATION ACCESSORIES 

All cable accessories like conduits, inserts, cable tag markers, clamps, sealing compound, pull 

boxes, marshalling boxes etc. shall be considered as part of the Bidders scop scope to complete the 

erection job in all respect. 

OTHER ITEMS 

Bidder shall provide all required switches, cabling and other devices needed for proper 

control, operation, interlocking and sequencing of the any other offered systems and 

technological mechanism, if specified in technological, e.g. hanging magnets and wi wipers (if 

applicable), roof exhaust fans & wall exhaust fans (if applicable), etc. 

All required safety items like rubber mats in front of MCC/DB/Panel, shock treatment chart, 

first aid boxes, danger boards, boards indicating 'Man on Work, Do not switch ON ON', 'Do not 

switch OFF', 'EARTHED' etc. shall be provided in each electrical premises. 

Wall mounted aux. AC and DC distribution boards shall be provided in sufficient number to 

facilitate proper distribution of the power supply to various users. 

Bidder to include closing of all cable and panel openings through a Fire sealing material. This 

shall include closing of all bottom opening of control room panels/desks, MCC switch boards, 

wall openings in all the areas, etc. Bidder shall also include earthing of all equipments/system, 

wherever required, under his scope of supply. 

Bidder shall include painting of all the plant and equipment with approved shades and include 

primers as well as finishing paints. 

Sufficient quantity of GI ladder type factory fabri fabricated cated cable trays made from 2.5 mm thick hot 

welded steel sheets grade ‘o’ as per IS: 2062 shall be provided. Hot dip galvanizing of 85 

micron thick as per IS-2629, 2629, IS IS-4759 and IS- 209. Trays shall be of standard length of 3 m with 

max deflection not exceeding ding 1/400 of span with sufficient load bearing capacity. 

4.16 ERECTION OF ELECTRICAL EQUIPMENT 

Bidder shall include erection of all the equipment under his scope of supply. Erection of 

equipment shall have to be carried out as follows: 


Page 78 of 97

1. Procedure mentioned in manufacturer’s manual 

2. Under the expert supervision 

3. Sequence and plan of erection as per the guidance of Purchaser’s Site In charge or their 

consultant 

4. During erection of supplier’s equipment, existing equipment /system shall not be 

disturbed. 

5. Erection shall be in accordance with approved layout drawing and installation details. 

6. Cable laying shall be as per approved cable layout drawings and work shall be carried 

out in a neat manner. 

All erection-installation installation accessories required for erectio erection/installation n/installation of equipment and 

handling equipment required for handling of equipment from store to installation site are 

included in the scope of work of Bidder as a whole. 

Bidder shall ensure that the work erection and erected equipment shall comply wit with all 

statutory norms, regulations and standards applicable to the works/equipment and any 

additional work/equipment required, if any, shall be under scope of the Bidder. 

Necessary clearance from the wall shall be maintained as per IS/IE Rules from front/ front/rear/ side 

of all the panels inside a room. 

HT Power cables and LT power/control cables shall be laid in different cable trays. LT power 

cables and LT control cables shall also be laid in different trays, however, if necessity arises 

due to space constraints ints or lesser number of cables, LT power cables and LT control cables can 

be put on the same trays keeping sufficient gap between them. 24V DC cables, if required, 

shall be laid entirely in different dedicated trays. 

Cable trays in single tier or in mul multitier titier shall be installed in vertical arrangement everywhere to 

avert coal accumulation and space reduction. 

Fire Prevention:- 

Proper design and use of quality material, equipment so as to avoid overloading in 

Distribution board, wiring system including sub main, switch & sockets shall be ensured by the 

bidder. 

Insulating mats in front of PCC, MCC or control panel, protective rubber gloves, earth rods, 

artificial respiration apparatus, line man’s belt etc shall be provided in substations by the 

bidder. 

Fire re extinguishers for various switch gear location, substations, PCC, MCC suitable for 

electrical fire (class –C) C) like dry chemical powder, carbon carbon-dioxide, dioxide, carbon carbon-tetra chloride type 

shall be provided along with fire buckets filled with sands. 

Comprehensive fire protection system in conformity with the requirements of national 

building code, ECBC 2007 shall be ensured by the bidder. 

5.0 INSPECTION AND TESTING 


Page 79 of 97

5.1 Inspection 

Extent of inspection 

The extent of inspection & testing by the Purchaser shall vary from equipment to equipment 

as per design requirements. 

However, indicative extent of inspection for electrical equipment is furnished below: 

Extent of inspection to be carried out shall be finalised with the Contractor after award of the 

contract on the basis of scope of supply, technical specification and approved GA drawings. 

However, in case of similar bulk manufactured items, methods of sampling for inspection of 

different lots shall be governed by relevant Indian or inter international national standards. 

In case of critical components, the Purchaser reserves the right to undertake 100% inspection. 

Final inspection & testing shall be done as per the following: 

• Verification of test certificates 

• Visual, Workmanship & painting 

• Dimensional 

• Witnessing of routine/acceptance/type/special tests as per relevant standards. 

• Witnessing of proto-type type tests, as applicable 

• Verification of type test certificates for identical equipment 

• Approved QAP 

The inspection shall be carried out on the basis of QAP dully approved by Purchaser / 

consultant. 

INSPECTION CATEGORIES 

All the electrical equipment have been classified in three categories for inspection and issuing 

dispatch clearance by the Purchaser/consultant. The three categories are: 

Category-A 

All the tests shall be inspected by the Purchaser/Consultant. Dispatch clearance shall be given 

by Purchaser/Consultant haser/Consultant after the equipment is inspected and found as per requirement and 

as per TS. All types tests certificates shall e submitted by the Bidder in this case. 

Category-B 

Inspection shall be carried out by prime bidder and inspection waiver cert certificate ificate shall be issued 

by Purchaser/Consultant based on type test certificates and routine tests certificates furnished 

by the Bidder. Purchaser/Consultant shall issue dispatch clearance accordingly. 

Category-C 


Page 80 of 97

Dispatch clearance shall be given by Prime bidder without any certificates based on technical 

data sheet furnished by the Bidder. 

5.2 Testing 

General 

S. N. DESCRIPTION 

1 HT CABLE 

2 LT MOTORS 

3 LT POWER AND CONTROL CABLES 

4 MCC 

5 TRANSFORMER 

6 PLC & CONTROL DESK 

7 UPS 

8 ON LOAD 33 kV ISOLATOR 

9 TRAILING CABLE / FLEXIBLE (EPR) CABLE 

10 PDB/LDB/SLDB/AUX. PDB 

11 SIGNAL, INSTRUMENTATION AND OTHER SPECIAL CABLES 

12 CABLE ACCESSORIE 

13 LIGHT FITTINGS 

14 EARTHING AND LIGHTNING PROTECTION MATERIALS 

15 FIRE SEALING MATERIALS 

16 LOCAL PUSH BUTTON STATIONS 

17 POWER SOCKET CABINET AND LIGHTING CABINET 

18 CONTROL AND RELAY PANEL 

19 415V FEEDER PILLAR 

20 33KV VCB 

21 LT DISTRIBUTION BOARD 

22 33KV LIGHTENING ARRESTER 

23 33KV ISOLATOR AND EARTH SWITCH 

24 33KV CT,PT 

25 BATTERY,BATTTERY CHARGER,DCDB 

26 FIRE EXTINGUISHER 

27 JB,RUBBER MAT,DANGER BOARD,FIRE BUCKET,FIRST AID 

BOX,HAND GLOVES,SHOCK TREATMENT CHART,DISCHARGE 

ROD.MEGGAR 

Test of all equipment shall be conducted as per latest BIS. Wherever no such standard exists, 

tests shall be as per International Standards like IEC/DIN/BS/IEEL/JIS, etc. 

All routine tests shall be carried out at manufacturer's works in presence of Purchaser or his 

representative. 


INSPECTION 

CATEGORY 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

A 

B 

B 

B 

B 

B 

B 

B 

B 

B 

Page 81 of 97 

C 

C 

C 

C 

C 

C

The Bidder shall submit type test certificates (not more than 5 years old) for similar equipment 

supplied by him elsewhere. In case type test ccertificates 

ertificates for similar equipment is not available, 

the same shall be conducted in presence of Purchaser or his representative, without any 

financial implications to Purchaser. 

The Bidder shall be responsible for satisfactorily working of complete integr integrated system and 

guaranteed performance. 

Site Tests and Checks 

General 

All the equipments shall be tested at site to know their condition and to prove suitability for 

required performance. 

The test indicated in following pages shall be conducted after installation. All tools, accessories 

and required instruments shall have to be arranged by contractor. Any other test which is 

considered necessary by the manufacturer of the equipment, contractor or mentioned in 

commissioning manual has to be conducted aat 

site. 

In addition to tests on individual equipment, some tests/checks are to be conducted / 

observed from overall system point of view. Such checks are highlighted under miscellaneous 

tests but these shall not be limited to as indicated and shall be fi finalized nalized with consultation of 

client before charging of the system. 

The contractor shall be responsible for satisfactory working of complete integrated system and 

guaranteed performance. 

All checks and tests shall be conducted in the presence of client’ client’s s representative and test 

results shall be submitted in six copies to client and one copy to Electrical Inspector. Test 

results shall be filled in proper Performa. 

After clearance from Electrical Inspector system/ equipment shall be charged in step by step 

method. 

Based on the test results clear cut observation shall be indicated by testing engineer with 

regard to suitability for charging of the equipment or reason reasons s for not charging are to be 

brought by the contractor. 

Trial Run Test 

After the successful test of each equipment as per standard test procedure the entire control 

system shall be put on trial run test on actual site conditions and operation of the sy system. 

Acceptance Test 


Page 82 of 97

The acceptance test on the system shall be carried out by the supplier as per mutually agreed 

test procedures to establish satisfactorily functioning of the system as a whole and each 

equipment as part of the system. 

Site Tests 

The tests to be carried out on the equipment at pre pre-commissioning commissioning stage shall include 

following but not limited to the following: 

MCC 

1. IR test before and after HV test. 

2. HV test with 2.5 kV megger 

3. Functional test for all feeders 

4. Testing and calibration of all meters 

5. Checking and calibration of protective relays as per supplier's commissioning manuals 

6. Check operation of contactors from local and remote points 

7. Checking of interlockings between incomers/bus coupler and other feeders. 

8. Test to prove interchangeability of similar parts 

9. Tests to prove correct operation of breakers at minimum and maximum specified 

control voltages 

10. Checking of earthing connection fo for neutral-earth earth bus, cable armour, location of E/F CT 

etc. as per the scheme. 

11. Check test, service and drawout position of all the breakers and operations of 

mechanical flag indicator and electrical indication lamps. 

12. Check functioning of various elect. sc schemes hemes like autochangeover signalling etc. 

13. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and 

between phases in off position 

MOTORS 

1. IR test of stator and rotor windings. 

2. Ensure that checking/testing of associated switchboard 

switchboard, , cables, relays /meter 

interlocks as mentioned in relevant are completed. 

3. Check tightness of cable connection 

4. Winding resistance measurement of stator and rotor. 

5. Checking continuity of winding. 

6. Check tightness of earth connections. 

7. Check space heaters and carryout heating of winding (if required) 

8. Check direction of rotation in de de-coupled coupled condition during kick start 

9. Measure no load current for all phases. 

10. Measurement of temperature of body during no load and load conditions. 

11. Check for tripping of motor from local/remote switches and from 

electrical/technological protection. 

12. Checking of vibration 

13. Checking of noise level 

14. Shaft voltage measurement (if required) 

15. Tan delta test, if required 


Page 83 of 97

16. During load running, measurement of stator and bearing temperatures (if applicable) 

for every half an hour interval till saturation comes. 

17. Checking tightness of foundation bolts 

18. Check operation of speed switch (if there) 

19. Check continuity of temp. detectors. 

20. Check alignment, paralleling oof 

f shafts, level of lubricating oil etc. as per manufacturer's 

manual 

21. Check for polarisation index of stator winding, R10/R1 by motorised megger (The value 

should not be less than 2.0). R60/R10 absorption co co-efficient efficient shall not be less than 1.5. 

TRANSFORMER 

1. IR test on each winding to ground and between windings. 

2. Turns ratio test on each tap 

3. Polarity and vector group test 

4. Measurement of winding resistance by Kelvin bridge 

5. IR, wiring and operational tests on all control devices in control cabi cabinet, oil level 

indicator, winding and oil temp. indicators etc. 

6. Checking of earthing wrt transformer tank (flexible from top cover to tank) other 

parts, neutrals. 

7. Testing of buchholz relay for alarm and trip conditions. 

8. For bushing CTs, tests applicable shall be as for current transformers. 

9. Setting of oil/winding temperature indicators, level gauge and checking of alarm/trip 

circuits. 

10. Check insulators for cracks. 

11. Checking for oil leakage and arresting of leakages (if tthere) 

12. Checking of operation of all valves. 

13. Checking for open position of all the valves (except drain and filter valves) 

14. Filtration of oil by using line filter, vacuum pump, and heater set. 

15. BDV test on oil samples from top and bottom. 

16. Checking of oil for acidity, water content tan delta etc. as per IS 335. 

17. Measurement of magnetising current and no load loss. 

18. Measurement of PI value. 

19. Checking of silica gel breather. 

20. Checking of noise level at no load and at full load. 

21. Checking of air circulation cconditions 

for indoor transformers. 

22. Conducting magnetic balance test 

23. Checking of other points given in manufacturer's commissioning manual. 

24. Frequency response analysis for HT transformers (at manufacturer’s works) 

UNINTERRUPTED POWER SUPPLY (UPS) 

1. Visual check 

2. IR value by megger 

3. Current limit test 

4. Ripple test 

5. Supply variation 


Page 84 of 97

6. Functional test 

7. Capacity test wrt time 

PDB/LDB/SLDB/AUX.PDB 

1. IR test before and after HV test. 

2. HV test with 2.5 kV megger 

3. Functional test for all feeders 

4. Testing and calibration of all meters 

5. Checking and calibration of overload relays and protective relays as per supplier's 

commissioning manuals. 

6. Check operation of contactors from local and remote points 

7. Checking of interlockings between incomers/bus co coupler upler and other feeders. 

8. Test to prove interchangeability of similar parts 

9. Tests to prove correct operation of breakers at minimum and maximum specified 

control voltages 

10. Checking of earthing connection for neutral neutral-earth earth bus, cable armour, location of E/ E/F CT 

etc. as per the scheme. 

11. Check test, service and drawout position of all the breakers and operations of 

mechanical flag indicator and electrical indication lamps. 

12. Check functioning of various elect. schemes like autochangeover signalling etc. 

13. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and 

between phases in off position 

CABLES & CABLE SUPPORTING STRUCTURES 

1. Checking of continuity/phasing and IR values for all the cables before and after HV test. 

2. Checking of earth arth continuity for armour. 

3. Check for mechanical protection of cables. 

4. Check for identification (tag number system) distance placement of cable marker, cable 

joint etc. as per the cable layout drawing. 

5. Check earthing of cable structures. 

6. Check clearances ces from light fittings for cable structures 

7. Check proper fixing of cable structures. 

8. Check for proper drainage and removal of water from cable trenches 

EARTHING & LIGHTNING PROTECTION 

1. Check tightness of all earth connections 

2. Check earthing of all metallic equipment, cable trays, busbar supporting structures, all 

elect. equipments, etc. as per the requirement of IE rules and IS 3043 

3. Measurement of earth resistance for each electrode. 

4. Measurement of total earth resistance. 

5. Measurement easurement of earth loop resistance for E/F path of biggest LT drive. 

ILLUMINATION 

1. Lux level measurement in each area/premise 

2. Test for black spot, if any 


Page 85 of 97

3. Check operation of complete lighting system 

MISCELLANEOUS 

1. Checking of continuity of the system 

2. Checking hecking safe accessibility of all operating points 

3. Ensure availability of first aid box, rubber glove, etc. 

4. Check for safe movement of operators to pump house w.r.t. proper illumination, light, 

uncovered openings, etc 

5. Placement of shock treatment chart, danger boards, provision of boards indicating Man 

on Work, Do not switch ON', 'Do not switch OFF', 'EARTHED' etc. 

6. Check proper dressing of cables, mechanical protection of cables, placement of cable 

markers 

7. Check sealing of all cable openings including conduit opening with fire resistance 

material 

8. Check sealing of all openings at bottom of panels 

9. Check proper road crossing of cables/earthing materials. 

LIST OF IMPORTANT INDIAN STANDARDS 

SN IS Standard with Latest 

Amendment 

Title 

1 IS : 732 – 1989 

Code of practice for electric al wiring installations. 

2 IS: 4648 – 1968 

3 IS : 8081 – 1976 

4 IS : 8884 – 1978 

5 IS: 5578 – 1985 

6 IS : 11353 – 1985 

7 IS: 5728 – 1970 

Guide for short-circuit calculations. 

8 IS:7752(Part 1) – 1975 Guide for improvement of power factor in consumer 

installation : Low and medium supply voltages. 

9 IS:3646(Part 1) – 1966 Code of practice for interior illumination : Principles 

for good lighting and aspects of design. 

10 IS:3646(Part-3) – 968 Code of practice for interior illumination: Schedule of 

illumination and glare index. 

11 IS:3646(Part-3)-1968 

12 IS:4347 – 1967 


Guide for electrical layout in residential buildings. 

Code of practice for design, installation and 

maintenance of service lines upto and including 650 

V. 

Code of practice for installation of electrical bells and 

call system. 

Guide for marking of insulated conductor. 

Guide for uniform system of marking and 

identification of conductors and apparatus terminals. 

Code of practice for interior illumination: Calculation 

of coefficients of utilization by the BZ method. 

Code of practice for hospital lighting. 

Page 86 of 97


Amendment 

Title 

13 IS:6665 – 1972 

Code of practice e for industrial lighting. 

14 IS:2672 – 1966 

Code of practice e for library lighting. 

15 IS:10118(Part 1) – 1982 Code of practice for selection, installation and 

maintenance of switchgear and control gear; General 

16 IS:10118(Part-2)-1982 1982 Code of practice for select ion, installation and 

maintenance of switchgear and control gear 

selection. 

17 IS:101118(Part-3)-1982 1982 Code of practice for select ion, installation and 


Installation. 

18 IS:10118(Part 4) - 1982 Code of practice for select ion, installation and 


selection. 

19 IS:4146 – 1983 

20 IS: 4201 – 1983 

21 IS:5547 – 1983 

22 IS:2309 – 1989 

23 IS:3043 – 1987 

Code of practice for earthing. 

24 IS:5216(Part01) – 1982 Guide for safety procedures and practices in electrical 

work : General. 

25 IS: 5216(Part 1) – 1982 Guide for safety procedures and practices in electrical 

work : Life saving techniques. 

26 IS:3696(Part-2) – 1966 Safety code for scaffolds and ladders: Ladders Electric 

fans. 

27 IS: 555 – 1979 

28 IS:1169 – 1967 

29 IS:374 – 1979 

30 IS:2997 – 1964 

31 IS: 2312 – 1967 

32 IS:3588 – 1987 

33 IS:3963 1987 

34 IS:4283 – 1981 

35 IS:6272 – 1987 

36 IS:4894 – 1987 

37 IS:11037 0 1984 

38 IS:12155 – 1987 


Application guide for voltage transformers. 

Application guide for current transformers. 

Application guide for capacitor voltage transformers. 

Code of practice for the protection and allied 

structures against lightening 

Electric table type fans and regulators. 

Electric pedestal type fans and regulators. 

Electric ceiling type fans and regulators. 

Air circulator type electric fans and regulators. 

Propeller type AC ventilating fans. 

Electrical axial flow fans. 

Roof extractor units. 

Hot Air fans. 

Industrial cooling fans (man coolers) 

Centrifugal fans. 

Electronic type fan regulators. 

General and safety requirements for fans and 

regulators for house hold and similar purposes, Low 

voltage switch gear and control gear. 

Page 87 of 97


Amendment 

Title 

SWITCH GEAR 

39 IS:4237 – 1983 

40 IS:675(Part-1) – 1973 Control Switches (switching devices for control and 

auxiliary circuits including contractor (relays) for 

voltages upto and including 1000 v AC and 1200 v DC: 

41 IS:6875(Part2) – 1973 Control Switches (switching devices for control and 

auxiliary circuits including contractor (relays) for 


42 IS:6875(Part-3)-1980 

43 IS:10027-1981 

44 IS:4064(Part 1) -1978 1978 Air break switches, air break disconnectors, air break 

switch disconnectors and fuse combination units for 

voltages not exceeding 1000 v AC or 1200 v AC : 

General requirements. 

45 IS:2675 – 1983 

46 IS:8828 – 1978 

47 IS: 13032 – 1991 

48 IS:12640 – 1988 

49 IS:2959 – 1985 

50 IS:2516(Part01/Sec 1 – Circuit breakers: Requirements and tests: Voltages 

1985 

not exceeding 1000 v AC or 1200 v DC. 

51 IS:12021 – 1987 

52 IS:5039 – 1983 


General requirements for switch gear and control 

gear for voltages not exceeding 1000 V ac or 1200v dc 

Control Switches (switching devices for control and 

auxiliary circuits including ncluding contractor (relays) for 


Composite unit o air break switches and rewireble 

type fuses for voltages not exceeding 50 V AC. 

Enclosed distribution fuse boards and cutouts for 

voltages not exceeding 1000 V. 

Miniature air break circuit breakers for voltages not 

exceeding 1000 volt. 

Miniature circuit breaker boards for voltages upto 

and including 1000 volts AC. 

Residual current operated circuit breakers. 

Voltages not exceeding 1000 v AC or 1200 v DC. 

Specifications for control transformers for switch gear 

and control gear for voltages not exceeding 1000 

volts AC. 

Distribution pillars for voltages not exceeding 1000 V. 

Page 88 of 97


Amendment 

Title 

53 IS:8623 (Part 1) – 1977 Factory built assemblies of switch gear and control 

gear for voltages up to and including 1000 v AC and 

1200 v DC : General requirements. 

54 IS:8623 (Part 2) – 1980. Factory built assemblies of switch gear and control 

gear for voltages up to and including 1000 v AC and 

1200 v DC : Particular requirements for bus bar 

trunking system (busways) 

55 IS:8544(Part 1) – 1977 Motor starters for voltages not exceeding 1000 v : 

Direct on line AC starters. 

56 IS:8544(Part 2) – 1977 Motor starters for voltages not exceeding 1000 v : 

Star-delta starters. 

57 IS:8544(Part 4 ) – 1979 Motor starters for voltages not exceeding 1000 v: 

Reduced voltage ac starters, two step auto 

transformer starters. 

POWER CABLE 

58 IS:694 – 1990 

59 IS:1554(Part 1) -1988 1988 PVC insulated (heavy duty) electric cables: For 

working voltages upto and including 1100 v. 

59 IS:3961 (Part 5) – 1968 Recommended current ratings for cables: PVC 

insulated light duty cables. 

60 IS:4288 - 1983 

60 IS:4289(Part 1) – 1984 Flexible cables for lifts and other flexible connections: 

Elastomer insulated cables. 

Electrical Wiring Accessories 

61 IS:9537(Part 1) – 1980 Conduits for electrical installations: General 

requirement. 

62 IS:9537(Part 2) – 1981 Conduits for electrical installations: Rigid steel 

conduits., 

62 IS: 3480 – 1966 

63 IS:2667 – 1988 

63 IS: 3837 – 1976 

64 IS:9537 (Part 4) – 1983 Conduits for electrical installations: Pliable self 

recovering conduits of insulating materials. 


PVC insulated cables for working voltages upto and 

including 1100 V. 

PVC insulated (heavy duty) electronic cables with 

solid aluminum conductors for voltages up to and 

including 1100 v 

Flexible steel conduits for electrical wiring. 

Fittings for rigid steel conduits for electrical wiring. 

Accessories for rigid steel conduits for electrical 

wiring. 

Page 89 of 97


Amendment 

Title 

64 IS:6946 – 1973 

Flexible (pliable) non-metallic metallic conduits for electrical 

installations. 

65 IS:3419 – 1989 

Fittings for rigid non-metallic conduits. 

65 IS:5133 (Part-1) – 1969 Boxes for enclosure of electrical accessories: Steel 

and cast iron boxes. 

66 IS:5133 (Part 2) – 1969 Boxes for enclosure of electrical accessories 

66 IS:2412 – 1975 

67 IS: 371 – 1979 

67 IS: 3854 – 1988 

68 IS: 4615 – 1968 

68 IS:4160 – 1967 

69 IS:1293 – 1988 

Electric Lamps and their Auxiliaries 

70 IS: 418 – 1978 

71 IS:2418 (Part 1 ) – 1977 Tubular fluorescent lamps for general lighting service 

: Requirements and tests. 

71 IS: 990(Part 1) – 1981 High pressure mercury vapor lamps: Requirements 

and tests. 

72 IS:9974(Part 1) -1981 1981 High pressure sodium vapor lamps : 

72 

General requirements and tests. 

73 IS: 1258 – 1987 

Bayonet lamp holders. 

73 IS: 3323 – 1980 

Bi-pin pin lamp holders for tubular fluorescent lamps. 

74 IS: 3324 – 1982 

74 IS: 2215 – 1984 

Starters for fluorescent lamps. 

75 IS: 1534 (Part 1) – 1977 Ballast for fluorescent lamps: For switch start circuits. 

75 IS: 1569 – 1976 

76 IS:6616 – 1982 

76 IS: 1913 (Part 1) – 1978 General and safety requirements for luminaries 

Tubular fluorescent lamps. 

77 IS: 10322 (Part 1 ) 1982 Luminaries : General requirements. 

77 IS: 10322(Part 2) - -1982 1982 Luminaries : Constructional requirements. 

78 IS: 10322 (Part5 / Sec 1 ) Luminaries : Particular requirements: Recessed 

1987 

luminaries 


Link clips for electrical wiring. 

Ceiling roses. 

Switches for domestic and similar purposes. 

Switch socket outlets (non-interlocking interlocking type). 

Interlocking switch socket outlet. 

Plugs and socket outlets of rated voltage upto and 

including 16 amperes. 

Tungsten filament general service electric lamps. 

Holders for starters for tubular fluorescent lamps. 

Capacitors for use in tubular fluorescent high 

pressure mercury and low pressure sodium vapor 

discharge lamp circuits. 

Ballasts for high pressure mercury vapor lamps. Light 

fittings and luminaries. 

Page 90 of 97


Amendment 

Title 

78 IS:10322 (Part 5 / Sec. 3) Luminaries : Particular requirements: luminaries for 

1987 

road and street lighting. 

79 IS:10322 (Part 5 / Sec.4) – Luminaries : Particular requirements: luminaries for 

1987 

road and street lighting. 

79 IS: 10322(Part 5 / Sec 5) 

1987 

Luminaries : Particular requirements: Flood lights. 

80 IS: 3287 – 1965 

81 IS: 2206 (Part 1) – 1984 Flame proof electric lighting fittings : Wall glass and 

bulk head types. 

82 Is:3528 – 1966 

83 IS: 3553 – 1966 

84 IS: 9030 – 1976 

85 IS: 7537 – 1974 

86 IS: 9583 – 1981 

87 IS: 9583 – 1981 

Electric Appliances 

88 IS: 6236– 1971 

Direct recording 

89 IS: 1248 (Part 1) – 1983 Direct acting indicating analogue electrical measuring 

instruments 

requirements. 

and their accessories: General 

90 IS:1248 (Part 2) – 1983 Direct acting indicating analogue electrical measuring 

instruments and their accessories: Ammeters and 

voltmeters. 

91 IS:1248 (Part 3) – 1983 Direct acting indicating analogue electrical measuring 

instruments and their accessories: Wattmeters and 

Varmeters. 


instruments and their accessories: ssories: Frequency meters. 


instruments and their accessories: Phase meters, 

power factor meters and synchronoscope. 

94 IS: 722 (Part 1) – 1988 AC electricity meters: General requirements and 

tests. 

95 IS: 722 (Part 2) - 1977 AC electricity meters: Single-phase phase whole current 

watt hour meters, class 2. 

96 IS:722 (Part 3) – 1977 AC electricity meters: Three phase whole current and 

transformer operated and single phase transformer 

operated watt hour meters, class 2. 


Industrial lighting fittings with plastic reflectors. 

Water proof electric lighting fittings. 

Water tight electric lighting fittings 

Luminarires for hospitals. 

Road traffic signals. 

Emergency lighting units. 

Emergency lighting units. 

Page 91 of 97


Amendment 

Title 

97 IS: 722(Part 5) – 1980 AC electricity meters: Volt-ampere ampere hour meter for 

restricted power factor range : General requirements. 

98 IS:722 (Part 7)/Sec.1 - AC electricity meters : Volt-ampere ampere hour meter for 

1987 

full power factor range: General requirement 

99 IS: 722 (Part 8) 1972 

100 iS: 722 (Part 9) 1972 

101 IS: 8530 – 1977 

102 IS: 2992 - 1987 

Instrument Transformers 

103 IS: 2705 (Part 1) -1981 1981 Current transformers: General Requirement 

104 IS: 2705 (Part 2) -1981 1981 Current transformers: Measuring current 

transformers. 

105 IS: 2705 (Part 3) -1981 1981 Current transformers: Protective current 

transformers. 

106 IS: 2705 (Part 4) -1981 1981 Current transformers: Protective current 

transformers for specific purpose applications. 

107 IS:6949 – 1973 

Fuses 

108 IS: 9224 (Part 1 ) – 1979 Low voltage fuses : General requirements. 

109 IS: 9224 (Part 2 ) – 1979 Low voltage fuses : Supplementary requirements for 

fuses for Industrial applications. 

110 IS: 2086 – 1982 

111 IS: 9926 – 1981 

112 IS: 8187 – 1976 

Miscellaneous 

113 10000/1980/Pt.1to12 Methods of tests for IC Engines 

114 10028/Pt.1/1985 Code of Practice for Selection ,installation & 

maintenance of Transformers - Selection 


AC electricity meters: Single phase 2 wire whole 

current watt-hour meter (Class 1.0). 

AC electricity meters: Three phase whole current and 

transformer operated Watt-hour hour meters, and single 

phase two wire transformer operated watt watt-hour 

meters (Class 1.0). 

Maximum demand indicators. 

Insulation testing testers 

Summation current transformers. 

Carriers and bases used in rewireable type electrical 

fuses upto 650 volts. 

Fuse wire used in rewireable type electric fuses upto 

650 volts. 

D – Type fuses 

Page 92 of 97


Amendment 

Title 

115 10028/Pt.2/1981 Code of Practice for Selection ,installation & 

maintenance of Transformers - Installation 

116 10322/Pt.3/1984 

117 10322/Pt.4/1984 

118 10322/Pt.5/ Sec.2/1985 Luminaries :Particular Requirements : Portable 

general purpose Luminarie 

119 1239/Pt.1/1990 

120 1239/Pt.2/1992 

121 1255/1983 

122 12640/Pt2/2001 

123 13118/1991 

124 1367/Pt.3/1991 

125 1367/Pt.XIII/1983 

126 13925/Pt1/1998 

127 13925/Pt2/2002 


Specification for Luminaries :Screw & Screw less 

Terminals 

Specification of Luminaries :Methods of Tests 

Mild Steel Tubes ,Tubulars & other wrought Steel 

Fittings : Mild Steel Tubes 

Mild Steel Tubes ,Tubulars & other wrought Steel 

Fittings : Mild Steel Tubulars and other wrought steel 

pipe fittings 

Code of Practice for installation maintenance of 

power cables upto and including 33KV rating 

Residual Current Operated Circuit Breaker for 

household and Similar uses : Circuit Breakers with 

Integral Over Current Protection (RCVOs) 

Specifications for High Voltage Alternating Circuit 

Breakers 

Fasteners -Threaded steel -Technical Technical Supply 

Conditions - Mechanical Properties and test methods 

for bolts ,screws and studs with full load ability 

Technical Supply Conditions for Threaded steel 

Fasteners --- Hot dip Galvanized coating on threaded 

fasteners 

Shunt Capacitors for ac power system having a rated 

voltage above 1000v : General performance ,testing 

rating safety requirements - guide for installation and 

operation 

Shunt Capacitors for ac power system having a rated 

voltage above 1000v : Endurance testing 

Page 93 of 97


Amendment 

Title 

128 13947/Pt.1/1993 Specification for Low voltage switchgear and control 

gear - General Rules 

129 13947/Pt.2/1993 

130 13947/Pt.3/1993 

131 1445/1977 

132 1460/2000 

133 14772/2000 

134 2016/1967 

135 2026/Pt.1/1977 

136 2026/Pt.2/1977 

137 2026/Pt.3/1981 

138 2026/Pt.4 / 1977 

139 2086/1982 

140 2121/Pt.1/1981 

141 2121/Pt.2/1981 

142 2268/1994 

143 2551/1982 

144 2713/Pt.1 to 3 

145 3043/1987 

146 3419/1988 


Specification for Low voltage switchgear and control 

gear - Circuit Breakers 

Specification for Low voltage switchgear and 

controlgear -Switches Switches ,Disconnectors ,Switch 

Disconnectors and Fuse combination Units 

Porcelain insulators for overhead power lines with a 

nominal voltage voltage up to and including 1000 

volts 

Diesel Fuels : Specification 

General requirements for enclosures for accessories 

for house hold and similar fixed Electrical installations 

- Specification 

Specification for plain washers 

Power Transformers :General 

Power Transformers :Temperature rise 

Power Transformers :Insulation Level and dielectric 

tests 

Power Transformers :Terminal marking ,tappings and 

connections 

Carrier and based used in rewireable type electric 

fuses for voltage up to 650 volts 

Conductors and earthwire accessories for overhead 

power lines : Armour rods ,winding wires and tapes 

for conductors 

Conductors and earthwire accessories for overhead 

power lines : Mid span jionts and repair sleeves for 

conductors 

Electric call bells and buzzers for indoor use 

Danger Notice Plate 

Specifications for Tubular Steel Poles for overhead 

Power Lines 

Code of Practice for Earthing 

Fittings for non metallic conduits 

Page 94 of 97


Amendment 

Title 

147 3427/1969 

AC Metal Enclosed Switchgear and controlgear for 

rated voltage Above 1kV and upto and including 52kV 

148 3764/1992 

149 3837/1976 

150 3842/Pt1 to Pt.12/1967 Pt.12/1967- 

1977 

Application guide for electrical Relays for ac system 

151 3854/1997 

152 398/Pt.1/1976 

153 398/Pt.2/1976 

154 398/Pt.3/1976 

155 398/Pt.4/1994 

156 398/Pt.5/1992 

157 4540/1968 

158 4722/2001 

159 4794 (Pt.1)/1968 

160 4794 (Pt.2)/1986 

161 5300/1969 

162 5613/Pt.1/Sec.1/1985 Code of Practice for Design , Installation and 

Maintenance of over head power lines - Lines upto 

and including 11kV: Design 


Code of Safety for excavation work 

Accessories for rigid steel conduits for electric wiring 

Switches for domestic and similar purpose 

Aluminium Conductor for Overhead transmission 

purpose : Aluminium stranded conductors 


purpose : Aluminium conductors, galvanised steel 

reinforced 


purpose :Aluminium conductors, aluminised steel 

reinforced 


purpose : Aluminium alloy stranded conductors 


purpose : Aluminium Conductor galvanised steel 

reinforced for extra high voltage 

Monocrystalline semiconductor rectifier assemblies 

and equipment 

Rotating Electrical Machines - Specifications 

Push Button Switches -General General Requirement and test 

Push Button Switches -Push Push Button Switches - type 1 

Specification for Porcelain Guy Strain Insulators 

Page 95 of 97


Amendment 

Title 


Maintenance of over head power lines - Lines upto 

and including 11kV: Installation and Maintenance 


Maintenance of over head power lines - Lines above 

11kV and upto and including 220kV: Design 


Maintenance of over head power lines - Lines above 

11kV and upto and including 220kV: Installation and 

Maintenance 


Maintenance of over head power lines --400 

kV Lines 

: Design 


Maintenance of over head power lines - 400 kV 

Lines : Installation and Maintenance 

168 6639/1972 

169 7098/Pt.1/1988 

170 7098/Pt.2/1985 

171 7098/Pt.3/1992 

172 7935/1975 

173 808/1989 


Specification for Hexagonal bolts for steel structure 

Crosslinked polyethylene insulated PVC sheathed 

cables : For Working voltage upto and including 1100 

volts 


cables : For Working voltage from 3.3 kV upto and 

including 33kV 


cables : For Working voltage from 66 kV upto and 

including 220 kV 

Insulator fittings for overhead power lines with a 

nominal voltage up to and including 1100 V 

Dimentions for Hot Rolled Steel Beam , column , 

Channel Angle Sections 

Page 96 of 97


Amendment 

Title 

174 8623/Pt.3/1993 

Specifications for Low Voltage Switchgear and 

Controlgear Assemblies : Particular requirements for 

Equipments Where unskilled Persons have access for 

their use 

175 9537/Pt.3/1983 

176 9537/Pt.4/1983 

177 9537/Pt.4/1984 

178 9974/Pt.1/1982 

179 IS: 1885 (Part 1) - 1961 Electrotechnical 

definitions. 

vocabulary : Fundamental 

180 IS: 1885 (Part 9) 1966 Electro technical vocabulary: Electrical Relays. 

181 IS: 1885 (Part 11) 1966 Electro technical vocabulary: Electrical 

Measurements. 

182 IS: 1885 (Part 16) Sec 1) Electro technical vocabulary: Lighting General 

1968 

aspects. 

183 IS: 1885 (Part 16) Sec Sec-2) Electro technical vocabulary lighting: General 

1968 

illumination, lighting fittings and lighting for traffic 

and signaling. 

184 IS: 1885 (Part 16/Sec.3) Electro Technical vocabulary Lighting: Lamps and 

1967 

Auxiliary apparatus. 

185 IS: 1885 (Part 17 1979 Electro Technical vocabulary Lighting : Switch gear 

and control gear 

186 IS: 1885 (Part 32 1971 Electro Technical vocabulary Lighting: Cables, 

conductors and accessories for electricity supply. 

187 IS: 4770 – 1991 

188 IS: 56424 – 1969 


Conduit for Electrical Installation :Regid plain 

Conduits of insulating Materials 

Specification for Conduit for Electrical Installations 

:Pliable self - recovering Conduits of insulating 

Materials 

Specification for Conduit for Electrical Installations 

:Pliable Conduits of insulating Materials 

High Pressure Sodium Vapour Lamps :Standard lamp 

data sheet 

Rubber gloves for electrical purposes. 

Rubber mats for electrical purposes. 

Page 97 of 97

SECTION 7 

(CIVIL) 

1.0 GENERAL 

1.1 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 Engineer, fabrication, erection and construction of the necessary civil, 

structural tural and architectural works associated with the wagon Tippler plant.. 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 wagon Tip Tippler Plant. 

1.2 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 th the e 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 respec respect t of interpretation of any portions of this document. 

2.0 LAYOUT AND LEVELS 

2.1 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. 

2.2 The contractor has to mobilize well qualified survey team along with the survey equipment 

for day today survey work. They should use “Total Station” survey instrument for this 

purpose. 

2.3 The contractor has to setup his own laboratory to facilitate the checking of quality of civil 

works with equipments for checking of aggr aggregate, egate, sand, concrete cube, etc. 

2.4 Area cleaning including jungle,rubbish,grass,trees etc are to be included in the scope of 

bidder. 

3.0 DRAWINGS / DOCUMENTS 

3.1 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 co contractor 

and approved by the Engineer. 

3.2 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. 

3.3 Design calculations shall be done in STRAPP / M.S. Office (latest version) and Drawings shall 

Technical Specification:Sec-7, Civil 

Page 1 of 21

e prepared in Auto Cad (latest version). The aanalysis 

nalysis shall be done by using STADD PRO / 

ANSYS / STRAPP (latest version). However design may be carried out by manually, using 

computer worksheets or by using suitable software programmes, as mutually agreed by 

Employer/RITES. Final calculations and dr drawings awings shall be submitted in Compact Disc (CD) (2 

Sets 

3.4 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 

3.5 Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works shall be 

submitted structure wise and area wise for Employer’s record. However each drawing shall 

indicate te approximate quantity of structure (Sectionwise) Concrete (Grade wise) and 

reinforcement Diameterwise.) 

3.6 Structural steel fabrication drawings to be prepared by the contractor will not be approved 

by the Employer/RITES. However, the Contractor for Emp Employer’s loyer’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 

3.7 Approval of construction drawings prep prepared ared by the contractor shall not relieve the 

Contractor of his responsibility regarding the adequacy of design and correctness of the 

drawing. 

4.0 WORK DESCRIPTION. 

It includes the Civil, Structural and Architectural works related mainly to the following areas 

(but not limited to): 

4.1 Wagon Tippler Hopper, Machinery Hatches and Underground Tunnel 

Wagon Tippler hopper and machinery hatches shall consist of underground portion, which 

shall be of R. C. C., and above ground portion, which shall be of structural steel shed covered 

with Aluminium Industrial troughed sheets. It essentially consists of R. C. C. frames with R. C. 

C. wall panels on the sides and R. C. C. raft at the bottom, fixed to the frames. The top beam 

of the R. C. C. frame supports the rail supporting beams and the hopper. Minimum thickness 

of R. C. C. raft at bottom shall be 600 mm. Minimum thickness of RCC side walls shall be 600 

mm at bottom and 300 mm at top. 

No columns shall be provided inside the Machinery Hatches. 

The vertical and inclined portion of coal hopper 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 otherw otherwise 

instructed. 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. 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 discharge point. 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 hopper and machinery 

hatches, tunnels, underground (i. e. baseme basement) nt) 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 ter 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 


Page 2 of 21

cementitious coating in two layers ( slurry mix application ) as per manufacturer’s 

specification. 50 mm thick ck 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. 

Hopper shall have removable type steel grating cover. The opening size for the grating shall 

be 300 mm x 300 mm. Machinery hatches shall have removable steel chequered plate cover. 

Hopper grating shall be built of min. 200mm x 36mm thick flats. No painting/galvanization 

shall be provided in gratings. However, two coats of red oxide primer to be provided 

immediately after fabrication. 

Catwalk shall be provided along the hopper. Each machinery hatch shall be provided with a 

pair of R. C. C. stair for providing access to the base of track hopper / machinery hatch. Both 

the stairs shall be interconnected at ssuitable 

height. 

Plinth protection along with drains shall be provided along the Hopper and around 

machinery hatches. However, paving shall also be provided around machinery hatches. 

The wagon tippler hopper is a deep underground structure which is subjecte subjected to direct load 

from the loaded wagons / loco due to the rake movement over it, in addition to load due to 

coal filled hopper and lateral earth pressure. The railway loads, analysis and design of 

hopper, machinery hatches, transfer point and the portion oof 

f tunnel subjected to rail loads 

shall be as specified in design criteria. Coefficient of dynamic augmentation shall be worked 

out for a train speed of 30 kms per hour. 

Earth pressure to be considered for design shall be due to earth pressure at rest (K 

0)condition 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 hopper, machinery hatches, wagon tippler, 

transfer points (underground or with basement) and tunnels, due to ground water shall be 

ensured during execution and after execution, considering dead weight of the structure to 

be 0.9 times only, groun ground d 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 wed wedge ge 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. 

Wagon n Tippler hopper structure shall be analyzed and designed for the worst load 

combinations. 

4.2 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 trussshall be provided at upp upper node points of 

latticed girders to form an enclosure. Themaximum span of overhead gallery shall be limited 

to 25 meters unless higher spanis 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 thevertical and horizontal bracing tied in proper position. The gallery should be 

checkedfor all erection stresses that are likely to develop during handling and erection and 

ifrequired, temporary strengthe strengthening ning of gallery members during erection shall be made.Seal 


Page 3 of 21

plates under the conveyor galleries shall be provided in such a way thatcomplete 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. Hand r rrailing 

should 

not be supported on conveyor supporting stringers. The walkways shall be chequered plate 

construction with anti - skid arrangement. 

Conveyor gallery shall have Aluminum industrial troughed sheets conforming to IS:1254 on 

roof & both sides. Adequate provision of windows shall be kept on both sides of conveyor 

gallery as appended in Mechanical Section. Windows shall be provided with wire mesh as 

specified elsewhere in this specification. Cross - over with chequered plate platform and 

ladder for crossing over the conveyors shall be provided at approximately every 100 M 

intervals of conveyor. Crossover shall preferably be located over four 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 dduring 

uring execution and afterwards. 

However at the location where the overhead conveyor gallery crosses road, minimum 

clearance of 8.0m above the road crest shall be provided. 

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. 

a) In between transfer houses / buildings, four legged trestl trestles es 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 legg legged ed 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 four-legged legged trestle can have either ends hinged or one hinge and 

the other on slide type depe depending nding 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 ferred 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 struc 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 colu columns mns / ground conveyor portal 

column base shall be kept 300 mm higher than the existing ground level. 

4.3 Transfer Houses 

The over ground portion of the transfer house shall be framed structure of structural steel 

work with Aluminium Industrial troughed she sheet et 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 


Page 4 of 21

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 d on the side cladding for natural lighting. 

4.4 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 pro 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 oned 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. 

4.5 Pump Houses 

These e shall be of R.C.C. or steel framed structure with columns, beams, slab andfoundations 

etc. cladding shall be of brick work with plastering on both sides. Roofshall be provided with 

roof water proofing treatment as specified elsewhere.Underground sump and water tanks 

shall be of R.C.C. Adequate number of doors,Windows and Rolling Shutters shall be 

provided.Galvanized steel ladder / rung ladder shall be provided for access to the roof level 

ofthe pump house and water tanks. 

4.6 Pent House 

These shall be of R. C. C. framed structures with columns, beams, slabs andfoundations etc. 

Cladding shall be of brickwork with plastering on both sides. Roofshall be provided with roof 

water proofing treatment as specified elsewhere. Adequate nos. of steel doors and window windows 

shall be provided for natural lighting and ventilation. 

4.7 Toilets 

Toilet with potable water line facilities shall be provided in each of the following locations: 

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 1 No. pattern, W.C. pan with high level 

flushing cistern ( C.I. ) and all requisite fittings 

ii ) Bowl type Urinal with automatic flushing 2 Nos. cistern ( C.I. ) and all requisite fittings 

iii ) Wash Basin 630 mm x 450 mm with 2 Nos.two taps and all requisite items 

iv ) Mirror 600 mm x 450 mm x 5.5 mm thick 2 Nos.with bevelled edges ( Superior sheet 

glass ) 

v ) C.P. Brass Towel Rod 600 x 20 mm 1 No. 

vi ) Liquid Soap Container 2 Nos. 

vii ) Washing Tap ( CP Brass ) 2 Nos. 

viii ) Overhead Polyethylene water tank 1 No.(min. 500 litres capacity) 

ix ) Suitable provision for installation of water coolers. 

4.8 Staircase 

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 (min (minimum imum 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 mediu medium m 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 ab about out 1.0 metre above platform level and pipe 

posts spaced not more than 1.5 metres apart. Angle handrail post may be provided when 


Page 5 of 21

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 ncluding inner dowels at splices, brackets, belts, bends, flanges and 

chains, where required shall be plugged and welded. A minimum radius of 3 times the pipe 

diameter shall be provided at all points of direction changes in the handrail. Treads and 

landing shall be suitable for the prescribed loading. The maximum width of openings in 

gratings shall not exceed 40 mm. The minimum thickness of main bars shall be 6 mm. The 

usual span of grating will not generally exceed 1.5 meters. Stair case gratings shall be 

galvanized to grade 610g/m2 Out side stairs to transfer points shall be open type. However 

RCC slab shall be provided at the top. Stairs of control room and M. C. C. room shall be of R. 

C. C. construction, and minimum 1200 mm wide, maximum rise should not be more than 

180 mm and minimum tread with 250 mm. Numbers and arrangement (including enclosures 

etc.) of stair cases shall be such as to meet the fire safety requirement as per guide lines of 

statutory regulatory bodies. 

4.9 Trenches 

All trenches for cables or any other underground facility as detailed out elsewhereshall 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 providedwith edge protectio protection 

angles and lifting hooks. All embedments / block outs asrequired and specified elsewhere in 

these specifications shall be provided. Properdrainage arrangement shall be provided. 

Trench pre - cast cover weight shall not bemore than 65 Kgs. Trench covers n nnear 

entry or at 

road crossings shall be designedfor 10 T wheel load at centre. Pre - cast covers shall be 

designed for central pointload of 75 Kgs. R. C. C. cable trenches shall be filled with sand after 

erection ofcables, up to top level and covered with pre - cast R. C. C. covers. For 

cabletrenches 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 protectionall around cut outs / openings 

in floor slabs, edges of drains supporting grating/precast RCC covers, edges of R. C. C. 

trenches supporting pre - cast covers, supported edges of pre - cast cover, treads of RCC 

stairs. 

4.10 Approach Road 

All approach road required within battery limit is under the scope of the agency with its 

connection ion to main road. All approach roads shall be constructed with RCC over suitable 

hard sub base. 

5.0 Drainage & Water Supply Works 

5.1 Drainage System: System:- 

The drainage arrangements shall be so planned so as to ensure quick disposal of drainage 

water without stagnation tagnation and / or overflow. The water shall overflow into contractor’s R.C.C 

drain, which will lead the discharge finally into owner’s drain. Contractor’s scope shall also 

include construction of necessary culverts under the rail lines / roads as per rai railway / I. R. C. 

standards and approval of Railway culverts from concern Railway authorities 

5..2 Internal and external water supply, drainage etc.: etc.:- 

The scope for potable water supply includes all distribution systems, tanks, pipes, fittings 

etc. as required ed 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 wagon tippler area. All 

buildings (including transfer houses and crusher house) shall be provided with open surface 


Page 6 of 21

drains of minimum size of 300 mm width and 300 mm depth all around the periphery. All 

drains shall be of R. C. C. construction. All open drains shall have removable steel grating 

designed for loads as specified under loading cclause. 

lause. 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 vers 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 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 stem 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 onveying 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, contro 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, and Conveyor galleries. Galvanising 

shall be as per IS: 4736. The minimum mass of zinc coating shall not be less than 400 

gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall be subjected to testing 

as per IS: 2633, for uniformity of coating. The zinc coating shall be free from all defects as 

per IS: 2629. All rain water down comers shall be prov provided ided 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 pip pipes es 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 sing R.C.C. box culvert to be provided. For sewerage below ground 

stoneware pipes conforming to IS: 651 with concrete bedding and haunch. 

6.0 COLOUR COATED AND OTHER SHEETING WORK 

Permanently colour coated sheet of approved shade and colour using galvanize galvanized 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 st steel eel 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 strengthof 350 as per AS1397. Steel shall be colour coate coated d 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 su surface rface 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) izing) 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 stren 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 


Page 7 of 21

preferably be not less than 4.5 cut pieces shall not be used, unless specifi 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. The nominal depth 

of trough shall be 30 mm. The polycarbonate sheet to be uused 

sed 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 ssheet 

heet minimum 6mm thick multi (twin) wall fire retardant 

(Continuous use under temperature 100 oC), impact resistant and ultraviolet resistant sheet 

shall be provided (as glazing) in transfer houses, pump houses, etc. 

7.0 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. For efficient 

disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This 

gradient can be provided ided either in structure or subsequently by screed concrete M MM-15 

(using 

12.5 mm coarse aggregate) and / or cement mortar (1:4). However, minimum 25 mm thick 

cement mortar (1: 4) shall be provided on top to achieve smooth surface.900 mm high and 

minimum 100 mm thick R. C. C. parapet wall shall be provided over roofs of all buildings. 

Parapet wall shall have suitable coping. External face of parapet wall of the buildings 

provided with metal cladding shall also be finished with metal cladding of design and col 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 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 provided ided using high solid 

content liquid applied urethane based elastomeric water proofing membrane to give 

uniform joint less dry film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898), 

with separate wearing course as per ASTM C - 898. This treatment shall also include 

application of polymerized mastic over the roof to achieve smooth surface and primer coat. 

Wearing course on the top of membrane shall consist of 25 mm thick P. C. C. (M (M-15) cast in 

panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized 

chickenwire 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 awidth of 

1000 mm in place of P. C. C. 

8.0 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 mi minimum nimum 6 mm thick o/p or as 

indicated on drawings. The chequered plate pattern shall be approved by Employer / RITES. 

Mild steel flats/angles of suitable size shall be welded to the bottom portion of chequered 

plates at a designed spacing to stiffen chequer chequered ed 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 st stair air case openings, chute openings and other similar cutouts. For 

conveyor walkways, angle runner to act as toe guard shall be provided. All along the 


Page 8 of 21

periphery of R. C. C. floors (where no brick masonry walls are provided)shall be provided 

with one brick thick hick 300 mm high brick wall and 700 mm high steel hand rails all around over 

this brick work. All buildings (including track hopper and machinery hatches, penthouse, 

transfer houses ) and ground conveyors shall be provided with 750 mm wide plinth 

protection n all around. It consists of 50 mm thick P.C.C. MM-20 

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 

shall be e paved. This paving will be in addition to plinth protection. Plinth level of all buildings 

shall be kept at least 500 mm above the finished grade / formation level. 

9.0 Brickwork and allied masonry works 

All brick walls shall be non - load bearing in-filled 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 sh shall all 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 pro provided vided 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. 

10.0 Earthing Mat 

2X40 mm Dia MS rod 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 aaround 

round the periphery of buildings, 

structures, and outdoor equipment, as per the approved drawings. Risers of 40 mm Dia MS 

rod and connecting to the above Earthing mat shall also be supplied and laid in position by 

the Contractor, as per the approved drawi drawings. ngs. 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 nec necessary essary number of 3.0 M deep vertical 40 mm Dia MS rod 

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 r's earthing mat separately at two locations. 

11.0 Fencing 

Fencing with toe wall and steel gates shall be provided around the transformers. Fencing 

shall comprise of PVC coated GI chain link fencing of minimum 8G (including PVC coating) of 

mesh size 75 mm and of height 2.4 m above the toe wall. The diameter of the steel wire for 

chain link fence (excluding PVC coating) shall not be less than 12G. Fence posts shall be of 

pre – cast R. C. C. of minimum M20 grade. All corner posts will have two stay posts and every 

tenth post will have transverse stay post. Suitable R. C. C. foundation for the post and stays 

shall be provided based on prevailing soil conditions. Gates shall be sturdy with locking 

provisions. Toe walls of brick masonry shall be provided between fence posts all along the 

run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above the 

formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend minimum 300 

mm below the formation level. Toe wall shall be plast plastered ered 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. 


Page 9 of 21

12.0 LOADING 

For consideration of loads on structures IS : 875 - ‘Code of practice for structural sa 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 Annexu Annexure re A and B respectively in Civil Section, 

whichever is governing. Wind and seismic forces shall not be considered to act 

simultaneously. The following minimum live loads shall be adopted for the design of various 

structures. If actual expected load is more than the specified load, then actual load is to be 

considered 

a )Roofs 150 Kgs. / Sq. M. for accessible roofs and 75 Kgs. / Sq. M. for non 

accessible roofs. In addition to this coal dust load of 150 KKgs. 

gs. / sq. m. shall also be 

considered. 

b ) R. C. C. floors 500 Kgs. / Sq. M. 

c ) Stair and balconies 500 Kgs. / Sq. M. 

d ) Toilet rooms 200 Kgs. / Sq. M. 

e )Chequered plate floors 400 Kgs. / Sq. M. 

f ) Walkways ( including walkways in 300 Kgs. / SSq. 

q. M.conveyor galleries ) 

g)Conveyor galleries In addition to the live loads, loads due to cable trays, fire fighting / 

service water pipes shall also be considered @ 125 Kgs. / m ( minimum ) on each of the 

longitudinal girder. Roof Roof-truss members are to o be checked for supporting fire fighting 

pipes/Service water pipes. 

h ) Road Culverts and its allied For class 'AA' loading and checked for structures including R. 

C. C. pipe class A loading as per IRC standard crossing & road crossing of trenches. 

i ) Channels / trenches In addition to earth pressure and water pressure, etc. additional 

earth pressure due to surcharge of 2T / Sq. M. shall 

j ) Covers for trenches/channels Covers for channels & trenches, shall be designed for a live 

load of 0.4T Sq.M. M. &loading mentioned under clause in trenches, whichever is critical. 

k ) Sumps and tanks and other In addition to earth pressure with a underground basement 

type surcharge of 2T / Sq. M. (or surcharge structures due to Railway loading whichever 

is critical for Railway load bearing structures etc.) and sub - soil water pressure etc. These 

are also to be designed for the following conditions : 

i ) Water / liquid inside and no earth outside (applicable only to such structures which are 

liable to be filled up with water or any liquid ). 

ii ) Earth with surcharge outside and no water / liquid inside 

iii ) For underground (basement) structures protection against buoyancy during execution 

and after execution shall be ensured without superimposed loadings with minimum factor 

of safety of 1.2 against buoyancy. 

l ) Unit weight of coal shallbe taken as 1100 Kgs. / cum. Fordesign purposesIf the er 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 windload or seismic load shall be as per relevant I. R. S. and I. 

S. code. 

13.0 DESIGN CRITERIA 

The loads for all railway load bearing structures e. g. track hopper includingmachinery 

hatches, wagon tippler, tunnel and under ground transfer houses etc. and the analysis and 

the design of these structures shall be made strictly in accordancewith the pr provisions of 

Indian Railway Bridge rules (latest edition), and Indian RailwayCodes of practice (latest 


Page 10 of 21

edition) with all amendments up to the date of opening ofbids. However, the axle load for 

analysis and design shall be considered as 35 MT.Coal heap of 1. 1.2m 2m height shall be 

considered above hopper top for design of, hopper and supporting elements of hopper. The 

analysis, design anddetail drawing for the structure coming below the railway track shall be 

got approvedby the contractor from the concerned railw railway ay authorities before taking 

upconstruction. 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 forplain 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 mum size of the angle section to be used as structural members shall be 

50X50X6. Minimum weld size shall be 6 mm. Connections shall bedesigned 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 supp 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. Th The e 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. Horizontal 

bracing system shall be provided at flo floor or 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 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 struct 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 tthe 

he deflection of metal sheet used is limited to 

span/250 under adverse loading condition. Minimum reinforcement shall be provided at the 

top face of the footing, even if, no reinforcements are required as per design 

14.0 CONCRETE 

All R. C. C. works to the done under this specification, unless specified otherwise shall be 

design mix concrete. Minimum grade of concrete for various structures shall be as follows: 

a ) M35 - For all railway load bearing structures 

b ) M25 - For underground / sub structural R. C. C. work (other than railway load bearing 

structures). 

C ) M20 - For R. C. C. superstructure works including ground floor slabs, trenches & drains. 

Minimum 75 mm thick P.C.C MM-7.5 

7.5 shall be provided as mud mat below all foundations. For 

concreting of underground structures requiring water tightness, plasticizer cum water 

proofing admixture shall be added to the concrete mix. Both coarse and fine aggregates shall 

conform to IS: 383 for concrete, shotcreting etc. unless otherwise directed. Batching plant 

or reversible drum mixer with weigh batcher and concrete pumps must be used for all 

concreting works(RCC). 

15.0 Excavation Details 

15.1 Excavation in soil 

Excavation for foundation shall be to the bottom of lean concrete and as shown on drawing 


Page 11 of 21

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: 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 ppiling, 

iling, 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 within 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. 

15.2 Excavation avation in rock 

For the work of excavation in rock, Contractor shall engage specialized 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 det details ails of relevant experience in 

support while seeking approval for the agency agency. Only Control Blasting shall be resort resorted to 

with the written permission of the Engineer. In case blasting method can not be adopted 

considering the safety aspect of the existing rrail 

ail network, buildings, structures etc, hard rock 

shall be excavated by using expansive chemical or any other suitable means means. 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 es 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 within plant boundary wall as directed by th 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 shuttering, , concreting, backfilling is 

completed. 

15.3 De-watering watering of Deep Excavations 

For deep underground structures like wagon tippler hopper, machinery hatches, tunnels and 

underground transfer houses, requiring open excavation with extensive de - watering, 

completely letely 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. 

15.4 Backfilling, ng, 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. 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 mate materials rials 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. If directed by the Engineer this material shall be 

used directly for filling illing 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 


Page 12 of 21

maintaining of the Kuccha roads shall be the responsibility of the Contractor. The 

transported material shall be neatly stacked as directed by the Engineer. Double handling of 

materials shall be avoided as far as possible. However, depending on site condition 

excavated materials carried beyond a lead of 500 m may also be required to be brought back 

for filling purpose. Materials to be used for filling purpose shall be stone, sand or other 

inorganic materials and they shall be clean and free from shingle, salts, organic m mmatter, 

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 ion 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 utilizationof borrow areas. 

16. 0 GALVANISING SING 

All burrs and irregular edges of the structural steel members to be galvanized shallbe ground 

smooth before galvanizing.Purity of Zinc to be used for galvanizing shall be 99.5 % as per IS : 

209 ( latestedition ).The weight of the zinc coating shall be at least 610 Gms. /m2unless 

noted otherwise. 

17.0 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 excee exceeding 1.5 

m c / c before concreting operation. Adequate precaution shall betaken to keep the nozzles 

plugged at both ends to prevent them from getting closedby concrete. For fixing of any 

nozzle in set concrete suitable size hole shall be drilled, preferabl preferably y 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 shal shall l be injected through the net - work of 

nozzles with low pressure grout pumps at a pressure of about 2.0Kgs. /cm2. Cement slurry 

shall be prepared by mixing cement with non non-shrink 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 solut solution ion (water and polymer/monomer) should not be 

more than 1.2 centipoises. Plasticizing agent shall be added wherever required. The grouting 

shall be started at very low pressure and increased gradually to a required pressure. The 

grouting shall continue, ti till ll 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 POLYMER MODIFIED CEMENTITIOUS COATING 

18.1 Materials 

Modified liquid polymer blend shall be a dispersion containing 100 % acrylic based polymer 

solids. Polymer shall be mixed in the ratio of 1 cement: 0.5 polymer (for minimum solid 

content of polymer 30%). Portland cement based dry powder. Clean, fine specially prepared 

quartz sand approximately 0.6 mm size. 

18.2 Mixing 

The liquid polymer shall be stirred well and cement based powder shall then be added 


Page 13 of 21

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. 

18.3 Properties of Coating 

It must adhere to wet surface. It should develop adequate bond strength, with the concrete 

surface, not less than 2N / Sq. mm.Co - efficient of permeability shall be about 5x10Cm / 

Sec.-1 0 Water r absorption after continuous soaking shall not be more than 1 %. The 

materials shall be permeable under water vapor. The material shall be resistant to acids and 

alkalis 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. Fo For r exterior underground part, 

application (b) pertaining to Brush topping Mix shall be followed. 

(a) For Slurry Mix 

A minimum of 2 coats shall be applied on the surface. The first coat being applied, when 

the surface is still damp and left to harden for 4 to 6 hours. After 4 to 6 hours of the 

application of second coat, it shall be finished by rubbing down with a soft dry sponge. 

The coverage shall not be less than 1 : 1 Kgs. / m in the 2 coats. A lap of 75 2 mm shall be 

provided at the joints. The coating shal shall l 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 firstapplied on the 

surface as first coat. After the coating has dried up, a coat of BrushTopping Mix shall be 

applied over it with a push broom or any other similar brush. Itshall be left in broom finished 

condition. The nominal thickness shall be 1.5 mm andminimum thickness shall be 1.0 mm. A 

lap of 75 mm shall be provided at the joints. Itshall be ensured that no pinhole exists and 

rebrushing shall be done to cover thepinholes, if any.The Coating shall be air dried for 4 to 6 

hours and thereafter cured for 7 days afterthe application of last coat.Rate of application of 

coating shall be established to achieve the required thickness. 

19.0 Architectural Features 

All architectural features of buildings like control rooms, M. C. C.rooms, transfer houses and 

conveyor galleries etc. shall be detailed by contr contractor’squalified actor’squalified architect. Necessary 

projections, fins etc. in addition to the minimumspecified elsewhere in this specification 

shall be provided as required. The Contractor for Employer/RITES’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 aadequate 

dequate 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 

skinreinforcement of the encasing. 

20.0 Glazing 

Window glazing for various locations shall be as below: 

(i)In transfer er houses and pump houses etc: Polycarbonate sheet. 

(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 therma thermal insulation at 

partition of A / C and non A / C areas. 


Page 14 of 21

(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. 

21.0 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 m mminimum 

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. Suitable M. S. channel (Minimum ISMC 75) 

grid shall be provided above the false ceiling level for movement of personnel to facilitate 

maintenance of lighting fixtures, AC 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 insulat insulation ion 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. 

22.0 Acid / Alkali Resis 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 / Cheque Chequered red plate cover and any 

other steel structure likely to come in contact with chemicals shall be provided with epoxy 

coating 150 microns thick over epoxy primer. Acid / Alkali resistant lining material shall 

conform to the following: Bitumen primer shall co conform nform 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. 

23.0 FINISHING SCHEDULE 

The contractor's scope also includes all doors, windows, glazing, rolling shutters, f ffinishes, 

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. 

23.1 Flooring 

I. P. S. ( cement concrete flooring ) with metallic hardener topping shall be provided for all 

floors in transfer houses, including ground floors of transfer houses, ground conveyors, 

operating floor of pump houses, M. C. C. rooms, cable vault / cable spreader rooms, 

maintenance enance 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, office rooms, laboratories, control rooms and control eq equipment 

rooms. Well polished Kota stone shall be provided for staircases, passages, lobbies and 

general circulation areas. The floor shall be laid on an already laid and matured concrete 

base. Sunken R. C. C. slab shall be provided in toilet area so as to keep the finished floor 

level of these areas same as that of the surrounding area Wherever specified metallic 

hardener topping shall be 12 mm thick using uniformly graded iron particles, properly 

treated. Wherever specified Heavy duty ceramic tiles of siz size e 300 x 300 x 7 mm thick 

(minimum) of reputed manufacturer (Kajaria, Spartek or equivalent) of approved finish, 

shade and colour to be used. The tiles shall have a scratch resistance of minimum 5 on 

Mohr’s scale and shall have a bending strength of 350 Kgs Kgs. . / cm.2 Paving details shall be 

similar to grade slab excluding metallic hardener. Skirting in general shall be 150 mm high. 


Page 15 of 21

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 ffinish. 

23.2 Interior Wall / Ceiling Finish 

For all air - conditioned areas and stair case acrylic emulsion paint of approved make and 

shade over 2-3 mm cement based putty of approved make shall be provided provided. For toilets 

minimum 5 mm thick decorative coloure coloured d 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 2-3 mm cement based putty of approved make above 2.10 m height shall be 

provided. For all other area areas s oil bound distemper ( IS : 428 ) of approved shade over cement 

based putty of approved make 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 e 2.1 m height. Up to 2.1 m height from finished floor level acid alkali resistant 

tiles shall be provided as specified elsewhere. All R. C. C. ceilings shall be oil bound 

distemper over cement based putty putty. 

23.3 Exterior Finish 

Aluminium Industrial troughed sheet 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. Exterior weathered coat paint 

shall be provided for the under mentioned areas : 

(a) All buildings with R. C. C. framework unless specified otherwise in this specification 

(b) Brick work in the lower portion of metal cladding. 

(c) Fire walls 

(d) Projections and facia : R. C. C. parapets ( excepting parapets of buildings 

(e) where metal cladding is specified )Exterior brick walls. 

24.0DOORS, DOORS, WINDOWS AND ROLLING SHUTTERS. 

24.1 Doors and Windows 

All doors, windows and venti ventilators of control room building and M. C. C. buildings shall have 

Electro colour coated (anodised) aluminium frame work with glazing. All doors of office and 

toilet areas shall be of factory made pre pre- laminated particle board (M D F exterior grade). All 

other buildings shall have steel doors, windows and ventilators. Single glaz 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. louv 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 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 ctrically 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 ovided with suitable stays. All windows and ventilators onground floor of all switchgear 


Page 16 of 21

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 pe per r 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. Thes These e doors shall be double cover 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. Doors and windows on ext external ernal walls of the buildings having brick enclosures i.e. 

enclosure other than with Aluminium Industrial troughed sheet cladding, shall be provided 

with sunshade over the openings with width 600 mm more than the opening width. 

Projections from the wall fo for r 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 a ) 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 als 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. TThe 

he frames shall be of ISMC 

100. 

24.2 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 f ffree 

performance. 

25.0 PAINTING 

Painting of all steel structures, including seal plates, hand rails, steel doors & windows, 

ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc. shall be as per 

specification mentioned elsewhere in this document. 

26.0 Miscellaneous 

26.1 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 an and d ceilings in control room and M. C. C. buildings. 

26.2 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 prov provided ided with steel frame doors preferably sliding type or otherwise 

open able inside, access platforms and ladders. 

26.3Steel Steel frame around openings in roof and on external walls for mounting of exhaust 

fans shall be provided. 

26.4 Ready mix non - shrink nk cementitious grout of reputed manufacturer as approved by 

the Employer shall be used for grouting of block outs and foundation bolts, underpinning of 

base plates and machine bases. Crushing strength of grout shall be one grade higher than 

the foundation concrete. Minimum crushing strength shall be 30 N / mm2 unless higher 

strength requirement is specified by the equipment supplier or the grout manufacturers. 

26.5The The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m 


Page 17 of 21

above e 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. 

26.6Polysulphide Polysulphide Sealing Compound shall be two two-part part polysulphide sealant and shall be 

from om 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 manufactur manufacturer’s 

guidelines 

27.0 SHOTCRETING 


27.2 Generally, shotcreting shall be done in accordance with IS : 9012. 

27.3 Reinforcement for shotcreting shall be as detailed below, unless specified otherwise. 

(i) Reinforcement in one directio direction n 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. 

(ii) Wire fabric conforming to IS : 1566 shall be used as reinforcement and sh 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. 

(ii) Clear cover r 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 25mm for ordinary 

surface protection work. 

27.4 Material 

Generally, the materials shall be in accordance wwith 

ith aggregates specification given 

hereunder. 

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.Fine aggregate (Sand) 

shall be well graded and particles shall range in size within the following limits. The Engineer, 

may ay approved the use of any other grading as per requirement or as erIS : 9012. 

The fineness modulus shall be preferably between 2.5 and 3.3. Any other value an be used, 

with prior approval of the Engineer. 


After the placement of reinforcement and / or welded mesh and not more than six ours 

prior to the application of shotcrete, the surface shall be thoroughly cleaned of all loose 

aterials and dirt. The Contractor shall properly prepare the surfaces, reinfo reinforcement and / or 

welded esh to receive the shotcrete. Cleaned surfaces shall be wetted not more than hour 

prior to hotcreting. 

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 mixed; ; not water shall be added after mixing and before 

sing 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. 

A uniform pressure of not less than 25 Kgf / Cm2 at the nozzle shall be maintained. 

Necessary adjustments shall be made to ensure this pressure, taking into account the length 

of ose and height of the place to be shotcreted, above location of the machine. 

The application shall proceed in an upward direction. Beams, stiffeners andintermediate 

walls, if any, shall be wrapped with wire fabric and completely covered with hotcreting hotcreting. All 

rebound shall be removed from the area of application as the work progresses andsuch 

rebound material shall not be reused. 


Page 18 of 21

As soon as the freshly shotcreted surface shows the first dry patches, a fine spray 0f water 

shall be applied to keep too moist moist. . After the surface has hardened, it shall be kept 

continuously moist for minimum seven days. If there is extreme heat, especially when 

ccompanied by hot winds, the shotcreted surface, immediately upon completion, shall be 

covered with burlap or similar co covering, vering, which must be kept continuously moist for 14 days 

after shotcreting. The temperature of the lining shall not be permitted to exceed 38 oC 

during placing and curing. 

28.0 PTFE (Poly Tetra Fluoroethylene) Bearing 

The bearing shall be of reputed make and manufacturer as approved by theEngineer, for 

required vertical load and end displacement/rotation. PTFE bearingshall be sliding against 

highly polished stainless steel and the coefficient of frictionbetween them shall be less than 

0.06 at 55 kg/sq.cm. In order to prevent cold flow inPTFE surface it shall be rigidly bonded by 

a special high temperature resistanceadhesive to the stainless steel substrata. The stainless 

steel surface that slidesagainst the PTFE is mirror polished. The stainless steel shall be 

bonded to the topplate by special high strength adhesive. The thickness of stainless steel 

plate shallbe between 1.0 mm to 1.5 mm. 

29.0 TESTS FOR MATERIAL / WORKMANSHIP 

All tests required for all materials, quality of workmanship or any other tests asdesired by 

the Engineer shall be at contractor’s cost. 

30.0 MATERIALS 

30.1 For Civil, Structural and Architectural works 

Employer will not supply any material. All materials including cement, reinforcementsteel 

and structural steel, whatsoever required ffor 

or execution and completion of theentire scope 

of work covered under this specification shall be arranged by thecontractor at his own cost. 

All materials procured by the contractor shall meet thequality requirements specified in this 

specification.The contractor ractor shall keep sufficient stock of cement and steel at site at any 

point oftime when the work is in progress excluding what has been already incorporated 

inthe works, so that any disruption / delay in availability of these materials 

duringprocurement will ll not affect the progress of work at site. The minimum quantity 

ofsuch 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 caseof Steel. 

30.2 Cement 

The contractor shall use cements conforming to, IS: 455, IS: 8112. Higher grade of cement 

namely GR - 53 of ordinary portland cement conforming to IS: 12269 can also be used. 

30.3 Reinforcement steel shall conform to 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). 

30.4 Structural steel: 

Rolled olled sections and plate shall conform to Grade A as per IS: 2062 2062-1992 1992 and/or as per 

specification specified at relevant clauses clauses. 

31.0 Guarantee for water proofing 

The contractor shall furnish guarantee for the water proofing or similsr work wherever it is 

included in civil work for three years. The contractor shall furnish a Bank Guarantee 

equivalent to 105 of the value of water proofing work to be valid additional two years 

beyond the defect liability period of the contract. The BG/SD towards the defect liability 

period can be returned only on submission of bank guarantee for water proofing as stated 

above. 

32.0 CODES AND STANDARDS 


Page 19 of 21

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 thi 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. 

nforcement. 

IS : 456 Code of practice for plain and reinforced concrete. 

IS : 458 Specification for concrete pipes. 

IS : 516 Method of test for strength of concrete. 

IS : 800 Code of practice for use of structural steel in general building construction 

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 ows 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 Masonry walls. 

IS : 1948 Specification for aluminium doors, windows and ventilators. 

IS : 2062 Steel for general structural purposes. IS : 2131 Method of standard penetration 

test for soils. 

IS : 2212 Code of practice for brickwork. 

IS : 2645 Specification for Integral cement water proofing compounds. 

IS:2720 (Part-II, Methods ethods of test for soils - determination for water content 

IV TO VIII, XIV, etc code of practice for earth work on canals. XXI, XXIII, XXIV, XXVII TO XXIX, 

XL) 

IS : 2911 Code of practice for design and construction of pile foundations. 

(Part-1/Sec.1) Driven iven cast in situ concrete piles. (Part (Part-1/Sec.2) 1/Sec.2) Bored cast cast-in-situ concrete 

piles. (Part-IV) IV) Load test on piles. IS : 2974 (Part – I Code of practice for design and 

construction of machine TO V) foundations. 

IS : 3370 (Part I to Code of practice for con concrete crete structures for the storage of IV) 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 cons construction truction 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 Cement. 

IS : 9103 Specification for admixtures for concrete. 


Page 20 of 21

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 89 Standard guide for use of high solid content, cold liquid liquid-applied 

elastomeric 

water proofing membrane for use with separate wearing course. AS/NZS 2728 Pre finis 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 


Page 21 of 21

1.0 GENERAL 

1.1 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. 

1.2 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 fo for the 

purpose of overall responsibility and co co-ordination 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. 

2.0 REGULATION OF LOCAL AUTHORITIES AND STATUTES 

2.0.1 In n 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 sub-contractors 

currently employed on or connected with the contract. 

2.0.2 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 pection 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 re-arranged arranged due to the fault 

of the Contractor or his Sub Sub-Contractor, Contractor, the additional fees for such inspection and/or 

registration shall be borne by the Contractor. 

2.1 Qualification ation 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 NALCO for review. 

Welding procedure shall indicate all essential aand 

non-essential essential parameters as per ASME 

Section IX. Makes of welding consumables shall be subject to employer’s approval. 

3.0 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 

Technical Specification:Sec-8l 

SECTION 8 

Page 1 of 23

Employer for review, Employer's acceptance of such site routings shall be obta obtained before the 

piping is erected. All these site run piping shall be installed in such a manner as to present an 

orderly and neat installation. They shall be located as to avoid obstruction of access and 

passages. Valves, instruments or any other special items shall be located convenient for 

operation by the operating personnel. Pipe runs shall be plumb or level except where pitch for 

drainage is required. Pipe runs that are not parallel to the building structure, walls or column 

rows shall be avoided. No miscellaneous pipe shall be routed and installed above or adjacent 

to electrical equipment. 

4.0 PIPING SUPPORTS 

4.1 Hangers, supports and anchors shall be installed as required to obtain a safe, reliable and 

complete pipe installation. All supports shall be properly levelled 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. 

4.2 The hanger assemblies shall not be used for the attachm attachment ent 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 onstant 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 s sshall 

be adjusted to 

the cold positions. If necessary, the spring support shall be re re-adjusted 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. 

5.0 CODE REQUIREMENTS 

The erection requirements and procedures to be followed during the installation of the 

equipment shall be in accordance with the relevant Indian Electricity Rules & Codes, Indian 

Boiler Regulations, ASME codes and accepted good practices, the Employer's Drawings and 

other applicable Indian recognised codes and laws and regulations of the Government of 

India. 

6.0 ELECTRICAL SAFETY REGULATION 

REGULATIONS 

6.1 In no circumstances will the Contractor interfere with fuses and electrical equipment 

belonging to the other Contractor or Employer. 


Page 2 of 23

6.2 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 appli appliances may 

be connected. 

6.3 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. 

6.4 The Contractor shall employ the necessary number of qualified, full time electricians to 

maintain his temporary electrical installation. 

7.0 REMOVAL OF MATERIAL 

No material brought to the Site shall be removed from the Site by the Contractor and/or his 

Sub-Contractors Contractors without the prior written approval of the Employer. 

8.0 INSPECTION, TESTING AND INSPECTION CERTIFICATES 

The provisions of the clause entitled Inspection, Testing and Inspection Certificates given in 

General Technical Requirement, shall also be applicable to the erection portion of the Works. 

The Employer shall have the right to re re-inspect inspect any equipment though previously inspected 

and approved by him at the Contractor’s works, before and after the same are erected at Site. 

If by the above inspection, the Employer rejects any equipment, tthe 

he 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 execution of such of those works of other CContractors 

ontractors and/or agencies, which might have 

got damaged or affected by the replacements or re re-work work done to the Contractor’s work. 

9.0 ACCESS TO SITE AND WORKS ON SITE 

9.1 Suitable access to site and permission to work at the Site shall be accorded to th the Contractor 

by the Employer in reasonable time. 

9.2 In the execution of the Works, no person other than the Contractor or his duly appointed 

representative, Sub-Contractor Contractor and workmen, shall be allowed to do work on the Site, except 

by the special permission, sion, in writing by the Employer or his representative. 

10.0 CONTRACTOR’S SITE OFFICE ESTABLISHMENT 

The Contractor shall establish a Office at the Site and keep posted an authorized 

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 


Page 3 of 23

esident representative oof 

f the Contractor and the same shall be deemed to have been 

communicated to the Contractor at his legal address. 

11.0 CO-OPERATION OPERATION WITH OTHER CONTRACTORS 

11.1 The Contractor shall co-operate 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 ex 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 expen 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 de delayed layed 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 sit site e at any time for inspection and surveillance 

checks. 

11.2 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 res if any, required to rectify this situation after inspection of the works 

and such decisions by the Employer shall be binding on the Contractor. 

12.0 DISCIPLINE OF WORKMEN 

The Contractor shall adhere to the disciplinary procedure set by the Employer i iin 

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 mis-conducted himself or is incompetent, mpetent, negligent or otherwise 

undesirable then the Contractor shall remove such a person objected to and provide in his 

place a competent replacement. 

13.0 CONTRACTOR’S FIELD OPERATION 

13.1 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. Su Such ch 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. 


Page 4 of 23

13.2 The Contractor shall have the complete responsibility for the conditions of the Work Work- Site 

including g the safety of all persons employed by him or his Sub Sub-Contractor 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 Work- Site, and their adequacy or otherwise. 

14.0 PHOTOGRAPHS AND PROGRESS REPORT 

14.1 The Contractor shall furnis furnish h 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. 

14.2 The above photographs shall accompany the monthly progress report detailing out the 

progress achieved on all erection activities as compare compared d to the schedules. The report shall also 

indicate the reasons for the variance between the scheduled and actual progress and the 

action proposed for corrective measures, wherever necessary. 

14.3 The Contractor shall submit the progress of work in video ccassettes 

assettes (2 copies) quarterly 

highlighting the progress and constraints at site. 

15.0 MAN-POWER REPORT 

15.1 The Contractor shall submit to the Employer, on the first day of every month, a man hour 

schedule for the month, detailing the man hours scheduled for the month, skill skill-wise and areawise. 

15.2 The Contractor shall also submit to the Employer on the first day of every month, a man 

power report of the previous month detailing the number of persons scheduled to have been 

employed and actually employed, skill- wise and the areas of employment of such labour. 

16.0 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 tthe 

he 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 supervi supervision sion 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 Contracto Contractor’s r’s Works the same shall be resolved as per the provisions of the 

as specified at clause no 11 of this chapter entitled “Co “Co-operation operation with other Contractors.” 

The Contractor shall not cause any delay in the repair of such damaged Works because of any 


Page 5 of 23

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. 

17.0 EMPLOYMENT OF LABOUR 

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 employe employed d after darkness. No person below the age of eighteen years 

shall be employed. 

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. 

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. Contractor’s employees shall wear id identification entification badges while on work at Site. 

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 Aboli Abolition tion Act or any other law due to act of 

omission by the Contractor, the Employer may make such payments and shall recover the 

same from the Contractor’s payments. 

18.0 FACILITIES TO BE PROVIDED BY THE EMPLOYER 

18.1 Space 

The Contractor shall advise the EEmployer 

mployer 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 assembly and fabrication areas, labour and staff colony area, 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 assembly and fabrication areas, labour and staff colony, toilets, etc. for Contractor's as 

well as his Sub-Contractor’s Contractor’s use. 

18.2 Electricity 

The Contractor shall submit to the Employer within thirty (30) days from the date of 

acceptance of the Notification of Award, his electrical power requirements, if any, to allow the 

planning anning of the same by the Employer. The Contractor shall be provided with supply of 

electricity on chargeable basis for the purposes of the Contract, only at two locations in the 

Employer’s Site and at 415V 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 colon colony. y. Power supply for labour and staff 

colony shall be provided at one point and the Contractor shall be charged at rates prevalent at 


Page 6 of 23

the site. Illumination of wagon tippler and the conveyor area shall be the scope of the 

tenderer. 

18.3 Water 

Contractor shall make all arrangements himself for the supply of construction water as well as 

potable water for labour and other personnel at the worksite/colony. 

18.4 Communication 

The Employer will extend the telephone facilities, if available at Site, for purpos purposes of Contract. 

The Contractor shall be charged at actuals for such facilities. 

19.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR 

19.1 Contractor's site office Establishment 

The Contractor shall establish a site office at the site and keep posted an autho authorized 

representative for the purpose of the contract, pursuant to GCC. 

19.2 Tools, tackles and scaffoldings 

The Contractor shall provide all the construction equipments, tools, tackles and scaffoldings 

required for pre-assembly, 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 Si Site te without the written permission of the Employer. The 

Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of fabrication, 

erection and commissioning. 

19.3 Testing Equipment and Facilities: 

The contractor shall provide the necessa necessary ry testing, equipment and facilities. 

19.4 Site laboratory for civil works: 

Contractor shall provide and maintain a site laboratory for the testing of construction material 

under the direction and general supervision of employer. 

19.5 First-aid 

19.5.1 The Contractor shall provide necessary first first-aid 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. 

19.5.2 The Employer will provide the CContractor, 

ontractor, in case of any emergency, the services of an 

ambulance for transportation to the nearest hospital. 

19.6 Cleanliness 

19.6.1 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 work-area area at least once in a day. All such 

rubbish and scrap material shall be stacked or disposed in a place to be identified by the 


Page 7 of 23

Employer. oyer. 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 prote protect the floor 

from such damage. 

19.6.2 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 bbe 

e provided by the Contractor, in the work work- 

areas, office and residential areas of the Contractor. 

20.0 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 yer 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 ng properly located may be removed and/or dismantled by the Employer at Contractor’s 

expense. 

21.0 FIRE PROTECTION 

21.1 The work procedures that are to be used during the erection shall be those which minimise 

fire hazards to the extent practicable. Comb Combustible ustible 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 fe 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 re removed 

and replaced with acceptable material before moving into the construction or storage area. 

21.2 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 wel welding ding sparks, cutting flames and other similar fire 

sources. 

21.3 All the Contractor’s supervisory personnel and sufficient number of workers shall be trained 

for fire-fighting fighting and shall be assigned specific fire protection duties. Enough of such trained 

personnel ersonnel must be available at the Site during the entire period of the Contract. 


Page 8 of 23

21.4 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. 

22.0 SECURITY 

The Contractor shall have total responsibility for all equipment and materials in his custody 

stores, loose, semi-assembled assembled and/or erected by him at Site. The Contrac 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. 

23.0 CONTRACTOR’S AREA LIMITS 

The Employer will mark-out out the boundary limits of access roads, parking spaces, storage and 

construction areas for the Contractor and the Contractor and his personnel shall not trespass 

the areas into other areas of the plant. In case of a need for the Contactor’s personnel to work 

in the areas beyond that marked out for him, the same shall be done only with the written 

permission of the Employer. 

24.0 CONTRACTOR’S CO-OPERATION 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 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 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. 

25.0 PRE-COMMISSIONING COMMISSIONING AND COMMISSIONING ACTIVITIES 

(a) GENERAL 

The Contractor upon completion of installation of equipments and systems, shall conduct 

pre-commissioning commissioning and commissioning activities, to make the equipment/systems ready for 

safe, reliable and efficient operation on sustained basis. All pre precommissioning/commissioning 

/commissioning activities considered essential for such readiness of the 

equipment/systems including those mutually agreed and included in the Contractor’s quality 


Page 9 of 23

assurance programme as well as those indicated in clauses elsewhere in the technical 

specifications cations shall be performed by the contractor. 

(b) The pre-commissioning 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 he 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 th 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. 

(c) The following activities shall be carried out by the contractor, prior to schedule date of 

commissioning ioning of the equipment/systems installed by him. 

(i) 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 deplo deployed yed 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. 

(ii) The contractor shall submit the bio bio-data data containing the details of experience of his 

operation and commissioning mmissioning engineers for the acceptance of employer. 

(iii) The contractor shall furnish the deployment schedule of his operation and commissioning 

engineers for the acceptance of the employer. 

(iv) Apart from above, contractor shall ensure deployment of sufficientskilled/semi- 

skilled/unskilled manpower during pre pre-commissioning commissioning and commissioning activities. 

(d) It shall be the responsibility of the Contractor to provide all necessary temporary 

instrumentation and other measuring devices required during sstart-up 

up and initial operation of 

the equipment/systems which are installed by him. 

(e) The Contractor shall also be responsible for flushing and initial filling of all oils and lubricants 

required for the equipment furnished and installed by him so as to make such equipment 

ready for operation. The Contractor shall be responsible for supplying such flushing oil and 

other lubricants unless otherwise specified elsewhere in these specifications and documents. 

26.0 COMMISSIONING DOCUMENTATION 

(a) The contractor shall submit the commissioning documentation, comprising of Standard 

checklists, pre-commissioning commissioning procedures, testing schedules, commissioning schedules and 

commissioning networks for various equipment/systems covered under the contract, f ffor 

the 

approval of employer. 

(b) 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. 


Page 10 of 23

(c) The testing schedule sh shall all be prepared for systematic commissioning of individual 

equipment/sub-system system Commissioning. The format of testing/Commissioning schedule shall 

be such as to maintain consistency of presentation, content and reporting 

(d) The contractor shall submit the li list st 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. 

(e) The Contractor r 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. 

27.0 COMMISSIONING ACTIVITIES 

(a) Upon completion ompletion of pre pre-commissioning commissioning activities/tests, the contractor shall initiate 

commissioning of facilities. During commissioning the Contractor shall carry out system 

checking and reliability trials on various sub sub-systems of the facilities. 

(b) Contractor shall carry out the checks/tests at site to demonstrate to the Employer that 

each of the equipment of the supplied complies with requirements stipulated and is installed 

in accordance with requirements specified. 

(c) Before the plant is put into initial opera operation tion the Contractor shall be required to conduct 

test to demonstrate to the Employer that each item of the plant is capable of correctly 

performing the functions for which it was specified and its performance, parameters etc. are 

as per the specified/appro 

specified/approved ved values. These tests may be conducted concurrently with those 

required under commissioning sequence. 

(d) Other tests shall be conducted, if required by the Employer, to establish that the plant 

equipment are in accordance with requirements of the specifica specifications. 

(e) 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 sco 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 

specifications(Section- VI) 

(f) Initial Operation 

Upon completion of system checking/Tests as above and as a pa part rt of commissioning of 

facilities, complete plant/facilities shall be put into initial operation as stipulated in General 

Technical Requirements. 


Page 11 of 23

28.0 MATERIALS HANDLING AND STORAGE 

(a) All the equipments furnished under the Contract and arriving at Site shall be promptly 

received, unloaded and transported and stored by the Contractor. 

(b) Contractor shall be responsible for examining all the shipment and notify the Employer 

immediately of any damage, shortage, discrepancy etc. for the purpose of Employe 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 eerection 

rection 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. 

(c) 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 available for 

the inspection of the Employer. 

(d) All equipment shall be handled with care to prevent any damage. No bare wire ropes, 

slings, etc. shall be used for unl unloading oading and/or handling of the equipment without the specific 

written permission of the Employer. The equipment stored shall be properly protected to 

prevent damage to the equipment. 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. 

(e) 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 nd 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. 

(f) The Contractor ontractor 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. 

(g) The consumables and other supplies likely to deteriorate due to sto storage must be 

thoroughly protected and stored in a suitable manner to prevent damage or deterioration in 

quality by storage. 

(h) All the materials stored in the open or dusty location must be covered with suitable 

weatherproof and flameproof covering mater material wherever applicable. 

(i) 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. 


Page 12 of 23

(j) 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, lubricant lubricants s 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. 

29.0 CONSTRUCTION MANAGEMENT 

(a) 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 Contracto Contractors rs and tradesmen of the Employer regarding scheduling and 

co- ordination of work. Such decision by the Employer shall not be a cause for extra 

compensation or extension of time for the Contractor. 

(b) The Employer shall hold weekly meetings of all the Con Contractors tractors working at Site, at a time 

and place to be designated by the Employer. The Contractor shall attend such meetings and 

take notes of discussions during the meeting and the decisions of the Employer and shall 

strictly adhere to those decisions in per performing forming 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. 

(c) 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 t tto 

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 comp compensate ensate for the delay. The 

Contractor shall not be allowed any extra compensation for such action. 

(d) The Employer shall however not be responsible for provision of additional labour and/or 

materials or supply or any other services to the Contractor excep except t for the coordination work 

with other Contractors, if necessary. 

30.0 FIELD OFFICE RECORDS 

The Contractor shall maintain at his Site Office up 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. 


Page 13 of 23

Such drawings and Engineering data shall be submitted to the Employer in requisite number 

of copies. 

31.0 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE 

(a) 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 Contracto Contractor r 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. 

(b) The Employer shall have a lien on such goods for any sum or sums which may at any time 

be due or owing to him by the Contractor, under, in respect of or by reasons of the Contract. 

After giving a fifteen (15) days notice in writing of his intention to do so, the Employer shall be 

at liberty to sell and dispose off any such goods, in such manner as he shall think fit including 

public auction or private treaty and to apply the proceeds in or towards the satisfaction of 

such sum or sums due as aforesaid. 

(c) After the completion of the Works, the Contractor shall remove from the Site u uunder 

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 oof 

f 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 31 (b) above and credit the proceeds thereto to the account of the 

Contractor. 

32.0 PROTECTION OF PROPERTY TY AND CONTRACTOR’SLIABILITY 

(a) 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 ot other her Contractors and Sub Sub- Contractors and 

all public and private property including structures, building, other plants and equipments and 

utilities either above or below the ground. 

(b) 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 utili utilities ties 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 utilities. 


Page 14 of 23

33.0 PAINTING 

All exposed metal parts of the equipment including pipings, structure railings, etc. wherever 

applicable, after installation unless otherwise surface protected, shall be first painted with at 

least two coats of suitable primer which matc matches hes the shop primer paint used, after throughly 

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/RITES for painting. nting. Afterwards, the above parts shall be finished painted with t ttwo 

coats of synthetic enamel paint paint. . 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. 

34.0 INSURANCE 

34.1 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 Sub-Contractor’s Contractor’s manufacturing Works. 

34.2 Workmen’s Compensation Insurance 

This insurance shall protect the Contractor against all claims applicable under the Workmen’ 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 Sub-Contractor’s Contractor’s employees, 

which for any reason are not covered under the Workmen’s Compensati 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 

Property Damage: Rs.100,000 for each occurrence 

34.3 Comprehensive General Liability Insurance 

34.3.1 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 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 nditions of Contract (GCC). 

34.3.2 The hazards to be covered will pertain to all the Works and areas where the Contractor, his 

Sub-Contractors, Contractors, his agents and his employees have to perform work pursuant to the 

Contract. 

34.4 The above are only illustrat illustrative ive list of insurance covers normally required and it will be the 

responsibility of the Contractor to maintain all necessary insurance coverage to the extent 


Page 15 of 23

oth in time and amount to take care of all his liabilities either direct or indirect, in pursuanc pursuance 

of the Contract. 

35.0 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 e 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. 

36.0 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 pro provide vide all necessary materials and assistance 

for such relocation of reference points etc. 

37.0 WORK & SAFETY REGULATIONS 

37.1 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. 

37.2 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 th manufacturer’s operation Manual and safety instructions and as per 

Guidelines/Rules of Employer in this regard. 

37.3 Periodical Examinations and all tests for all lifting/ hoisting equipment & tackles shall be 

carried-out out in accordance with the relevan relevant t 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. 


Page 16 of 23

37.4 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 thes these e safety equipments to determine their suitability, reliability, 

acceptability and adaptability. 

37.5 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. 

37.6 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 equipment. 

37.7 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. 

37.8 The Contractors shall employ necessary number of qualified, full time Electricians/ Electrical 

Supervisors to maintain his temporary electrical installations. 

37.9 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 authoritie authorities 

envisaged under the applicable laws. 

37.10 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 elt 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. 

37.11 The Contractor shall not be entitled fo for r any damages/ compensation for stoppage of work due 

to safety reasons as provided above and the period of such stoppage of work will not be taken 

as an extension of time for completion of the facilities. 

38.0 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES 


Page 17 of 23

38.1 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. 

38.2 All the equipment/ equipment bases, shall be grouted and finished as per these specifications 

unless otherwise recommended by the equipment manufacturer. 

38.3 The concrete foundation surfaces shall be properly prepared by chipping, grinding as required 

to bring the top of such foundation tto 

o the required level, to provide the necessary roughness 

for bondage and to assure enough bearing strength. 

38.4 Grout 

The grout shall be high strength grout having a minimum characteristic compressive strength 

of 60 N/mm2 at 28 days. The grout shall be chloride - free, cement based, free flowing, non non- 

metallic grout. The Grout shall have good flowability even at very low water/ grout powder 

ratio. The Grout shall have characteristics of controlled expansion to be able to occupy its 

original volume to fill l the voids and to compensate for shrinkage. Grout shall be of pre 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. 

38.5 Finishing of the Edges of tthe 

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 remov removed. ed. 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. 

38.6 CHECKING OF EQUIPMENT AFTER GROUTING 

After the grout is set and cured, the Cont Contractor ractor shall check and verify the alignment of 

equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals, 

centering of rotors with respect to their sealing bores, couplings, etc. as applicable and the like 

items to ensure that hat no displacement had taken place during grouting. The values recorded 

prior to grouting shall be used during such post grouting check 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. 

39.0 SHAFT ALIGNMENTS 

All the shafts of rotating equipment shall be properly aligned to those of the matching 

equipments to as perfect an accuracy as practicable. The equipment shall be free from 

excessive vibration so as to avoid overheating of bearings or other conditions which may tend 

to shorten the life of the equipment. The vibration level of rotating equipments measured at 


Page 18 of 23

earing housing shall not exceed forty (40) microns and shall conform to VDI 2056.All 

bearings, gs, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated 

before starting. 

40.0 DOWELLING 

All the motors and other equipment shall be suitably doweled after alignment of shafts with 

tapered machined dowels as per the directi direction of the Employer. 

41.0 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 equipmen equipment t furnished and installed under these specifications and documents. 

42.0 COMMISSIONING SPARES 

42.1 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 op operation eration 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. 

42.2 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. Employer 

will be informed of the list of commissioning spares brought to site by the contractor before 

bringing the same to the site. 

43.0 CABLING 

43.1 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 ccables 

ables are run on cable trays, they 

shall be clamped at a minimum intervals of 2000mm or otherwise as directed by the 

Employer. 

43.2 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 


Page 19 of 23

cable adjacent to the terminations. Cable routing is to be done in such a way that cables are 

accessible for r any maintenance and for easy identification. 

43.3 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 igh voltage, coaxial, screened, compensating, mineral insulated shall be in 

accordance with the cable manufacturer’s recommendations. 

43.4 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. 

43.5 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 equired 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. inated. The bundles shall be firmly but not tightly tied utilizing plastic or nylon ties or 

specifically treated fungus protected cord made for this purpose. Control cable conductor 

insulation shall be securely and evenly cut. 

43.6 The connectors for control rol 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. 

44.0 EQUIPMENT DELIVERY AND ERECTION 


(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 covering detailed instructions, write up, technical data, drawings, check check-lists, 

documentation formats for all activities after equipment manufacture upto installation of 

equipment. This manual shall cover genera general l instructions for all equipment and specific 

instructions for individual equipment wherever required and shall include at least the 

following : 


i. Instructions for packing, shipping, receiving handling, ware ware-housing housing and storage. 

ii. Instructions for location an and d installation of equipment furnished by this specification. 

iii. Installation drawings for field mounted equipment, panels, cubicles and other 

equipment covered under this specification. 

iv. Instruction relating installation of piping/ tubing, support and routing drawings of 

impulse pipes/signal tubes and tube/cable trays. 

Page 20 of 23


v. Check lists and quality assurance hold points. 

vi. Format for all related documentation. 

(c.) The Manual shall conform to the requirements of this specification, all applicable codes and 

standards, recommendations mendations 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 is specification, Employer approved Manual and drawing/documents 

approved by the Employer during detailed engineering stage of work. 

44.2 Crating 

(a) All equipment and materials shall be suitably coated, wrapped, or covered and boxed or 

crated for moist humid tropical shipment and to prevent damage or deterioration during 

handling and storage at the site. 

(b) Equipment shall be packed with suitable desiccants, sealed in water proof vapour 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 s 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 dur 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 mmarkings 

arkings 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 eight and net weight in Kilograms 

4. Dimensions in centimeters 

5. Complete description of material 

Page 21 of 23

(h) Packaging or shipping units shall be designed within the limitations of unloading facilities 

and the equipment which will be used for transport. Complicatio Complications ns 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 coa coated ted 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, ing, 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. 

44.3 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 install installation ation 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 ac accordance cordance with the recommendations of 

the equipment manufacturers. The procedures shall be acceptable to the Employer. The 

Contractor shall coordinate his work with other suppliers where their instruments and devices 

are to be installed under specifications 

specifications. 

(b.) Installation Materials 

All materials required for installation, testing and commissioning of the equipment shall be 

furnished by the Contractor. 

(c.) Regulatory Requirements 


Page 22 of 23

All installation procedures shall confirm with the accepted good engineering practi 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 to installation site. 

(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 commi ssioning work described in these specifications 

specifications. 

(f.) 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 inclu included ded as a part of the work 

under these specifications. The removal of control and instrument equipment in order to 

allow bench calibration, if required, and the re re-installation installation of the said equipment after 

calibration shall also be included as a part of the work under these specifications. 

45.0 DEVIATIONS DISPOSITIONING: 

Any deviation to the contract and employer approved documents shall be properly recorded 

in the format prescribed by NALCO. Al the deviations shall be bought to the knowledge of 

employer’s representative for suitable dispositioning. 

46.0 NON-DESTRUCTIVE 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 sh shall be handed 

over to the employer. Sensitivity of all the test equipment shall be compatible to the job & 

acceptance norms agreed. 

47.0 TESTING EQUIPMENT & FACILITIES: 

Contractor shall provide the testing equipment and facilities necessary to carry out tests & 

inspections. 


Page 23 of 23

PAINTING 

1.0 GENERAL 

1.1 This specification covers the materials, tools, facilities and quality requirement for surface 

preparation and painting of steel structures, equipment, piping including supports, hangers, 

gas and air ducts including hangers, chutes etc. 

The term "painting" g" referred herein covers rust preventive, preventive and decorative coating 

along with surface protection. 

1.2 Surfaces in direct bonded contact with concrete, aluminium, asbestos, brass; bronze, 

galvanized steel, stainless steel, cast iron and other ccorrosion 

orrosion resistant alloys, 

rubber/synthetic polymers are not required to be painted unless specified except for aesthetic 

purposes or for identification bands. Except for such surfaces, painting and surface 

preparation shall be provided to protect all surf surfaces aces that shall be subjected to atmospheric 

action and exposed to corrosive medium. 

All machined mating surfaces (eg. flanges) shall be properly cleaned, greased and protected 

before dispatch. 

1.3 The complete paint system for any item includes the fo following activities: 

i) Proper surface preparation 

ii) Application of primer coats 

iii) Application of intermediate coats 

iv) Application of finished coats 

All the above coats shall be of quality paint products and of approved make as stipulated in 

this specification. The he work shall also include supply of all paint materials as per specification 

described herein and of approved quality. 

2.0 SURFACE PREPARATION 

2.1 Surface preparation being a pre requisite for any paint application, shall be such as to clean 

the surface ace thoroughly of any materials which will be conducive to premature failure of the 

paint substrates. 

2.2 All surfaces shall be cleaned of loose substances and foreign materials, such as dirt, rust, scale, 

oil, grease, welding flux, etc. irrespective of whether the same has been spelt out in the 

standards in order that the prime coat is rigidly anchored to the virgin metal surface. The 

surface preparation shall conform to pictorial representation of surface quality grade of DIN 

Technical Specification:Sec-9,Miscellaneous 

SECTION 9 

(MISCELLANEOUS) 

Page 1 of 55

55928 (Part 4) or BS 4232 or IS 1477 - 1971 ( Part I ). Any grease, oil, dust or foreign matter 

deposited on the surface after preparat preparation ion shall be removed and care taken that the surface is 

not contaminated with acids, alkalis moisture or other corrosive chemicals. The prime coat 

shall be applied as soon as possible after the surface preparation is completed. 

2.3 The acceptable surface e preparation quality / grades are described under each painting system. 

The procedures covered are solvent cleaning, hand tool cleaning, power tool cleaning and 

blast cleaning. 

2.4 Solvent cleaning 

The surface shall be cleaned by wiping, immersion, sspraying 

praying or vapor contacting of a suitable 

solvent or washing with an emulsion or alkaline solution to remove oil, grease, dirt, old paint, 

etc. Solvent cleaning shall not remove rust, scales, mill scales or weld flux. Therefore, before 

application of paint, , solvent cleaning shall be followed by other cleaning procedures as stated 

elsewhere. 

2.5 Hand tool cleaning 

The surface shall be cleaned by vigorous wire brushing done manually to St St-2 quality. This 

method effectively removes loosely adherent materi materials, als, but would not affect residues of rust 

or mill scales that are intact and firmly adherent. 

2.6 Power tool cleaning 

Electric or pneumatic tools shall clean the surface to St - 3 quality. The tools shall be used 

carefully to prevent excessive roughi roughing ng of surface and formation of ridges and burns. This 

method will remove loosely adherent materials but would not affect residues of rust or mill 

scales that are firmly adherent. 

2.7 Blast cleaning 

The surface shall be cleaned by impingement of abrasi abrasive ve materials, such as graded sand at 

high velocity created by clean and dry compressed air blast. This method will remove loosely 

adherent materials as well as adherent scales and mill scales. Prior to application of blast, 

heavy deposit of oil and grease are removed by solvent cleaning and excessive surface scales 

are removed by hand tools or power tool cleaning. The surface shall be cleaned to Sa - 2 1/2 

quality i.e. 95 % of surface area is free from all rust, mill scales and visible residues, foreign 

materials, erials, etc. The blast cleaning is not recommended for sheet metal work. 

3.0 PRIMER PAINTS (P) 

Primer paints shall be applied only on dry and clean surfaces. 

3.1 Primer paint P1 - (Phenolic - Alkyd based) 


Page 2 of 55

A single pack air drying phenolic modified alkyd composition with zinc phosphate as 

a primer paint. 

Air drying time - About 60 minutes (touch dry) 

-Overnight (hard dry) 

Dry film thickness - 40 microns (min) 

(DFT / Coat) 

3.2 Primer paint P2 - (Epoxy based) 

A two pack air drying Epoxy polyamide with zinc dust of at least 92 % zinc dust on 

the dry film. 

Epoxy content (% wt.) - 8 to 10 

Air drying time 

- 10 minutes (touch dry) 

- 2 hours (hard dry) 

DFT / coat 

- 40 microns (min) 

3.3 Primer paint P3 - (Ethyl zinc silicate, EZS, based) 

A two pack heavy duty zinc dust rich silicate primer which protects the surface with 

just a single coat. 

Total solids ( % wt ) - 84 +/- 2 

Density ( g / cc ) - 3.07 +/- 0.05 


- To top coat 16 hours 

DFT / coat 

- 60 microns 

4.0 INTERMEDIATE PAINTS ( I ) 

These paints shall be applied over primer coats as an intermediate layer to provide 

weatherproof seal of primer coats. 

4.1 Intermediate Paint I-1 1 (Phenolic alkyd based) 

A single pack high build phenolic based paint of synthetic micaceous iron oxide. 


-4 to 6 hours (touch dry) 

-2 days (hard dry) 

DFT / coat 

-75 microns (min) 

Temperature resistance --upto 

100 deg C dry heat 

Compatible with --Primer 

P1 

4.2 Intermediate Paint II-2 

A two-pack pack air drying high build epoxy resin based paint with MIO. 


- 6 to 8 hours (touch dry) 

- 7 days (full cure) 

DFT / coat 

- 100 microns 

Compatible with - Primer P2 


Page 3 of 55

5.0 FINISH PAINTS (F) 

Finish paint coats shall be applied over primer coats and intermediate coats after proper 

cleaning and touch up of primed coats. 

5.1 Finish Paint F1 

A single pack air drying high gloss phenolic alkyd modified synthetic enamel paint suitably 

pigmented. 

Air drying time -3 to 4 hours (touch dry) -24 24 hours (hard dry) 

DFT / coat 


Compatible with 

Intermediate I1 - Primer P1 

Colour 

- generally all shades 


A two pack air drying epoxy polyamide enamel suitably pigmented. 

Air drying time - 2 to 3 hours (touch dry) 

- 7 days (full cure) 

DFT / coat 


Compatible with 

Intermediate I2 - Primer P2 

Colour 

- generally all shades 


A single pack heat resistant silicon resin based paint with leafing Aluminium powder. 


- 3 to 4 hours (touch dry)/24 hrs (hard dry) 

DFT / coat 


Compatible with - no primer paint except P3 

(shall l be applied on blast cleaned steel surface) 

Colour 

- smooth aluminium 

6.0 PAINT APPLICATION 

6.1 Paint shall be applied in accordance with paint manufacturer's recommendations. 

Manufacture of paints, mixing of paints, etc. shall be as per the IS codes of practice. The work 

shall generally follow IS 1477 -1971 1971 (Part II) for jobs carried out in India and or DIN 55928 

(latest) or equivalent for jobs carried out outside India. 

6.2 Paint shall not be applied when the ambient temperature is 50 

below. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and 

above unless the manufacturer's recommendations permit. Application of paint shall be only 

by spraying or brushing as per IS 486 

0 C and d above or 45 

. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and 


by spraying or brushing as per IS 486 - 1983 and IS 487 - 1985. 

0 C and 

. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and 



Page 4 of 55

6.3 Each coat of paint shall be continuous, free of pores and of even film thickness without thin 

spots. 

6.4 Each coat of paint shall be dry sufficiently before application of next coat. 

6.5 The colour code to be followed during painting shall be intimated to the successful Tenderer 

during finalization of order. 

6.6 In the event of conflict between this general procedure for painting and the paint 

manufacturer's specification, the same shal shall l be immediately brought to the notice of the 

Purchaser. Generally in cases of such conflicts, manufacturer's specifications / 

recommendations shall prevail. 

6.7 General compatibility between primer and finishing paints shall be certified by the paint 

manufacturer anufacturer supplying the paints. 

6.8 Areas that become inaccessible after assembly shall be painted before assembly (after 

painting clearance has been given by the inspecting authority) after requisite surface cleaning 

as specified. 

6.9 Surfaces which h cannot be painted but require protection shall be given a coat of rust inhibitive 

grease according to IS 958 - 1975 or solvent deposited compound according to IS 1153 - 1975 

or IS 1674 - 1960. 

6.10 Parts of steel structures embedded in concrete shall be given a protective coat of Portland 

cement slurry immediately after fabrication and after surfaces of this part is thoroughly 

cleaned from grease, rust, mill scales, etc. No paint shall be applied on this part. 

6.11 The proposed make, quality and shad shade e of the paint shall have the approval of the Purchaser. 

6.12 Zinc rich primer paints which have been exposed several months before finishing coat is 

applied shall be washed down thoroughly to remove soluble zinc salt deposits. 

6.13 The machine finished hed surfaces shall be coated with white lead and tallow before shipment or 

before being put out into the open air. 

6.14 Total DFT for heat resistant paints should not exceed 100 -120 120 microns, otherwise flaking 

occurs ( as per paint manufacturer's recomme recommendations ). 

6.15 Heat resistant paints should be applied by brush. 

7.0 PAINTING SCHEME 

7.1 For a complete painting scheme of any item being painted, all types of paints are to be 

procured from the same manufacturer as approved by the Purchaser. 

7.2 Legend 


Page 5 of 55

SP - Surface preparation quality 

2P1 - Two (2) coats of primer paint type P1 

1I1 - One ( 1 ) coat of intermediate paint type 

I1 2F1 - Two ( 2 ) coats of finish paint type F1 

DFT - Dry film thickness 

Type of paint products like P1, P2, P3, I1, I2, F1, F2 and F3 have been specified under sl. 

nos.03, 04 and 05 of this specification. 

7.3 The painting scheme to be followed for various equipment/ structures is briefly given below 

for guidance to the Tenderer. 

Sl. No. Description 

Painting scheme 

At shop At site 

SP - St 3 

DFT Total 

1. Steel structure 2P1+1I1 2F1 100 

2. 

Mechanical 

equipment(temp. 

not over 80 deg C) 

Both static and 

rotary equipment 

for indoor or 

outdoor duty 

Equipment with 

3. hot surfaces SP- Sa 2 1/2 

(temp. 200 deg C 

and above) 

P3 2F3 100 

8.0 Colour code 

For painting certain standard colour as listed below, shall be used by the bidder. 

8.1 For electrical equipment 

DESCRIPTION 

11 kV, AC machine 

3.3 kV, AC machine 

400 V, AC machine 

460 V, DC machine 

250 V, DC machine 

230 V, AC equipment Light orange 

110 V, AC equipment Canary yellow 

All indoor control and switchgear panels Grey 


SP - Sa 2 1/2 (or St 3) 

2P1+1I1 

or 2P2+1I2 

2F1 & 2F2 

COLOUR 

Light grey 

Post office red 

Brilliant green 

Azure blue 

Oriental blue 

205 

(260) 

SHADE AS 

IS:5 

631 

538 

221 

104 

174 

557 

309 

697 

Page 6 of 55

All outdoor transformers, switchgear, control Dark admiralty 

panel etc. 

grey 

Instrumentation panels Opaline green 

Telecommunication panels Smoke grey 

8.2 For mechanical equipment 

-Indoor Indoor and outdoor mechanical equipment excepting cranes : Grey. 

8.3 For pipes, ducts, conduits and others 

Service 

River water (untreated) 

Cooling Water 

Boiler feed water 

Condensate 

Drinking water 

Industrial water 

Hydraulic power water 

Compressed air 

Instrument air 

Vacuum 

Steam below 3.5 kg/cm2 (g) 

3.5-20 kg/cm2 (g) 

21-40 kg/cm2 (g) 

Above 40 kg/cm2 (g) 

Drainage 

Lubricating oil 

Hydraulic oil 


Colour 

Base - Sea green 

Band - White 


Band - French blue 



Band - Light brown 


First band - French blue Second 

band - Signal red 


Band - Light orange 


Band - Black 

Base - Sky blue 




Band - Black 

Base - Silver grey if Bitulac or Al Aljacket 

Band - Brilliant green 

628 

221 

Base - Silver grey if Bitulac or Al Aljacket 


628 

166 

Base - Al-jacket 

Band - Dark violet 

Base - Al-jacket 

Band - Signal red 

Base - Black 

Base - Light brown 

Band - Light grey 

Base- Light brown 

632 

275 

692 

Page 7 of 55 

Shade as IS:5 

217 

- 

217 

166 

217 

217 

410 

217 

166 

537 

217 

557 

217 

- 

101 

101 

410 

101 

- 

- 

796 

537 

- 

- 

410 

631 

410

Transformer oil 

Fuel oil 

Coke oven/coal gas/other fuel gases 

Freon (chlorofluore derivative of 

methane and ethane) 

Argon 

Acetylene 

LP gas 

Nitrogen 

Oxygen 

Regenerated acid (dilute) (1) 

Hydrochloric acid (conc.) (1) 

Spent liquor 

Wash liquor 

Dilute acidic liquor 

Hydrofluoric acid (conc.) (1) 

Acidic slurries 

Alkalis 

Non-acidic slurries 

Fire fighting system 

Rain water down pipes 




Band - Light orange 



Base - Canary yellow 









First band - Signal red 

Second band - Traffic green 


Band - Black 


Band - White 

Base - Dark violet 



First band - Light brown Second 

band - Light brown 


First band - Light brown 

Second band - Light brown 




First band - Light grey 

Second band - Brilliant green 


Band - Silver grey 


Band - White 


Band - Deep buff 


Band - White 

Base - Signal red 


Band - Sky blue 

796 

410 

557 

410 

537 

309 

537 

309 

631 

309 

166 

309 

796 

309 

537 

267 

309 

- 

309 

– 

796 

410 

796 

410 

410 

796 

631 

410 

796 

631 

796 

631 

221 

796 

628 

796 

- 

796 

360 

217 

- 

537 

217 

101 

Page 8 of 55

Duct work 

Lighting conduits 

Instrument conduits 

Power conduits 


Base - Aluminium 

Base - Black 

Band- Yellow 

Base - Black 

Band - Red 

Base - Black 

- 

- 

309 

- 

537 

– 

Page 9 of 55

LIST OF MANDATORY SPARES 

A. MECHANICAL 

1.0 Belt Conveyor 

Sl.No. DESCRIPTION 

1. 

2. Idlers 

Pulleys 

-Driving Pulley 

-Non-Driving Driving Pulley 

3. Input shaft assembly (only pinion & input shaft) 1 no. each type 

4. 1st Reduction Gear 1 no. each type 

5. Oil seal 

6. Coupling 

7. Hold back 

8. 

Safety devices 

- Pull chord switches 

- Belt sway switches 

- Zero speed switches 

2.0 Actuator operated flap gate 

SL. NO. DESCRIPTION 

1. Plummer box 

2. Self aligning ball bearing 1 set. 

3. Gaskets 

1 set. 

4. Limit Switch 

5. Sealing 

6. Oil Seal 

3.0 Side Arm Charger 


1. Gear box spares (complete gear box assy., oil seal and 

bearing) 

1 set. 

2. Carriage wheels a) Bearings b) Oil Seals c) Plummer 

block d) Carriage wheel fitted with shaft (without 

Plummer Block) 

3. Coupling 

4. Travel wheel assembly 1 No. 

5. Bearing 

6. Motor including slip ring motor, Bearings and Oil seal 1 set.each of 

type and size 


QTY. 

1 no. of each size & type. 

1 no. of each size & type 

2 nos. each type 

1 no. each type 

1 no. each type 

5% of total quantity 



QTY. 

1 set. 

1 set. 

1 set. 

1 set. 

QTY. 

a)1 set. b) 2 sets 

c) 1 set d) 1set 

1 set. 

1 set. 

Page 10 of 55

7. Brakes complete assembly with lining and springs 1 set. 

8. Couplings with complete assembly, pins, bushes, and 

nuts 

1 set. 

9. Hydraulic power Pack with all accessories 1 set. 

3.0 Wagon Tippler and Accessories 

SL. 

NO. 

DESCRIPTION 

1. Speed Reducers (a)complete gear box assy., (b)oil seal and a)1 set. b) 4 sets 

(c) bearing) 

c) 2 set of each type and 

rating 

2. Motor a) Motor including slip ring motor, b)Bearings c) Oil a)1 set. b) 1 sets 

seal 

c) 1 set of each type and 

rating 

3. Brakes a) Complete assembly b) Linings and springs 1 set. of each type and rating 

4. Couplings with complete assembly, pins, bushes, and nuts 1 set. each type and 

rating/sise 

5. a) Thyristor /VVVF cards/ Modules a) 1 No. of each type. B) 2 

b) Relays 

No. of each type and rating 

6 (a) Hydraulic Pump with electric motor, coupling, valves 

(mounted on pump) etc: 

1 Set of each type and size 

(b) Hydraulic Motor 

1 No. of each type and size 

(c) Valves 


(d) O.P. Coolers 

1 No. 

(e) Filter Elements 

10 Nos. of each type 

(f)Pressure Switch 

1 No. of each type 

(g)Temperature Switch 

1 No. of each type 

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 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 

13 Gear box total 

14 Gear flexible coupling 1set 

15 Rod end bearings with housing 1 set for all four clamps 

16 Pressure Switches, Common manifold block complete with 

all valves mounted on it, Main Pivot bearing, 

17 Pinion support & bearing 1 No each type 

18 Pinion 

19 Latch (Pinion & rack segment locking device) 1 No. 

20 Chain & Sprocket 1 set 

5.0 Apron Feeder 


QTY. 

2 sets 

1 set 

1 no. each 

2 nos 

Page 11 of 55

6.0 Electric Hoist 

7.0 Manual Hoist 

SL. NO. DESCRIPTION QTY. 

1. Head Pulley complete with shaft 1 No. 

2. Tail pulley complete with shaft 1 No. 

3. Drive Motor 1 No. of each type and size 

4. Gear Box 1 No. of each type and size & direction. 

5. Complete internals of gear box 

including input and output shafts 

6. Reduction gears 1 Set of each type and size 

7. Fluid coupling, flexible coupling etc. 1 Set 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 

Pans (flights) 10% 

14 Hydraulic cylinder 1 set of each type and size 

15 Seal kit of hydraulic cylinders 1 set 

16 Plummer blocks 1 No. of each type and size 

17 Bearings 1 Set of each type and size 


1. Ball bearing 1 set. 

2. Needle bearing with inner race 1 set. 

3. Bush bearing 1 set. 

4. Rope tightener 1 set. 

5. Rope guide 1 set. 

6. Rope sheave 1 set. 

7. Thrust bearing 1 set. 

8. Roller bearing with inner race 1 set. 

9. Brake lining 1 set. 

10. Limit switch complete 1 set. 

11. Rotor pinion 1 set. 


1. Grooved sheave 2 sets 

2. Pinion 1 set 

3. Bearing 1 set 



Page 12 of 55

B. ELECTRICAL 

33 KV SYSTEMS 

MOTORS 

4. Shaft pin 1 set 

Sl. No. DESCRIPTION QUANTITY 

MCC 

1. Busbar support insulators 10 Nos. of each type / MCC 

2. Current transformers 1No. of each type & rating / MCC 

3. Potential transformers 415/110V 1 No. / MCC 

4. Male contact of ACB (main and aux.) 1 set /MCC 

5. Female contact of ACB (main and aux.) 1 set / MCC 

6. Limit switch of ACB 3 Nos. /MCC 

7. Spring charging motor of ACB 3 Nos. /MCC 

8. Closing coil of ACB 2 Nos. /MCC 

9. Tripping coil of ACB 2 Nos. /MCC 

10. Breaker control switch 2 Nos. /MCC 

11. Relays 1No. of each type/ MCC 

12. Auxiliary relay 2 Nos. of each type / MCC 

13. Indicating Lamp assembly (LED LVGP 

type) 

14. Phase sequence meter 2 Nos. 

Sl. No. DESCRIPTION QUANTITY 

1. Lightning arrester 1 set each at receiving and WT 

substation 

2. Isolator with earth heel 1 set each at receiving and WT 

substation 

3. Relays 1No. of each at receiving and WT 

substation 

1. Bearing (drive end) 1 No. of each type 

2. Bearing (Non (Non-drive end) 1 No. of each type 

3. End shield (DE and NDE) 1 set of each type 

4. Cooling fan of motors 1 No. of each type 

5. Fan cover 1 No. of each type 

6. Bearing puller 1 Nos. of each type 

7. Grease gun 2 Nos. 


10 Nos. of each type & colour 

/MCC 

Page 13 of 55

PDB/LDB/SLDB/AUX. PDB 

LT TRANSFORMER 

UPS/PLC 

1. Bus bar support insulators 3 Nos. of each type / DB 

2. MCCB 

2 Nos. of each rating/DB 

3. MCB 

4. Breaker control switch 2 Nos. /DB 

5. Control switch 2 Nos. of each type/DB 

1. HV bushing (1 set = 3 nos.) 1 set 

2. LV bushing (1 set = 3 nos.) 1 set 

3. Temp. scanner 1 no. 

4. Neutral bushing CT 1 no. of each type/ ratio 

1. Thyristor fuse 1 no. of each rating 

2. Electronic logic card for UPS 1 no. of each type 

3. Electronic logic card for PLC 1 no. of each type 

CONTROL DESK/ AMMETER CONTROL PANEL 

ILLUMINATION 

1. Ammeter 1 No. of each range 

2. Indicator Lamp Assembly 5 sets 

3. Control switch 1 no. of each type 

4. Push button 1 no. of each type 

1. Lamps 4 Nos. of each type 

2. Fittings 2 Sets of each type 

3. Control gear complete 2 Sets of each type 

4. Timer 

C. VENTILATION, AIRCONDITIONING & DRY FOG DUST SUPPRESSION SYSTEM 

SYSTEM / EQUIPMENT DESCRIPTION QUANTITY 

Air Washing type Ventilation Systems. 

Centrifugal Fans & Filters V -Belt 

Bearings 

Flexible 

Connection Filter element 

Water Pump 


2 Nos. of each rating/DB 

1 No. 

1 set of each type 



20% of requirement 

Impeller 1 set of each type 

Page 14 of 55

Nozzles 

Valves 

Exhaust Fans 

Dry Fog & Plain Water Sprinkling type Dust Suppression Systems 

Water Pump 

Nozzles 

Sprinklers 

Solenoid Valves 

Pressure gauges 

Sensors and Instruments Sensors & Instruments 1 set of each type 

Valves 

Valves 1 set of each type 

Pressure Regulating Units 

(PRU) 

PRU 1 set of each type 

Flow Activation Station 

(FAS) 

FAS 1 set of each type 

Compressor 


Coupling 


Bearings 


Gland Packing 

2 sets of each type 

Nozzles 10% of requirement 

Valves 1 set of each type 

Bearings 1 set of each type 

Impeller 

Coupling 

Bearings 

Gland Packing 

Nozzles 

Nozzle tips 




2 sets of each type 

10% of requirement 20% 

of requirement 

Nozzles 10% of requirement 

Solenoid Valves 10% of requirement 

Pressure Gauges 1 set of each type 

Bearings 

Couplings / V Belts 

Pulleys 

Filters 

Gaskets / O Rings 

Valves /Safety valves 

Piston rings 








Page 15 of 55

INFORMATIONS TO BE FURNISHED BY THE BIDDER 

Check List for Bid submission 

1. All drawings and documents duly signed as per TS submitted along 

with Bid 

- Yes/ No 

2. Clause wise list of deviations from TS furnished 

- Yes/ No 

3. Time bar chart and level of PERT network furnished as per the TS 

4. Separate price bid submitted 

5. Necessary particulars to establish the possession of technical know know- 

how and facilities available furnished as per TS 

- Yes/ No 

6. Reference list for supply of similar equipment along with users’ 

certificate furnished as per the TS 

- Yes/ No 

7. Write up of testing facilities available at works furnished as per the TS - Yes/ No 

8. Brief scope of collaboration for collaboration agreement furnished as 

per the TS 

- Yes/ No 

9. Clause wise list of deviations / exclusions furnished as per the TS - Yes/ No 

10. Delivery schedule indicated as per TS 

11. Bought out items conforms to TS 

12. Location and size of MCC & control room indicated 

13. List of tools furnished as per TS 

14. List of commissioning spares furnished as per TS 

15. List of spares for two years operation along with item wise price 

furnished as per TS 

- Yes/ No 

16. List of insurance spares with price furnished as per TS 

17 Erection plans furnished as per TS 

2.0 Questionnaire 

The Bidder shall fill in this questionnaire and submit in hard as well as a soft copy with their 

Bid. This data shall form a part of the contract with successful Bidder. 

2.1 General 

1. Name and address of the Bidder 

2. Previous experience of the Bidder 

3. List of similar equipment supplied 

4. Whether the Bidder has any technical collaboration with any other 

company / organization for his equipment 

5. If answer to question 4.0 is yes, furnish the following details. 

a) Name and address of the collaborator 

b) Nature of the collaboration in detail 

c) Previous experience of the collaborator 

6. List of drawings literatures enclosed with the offer 


- Yes/ No 

- Yes/ No 

- Yes/ No 

- Yes/ No 

- Yes/ No 

- Yes/ No 

- Yes/ No 

- Yes/ No 

- Yes/ No 

Page 16 of 55

7 Is it the Bidder's intention, if awarded the contract, to comply fully in 

all respects with owner’s specifications covering the work? If not, he 

shall state specific exception in details 

A. WAGON TIPPLER 

GENARAL 

Type: 

Designed capacity 

Guaranteed capacity 

Make: 

Capacity: 

Angle of tipping: 

Drive: 

Tippler drive: 

Side arm charger: 

Indexer: 

Clamping: 

Wt. of the machine 

Tippling time cycle: 

Rail Gauge: 

Drive Rack Assembly 

Spherical roller bearing SKF NO.24168 

ECACK30/W33/Equivalent. 

CLAMP CYLINDER 

Bore 

Rod 

Stroke 

Tippler Ballast-25T 25T at each end frame Made 

from concrete with steel scrap 

DRIVE PINION 

P.C.D 

Face width 

No.of teeth 

Pressure angle 

Material 

CYLINDER FOR INHAUL CLICKING STOP 

Bore 

Rod 

Stroke 


Page 17 of 55

HYD.POWER PACK DETAILS FOR WT 

Type 

Oil pump proportional control of capacity 

Tank capacity 

Electric motor for WT main drive 

Electric motor for WT clamp 

Cooling 

HYDRAULIC MOTOR DATA FOR WAGON 

TIPPLER 

Type 

Model 

Displacement 

Speed 

Details of Motor 

Pressure (Max) 

Torque theoritical 

Power theoritical (Max) 

Speed (Max) 

HYDRAULIC CYLINDER DATA FOR WAGON 

TIPPLER 

Bore 

Rod 

Stroke 

SIZE OF WAGON TO BE HANDLED 

Length 

Width 

Height 

B. APRON FEEDER: 

GENERAL 

Make: 

Capacity: 

Pan width: 

Length: 

Motor 

DRIBBLE CONV. 

GENERAL 

Conv.Belt 

Belt width 

Belt length 


Page 18 of 55

C. WEIGHBRIDGE 

GENERAL 

Make 

Quantity required 

Carrying capacity /strength 

Weighing capacity 

Type 

Platform size 

Mounting 

Resolution 

Taring facility 

Auto tare 

Purpose 

Cycle of weighment 

Duty 

Power supply required 

Operating temp.range 

Platform size 

Material of construction 

Load cell 

Load cell capacity 

D. SPECIFICATION OF LOAD CELL 

GENERAL 

Characterstic 

Make 

Type 

No.of loadcells 

Capacity of each loadcell 

Rated output 

Combined error 

Repeatability 

CREEP ON LOAD (30min) 

Zero balance voltage 

Input resistance 

Output resistance 

Compensated temp.range 

Operating temp.range 

Temp.effect on span 

Temp.effect on tare 


Specification 

Page 19 of 55

Excitation voltage 

Safe overload 

Ultimate overload 

Insulation resistance 

Protection 

Cable 

E. CONTROLLER 

GENERAL 

CHARACTERISTIC 

F. 

Model no. 

Type 

Power supply 

Operating temperature 

Range 

Resolution 

Non - linearity 

Repeatability 

Excitaton to transducer 

Display 

Input 

Output 

Programmable parameters 

Casing dimension 

SIDE ARM CHARGER 

Type of side arm charger (sac) 

Sac pulling capacity 

SAC total travel 

Max.wagon size that sac can handle 

Type of luffing system for sac 

Track gauge 

Operating speed of sac in m/s 

Forward with single wagon 

Return 

Type of power supply system for sac 

Support roller wheel 

Guide roller wheel 

Feston support post 

Electric motor for sac 

Cooling 

DRIVE PINION 

P.C.D 

Face width 


SPECIFICATION 

Page 20 of 55

No.of teeth 


Material 

RACK FOR SAC TRAVEL 

Total nos 

Pitch 


Teeth per rack 

Material 

HYD.POWER PACK DETAILS FOR SAC 

TYPE 


Tank capacity 

Electric motor for SAC 

Cooling 

HYD.MOTOR DETAILS FOR SAC 

Hyd.motor double displacement type 

Motor model: 

Displacement: 




Power 

Speed (Max) 

SAC RAISE & LOWER CYLINDER 

Bore 

Rod 

Stroke 

SAC UNCOUPLING CYLINDER 

Bore 

Rod 

Stroke 

SAC DELATCH CYLINDER 

Bore 

Rod 

Stroke 

G. INDEXER 

Type of side arm charger (sac) 

Max.rake (Train) size that Indexer can handle 

Type of luffing system for Indexer 

Track gauge 


Page 21 of 55

No.of wagon handled by Indexer 

Operating speed of Indexer in m/s 

Forward with rake 

Return 

Type of power supply system for Indexer 

Fixed support roller wheel 

Guide roller wheel 

Sprung support roller assembly 

Feston support post 

Indexer normal travel 

DRIVE PINION 

P.C.D 

Face width 

No.of teeth 


Material 

RACK FOR INDEXER TRAVEL 

Total nos 

Pitch 


Teeth per rack 

Material 

HYD.POWER PACK DETAILS FOR INDEXER 

TYPE 


Electric motor for Indexer 

Cooling 

HYD.MOTOR DETAILS FOR INDEXER 

Hyd.motor double displacement type 

Motor model: 

Displacement: 


Wt 



Power theoritical (Max) 

Speed (Max) 

INDEXER ARM RISER CYLINDER 

Bore 

Rod 

Stroke 

INDEXER UNCOUPLING CYLINDER 


Page 22 of 55

Bore 

Rod 

Stroke 

2.2 BELT CONVEYORS 

Sl. No Description 

Belt Conveyor System 

1 Conveyor capacity, Mt/h 

a) Rated (guaranteed) 

b) Design 

2 Belt width, mm 

3 Belt speed, m/sec 

4 Length, centre to centre, m 

5 Lift, m 

6 Max. angle of inclination, degree 

7 Radius of curvature for : 

a) Concave 

b) Convex 

8 Details of take-up 

9 Belting 

i) Type of take-up 

a) For Boom conveyor of stacker / reclaimer 

b) For Intermediate Conveyor of stacker 

c) For all other conveyors 

i) Type of fabric 

ii) Cover grade 

iii) Cover thickness, mm 

- Face cover, mm 

- Back cover, mm 

iv) No. of plies 

v) Troughing angle 

vi) Factor of safety 

vii) Normal working tension 

viii) Type of belt joint 

10 i) Idler type: 

a) Carrying (except in case of reversible conveyor) 

b) Return 

c) At loading point 

ii) Idler Spacing 

a) Carrying 

b) Return 

c) At loading point 

d) Self aligning (carrying side) 

e) Self aligning (return side) 

11 Pulleys : 

i) Minimum shell thickness 

ii) End disc thickness 


Page 23 of 55

iii) Shaft deflection at hub 

iv) Lagging thickness 

v) Lagging 

vi) Pulley Material (For ILMS conveyor) 

vii) Shaft material 

12 Drive Pulleys 

i) Lagging 

ii) Diamond pattern groove 

iii) Minimum angle of wrap 

iv) Maxm. out of roundness 

13 Rubber for pulley lagging 

i) Type 

ii) Shore Hardness 

iii) Elongation 

iv) Strength 

v) Abrasion loss 

vi) Specific gravity 

vii) Adhesion Strength 

14 Emergency Stop Switch & Belt Sway Switch System 

i) Spacing (Emergency stop) 

ii) Spacing (Belt Sway Switch) 

iii) Degree of protection 

15 Zero Speed Switch 

i) Type 

ii) Mounting location 

16 Conveyor Gallery 

a) Walkways width 

b) Side windows in staggered fashion 

i) Spacing (c/c) 

ii) Size 

17 Deck plates 

a) Material 

b) Thickness, mm 

18 Seal plates 

a) Material 

b) Thickness 

19 Stone picking arrangement 

20 Chute Jamming Detector 

(a) Type 

(b) Degree of Protection 

21 Reduction gears 

a) Type 

b) Size 

22 Fluid Couplings 

a) Type 

23 Brakes 

b) Rating, kW 


Page 24 of 55

a) Type 

b) Rating 

c) Protection 

24 Flexible couplings 

a) Type 

b) Rating 

25 Drive motors 

a) Type 

b) Make 

c) Insulation class 

d) Motor nameplate rating, kW at 500 C ambient 

e) Protection Class 

2.3 CHUTES, HOPPERS,SKIRT BOARD 


1 Chutes & hoppers construction 

2 Minimum valley angle (from the horizontal), degree 

3 Material & Plate thickness 


a) Sliding zones and adjacent sides 

b) Non striking/ non sliding zones 

c) Chute with valley angle 80° and above 

d) In the zone of magnetic field of ILMS 

e) In the zone of flap gates 

f) Discharge Hoods over head pulleys 

g) Location of Inspection door/sealing 

4 Skirt board 

a) Plate thickness, mm 

b) Length of each skirt board, m 

c) Height, mm 

d) Width, mm 

e) Top cover plate thickness , mm 

2.4 ACTUACTOR OPERATED FLAP GATE 


1. Make 

2. Dimensions 

3. Material of construction of the gate 

4. Liner plate specification 

5. Method of fixing of liner plates 

6. Type and make of drive and rating 

7. Capacity and designation of the equipment 

8. Total weight and weight of individual parts 

9. Type of actuator and thrust in kg of each actuator 

10. Stroke in mm of each actuator 

11. Velocity mm per of each actuator 

12. Motor: Type, rating, power supply, class of duty, insulation, make 

number of starts/ hours 

Page 25 of 55

13. Make, ratings, type of limit switches 

14 Effort required for manual operator, kgf 

15. Type of limit switches 

2.5 ELECTRIC HOISTS 


1. Location 

2. Capacity 

3. Duty classification as per IS:3938 IS:3938-1983 

4. Total weight of hoist including electrical equipment 

5. Make of hoist block 

6. Speeds with safe working load 

7. Lifting height 

a) Above floor level 

b) Below floor level 

8. Wire ropes 

a) Type of construction 

b) Size 

c) Number of falls 

d) Factor of safety 

9. Rope drum 

a) Materials 

b) Diameter 

10. Drives 

11. Motors 

a) Type & material of gear box 

b) Gear & pinion 

c) Material & hardness 

a) Type & number 

b) Kw rating 

c) Synchronous speed 

d) Class of insulation 

e) Pull out torque 

f) Frame size 

12. Brakes 

a) Type 

b) size 

c) Torque rating 

13. Type & details of limit switches 

14. Type of couplings 

15. Type of bearings 

16. Lifting hook 

a) Type 

b) Material 

17. Type & details of control 

18. Trolley Speed with safe working load 

19. Wheels 


Page 26 of 55

20. Drive 

a) Numbers 

b) Diameter 


d) Max. wheel load 

e) Wheel base 

a) Type & material of gear box 

b) Gears & pinions 


d) Kw rating 

e) Synchronous speed 

f) Class of insulation 

g) Pull out torque 

h) Frame size 

21 Brakes 

a) Type 

b) Size 

c) Torque rating 

22. Type & details of limit switches 

23. Type of coupling 

24. Type of bearings 

25. Type & details of controls 

26. Clearance diagram indicating the basic dimensions 

27. Type & lubrication provided 

28. Type & size of cables 

29. Location & control details of hoist block power feeding 

30. Any other information 

2.6 EOT CRANE 

Sl. No. Description 

(a) During participation in technical Bid: 

1.0 G.A. Drawing. VENDER TO CONFIRM 

2.0 Wheel Load Diagram (Wheel Distance & Wheel Load). 

3.0 Sketches showing full details of cranes with dimensions/ end clearances 

(between centre of LT rails to column face of building), overhead clearance 

from LT rails, hook approach limits, llift 

ift height, Details of Web thickness baffle 

plates, Stiffeners ,of Girder section , End carriage (Boggies) Trolley Section etc. 

4.0 Vendor to submit appropriate Q.A. Plan. 

(b) After Receipt of Order: 

1.0 Calculation for Box Girder, End Carriage structural plates/ Web / Stiffener 

plate, Wheel Load calculation & Calculation for selection of Diameter of 

Wheel, Motor, Gearbox and Brake etc. 3 - sets of followings documents like 

G. A Drawings, Structural drawin drawings like End-carriage, carriage, Box Girder, Assembly 

Drawings/ Sub-- 

assembly Drawings, Gear Box Drawings (specially of Typical 

Gears having Helix Angle, Pressure Angles, Modules etc.) ,Bracket/ Current 

Collector System, Hook Block, LT & CT wheel, Main Hook assembly LT 

machinery, Hoisting machinery, Electrical Drawings comprising Power , 


Page 27 of 55


Control Circuits , Electronic Circuitry diagram for RRC etc. No fabrication / 

purchase of BO. Items should be taken up before the approval of the 

drawings. 

(c) With the supply of ccrane: 

1.0 Operating manuals of Crane - 3 Sets. 

2.0 Detailed Maintenance manual of Crane. Spares Spares- part list / concerned drawing 

of the spares -3 3 Sets. 

3.0 Maintenance, Interface & commissioning manuals for Controller & drives - 2 

Sets along with drive parameterisation software. 

4.0 Catalogues, O&M Manuals of all bought out items including drawings, 

wherever applicable. 

5.0 Detailed specification of all rubber items like Oil Oil- Seals / O- Rings etc. 

6.0 One Soft copy for the above requisites shall also be supplied in CD. 

2.7 MANUAL HOISTS 


1. Name of the manufacturer, type & model no 

2. Numbers offered & their location 

3. Safe working load for each hoist (in tones) 

4. Duty class as per IS:3832 IS:3832-1983 

5. Head room, mm 

6. Lift, mm 

7. Minimum radius of curvature of which this hoist can negotiate (mm) 

8. Weight of each hoist 

9. Specification of each chain 

10 Tools & tackles included in offer 

11. Commissioning spares & 2 years 

12. Operating spares included in offer 

13. Any other information 

3.0 DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE BIDDER 

Drawings /Data along with the Bid 

1) Schematic drawings showing flow of materials. 

2) Layout drawings of Additional Coal Storage and Handling System showing clearly the Major 

Equipment, Junction Houses, Conveyor Galleries, Approach Road, Rail Track for Yard 

Equipment, Yard Drainage Scheme etc. 

3) General Arrangement Drawing of Additional Coal Storage and Handling System showing 

clearly the Major Equipment, Junction Houses, Conveyor Galleries, Belt Conveyor with drive, 

tail and take up arrangement, hoisting & handling facilities envisaged for maintenance of 

equipment. 

4) Cross Section of Additional tional Coal Storage Yard showing the coal stock pile, yard equipment, 

track rail for stacker and reclaimer, yard drainage system etc. 

Page 28 of 55

5) General Arrangement of Major Equipment showing plan, elevation, cross sections along with 

mounting details, with broad ddimensions 

and technical parameters. 

6) Basic calculation substantiating selection of all major equipment, motors, gear boxes, 

couplings, brakes etc. 

7) Equipment wise List of commissioning spares and consumables with item wise description and 

quantity included d in the main offer. 

8) Equipment wise list of 2 years operational spares (un (un-priced). priced). The list shall indicate description 

and quantity for each item. 

9) List of special tools and tackles 

10) Details /drawings for Civil & Structural Engineering works. 

11) Single line diagram of power distribution system. 

12) Electrical schematic diagrams 

13) Cable specifications, cables schedule and cable layout drawings. 

14) Any other structural / mechanical / electrical etc. drawings / data mentioned elsewhere in 

the technical specification as well as considered necessary by the Purchaser/ Consultants. 

15) List of exclusion, if any from Bidder’s Scope of Work. 

16) List of deviations from technical specification. 

4.0 ELECTRICS 

4.1 DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE TENDERER 

Drawings / Data / Documents along with the Bid 

1. Detailed scope of work with general description of the system & equipment offered 

specifying the important features and detailed design criteria and design philosophy 

including full details of reference data, assumptions, etc. 

2. Description to be accompanied by single line diagrams and equipment layout to enable 

owner to have proper appreciation of equipment offered and its operation. 

3. Bill of Quantities (un --priced) 

priced) in specified format, with division list of supplies from foreign 

and indigenous sources. 

4. List of specific exclusions, if any, from Bidder’s Scope of Work. 

5. List of deviations from technical specifications, 


Page 29 of 55

6. Equipment wise List of commissioning spares and consumables with item wise 

description and quantity included in the main offer. 

7. List of 2 years operation spares, equipment wise (un (un-priced). priced). The list shall indicate 

description and quantity for each item. 

8. List of special tools and tackles 

9. Work Schedule with bar chart indicating all activities for electrics. 

10. Phase-wise wise construction power requirements for erection / testing activities. 

11. Questionnaire as asked, duly filled filled-in. 

12. Reference list of similar jobs carried out 

13. Dimensional details & weights of each equipment offered (tentative) 

Technical Data to be submitted with the Bid. 

1. Name and capacity of MCC considered 

2. List of LT drives of each MCC along with single line diagrams 

3. Connected load and Maximum demand of each section of 33 kV switchboard/ 415 V PCC 

4. Connected load and Maximum demand of each section of MCC. 

5. List of motors with ratings ( working working+ + standby) 6. List of performance tests proposed by 

the tenderer to demonstrate the guaranteed parameters for the electrical equipments. 7. 

Specific energy consumption, maximum demand and annual energy consumption. 8. 

Type test certificates for major categ categories ories of equipment, issued by independent testing 

authority. 9. Technical catalogues of major equipment offered. 10. Services to be 

provided by owner at battery limit with specification 11. Single Line Diagram of each 

MCC/ DB 12. Capacity of UPS for stacke stacker r & reclaimer 13. Capacity of PLC for stacker & 

reclaimer 14. Size of HT/LT trailing cables considered 15. Rating of 33 kV on load isolators 

considered 

4.2 TECHNICAL PARTICULARS TO BE SUBMITTED BY THE BIDDER ALONG WITH THE BID 

GENERAL 

The information /data data asked under this section shall be furnished by the tenderer along with 

the offer. In the event of the contract being awarded , the data/technical particulars furnished 

here under and accepted by the owner shall be deemed to form a part of the contract contract. 

Design Considerations 

: 

1. List of Drives/ Mechanism with kW Rating : 


Page 30 of 55

2. Aux. Power Consumption : 

Spares and tools & tackles 

1 .List of commissioning spares : List to be submitted 

2. List of mandatory spares : List to be submitted 

3. List of special tools and tackles : List to be submitted 

Summary Of Technical Parameters Of Major Electrical Equipment 

Sl. 

No. 

Equipment 

Description 

& Qty 


Make & type 

/ Country of 

manufacture 

MOTOR 

1. Make, type & applicable standard 

2. Furnish following for all drives 

Sl. No Application 

Rated Parameters 

kW Voltage Speed Enclosure Qty 

MCC 

1. Make, Type & Applicable Standard : 

2. Rated Voltage, current & Frequency : 


: 

4. Bus bar material & type of sleeving : 

5. Protection class 

: 

Components of MCC 

1 Air Circuit Breaker 

2. MCCB 

3. AC Contactor 

4. DC Contractor 

5. Thermal Relay 

6. Control Devices 

7. Meters 

Total 

Weight 

: 

: 

: 

: 

: 

: 

: 

Dimension Rating as 

per design 

condition of 

Tender 

Make & Type 

Guaranteed 

Tech Data 

Working 

/Standby 

Page 31 of 55

MCC WISE DATA 

Sl. 

No 

RELAYS 

METERS 

MCC 

Designation 

1. Make 

2. Type 

Rating of 

Volt, 

Amps 

3. Draw out type with built in test facility 

4. Relay details 

1. Make 

2. Type 

3. Reference standard 

4. Size 

CURRENT TRANSFORMER 

POTENTIAL TRANSFORMER 

1. Make, type & applicable standard 

2. Ratio & accuracy class: metering/protection 

3. Rated voltage – short time rating 

1. Type 

2. Primary/secondary voltage ratio 

3. Method of connection 

4. Rated voltage factor 

5. Class of insulation 

PDB/LDB/SLDB/AUX. PDB (SEPARATELY FOR EACH DB) 

1. Make, Type & Applicable Standard 

2. Rated Voltage, current & Frequency 


4. Bus bar material & type of sleeving 

5. Protection class 


Rating of Single 

Front/ 

Double 

Front 

No. of 

bus 

sections 

Connected 

load per 

section 

Max. 

load d per 

section 

No. of 

panels 

Page 32 of 55 

Overall 

dimensi 

ons

Components of DB 

DB-WISE DATA 

Sl. 

No 

1. Breaker 

2. MCCB/MCB 

3. AC Contactor 

4. Thermal Relay 

5. Control Devices 

6. Meters 

DB 

Designation 

TRANSDUCER (For each type) 

1. Make 


Rating 

of 

Volt, 

Amps 

2. Output range 

3. Accuracy 

4. Maximum burden on CT/PT 

5. Nominal input/rated I/V 

6. Overload capacity without loss in accuracy 

LIGHTNING PROTECTION 

1. Whether lightning conductors have been 

envisaged for the lightning protection : Places to be indicated 

2. Angle of protection 

: 

3. Whether building is also protected : Yes/No 

4. Number of electrodes provided : 

5. Earthing resistance value : 

6. Size of down conductors : 

EARTHING 

Single 

Front / 

Double 

Front 

No.of 

bus 

sections 

1. Material and size of earth strip for the 

various places 

: 

2. Size of main outer strip : 

3. Galvanising content on GI strip : 

Connected 

load per 

section 

Max. 

load 

per 

section 

No. of 

panels 

Page 33 of 55 

Overall 

dimensions

4. Value of earthing resistance 

(proposed to be achieved) : 

5. Type & size of electrodes : 

6. Construction of earthing mat, etc as per TS : Included 

UPS SYSTEM 

1. Make of the system 

: 

2. Capacity in kVA 

: 

3. Battery back up time 

: 

4. Make & type of battery 

: 

5. Number of cells per battery : 

6. Overall dimension(L x B x H) mm of battery : 

7. Ventilation requirements : 

8. Make, Rating & type of charger : 

9. Make, Rating & type of rectifier transformer : 

10. Make & current rating of SCR & Diode : 

11. Make & rating of inverter : 

12. Make & type of static transfer switch : 

13. Make & rating of manual bypass switch : 

TRANSFORMER 

1. Name of manufacturer 

: 

2. Service-whether whether indoor or outdoor : 

3. Type of cooling 

4. Rating 

: 

a. Rated KVA 

: 

b. Rated current, amp (rms), HV/LV : 

c. Rated voltage, kV (HV/LV) : 

5. Temperature rise above 500C ambient 

a. In oil by thermometer, 0C : 

b. In winding by resistance, 0C : 

c. Hot spot temperature in winding limited to, 0C : 

6. Insulation class 

: 

7. Vector group 

: 

8. Type of tap changer with capacity/steps/range : 

9. Tapping provided on HV side? 

10. Losses 

: Yes/No 

a. No-load load loss at rated voltage and frequency : 

b. Load loss at rated load : 

c. Cooler loss 

: 

11. Impedance at rated current frequency : 

12. Reactance at rated current and frequency, % : 

13. Efficiency at 0.80 p.f lag % at 100%/75%/50% load : 

14. Load/p.f. at which max. efficiency occurs, % full load : 


Page 34 of 55

15. Maximum efficiency, % : 

16. Minimum clearances in mm HV LV 

a. Between phases 

: 

b. Between phase and ground : 

17. Withstand time without injury for 3 ph short circuit, sec : 

18. Insulation strength 

a. one minute power frequency test KV rms : 

b. Impulse withstand voltage, KV 

19. Tap changer provided with 

: 

i. Tap position indicators ? : Yes/No 

ii. Operation counter ? 

: Yes/No 

iii. Padlocking provisions ? 

20. Details of tank 

: Yes/No 

i. Material 

: 

ii. Maximum internal withstand pressure of tank kg/cm2: 

21. Enclosure details (for dry type transformer) 

i. Material 

: 

ii. Thickness 

: 

iii. Degree of protection 

: 

22. Details of core material : 

23. Insulation material 

: 

24. Details of bushings 

HV LV LV- Neutral 

a. Make 

: 

b. Type 

: 

c. Voltage class, KV 

25. Insulating oil 

: 

a. Approx volume of oil, liter : 

b. Whether first filling of oil with 10% excess included ? : 

c. Oil conforms to IS:335 :335 ? 

26. Marshalling Box 

: 

a. Weatherproof, suitable for outdoor for oil filled type ?: Yes/No 

b. Degree of protection 

: 

27. Each transformer with fittings andaccessories : Yes/No 

28. Approximate overall dimensions, (LxBxH) mm : 

29. Approximate weights, Kg : 

a. Core and coil 

: 

b. Tank and fittings 

: 

c. Oil 

: 

d. Total weight 

: 

30. List of special maintenance tools and accessories : Furnished 

Neutral CT of transformers (for each type) 

1. Make, type & applicable cable standard : 

2. Ratio & accuracy class: metering/protection : 

3. Rated voltage – short time rating : 


Page 35 of 55

LIGHTING MAST 

General 

1. Make 

: 

2. Material of construction : 

3. Cross section of mast in polygon (No. of sides) : 

4. Thickness in mm (bottom/middle/top sections) : 

5. Length of individual sections (mm) : 

6. Base dia & top diameter (OAF) : 

7. Type of joints 

: 

8. Length of overlap (joint at site mast Section in mm): 

9. Thickness of galvanization (minimum) : 

10. Size of opening door at base (mm) : 

11. Type of locking arrangement & door construction: 

12. Weights in kgs of 30 mtrs high mast : 

13. Dynamic loading as prevailing actual at site : 

14. Maximum wind pressure (Basic wind speed) : 

15. Maximum gust speed ed time : 

16. Factor of safety for wind load : 

17. Factor of safety for other loads : 

Lantern Carriage 

1. Diameter of carriage ring (mm) : 

2. Load carrying capacity : 

3. Total weights of assembly with fittings : 

4. Number of fittings 

: 

Winch 

1. Make of winch, number of drums per winch : 

2. Capacity 

: 

3. Operating speed 

: 

4. Method of operation 

: 

5. Tested load per drum (kg) 

Wire Rope 

: 

1. Grade 

: 

2. Number of ropes/thickness : 

3. Construction 

: 

4. Breaking load capacity : 

5. Factor safety 

: 

Cable 

1. Type 

2. Make 

3. Current carrying capacity 

4. Cable size 

3. Current carrying capacity : 

: 


: 

: 

Page 36 of 55

Power Supply arrangement 

1. Input supply : 

2. KW rating of motor : 

3. Speed of motor : 

4. Reversible / Non reversible : 

5. Remote control switch type : 

6. Lifting capacity of torque Limiter : 

5.0 Ventilation, Air Conditioning and Dust Suppression System. 

5.1 Bidders shall furnish all information as stipulated in relevant chapter. Bidders shall 

also furnish the following information: 

a) Process flow, process instrumentation and control diagram and water and 

compressed air balance diagrams. 

b) Dimensioned general arrangement and relevant cross sectional drawings of the 

pump house, compressed ai air r station etc. with specification and bill of material. 

c) Dimensioned general arrangement drawings of all equipment. 

d) All relevant basic design calculations supporting the selection of equipment, location 

of valves, specials and supports along with forces and moments of fixed support. 

5.2 Ducting including Supply Air Diffusers with Volume Control Dampers 

a) Duct : Material, thickness & quantity 

b) Damper: material, thickness, size, quantity 

c) Supply Air Diffuser: material, thickness, size, quantity 

5.3 Ventilation Systems 

a) Type of ventilation system 

b) Capacity of each ventilation system 

c) Make of equipment 

d) Design heat load for each premise 

e) Indoor climatic condition to be maintained 

f) Power requirement of each system 

g) Air change/hr 

h) Any specific design consideration 

i) Noise level at 1 m distance from the ventilation equipment 

j) Noise level at served premises 


Page 37 of 55

5.4 Centrifugal Fan 

a) Make & Model No 

b) Quantity, no. 

c) Type of blade 

d) Capacity, m3/h 

e) Total pressure, mm WC 

f) Speed, rpm 

g) Shaft power, KW 

h) Total Efficiency, % 

i) Motor rating, KW/ pole 

j) Fan Characteristic Curve 

k) Impeller Diameter, mm 

l) Velocity at inlet & outlet of fan, m/sec m 

m) Weight of fan and motor, kg 

n) Coupling details 

o) Vibration isolator type & quantity 

p) Thickness of scroll, blade, Back plate, shaft mm 

q) Noise level at 1m distance 

r) Overall size 

s) Drive Motor rating suggested 

5.5 Fan Drive Motor Details 

a) Type & make 

b) Voltage, phase & frequency 

c) Rated power 

d) Speed 

e) Starting/ pull out torque 

f) Line current 

g) Starting current 

h) Overall efficiency 

i) Class of insulation 

j) Type of enclosure 

k) Any other information 

5.6 Exhaust fan 

a) Make & Model 

b) Capacity in m3/h. 

c) Total Pressure, mm WC 

d) Material of construction and its thickness 

e) Speed in rpm. 

f) Drive details. 

g) Shaft Power consumption. 

h) Wheel diameter 

i) Efficiency 

j) Static & Dynamic weight of fan & motor assembly 


Page 38 of 55

k) Critical speed of fan 

l) Noise level at 1m distance in dB(A 

m) Performance curve. n 

n) Air flow direction. o 

o) Fixing details. p 

p) Vibration level. 

5.7 Dry Panel type filter 


b) Capacity in m3/h 

c) Pressure drop in mmWC. – both in clean & in dirty condition 

d) Effective cross sectional area in m 

e) Velocity through filter in m/sec. 

f) Material of filtering panel. 

g) Cleaning efficiency Vs particle size 

h) Methods of surface regeneration. 

i) Filter box construction details. 

j) Overall dimensions & no. of filters. 

k) Fixing frame details. 

l) Total weight. 

2 

Velocity through filter in m/sec. 

Material of filtering panel. 

Cleaning efficiency Vs particle size 

Methods of surface regeneration. 

Filter box construction details. 

Overall dimensions & no. of filters. 

5.8 Air Washer Unit 

a) Make & Model No. 

b) Type of unit (Horizontal/vertical) 

c) Overall dimensions (mm) 

d) Weight (kg) with and without water Capacity in m3/h. 

e) Total Pressure drop, kgf/ m 

f) Material, dia and nos. of nozzles 

g) Make up water requirement 

h) Details of makeup, overflow, drain, supply & return 

i) Saturation efficiency 

j) Amount of water and its pressure at the nozzle 

k) Casing and tank thickness 

l) Water tank capacity 

2 g 

Material, dia and nos. of nozzles 

Make up water requirement 

Details of makeup, overflow, drain, supply & return water pipe lines 

Amount of water and its pressure at the nozzle 

Casing and tank thickness 

5.9 Centrifugal Pump (indicate separately for ventilation and dust suppression) 

a) Make and model no. 

b) Type of pump 

c) Capacity in m3/hr. 

d) Total head in m WC. 

e) Quantity 

f) Material of construction 

g) Shaft 

h) Impeller Casing 

i) Pump speed (rpm) 


Page 39 of 55

j) Shaft power 

k) Drive details 

a. Motor make 

b. Motor KW 

c. Insulation class 

d. Frame size 

l) Bearing type & make 

m) Type of coupling 

n) Vibration level 

o) Noise level at 1 m distance from pump set 

5.10 Dry Fog & Plain Water Sprinkling type Dust Suppression Systems 

a) Technical details and quantity of main equipment including Nozzles, PRU, FAS and 

Instrumentation for Auto Operation. 

b) Technical details and qua quantity ntity of auxiliary equipment including air compressors, pumps, 

etc. 

c) Technical details of circular swiveling sprinklers 

d) Compressed air & water requirement, capacity of compressor, air receiver, capacity of 

water pump unit etc. 

e) Total power consumption. Capacity of each motor for pump and compressor. 

f) Details of air & water pipelines with sizes and quantities. 

g) Details of valves and fittings 

h) Details of solenoid valves, sensors, pressure gauges and other instruments. 

i) Details of tanks 

j) Details of hood / skirt boards modification 

k) Size of compressor cum pump house. 

l) Size of only pump house (In case compressed air is not provided) 

5.11 Split Air – Conditioner 


b) Quantity 

c) Capacity in TR (Nominal / Actual 

d) Air Flow m3/h 

e) Flow direction and volume control grill 

f) Material of construction 

g) Compressor type 

h) Drive details and total power consumption 

i) Overall dimensions 

j) Refrigerant type 

k) Filter efficiency 


Page 40 of 55

l) Weight of unit 

m) Noise level at 1m distance in dB(A) 

n) Fixing details. 

o) Vibration level. 

p) Accessories included 

6.0 Drawings/documents for Fire Protection System 

Drawings/documents to be furnished with offer 

The tenderer shall submit the offer along with the following drawings / documents. 

a) Scope of work with general description of the sy system stem and equipment offered specifying the 

important features. The tenderer has to give a confirmation with respect to the scope of 

work as detailed in this specification excepting for the deviations, if any, to be listed in the 

schedule of deviation. The ddescription 

escription to be accompanied by single line diagrams, and 

equipment layout to enable the Purchaser to have a proper appreciation of the equipment 

offered and its operation. 

b) Specific exclusions, if any, from scope of work . 

c) Block Scheme diagram for all fire protection system along with tentative BOQ for major 

equipments. 

d) Specification of equipment along with their makes/catalogues and material of construction. 

e) Reference list of job executed for each type of system. 

f) List of mandatory spares as per requ requirement irement for 2 years operation and maintenance. 

g) List of special tools and tackles. 

h) Amp. hour capacity of DC battery required for MFAP. 

i) Write up with control schematic on working of all fire protection systems. 

j) Detector type and Catalogues 

k) Linear heat t sensing cable details 


Page 41 of 55

1.0 FORMAT FOR GENERAL AND COMMERCIAL PARTICULARS 

COMPANY SEAL 

1. Name and Address of Bidder. 

2. Telegraphic Address of Bidder 

3. Name and designation of the person to whom all 

references shall be made to expedite technical 

coordination 

4. Place of Manufacturer 

5. Proposal No. & Date 

6. Current Registration No. with D.G.S. & D 

7. Whether all service facilities available? 

8. Whether necessary spare parts available? 

9. Has tenderer paid Earnest Money Deposit? 

10. Is offer valid for four (4) months from Price bid 

opening? 

11. Has bidder quoted F.O.R site prices? 

12. Is price break up given in Price Bid? 

13. Are prices quoted FIRM? (Price should be firm.) 

14 Is the tenderer agreeable to the terms of payment? If 

not, has terms of payment acceptable to him been 

indicated? 

15. Does the tenderer agree to the delivery periods 

indicated? 

16. Are the delivery periods guaranteed under penalty 

clause? 

17. Is the tenderer agreeable to pay 10% Security 

Deposit? 

18. Are all schedules for technical particulars and prices 

filled in? 

19. Has tenderer brought out all deviations in schedule of 

deviations? 

20. Warranty period from takeover of plant / equipment. 

21. Are equipment guaranteed as per various guaranteed 

clauses of tender documents? 


SIGNATURE ___________________ 

DESIGNATION ___________________ 

COMPANY ____________________ 

DATE ____________________ 

Format - 1 

Page 42 of 55

2.0 FORMAT FOR BIDDERS EXPERIENCE LIST 

Sl. 

No 


Purchaser & Customer’s 

Location PO No. and 

Date 

1 2 3 

NOTE: Bidder may also furnish the above details for ongoing assignments. 


Period & 

Year of 

Completion 

Details 

of work 

Capacity 

of plant 

4 5 6 7 8 9 

SIGNATURE ___________________ 

DESIGNATION ___________________ 


DATE ____________________ 

Format - 2 

Page 43 of 55 

Total cost of 

work done by 

bidder

8.0 LIST OF DRAWINGS ENCLOSED WITH BID 


Sl. No. 

1 


Drawings Title 

2 3 

SIGNATURE ___________________ 

DESIGNATION ___________________ 


DATE ____________________ 

Format - 3 

Page 44 of 55

SCHEDULE OF COMPONENTS IN USE AT NALCO’S EXISTING COAL HANDLING PLANT, CPP, ANGUL 

Components schedule given below are for information to Bidders for standardization and 

interchangeability with existing Coal Handling Plant only. Bidders must take a note o oof 

these 

components details while selecting a new supply to control the inventory level. 

A) Conveyor Pulley Schedule 

Pulley 

Type 

Drive/ 

Discharge 

Pulley 

Non Drive 

Pulleys 

Pulley 

Diameter 

(mm) 

630 

630 

630 

800 

400 

400 

500 

B) Bearing & Plummer Block Schedule. 

Shaft diameter (mm) Bearing size Plummer Block Schedule 

Drive Pulleys Non Drive Pulley 

65 22215K 1 – 1328 - AL 1 – 1328 - AL 

75 22217K 1 – 149 - AL 1 – 149 - AL 

90 22220K M – 1034 - BL M – 1034 - BL 

100 22222K M – 1033 - CL M – 1033 - CF 

115 22226K M – 1035 - AL M – 1036 - AF 

125 22228K M – 1036 - BL M – 1036 - BL 

140 22232K M – 1035 - CL M – 1036 - CF 

150 22234K 1 – 829 - AL 1 – 1330 – AF 

160 22236K 1 – 1487 - L 1 – 1488 - F 

C) Gear Box Schedule. 


Gear box size Reduction Ratio 

SZN-200 

SZN-225 

SZN-250 

SZN-280 

SZN-320 

SZN-250 

Face 

width 

(mm) 

Shaft 

Diameter 

(mm) 

KDA-200 200 125:1 

Bearing 

Diameter 

(mm) 

Shaft 

length 

(mm) 

1150 125 115 1690 1550 

1150 150 140 2095 1650 

1150 165 150 2100 1650 

1150 175 160 2120 1650 

1150 90 75 1760 1650 

1150 100 90 1760 1650 

1150 115 100 1770 1650 

16 : 1 

16 : 1 

16 : 1 

20 : 1 

20 : 1 

16 : 1 

PlummerBlockCenter 

(mm) 

Page 45 of 55

D) Fluid Coupling Schedule 

E) Idler Schedule 


Fluid coupling size Baffle Ratio 

FCU-16.25 16.25 1.5B 

FCU-17.75 17.75 1.5B 

FCU-23 

1.5B 

FCU-41 

The idlers are drop in slot type. 

1.5B 

Page 46 of 55

LIST OF PREFERRED MAKES 

1.1. MECHANICAL 

SL. NO. EQUIPMENT 

1. GEAR BOXES 

2. CONVEYOR BELTS DUNLOP, NIRLON, MRF, PHOENIX, NORTHLAND, FORECH, ANIL 

RUBBERS, ORIENTAL. 

3. IDLER 

4. PULLEY 

5. BEARINGS 

6. SLEW RING BEARINGS ROTHE ERDE, TITANUS, LYC-CHINA 

7. FLEXIBLE COUPLING FMG, DAVID BROWN, HICLIFF, CONCORD, ROMA, WELLMAN 

INCAD. GREAVES LTD., NAW, GBM, ALLFLEX 

8. FLUID COUPLING PEMBRIL, FLUDOMAT, VOITH, ELECON 

9. FASTENERS 

10. MANUAL HOISTS WH BRADY, KANUBHAI, HERCULES, TRACTEL TIRFOR, REVA 

ENGG. MM ENGRS, BRADY&MORRIS 

11. OIL SEALS 

12. LUBRICATION 

13. POWER PACK 

14. HYDRAULICS 

15. HOSES 

16. a) BELT CLEANERS a) HOSCH, KAVERI,TECHNOFAB, PROMAC, BMH CONCARE 

b) SKIRTS AND SKIRT 

SEALING 

ARRANGEMENT 

17. ACTUATOR OPERATED 

FLAP GATES 

UNITED TECHNOMECH, PREPEC, PEBCO 

18. IN LINE MAGNETIC ELECTRO-ZAVOD, ZAVOD, MBIL, ELECTROMAG, POWER BUILD, MCI, 

SEPARATORS ELECTROMAGNETIC INDUSTRIES 

19. BELT WEIGH SCALES SCHENK-JENSON, JENSON, TRANSWEIGH, IPA, SARTORIUS 

20. BELT SWITCHES 

21 BRAKES 

22 ELEC. HOISTS 


MAKE 

ELECON, FLENDER, SHANTHI, SEW, NAW, GRAEVES 

ELECON, TRF, KALI, KRUPP, MACMET, HINDUSTAN UDYOG 

ELECON, TRF, KALI, HEC, HINDUSTAN UDYOG, McNALLY 

BHARAT, HITECH, MASYC, KRUPP, SIMPLICITY, ARUDRA, 

MACMET. 

SKF, FAG, NTN, NBC, NORMA, TATA, EAST EUROPIAN EUROPIAN, ZKL 

GKW, SUNDERAM, PRECISION FASTENERS 

VACCA, RUBBER EQPT. & ENGG. CO. L TD 

TECALEMIT, SURMAC, LUBCON, PRAKASH, AFMC, HELIOS 

PROTOS, LINCOLN HELIOS 

REXROTH, PARKER, ETON, YUKEN, VICKERS, HAGGLUNDS 

REXROTH, YUKEN, CARTER, VELJAN CYLINDERS UTL, 

MONTECH, WIPRO, OSCAR, HAGGLUNDS, PARKERCALZONI 

AEROLEX, GATES INDIA PVT. LTD 

b) UNITED TECHNO MECH, TEGA, KAVERI, HOSCH 

JAYSHREE, SCHNEIDER, TELEMECHANIC, INDUSTRY SYNDICATE, 

PROTO CONTROL 

BCH, INDUSTRIES SYNDICATE, STORM KRAFT, ELECTROMAG, 

SPEED O CONTROL, STROMAG 

ARMSEL, SHIVPRA, WH BRADY, BRADY & MORRIS, GRIP 

ENGRS., HI-TECH, TECH, CENTURY CRANE, TUOBRO FURGUSON, 

UNITECH 

Page 47 of 55

In case the Tenderer/ Contractor intends to substitute any particular make of equipment / 

components/ ents/ materials by their/ his own make other than that listed in this document, the 

Tenderer shall clearly bring out the same in his tender along with justification and indicate the 

makes offered by him. It will be prerogative of the Purchaser to accept or reject the tenderer’s 

own makes so offered. 

1.2. ELECTRICAL 

Sl.No ITEM 

APPROVED SUB VENDORS 

1. 415 V MCC/ (Drawout type) 1. ABB 

2. GE Power Control Ltd 

3. L&T 

4. Siemen Ltd 

5. Schneider Eectric India Pvt.Ltd 

2. 415 V PDB/DB (Fixed type) 1. Control & Switchgear Co. Noida 

2. GE Power Control Ltd 

3. L&T 


5.ABB 

6.SIEMENS 

3. HT Cables 

1. CCI 

2.Universal 

3.Polycab 

4.NICCO 

5.KEI 

4. LV Motors 

1. Alstorm 

2. Asea Brown Boveri Ltd, Faridabad 

3. Bharat Bijlee 

4. Kirloskar Electric Co.Ltd, Banbalore & Hubli 

5. Siemens 

6. CGL 

5. Local Control Stations (Weather 1. Bhartiya Industries 

Proof) 

2. Baliga Lighting Eqpt(p)Ltd 

3. Ex-protecta 

4. Electrical Equpt.Corporation 

5. Flexpro Electricals Pvt.Ltd 

6. Prompt Engineering Works 

6. Bimetal Relays 1. ABB,Bangalore 

2. Bhartiha Industries 

3. L&T 

4. Siemens 


7. Contactors 

1. ABB,Bangalore 


3. Control & Switchgears Contactors Ltd. 

4. GE Power Control India Ltd 

5. L&T 

6. Siemens Ltd 

7. Schneider Electric India Pvt.Ltd 

8 Control Switches/Selector 1. Alstom Ltd 

Switches 

2. Havells India 

3. Hotline Switchgear &Controls 

4. Kaycee Industries 

5. L&T 


Page 48 of 55

9. Fuse Switch 

6. Reliable Electronic Components Pvt. Ltd 


8. Switron Devices 

1. ABB Ltd, Bangalore 

2. Control & Switchgears Co Ltd 


4. Indo Asian Fuse Gear 

5. L&T 


7. Standard Electricals 

8. Alstom 


10 Timers 


2. Concord Controls 

3. Electronic Automation Pvt Ltd 

4. L&T 



11 Fuse 

1. GE Power Controls 


3. L&T 


5. Ferraz 

6. Bussman 

12 ELCBs 

1. Datar Switchgear Pvt Ltd 


3. Legrand India 

4. ABB 

5. Siemens 


7. GE 

13. MCBs 

1. Datar Switchgear Pvt Ltd 



4. Indian Current Control 



7. ABB 

8. Siemens 

9. GE 

10.L&T 

14 MCCBs 

1. GE Power Controls 

2. L&T 


4. Siemens 

5. ABB 

15 Meters 

1. Automatic Electric 

2. Meco Instruments Pvt Ltd 

3. Nippen Electrical Instruments Co 

4. Risabh Instruments Pvt.Ltd 

5. Industrial Meters(P) Ltd 

16 Push Buttons & Indicating Lamp 1. Bhartiha Industries 

2. Concord Controls 


4. Hotline Switchgears & Controls 

5. L&T 


Page 49 of 55

17 Lighting & Power panels 

6. Precifine Products Pvt. Ltd 

7. Siemens 

8. Shri Tulsi Switchgears 

9. Teknick Controls 


11. Binoy Opto Electrics,Kolkata 



3. Masstechm Switch gear 



18 Lighting Fixtures 1. Bajaj Electricals 

2. Comptron Greaves 3. Philip India 

19 Terminal Blocks 1. Essen 

2. Connect well 

3. Elmex 

20 Switch socket outlets 1. ALSTOM 

2. CGL 

3. B & C 

4. ESSEN 

21 Transducer 

1. ABB 

2. MECO 

22 LT Transformer 1.CGL 

2.KEC 

3.BBL 

4.BHEL 

5.AREVA 

6.BMCC 

7.T&R 

8.VIJAY ELECTRICAL 

23 PLC 

1.GE-FANUC 

2. ALLEN BRADLY 

3.SCHNEIDER 

24 UPS 

1.EMERSION 

2.HI-REL 

3.NUMERIC 

4.TATA LIBERT 

25 Control Desk 

1. SIEMENS 

2. ALSTOM 

3. L&T 

4. ABB 

27 VVVF Drive 

1. ALSTOM 

2. BHEL 

3. DANFOS 

4. L&T 

5. NELCO 

6. ROCKWELL 

7. SIEMENS 

8. ABB 

9. SCHNEIDER 

10. YASKAWA 

29. 33 K V Isolator 1. PANICKER 

2. BOND STRANDS 

3. DRISCHER 

30 Trailing Cables 1. KEI 

2. NICCO 


Page 50 of 55

31 HT Switch gear 1. BHEL 

2 Siemens 

3. ABB 

32 HT Transformer 1. BHEL 

2 Siemens 

3 TELK 

4 ABB 

5 AREVEA 

33 33KV VCB 

1. ALSTOM 

2.ABB 

3.SIEMENS 

34 Protection relays 1.ABB 

2.ALSTOM 

3EASUN REY ROLLE LTD 

4L&T (FOR NUMERICAL RELAYES ONLY) . 

5SIEMENS (FOR NUMERICAL RELAYES ONLY) . 

35 Breaker Control switches 1.ALSTOM 

2.RELIABLE RELIABLE ELECTRONIC COMPONENT PVT.LTD. 

3.SWITORN DEVICES 

36 LV CT/PT 

1.COTROL AND SWITCH CO.LTD. 

2.GEILBERT & MAXWELL ELECTRICAL 

3.KAPPA ELECTRICALS 

4.L&T 

5.NARYAN POWER TRON PVT.LTD. 

6.SILKAANS ELECTRICAL 

7.PRECISE ELECTRICAL 

8.PROGATI ELECTRICAL PVT.LTD. 

37 HVCT/PT 

1.AE 

2.BHEL 

3.CGL 

4.SILKAANS 

5.JYOTI 

6.KAPPA 

7.ABB 

8.PROGATI. 

38. Solid State Annuncitaor 1.APLAB 

2.MINILEC 

3.IL 

39. Lightning Arrests 1.WSI 

2.ELPRO. 

40. 33KV Air Break switch 1.DRIESCHER PANNIKER 

41. High Mast Tower 1.BAJAJ 

2.PHILIPS 

42. Cable accessories 1.DOWELLS 

43. ACSR/AAAC Conductor 1.RELIANCE CONDUCTORS 

44. 415V PCC 

1. L&T 

2.SIEMENS 

45. Cable termination 7 jointing 1.RAYCHEM RPG 

kits 

46. LT power and control cables 1.CCI 

2.UNIVERSAL 

3.POLYCAB 

4.NICCO 


3. UNIVERSAL 

Page 51 of 55

47. Signal and Instrumentation 

5.KEI 

6.CORDS 

7.GEMSCAB 

1.CCI 

cable 

2.UNIVERSAL 

3.POLYCAB 

4.NICCO 

5.KEI 

6.CORDS 

7.GEMSCAB 

48. VRLA battery 

1.AMAR RAJA 

2.EXIDE 

49. Battery charger 1. AMAR RAJA 

2.CHABI ELECTRICAL 

3.CALDYNE 

4.HBL NIFE 

1.3. AIR CONDITIONING, VENTILATION & DUST SUPPRESSION SYSTEM 

Ventilation system 

- EFE, C. Doctor, Voltas 

Dust Suppression System - TPS, Kaveri, F. Harley 

Air Conditioning system - Blue Star, Voltas, Carrier 

1.3 CIVIL 

CEMENT- ACC,L&T Ultra Tech, Zuari, RAASI GOLD or equivalent approved manufacturer. 

REINFORCEMENT STEEL STEEL-SAIL,Tata SAIL,Tata Steel, RINL, or equivalent approved manufacturer. 

Note: 

1. Makes indicated above shall also be read with preferred makes as listed elsewhe elsewhere in 

this specification. 

2. For make of any item, not appearing in the above list, specific approval shall be taken by 

the bidders from Purchaser. 


Page 52 of 55

1.0 LIST OF TOOLS AND TACKLES 

S.NO DESCRIPTION 

1. Manually operated Hydraulic Jack 

i) 50T X 150 mm stroke 

2. Bastard (Rough Cut) Files 250 mm size 

i) Flat 

ii) Round 

iii) Half Round 

iv) Triangular 

3. Fine Cut Files 250 mm size 

i) Flat 

ii) Round 

iii) Half Round 

iv) Triangular 

4. Adjustable Outside Micrometer Interchangeable Anvil 

Type 

i) 0-150 mm 

ii) 150 – 600 mm 

5. Inside Micrometer 

i) 50 – 150 mm 

6. Vemier Calipers – 

i) 0-150 mm size 

ii) 0 – 300 mm size 

7. Feeler Gauge 

i) 10 mm thk. 6 inch 

ii) 10 mm thk. 12 inch 

8. Sprit Level 

i) 150 mm 

9. Torque Wrench with socket 

75 – 150 kg.m 

10. Standard Ring spanners 

(Upto 32 mm ) 

11 Standard D.E. spanners 

(Upto 32 mm ) 

12. Adjustable spanners 

(Upto 50 mm each set of 3 Nos.) 

13. Socket Head Spanners 

(Box Spanners 10 to 32 mm ) 

14 Sledge Hammers 

i) 5 kg. 

ii) 10 kg 

15. Nylon Faced Hammers (4 Sizes) 


QUANTITY 

2 Nos 

1 No. 

1 No. 

1 No. 

1 No 

1 No. 

1 No. 

1 No. 

1 No 

1 No. 

1 No 

1 No 

1 No. 

1 No 

1 No. 

1 No 

2 No 

1 set 

1 set 

1 set 

1 set 

2 set 

2 Nos. 

2 Nos 

1 set 

Page 53 of 55

16. 4” dia portable motor operated grinding m/c with flexible 

grinder 

2 Nos 

17 Ball Pein Hammers in different sizes. 

18. Dial Gauge 00-10 

mm LC-0.01 mm with mag. 

Stand 

19. Steel Tapes 

i) 3 m Size 

ii) 6 m Size 

20 Steel Scales 

i) 0.3 m Size 

ii) 0.5 m Size 

21. Internal Calipers 

i) 150 mm Size 

ii) 300 mm Size 

22. External Calipers 



23 Hand operated Hacksaw Frame with 1 Doz. Blades (12”) 1 Set 

24 Tri-square square (6” x 12”) 

25. Screw Operated Coupling and Bearing Puller – 300 mm 

Size 

2 Nos 

26. Grease Gun with hose & adopter (Manual) 

27 Bucket Grease Gun (Manual) 

28. Self supporting, extendable aluminum ladder with 

maximum height of 6m 

2 Nos 

29 Hydraulic flange puller of reputed make 

2 Sets 

30. Pipe Wrenches – 6” & 12” 

31 Digital Tachometer (0 – 3000 rpm) 

32 Screw Drivers 



33 Sling with Eye Bolt and DD-Shackle 

of 2,3,5 &10 tonnes 

34. Plum Bobs 

35. All types of Pliers of different size of reputed make to suit 

the eqpt. 

i) Cutting pliers 

ii) Internal Circlip 

iii) External Circlip 

36. Adjustable Pliers 

37 Marking Punches 

38 Scribers 

39 Insulation resistance Tester (Megger) 

i) 500 V 

ii) 1000 V 


6 Nos 

2 Nos 

1 No. 

1 No 

1 No. 

1 No 

1 No. 

1 No 

1 No. 

1 No 

2 Nos 

2 Nos 

1 No 

4 Nos 

2 Nos 

2 Nos. 

2 Nos 

2 Sets 

2 Nos 

2 Nos. 

2 Nos. 

2 Nos 

2 Nos 

2 Sets 

4 Nos 

1 No. 

1 No 

Page 54 of 55

40. Tong Tester 

41. Portable Emergency Light (Hand Torch with Dry Cells) 

42. 100 W Hand Lamp with 50 M Flexible Wire 

43. Hand drills (pistol) 

44. Digital Multimeter 

45 Digital Clamp meter 

46 Hand drill – Electrical ½ “ & 1” 

47 Crimping Tool ( Hand Operated) - 5 mm 

48. Crimping Tool ( Hand Operated) 

2 to 16 mm 2 

Crimping Tool ( Hand Operated) -16 mm 2 to 240 mm 2 

49 Milli Ohm Meter 

50 Combination Plier 

51 Nose Plier 

52 Earth Megger 

53. Phase Sequence meter (0 – 415V) 

2.0 LIST OF TENDER PURPOSE DRAWINGS FOR BIDDER’S REFERENCE 

SL. NO. DESCRIPTION DRAWING NO 

1 

2 

3 

4 

5 

6 

7 

Handling System 


Layout of Coal Storage Yard & 1034/Q6Q3/A-02A/LO 02A/LO-001 Rev 05 

Coal Flow Diagram FD-CHP 

General Layout of CPP, NALCO 6-08-0-07734-01 

G.A. & Marking of Conveyor BC BC-115 02728-M-BM-CS-GA--0027 

Rev C 

G.A. & Marking of Conveyor BC BC-103 CKIH-3901-M0-B057 B057 Rev D 

G.A. of Junction House JH JH-1 CKIH-3901-M0-B004 B004 Rev C 

G.A. of wagon tippler & receiving RITES/PORTS/NALCO/FS/L 

RITES/PORTS/NALCO/FS/L-01 

conveyor 

(Set of three drawings) 

(Set of five drawings) 

2 Nos 

2 Nos 

2 Nos 

2 Nos 

1 No 

1 No 

2 Sets 

1 Set 

1 Set 

1 No 

2 Nos 

2 Nos 

1 No 

1 No. 

Page 55 of 55

1.0 COMPLETION SCHEDULE 

Special Instructions to Bidders 

Annexure - II 

The schedule for completion in all respect as per Tender Documents from Brief Order (BO) date is 

specified in Instruction to Bidders. 

2.0 DUE DATE 

Please ensure your offer, complete in all respects reaches us by the bid due date specified in 

Instructions to Bidders. Offers received after the bid due date and time will be considered as Late 

Offers and will not be considered. 

3.0 PRICE FORMAT 

Please furnish the prices strictly as per the format enclosed. Prices shall not appear any where 

else in the offer, and if prices are mentioned any where else the same shall not be considered. 

Prices should be submitted in duplicate sealed super scribed envelope along with un-priced copies 

as per Tender documents (Un-priced copy of price bid should also be enclosed with un-priced 

copies with prices blanked out but “Quoted/ Not Quoted” marked against respective clauses). 

4.0 VALIDITY OF BIDS 

The bid should be kept valid for acceptance for a period of 4 (four) months from the final due date 

for bid submission. 

5.0 EVALUATION/ LOADING/ REJECTION CRITERIA 

5.1 All evaluation shall be made on landed and erected on destination basis including design and 

engineering, supply of equipment, spares etc. (excluding One Year O&M Spares) and all other 

erection, construction, installation, supervision and commissioning charges along with the taxes 

and duties for the same, as per scope of Tender Documents. 

5.2 Supply prices shall be evaluated as follows: 

1. FOT Despatch Point : As quoted 

2. Add ED & E-cess : As Quoted 

3. Add CST/ LST/ VAT : As Quoted 

4. Total Price : 1+2+3 

5. Transit Insurance : 0.25% on (4) 

6. Freight Charges : As quoted 

7. Total FOT Site : 4+5+6 

8. Entry Tax : @ 2% on (7) 

9. Total Price : 7+8 

10. Technical loadings, if any : On FOT Despatch point price 

Annexure II, Special Instructions to Bidders Page 1 of 9

11. Commercial loading, if any : On FOT Despatch point price 

12. CENVAT Benefit (-) 2 

13. Total Comparable Price : 9+10+11+12 

5.3 Price loading on account of payments and other conditions required by various vendors will be 

based on following:- 

(i) Payment terms: 

a) Price loading on account of payment terms at variance with Bidding Document 

payment terms will be loaded @ 12% per annum for the relevant period. 

(ii) Price Variation:- 

Terms offered by vendor price loading 

(a) Firm Price : No loading 

(b) In case of ceiling on : Loading by ceiling percentage offered 

Price Variation Clause 

(c) No ceiling on the formula : Offer may be rejected 

(d) No formula and no : - do - 

ceiling specified by vendor 

(iii) Vendors should quote firm inland freight charges from dispatch point to Site at Angul, 

Orissa. If a vendor does not quote firm inland freight charges then their offer will be loaded 

with maximum of the inland freight charges as quoted by the other bidders from that region 

or based on estimation by NALCO in case there is no other offer from that region. 

(v) Any differential in taxes and duties will be cost loaded on case-to-case basis. If a vendor 

states that taxes/duties are not applicable at present and will be charged as applicable at 

the time of delivery then no advantage will be given. 

(vi) All materials are required to be transported by Bank-approved carriers, preferably having 

an office at the place of concerned unit. 

(vii) Cost loading in respect of utilities will be considered where guaranteed consumptions have 

been asked in NIT as per methodology defined in the NIT. 

5.4 All cost loadings will be calculated on F.O.T. despatch point prices. 

5.5 No deviation to terms & conditions of the bid documents is allowed. Further Non acceptance of 

following commercial clauses shall lead to rejection of bid: 


(i) Bids that do not meet the qualification criteria as specified in the NIT/ bid documents shall 

be summarily rejected. 

(ii) A bid with incomplete scope of work and / or which does not meet the technical 

specifications and requirements as specified in the NIT documents shall be considered as 

non-responsive and rejected. 

(iii) Prices must be furnished in accordance to the price schedule format enclosed and strictly 

based on the terms specified related to the bid prices in the instructions / conditions. Non 

compliance to this requirement shall make the bid liable for rejection. 

(iv) Bidders are requested to note that exceptions / modifications taken by them to the 

following clauses of Tender Documents - Commercial may result in rejection of their bid :- 

6.0 REFERENCE LIST 

(a) Proforma of Bank Guarantee for Advance Payment, if any, and Contract - cum - 

Performance Bank Guarantee 

(b) Contract Performance Guarantee clause 

(c) Completion Schedule 

(d) Period of validity of bid 

(e) Guarantee / Warranty 

(f) Replacement of Defective parts and materials 

The bidders are requested to submit a list of buyers to whom the same or similar type of equipment 

have been supplied by them and which are under operation. The detailed addresses of such 

buyer’s office/works including Telephone, Fax Nos. and Contact Person and Order Reference are 

to be mentioned. 



1.0 COST OF BIDDING 

2.0 SITE VISIT 

3.0 BIDDING DOCUMENT 

APPENDIX - A 

TO 

SPECIAL INSTRUCTIONS TO BIDDERS 

INDEX 

4.0 CLARIFICATION OF BIDDING DOCUMENT 

5.0 AMENDMENT OF BIDDING DOCUMENT 

6.0 CONFIDENTIALITY OF BIDDING DOCUMENT 

7.0 LANGUAGE OF BID 

8.0 FORMAT AND SIGNING OF BIDS 

9.0 MODIFICATION & WITHDRAWAL OF BIDS 

10.0 OPENING OF UN-PRICED BIDS 

11.0 OPENING OF PRICE BIDS 

12.0 COMPARISON OF BIDS 

13.0 CONTACTING THE OWNER/CONSULTANT 

14.0 AWARD CRITERIA 

15.0 OWNER’S/CONSULTANT’S RIGHT TO ACCEPT ANY BID AND TO REJECT ANY 

OR ALL BIDS 

17.0 ISSUE OF ORDER 


1.0 COST OF BIDDING 

1.1 All direct and indirect costs associated with preparation and submission of bid (including clarification 

meetings and site visit, if any) shall be to bidder’s account and NALCO / RITES, will in no case, be 

responsible or liable for these costs, regardless of the conduct or outcome of the bidding process. 

2.0 SITE VISIT 

2.1 Bidder is advised to visit and examine the Site, its surrounding and familiarize himself of the 

existing facilities and environment and collect all other information which he may require for 

preparing and submitting the bid and entering in to the contract. Claims and objections due to 

ignorance of existing conditions or inadequacy of information will no be considered after 

submission of the bid and during implementation. 

2.2 The bidder or any of his personnel or agents will be granted permission by the Owner to enter upon 

his premises and land for the purpose of such inspection but only upon the explicit condition that 

the bidder, his personnel or agents will release and indemnify the owner and his personnel or 

agents from and against all liability in respect thereof and will be responsible for personnel injury 

(whether fatal or otherwise), loss of or damage to property and any other loss, damage, cost and 

expenses incurred as a result thereof. 

2.3 For site visit, the intending bidder may contact General Manager (CPP), NALCO, Angul, Orissa 

Phone- 06764- 220 158, Telefax – 06764- 220 646 or General Manager (Projects), RITES Ltd, 

Bhubaneswar, Phone: 0674 2572690, 09438677075. Fax – 0674 2575 284. or Sr. 

DGM(Civil)/RITES, Bhubaneswar, phone-09437283829. 

3.0 BIDDING DOCUMENT 

3.1 The Bidder is expected to examine all instructions, forms, terms and specifications in the 

Bidding Document. The Bidding Document together with all its attachments thereto, shall be 

considered to be read, understood and accepted by the Bidder, unless deviations are specifically 

stated in seriatim (giving reference s. no. of Bidding Document) by the Bidder. Failure to furnish all 

information required by the Bidding Document or submission of a bid not substantially responsive to 

the Bidding Document in every respect will be at Bidder’s risk and may result in the rejection of his 

bid. 

3.2 The Bidders must fulfill the Qualification Criteria given in the Instructions to Bidders and furnish all 

necessary documentary evidence in support of Bidder’s experience/ capability as required, along 

with the bid. In the absence of the requisite documents, NALCO / RITES reserves the right to reject 

the bid without making any reference to the Bidder. Bidders must make their own judgment on 

the adequacy of the documents/ information they provide. In case any information provided by 

Bidder is found to be incorrect, the bid will be rejected, and the Earnest Money Deposit of 

such Bidder will be liable for encashment. 

3.3 Bidder must buy Bidding Document by paying the requisite document fee before the sale 

closing date & time. In case the Bidding Document is downloaded from website t h e requisite 

Bidding Document Fee in the form of DD payable to NALCO shall accompany the bids. 


4.0 CLARIFICATION OF BIDDING DOCUMENT AND PRE-BID MEETING 

4.1 Bidder shall examine the bidding document thoroughly in all respect and if any conflict, discrepancy, 

error or omission is observed, bidder may request clarification within the cutoff date and 3 weeks 

prior to the bid closing date. Such clarifications request shall be addressed to the following: 

GM (Projects), RITES Ltd.,Regional Project Office, Bhagwan Tower(1 st Floor), Cuttack Road, 

Bhubaneswar -751006, Phone:-0674-2575493, Fax:0674-2575284, E-mail : bbsrpo@rites.com 

4.2 Any failure by bidder to comply with the aforesaid requirement shall not excuse the bidder, after 

subsequent award of contract, from performing the work in accordance with the contract. 

4.3 Response to queries/ clarifications raised will be sent as expeditiously as possible. The response 

shall not form part of the bidding document unless issued as an addendum/ amendment. 

4.4 Bidders are expected to resolve all their clarification/ queries to the bidding document and submit 

their bid in total compliance to biding document without any deviation/ stipulation/ clarification. 

4.5 PRE-BID MEETING 

The Tenderer or his official representative is invited to attend a pre-bid meeting which will take place at 

the Office of General Manager(Project), CPP, Nalco,Angul on 10.09.2012 at 10.30 hours. 

The Tenderers are required to submit any question on issues relating to the tender, in writing or by 

telefax or by E-mail so as to reach general Manager(Project), RITES Ltd.,Regional Project Office, 

Bhagwan Tower(1 st Floor), Cuttack Road,Bhubaneswar -751006 not later than 3 (three) days before 

the date fixed for the meeting. 

The purpose of the meeting will be to clarify the issues raised and to answer supplementary questions 

on such issues. 

Minutes of the meeting including the text of the questions raised (without identifying the source of 

enquiry) and the responses given will be uploaded on RITES website. Any modifications of the 

Tender Document which may become necessary as a result of the Pre-bid Meeting shall be made 

exclusively through the issue of an Addendum / Corrigendum and not through the Minutes of the Pre- 

Bid Meeting. The Minutes of the Meeting as described above and the Addendum / Corrigendum, if 

any, will be uploaded on RITES website only. 

Non-attendance at the Pre-bid Meeting will not be a cause for disqualification of a tenderer. 

5.0 AMENDMENT OF BIDDING DOCUMENT 

5.1 At any time prior to the bid due date, NALCO / RITES may, for any reason, whether at its own 

initiative or in response to a clarification requested by a prospective Bidder, modify the Bidding 

Document and issue amendment in the form of Addendum. 


5.2 Any addendum thus issued will become part of bidding document and bidder shall submit original 

addendum/ compliance letter duly signed and stamped in token of his acceptance. 

5.3 In order to afford prospective Bidders, reasonable time in which to take the amendment into account 

in preparing their bids, NALCO /RITES may, at its discretion, extend the bid due date. 

6.0 CONFIDENTIALITY OF BIDDING DOCUMENT 

6.1 Bidders shall treat the biding documents and contents therein as strictly confidential. 

6.2 The bidding document is and shall remain the exclusive property of the OWNER without any 

right to bidder to use them for any purpose except for the purpose of bidding. 

7.0 LANGUAGE OF BID 

7.1 The bid prepared by the Bidder and all correspondence/ drawings and documents relating to 

the bid exchanged by Bidder and NALCO /RITES shall be written in ENGLISH language. Any 

printed literature furnished by the Bidder written in another language should be accompanied 

by an ENGLISH translation. In case of any conflict, for the purpose of interpretation of the bid, the 

ENGLISH translation shall govern. 

8.0 FORMAT AND SIGNING OF BID 

8.1 The Bidder shall prepare required number of copies of the bid, clearly marking each ‘Original 

Bid’ and ‘Copy of Bid’ as appropriate. In the event of any discrepancy between them, the ‘Original 

Bid’ shall govern. 

8.2 The original and all copies of the bid shall be typed or written in indelible ink and shall be signed 

by the Bidder or a person duly authorized to bind the Bidder to the Contract. The name and 

position held by each person signing must be typed or printed below the signature. The person 

or persons signing the bid shall initial all pages of the bid, except for unamended printed 

literature. 

8.3 The complete bid shall be without alterations, interlineations or erasures, except as may be 

necessary to correct errors made by the Bidder, in which case such corrections shall be rewritten & 

initialed by the person or persons signing the bid. 

9.0 MODIFICATION AND WITHDRAWAL OF BIDS 

9.1 The Bidder may modify or withdraw his bid after the bid’s submission, provided that the 

modification/ withdrawal notice is received by the Owners/ Consultant prior to the bid due date & 

time. 

The Bidder’s modification or withdrawal notice shall be prepared, sealed, marked and despatched 

in accordance with the provisions of Bidding Document. A withdrawal notice may also be sent 


y Cable or Telefax but must be followed by a signed confirmation copy dated not later than 

the deadline for submission of bids. 

9.2 No bid shall be modified subsequent to the due date & time or extension, if any, for submission 

of bids. 

9.3 No bid shall be allowed to be withdrawn in the interval between the deadline for submission of 

bids and the expiration of the period of bid validity specified by the Bidder. Withdrawal of a bid 

during this interval shall result in the forfeiture of Bidder’s Earnest Money Deposit . 

10.0 OPENING OF UN-PRICED BIDS 

10.1 Un-priced part of the Bid shall be opened in the RITES, Bhubaneswar Office, in the presence 

of Bidder’s representatives (duly authorized by a competent person and having the Letter of 

Authority who choose to attend, on date, time as mentioned in the Instructions to Bidders. The 

Bidder’s representatives, who are present, shall sign a register evidencing their attendance. 

Bidders’ whose bids are not opened for any reason, including non-receipt of original Earnest 

Money Deposit, will not be allowed to be present during bid opening. 

10.2 The Bidder(s) names, modifications, bid withdrawals and the presence or absence of the 

requisite Earnest Money Deposit and such other details as the NALCO/RITES, at its discretion, 

may consider appropriate will be announced and recorded at the time of opening of un-priced 

bids as specified in the Instruction to Bidders/ Tender Documents. 

11.0 OPENING OF PRICE BIDS 

11.1 Bidders’ found to be substantially responsive a n d t e c h n o - c o m m e r c i a l l y a c c e p t a b l e 

will be advised of date & venue for the priced bid opening. Bidders may depute their 

authorized representative, along with letter of authority to attend price bid opening. The price bids 

of those Bidders determined to be not substantially responsive will be rejected and will not be 

called for price bid opening. 

The Bidder’s names, bid prices, modifications and bid withdrawals and such other details as the 

Consultant, at its discretion, may consider appropriate, will be read out at the time of opening of 

priced bids of technically and commercially acceptable Bidders. 

12.0 COMPARISON OF BIDS 

12.1 The Consultant will evaluate and compare bids previously determined to be substantially responsive 

pursuant to the provisions of the Bidding Document. 

12.2 Arithmetical errors will be rectified on the following basis:- 

If there is a discrepancy between the unit price and the total price that is obtained by 

multiplying the unit price and quantity, the unit price shall prevail and the total price will be 

corrected. If there is a discrepancy between the total amount and the sum of total prices, the sum 

of the total prices shall prevail and the total bid amount will be corrected. Further, if there is a 


discrepancy between the quoted lump sum price, and its separate break-up prices (if any), the 

quoted lump sum price shall prevail. 

13.0 CONTACTING THE OWNER/ CONSULTANT 

13.1 No Bidder shall contact the NALCO / R I T E S on any matter relating to its bid, from the time 

of bid opening to the time the Contract is awarded. 

13.2 Any efforts by a Bidder to influence the NALCO / RITES in the Owner’s/ Consultant’s bid 

evaluation, bid comparison or contract award decisions may result in the rejection of the Bidder’s 

bid. 

14.0 AWARD CRITERIA 

The Owner will award the Contract to the successful Bidder whose bid has been determined to 

be the lowest evaluated, responsive bid, provided further that the Bidder is determined to be 

qualified to satisfactorily perform the Contract. 

15.0 OWNER’S/CONSULTANT’S RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL 

BIDS 

15.1 NALCO / RITESO reserves the right to accept or reject any bid, and to annul the bidding process 

and reject all bids, at any time prior to award of contract, without thereby incurring any liability to 

the affected Bidder or Bidders or; any obligations to inform the affected Bidder or Bidders of the 

ground for the Owner’s/Consultant’s action. 

15.2 The submission of any bid connected with these documents and specifications shall 

constitute an agreement that the Bidder shall have no cause for action or claim, against the 

Owner for rejection of his bid. The Owner shall always be at liberty to reject or accept any bid or 

bids at his sole discretion and any such action will not be called into question and the Bidder shall 

have no claim in that regard against the Owner. 

16.0 ISSUE OF ORDER 

16.1 The Owner will send to the successful bidder B r ief Order/ Work Order incorporating all 

the terms and conditions agreed between the parties. 

16.2 Within 15 days of receipt of the Order, the Bidder shall sign and return it to the Owner for their 

records. 

17.0 In case of contradiction between relevant Indian Standards, General Conditions of Contract, 

Special Conditions of Contract, Specifications, Drawings, Schedule of Prices / Rates, the following 

shall prevail in order of precedence: 

i) Brief of Order, Detailed Letter of Acceptance along with Statement of Agreed Variations (if any) and 

its enclosures. 

ii) Schedule of Rates. 

iii) Technical Specifications 

iv) Drawings. 

v) Addendum to Tender Documents (Commercial). 

vi) Tender Document Commercial(Indigenous). 

vii) Relevant Indian Standards / Specifications 


. 

TENDER DOCUMENTS 

COMMERCIAL (INDIGENOUS) 

NATIONAL ALUMINIUM COMPANY LIMITED 

(A GOVT. OF INDIA ENTERPRISE) 

REGISTERED OFFICE: NALCO BHAVAN, 

P/1, NAYAPALLI, 

BHUBANESWAR - 751 061 

Tender Documents Commercial (Indigenous) Page 1 of 56

. 

GENERAL CONDITIONS OF CONTRACT 

CONTENTS 

Sl. No. Page No. 

1.00 APPLICATION 04 

2.00 DEFINITION OF TERMS 04 

3.00 CONTRACTOR TO INFORM HIMSELF FULLY 06 

4.00 SCOPE OF WORK 07 

5.00 DESIGN REQUIREMENTS 08 

6.00 CONTRACT PRICE 10 

7.00 TAXES 10 

8.00 PERFORMANCE BOND 11 

9.00 PROTECTIVE PAINTING, PACKING & MARKING 12 

10.00 SHIPMENT PARTICULARS 14 

11.00 INSURANCE 14 

12.00 DELIVERY 15 

13.00 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION 15 

14.00 IMPORT LICENSE AND FOREIGN EXCHANGE 15 

15.00 CONTRACTOR’S DOCUMENTS, DRAWINGS AND 15 

INSTRUCTION MANUALS 

16.00 MISTAKES IN DRAWINGS 18 

17.00 MATERIALS AND WORKMANSHIP 18 

18.00 SPARE PARTS AND SPECIAL MAINTENANCE TOOLS 19 

19.00 COMPLETENESS OF EQUIPMENT 19 

20.00 INSPECTION AND TESTING AT CONTRACTOR’S PREMISES 19 

21.00 TESTS ON COMPLETION AND TRIAL RUN AT SITE 21 

22.00 TAKING OVER 22 

23.00 REJECTION OF DEFECTIVE PLANT 22 

24.00 COMPLETION CERTIFICATE & FINAL CERTIFICATE 23 

25.00 ENGINEER’S DECISION 25 

26.00 CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE 26 

PURCHASER OR THE CONTRACTOR 

27.00 MINTENANCE AND GUARANTEE - WARRANTY PERIOD 27 

28.00 NEGLIGENCE 27 

29.00 POWER TO VARY OR OMIT WORK 28 

30.00 SETTLEMENT OF DISPUTE 28 

31.00 TERMINATION OF CONTRACT 29 

32.00 DEDUCTION FROM CONTRACT PRICE 29 

33.00 CO-OPERATION WITH OTHER CONTRACTORS AND 30 

CONSULTING ENGINEERS 


. 

34.00 ASSIGNMENT OF CONTRACT 30 

Sl. No. Page No. 

35.00 SUBLETTING OF CONTRACT 31 

36.00 SUSPENSION OF WORK 31 

37.00 FORCE MAJEURE 31 

38.00 PROGRESS REPORT AND PHOTOGRAPHS 32 

39.00 PATENT RIGHTS 32 

40.00 TRAINING OF ENGINEERS 32 

41.00 EFFECT AND JURISDICTION OF CONTRACT 33 

42.00 TIME IS THE ESSENCE OF CONTRACT 33 

43.00 ERECTION SUPERVISION SERVICES 33 

44.00 ERECTION PLANT AND MATERIALS 35 

45.00 FOREIGN PERSONNEL 50 

46.00 DEATH, BANKRUPTCY ETC. 50 

47.00 GRAFTS AND COMMISSION ETC. 51 

48.00 COMPLETION OF CONTRACT 51 

49.00 DEFENSE OF SUITS 51 

50.00 ARBITRATION 51 

51.00 CORRESPONDENCE 52 

52.00 CONTRACT AGREEMENT 53 

53.00 PAYMENTS 53 

54.00 MISCELLANEOUS 55 


. 

1.00 APPLICATION 

Unless otherwise provided in the Contract Agreement, these General Conditions of Contract shall 

govern the work of the annexed Specification. 

2.00 DEFINITION OF TERMS 

In construing these General Conditions and the annexed Specification, the following words shall 

have the meanings herein assigned to them unless there is something in the subject or context in 

consistent with such construction. 

2.01 The “Owner/Purchaser” shall mean the “National Aluminium Company Limited” , a company 

incorporated in India, whose Registered Office is situated at NALCO BHAVAN, P/1, Nayapalli, 

Bhubaneswar - 751 061. 

2.02 “The Contractor” shall mean person, firm or a company whose tender has been accepted by the 

Purchaser and shall include his/its heirs, executors, administrators, representatives and permitted 

assigns. 

2.03 The term Sub-Contractor used herein refers to a party or parties having a direct contract with the 

Contractor to whom any part of the contract has been sublet by the Contractor with the consent in 

writing of the Owner and shall include his heirs, executors, administrators, representatives and 

assigns. 

2.04 The “Engineer” shall mean an officer of the owner/purchaser as may be duly appointed and 

authorized in writing by the purchaser to act as the Engineer on its behalf for the purpose of the 

contract. 

2.05 The Èngineer’s Representative’ shall be the person nominated by the Engineer in writing to act on 

his behalf. 

2.06 The term `Consultants/Consulting Engineer’ refers to consultant(s) nominated by the Engineer in 

writing for the contract and referred to throughout in the Contract Documents by `Consulting 

Engineer’ or `Consultant’. 

2.07 “The Inspector” shall mean any firm or person including any employee of the owner/purchaser as 

may be duly appointed and authorized in writing by the owner/purchaser to inspect plant, 

equipment and works included by the Contractor. 

2.08 `Plant’, ‘Equipment’, ‘Works’ shall mean and include plant, stores and materials to be provided and 

work to be done by the Contractor. 

2.09 ‘Contract’ means the Notice Inviting Tenders, Conditions of Tendering, and Tender Form, General 

Conditions of Contract, Supplementary Conditions of Contract, Technical Specifications, price 


. 

Schedule of Prices & Quantities, Letter of Intent of Purchaser, Drawings, Subsequent amendments 

mutually agreed upon, and agreement to be entered under clause “Contract Agreement” of this 

General Condition. 

2.10 The `Specification’ shall mean the Specification annexed to these General Conditions and any 

subsequent modifications thereof and the drawings and Schedules attached thereto (if any). 

2.11 `Site’ means the lands and other places on, under, in or through which the Works are to be 

executed or carried out and any other lands or places provided by the Owner for the purpose of the 

Contract. 

2.12 `Tests on Completion’ shall mean such tests as are prescribed by the Specification and/or tests 

mutually agreed upon by the Purchaser and the Contractor to be made by the Contractor after 

erection of the equipment to prove satisfactory operation as required by the Specification. 

2.13 `Commissioning’ shall mean the first successful operation of the plant and equipment after all initial 

adjustments, trials, cleaning and reassembly required at site, if any, have been completed. 

2.14 Àcceptance Tests’ shall mean such tests as are required to prove the performance guarantees of 

the plant given by the Contractor, before taking over of the plant by the Purchaser. 

2.15 ‘Initial Operation’, `Reliability Run’ or ‘Trial Operation’ shall mean continuous operation of the 

contract plant and materials under varying loads to furnish proof of satisfactory operation for a 

specified period which shall not be less than two (2) weeks. 

2.16 ‘Commercial Use’ shall mean that use of the equipment which the Contract contemplates or of 

which it is to be commercially capable. 

2.17 ‘Warranty Period’ shall mean the period of guarantee as explained under clause `Maintenance and 

Guarantee’ of these General Conditions. 

2.18 ‘Codes’ shall mean the applicable codes of State or Orissa as on the date of Letter of Intent and 

any subsequent modification thereof before the plant has been delivered. 

2.19 ‘Month’ shall mean calendar month. 

2.20 ‘Notice of Award of Contract’ / ‘Letter of Intent’/ ‘Award Letter shall mean the Purchaser’s letter / 

Telex conveying his acceptance of the Tender subject to such reservations as may have been 

stated therein. 

2.21 ‘Erection Supervision’ shall mean the supervision services rendered or exercised by the Contractor 

during the erection of the plant as explained under clause Èrection Supervision Services’ of these 

General Conditions. 


. 

2.22 `Writing’ shall include any manuscript, typewritten or printed statement under or over signature or 

seal as the case may be. 

2.23 ‘Approved’, ‘Subject to Approval’, ‘Satisfactory’, ‘Equal to’ ‘Proper’, ‘As directed’, ‘Where directed’, 

‘When directed’ ‘Determined by’, ‘Accepted’, `Permitted’, ‘To approval’, or words phrases of like 

import are used, the approval, judgment, direction, etc. is understood to be a function of Consulting 

Engineer or Purchaser. 

2.24 Words importing `Persons’ shall include firms, companies, corporations and other bodies whether 

incorporated or not. 

2.25 Words importing the singular only shall also include the plural and vice versa where the context 

requires. 

2.26 ‘F.O.B.’ shall mean delivery free of expenses to the Purchaser on board the vessel at the port of 

shipment. 

2.27 ‘F.O.R. Destination’ shall mean delivery free of expenses to the purchaser on rail wagons at 

destination Railway Station/Siding as may be named. 

2.28 ‘F.O.R. Works’ shall mean loaded and stowed or trimmed, free of expenses to the Purchaser on 

board rail wagons at the Contractor’s siding or at the nearest Railway Station for transportation. 

2.29 ‘Tonne’ shall mean 1000 kilogram weight, `Gallons’ shall mean imperial gallons unless mentioned 

specifically. 

2.30 `Manufacturers’ works’ or `Contractor’s works’ shall mean the place of work used by the 

manufacturer, their collaborators or approved sub-contractors for the performance of the works. 

2.31 Construction of Contract 

Terms and conditions not herein defined shall have the same meanings as are assigned to them in 

the Indian Sale of Goods Act (Act III of 1930) falling that in the Indian Contract Act (Act IX of 1872) 

and falling that in the General Clause Act 1897. 

3.00 CONTRACTOR TO INFORM HIMSELF FULLY 

The Contractor shall be deemed to have carefully examined the General Conditions, Specification, 

Schedules and Drawings and also to have satisfied himself as to the nature and character of the 

work to be executed and, where necessary, of the site conditions and other relevant matters and 

details. Any information thus had or otherwise obtained from the Purchaser, Consulting Engineer or 

the inspector shall not in any way relieve the Contractor from his responsibility for supplying the 

plant and equipment and executing the work in terms of the specification including all detail and 

incidental works and supply of the all accessories or apparatus which may not have been 


. 

specifically mentioned in the specification or drawings, but otherwise necessary for ensuring 

complete erection and safe and efficient commercial working of the plant and equipment. If he shall 

have any doubt as to the meaning of any portion of these General Conditions and/or specification, 

he shall set forth the particulars thereof and submit them to the Engineer in writing for clarification. 


4.01 For Manufacture, Supply & Delivery of Plant & Materials 

The Contractor shall design, manufacture and deliver suitably packed the plant, equipment and 

materials as described in the attached specification F.O.R. Works/F.O.R. Destination and, if of 

foreign origin, F.O.B. port of shipment, as the case may be. 

The Contractor shall sell and deliver the said plant, equipment and materials to the Purchaser and 

Purchaser shall accept the delivery of and pay for at the price agreed upon between the Purchaser 

and the Contractor and upon fulfillment of the terms and conditions hereinafter specified or 

subsequent agreed modification thereof. 

The Contractor shall inform the Purchaser if the plant, equipment and materials or any part thereof 

to be supplied under the scope of work shall be of origin and/or manufactured outside the Union of 

India in which case the Contractor shall give a certificate to this effect in the form required by the 

Purchaser. This certificate shall be called the `Certificate of Origin’. The foreign currency 

component for importing of plant and materials manufactured outside of India shall be specified 

and the estimated total C.I.F. value shall also be stated. It is clearly understood that the owner shall 

not give any of its import licenses for importation of these items. 

The Contractor shall also supply the spare parts and special tools at the quoted price and in 

quantities mentioned in clause `Spare Parts and Maintenance Tools’ or subsequent modifications 

thereof. 

The Contractor shall undertake that supply of necessary spare parts and special tools will be made 

available at any time later during the life of the plant. The price of the imported spare parts shall not 

be in excess of the landed cost plus a reasonable percentage towards handling charges. The price 

for indigenous spare parts shall be at fair market price. 

The Contractor shall also undertake that before going out of production of any of the spare parts, 

he shall give adequate advance notice to the Purchaser so that sufficient quantity of spare parts 

might be procured if the Purchaser so desires. Further, the Contractor shall supply the necessary 

drawings and specifications of these spare parts which the Contractor proposes to take off his 

production range to enable the Purchaser to arrange manufacture of the spa re parts by other 

agency. 


. 

4.02 For Erection Supervision Services 

The Contractor has to supply erection supervision personnel to supervise the work of erection of 

the plant and equipment to be conducted even by other agencies including owner. Classification 

and number of personnel required shall be mutually agreed to. The services would be generally as 

specified in Clause Èrection Supervision Services’ hereinafter at Clause No. 43.00 

4.03 For Erection of Plant & Materials 

The Contractor shall render complete erection services of the plant and materials supplied under 

the Contract if so required by the Purchaser. The services to be rendered shall be as generally 

described in clause Èrection of Plant and Materials’ hereinafter. 

5.00 DESIGN REQUIREMENTS 

5.01 All equipment and materials shall be designed and manufactured in conformance with standards 

stated hereinafter. 

5.02 Wind Load 

Structures and outdoor equipment shall be designed to withstand a wind load as set forth in the 

latest revision of Indian Standards IS: 875 of the Indian Standards Institution. 

5.03 Earthquake 

In general IS: 1893 shall be followed. Specific conditions/technical specification shall be referred 

for specific design criteria. 

5.04 Safety Features 

The Contractor shall provide adequate guards for all couplings and other moving parts which could 

be considered a hazard. Safety, sentinel and relief valves are to be located or piped in such a 

manner as to safeguard personnel and property. All safety devices shall be in accordance with the 

applicable Government regulations and requirements. 

5.05 Language & Measurement System 

All documents pertaining to the contract including specifications, schedules, notices, 

correspondence, operating and maintenance instructions, drawings or any other writing shall be in 

English language. 

All instruments, recorders, etc. will be calibrated in the metric (C.G.S./ M.K.S.) system of units. 

Details of calibration will be provided later. 


. 

In drawings or specifications wherever both Metric and British units are indicated, the Contractor 

shall indicate the equipment dimensions on both the units. Location marking of all equipment shall 

be in Metric Units. 

5.06 Accessibility 

Special attention shall be given to the design, arrangement and assembly of all equipments to 

ensure ease of maintenance and renewal of parts. 

5.07 Standard Equipment & Materials and Alternates 

a) Equipment, material and erection and other services shall be completed in all respects and 

in strict accordance with the specifications, except that alternative proposals may be 

submitted where stipulated provisions depart from the Contractor’s Standards, provided 

that the substitutions are approved as equivalent by the Engineer and the reasons 

therefore are stated by the Contractor in his proposal as a result of such substitution. 

b) Any request for substitution after the contract is awarded, shall be accompanied with the 

difference in price and such substitution can only be made on approval by the Engineer on 

behalf of the Purchaser in writing, provided that such substitution does not cause any 

addition to the contract price. 

5.08 a) All work shall be done in accordance with the applicable portions of the current editions of 

the codes and standards of the respective U.S.A., U.K. National and Technical Societies or 

equal or with the standards and codes of the Government of India, and in accordance with 

the applicable portions of the following codes and standards in particular: 

Indian Boiler Regulations 

Indian Electricity Act 

Indian Electricity Rules 

Indian Factories Act 

Indian Explosives Act 

Indian Standard Institution (IS) 

British Standard Institution (BS) 

American Society of Mechanical Engineers (ASME) 

Institute of Electrical & Electronics Engineers Inc. (IEEE) 


. 

American Petroleum Institute (API) 

American Society of Testing Materials (ASTM) 

Hydraulic Institute 

National Electrical Manufacturer’s Association (NEMA) 

American Water Works Association (AWWA) 

American Standards Association (ASA) 

American Institute of Steel Constructions (AISC) 

National Board of Fire Underwriters 

Insulated Power Cable Engineers Association (IPCEA) 

All the work must be in accordance with the above mentioned codes or equivalent. 

b) Where conflicts occur between any of the laws, rules, regulations, standards, and so forth, 

specified herein, the more stringent requirements shall govern the work. 

6.00 CONTRACT PRICE 

The lump sum prices quoted by the Contractor in his bid with additions and deletions as may be 

agreed before signing of the Contract, for the entire scope of the work viz. supply and erection of 

equipments covered under the specification and documents shall be treated as the Contract Price. 

7.0 TAXES 

7.01 The Contractor shall include all taxes, duties, royalty of whatever nature, octroi, other local taxes, 

etc., if any, in the quoted price. 

7.02 Sales tax or any other tax on material required for the work as also tax on works contract shall be 

payable by the Contractor and Owner will not entertain any claim whatsoever. 

7.03 Notwithstanding anything contain elsewhere in the contract the Owner shall deduct at source from 

the payment due to the contractor the taxes as required under 13(A) of Orisaa Sales Tax Act or 

amended from time to time or under any other statute. The amount so deducted shall be paid by 

the Owner to the Sales Tax authority as per law. This is for the Contractor to deal with the Sales 

Tax authority directly in respect of any claim or refund relating to the above tax and Owner shall not 

be liable or responsible for any type of payment or reimbursement in this regard. 


. 

7.04 All benefits of taxes duties by way of credit under CENVAT shall be passed on to the 

Owner/Purchaser 

8.0 CONTRACT - CUM - PERFORMANCE BOND 

GUARANTEE FOR DUE EXECUTION OF THE CONTRACT AND PERFORMANCE DURING THE 

GUARANTEE PERIOD 

The Contractor within thirty (30) days of award of contract shall furnish a Bond by way of a bank 

guarantee to be kept alive till 12 months after successful completion of contract in all respects and 

equal to ten percent (10%) of the contract price for faithful and due fulfillment by the Contractor of 

all obligations under the terms and conditions of the contract and for fulfilling the terms of 

guarantee for a period of 12 months after successful completion. 

If during the contract period the bond amount gets reduced on account of any recoveries or 

otherwise, the contractor shall furnish a bond covering short fall to bring it to 10% of the contract 

value. The form of the aforesaid Bond is enclosed. 

9.00 PROTECTIVE PAINTING, PACKING & MARKING 

The Contractor and/or Manufacturer shall properly clean and/or send blast equipment and apply an 

initial coat of rust inhibitor and a flat shop coat of paint (except shop finished equipment). All shop 

primer and paints shall be subject to approval of the Engineer. All closely machined parts shall be 

covered with an approved protective coating to prevent deterioration of surfaces during 

transportation and storage. 

The Contractor shall include and provide for securely protecting and packing the equipment so as 

to avoid damage in transit under proper conditions and he shall be responsible for all losses or 

damage caused or occasioned by any defect in packing. 

All equipments shall be packed in accordance with approved packing specifications. All 

equipments and parts susceptible to corrosion by exposure to moisture and all electrical 

equipments shall be thoroughly protected against damage during transit and storage. The 

Purchaser will take no responsibility for any damage done to the equipment enroute to the “site of 

work”, or “place of delivery” whichever may be specified due to the packing being faulty. Special 

packing with identification mark on packages should be provided for fragile materials. The 

identification marking indicating the name and address of the consignee shall be clearly marked in 

indelible ink on two opposite side and top of each of the packages. In addition, the Contractor shall 

include in the marking gross and net weights, outer dimensions and cubic measurements. 

Each bale or package shall be accompanied by a packing Note quoting specifically the name of the 

Contractor, the number and date of contract, the name of the office placing the contract and 

nomenclature of contents. 


. 

Dimensions of each package shall not exceed the maximum dimensions of packages which can be 

accepted for transport over the `broad gauge system’ of the Railway concerned. 

10.0 SHIPMENT PARTICULARS 

10.01 Shipments 

a) Foreign Items 

Responsibility of shipment of plant and equipment shall lie with the Contractor wherever 

the contract is for complete supply and installation or supply delivered at site basis. The 

Contractor shall notify the Purchaser of the date of each shipment from the port of 

embarkation as well as date of arrival of such shipment at designated port of arrival for 

information. 

Responsibility of cleaning the same in the port including all handling shall lie with the 

Contractor. Purchaser will only arrange to pay the customs duty as per information on CIF 

values given by the Contractor sufficiently in advance. 

The Contractor shall give complete shipping information concerning the weight, size, 

content of each package including any other information the Purchaser may require. 

b) Indigenous Item 

For all contracts for supply and installation or supply delivery at site basis, responsibility of 

all transportation from works to site shall lie with the Contractor. 

The Contractor shall notify the Owner of the date of each shipment from his works and the 

expected date of arrival at the site for information of the Purchaser. 

The Contractor shall also give all information concerning the weight, size and content of 

each packing including any other information the Purchaser may require. 

c) The Contractor shall further be responsible for all inland transportation up to site for foreign 

items after clearing through the port. Contractor shall also be responsible for making all 

necessary arrangements for loading, unloading and other handling right from his works till 

the site and also till the equipment is erected, tested and commissioned. He shall be solely 

responsible for proper storage and safe custody of all equipment. 

10.02 Shipping Documents 

After shipment is affected following documents shall be forwarded to the Purchaser: 


. 

a) Foreign Items 

Within seven (7) days of shipment following shall be airmailed to the Purchaser for 

purpose of progress payment and necessary arrangement of payment of customs duty. 

- Application of payment in standard format of the Owner (3 copies) 

- Bill of Lading (5 non-negotiable copies) 

- Invoice including break-up for customs purposes (6 copies) 

- Packing list (6 copies) 

- Pre-dispatch clearance certificate or shipping release, if any (3 copies) 

- Test certificates, wherever applicable (3 copies) 

- Certificate of origin 

b) Indigenous items 

- Application for payment in standard format of Purchaser (3 copies) 

- Invoice (6 copies) 

- Packing list (6 copies) 

- Pre-dispatch clearance certificate or shipping Release, if any (3 copies) 

- Test Certificates wherever applicable (3 copies) 

10.03 Demurrage, Wharfage etc. 

All demurrage, wharfage and other expenses incurred due to delayed clearance of the material or 

any other reason shall be to the account of the Contractor. 

10.04 Consignee 

All consignment shall be addressed to and the Bill of Lading and other shipping documents shall be 

made in the name of the Purchaser’s Office as may be advised. 


. 

11.0 INSURANCE 

11.01 The Owner will arrange for INSURANCE of equipment and material, included under the scope of 

contract, to cover - 

a) Risk in transit by ship/air between Contractor’s port of shipment/air port and Indian port of 

entry. 

b) Risks in transit by rail/road during inland transportation up to the Project Site. 

c) Risks during storage and erection at the Project Site till the plant is fully commissioned 

under an open general insurance policy. The Owner shall intimate the name of Insurance 

Company and other details in due course. 

11.02 The Contractor shall furnish dispatch particulars of each consignment including its value 

immediately to the Insurance Company. If for any delay in intimating of dispatch particulars to the 

Insurance Company on the part of the Contractor the claims for damages are rejected, the 

contractor shall be fully responsible for replacement of the damaged equipment. 

11.03 The risks that are to be covered under the insurance shall include, but not limited to, the loss or 

damage in transit, theft, pilferage, riot, civil commotion, weather conditions, accidents of all kinds, 

fire, war risk, etc. The scope of such insurance shall cover the entire value of the Works from time 

to time. 

11.04 In respect of equipment damaged in transit or during erection and commissioning, the Contractor 

shall replace them expeditiously and the replacement cost payable by the Owner shall be limited to 

the invoice of damaged equipment. In case of consignment received at the project site in outwardly 

sound condition of package but found shortage/damage on being opened the liability for free 

replacement will be accepted by the Contractor. 

It is the responsibility of the Contractor to lodge a claim on the Insurance Co. on behalf of the 

Owner. On receipt of all relevant document relating to the claim, Owner will pursue the matter with 

the Insurance Co. 

12.00 DELIVERY 

Notification of delivery or dispatch in regard to each and every consignment shall be made to the 

Purchaser immediately after dispatch or delivery. The Contractor shall further supply to the 

Consignee a price invoice and packing account of all stores delivered or dispatched by him. All 

packages, containers, bundles and loose materials forming part of each and every consignment 

shall be described fully in the packing account, and full details of the contents of packages and 

quantity of materials shall be given to enable the Consignee to check the stores on arrival at 

destination. 


. 

12.01 Passage of Risk/Ownership 

The title to all Indian materials, delivered by the contractor, shall pass on to the Purchaser on its 

being handed over to the nominated transporter. 

13.00 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION (LD) 

If the contractor fails in the due performance of the contract to supply / erection/ testing/ 

commissioning the equipment within the time fixed by the contract or any extension thereof, he 

shall be liable at the discretion of the Engineer to the Liquidated damages and not by way of 

penalty amounting to one half of one percent (1/2%) of the contract price per week. The 

contractor’s liability for delay shall not in any case exceed ten percent (10%) of the total contract 

price. 

If the Contractor shall fail to supply the equipment or any part thereof within a reasonable period 

after the expiry of the appointed time or extended time as may be provided for in the contract, the 

provisions in Clause No. 28 “Negligence” shall become operative, in addition to the liability of L.D. 

as above. 

14.00 IMPORT LICENCE AND FOREIGN EXCHANGE 

In case of supply of equipment of indigenous manufacture including any imported components, the 

Contractor shall arrange for necessary Import License & Foreign Exchange. 

In the event of Contractor requiring Actual User’s for import of equipment and/components, 

Purchaser shall arrange for obtaining necessary assistance in this regard. Government 

authorization may be required to permit the manufacture of certain equipment. The parties shall 

assist each other in every manner possible in securing such authorization. 

15.00 CONTRACTOR’S DOCUMENTS, DRAWINGS AND INSTRUCTION MANUALS 

15.01 The Contractor shall be responsible for developing detail drawings to adapt his equipment and 

materials to the requirement indicated in the tender specification. 

15.02 Within a reasonable time not exceeding thirty days from the date of receipt Purchaser’s Letter of 

Intent, the Contractor shall provide the Purchaser with the following drawings and data: 

a) Six (6) marked up copies of technical particulars to make them conforming to accepted 

proposals. 

b) Outline drawings of all equipment together with weights and sufficient overall dimensions 

to enable the Purchaser to design foundations and structures and associated equipment. 


. 

c) Drawing submission schedule indicating list of all drawings with their respective titles and 

dates shall be submitted to the Purchaser. The schedule shall also indicate the latest date 

by which Contractor shall furnish all design calculations. The schedule shall be amended 

or extended by the Contractor in consultation with the Purchaser as and when necessary. 

15.03 Within a stipulated time period the Contractor shall submit for approval of the Purchaser the 

following drawings and technical data: 

a) Dimensional layout drawings of the plant and equipment to be supplied under the contract 

and all certified data relating to the design on foundation structures to enable the 

Purchaser to arrange for construction of the necessary foundations and civil works. 

All information regarding material and size of anchor bolt, nuts, sleeves, inserts and 

supports which shall have to be embedded in concrete shall be furnished in the detailed 

foundation drawing. 

b) Dimensional drawings showing individual equipment being supplied under the contract, 

method and sizes of connections to the Purchaser’s other equipment, giving also the limits 

of variations of the dimensions. 

c) All efficiency and characteristic curves required under the specification. 

d) Schematic drawings of all wirings, connections and interlocking diagrams showing the 

points where the connections have to be made by the Purchaser. 

e) Necessary structural and other calculations and data required for demonstrating fully that 

all parts of the equipment to be furnished shall conform to the provisions and intent of the 

contract. 

The Contractor shall submit six (6) prints of each drawing for approval. Two (2) prints shall be 

forwarded to the Purchaser and four (4) prints shall be forwarded to the Consulting Engineer. 

When prints of drawings have been marked “Approved except as noted, Resubmission required” 

the Contractor shall make necessary corrections and again submit corrected copies for approval as 

per details stipulated. Further revision will be shown by number, date and subject in a revision 

block. 

Upon receipt of the prints which have been marked “Approved” or “Approved except as noted: 

Forward Final drawing” the Contractor shall furnish within a reasonable time fourteen (14) 

additional prints of each of drawings and one (1) reproducible transparency after minor corrections, 

if any, to the Purchaser. 

Relevant civil construction drawings if felt necessary by Consulting Engineer, shall be forwarded to 

the Contractor in triplicate. He shall review incorporation of information furnished by him, such as, 


. 

anchor bolt location, elevation etc. and return one certified copy each to the Purchaser and to the 

Consulting Engineer. 

Any manufacturing work in connection with the equipment prior to the approval of drawings shall be 

at the Contractor’s risk. The Contractor shall make any change in the designs, with prior approval 

of the Engineer, which are necessary to make the equipment conform to the provisions and intent 

of the contract, without additional cost to the Purchaser. Approval of Contractor’s drawings shall 

not be held to relieve the Contractor of any part of Contractor’s obligations to meet all the 

requirements of the contract or of the responsibility for the correctness of the Contractor’s 

drawings. 

15.04 The details to be furnished shall include, but not restricted to the following: 

a) Finals plans and layout giving complete details against the above mentioned arrangement 

plans including foundations plans. 

b) Assembly, sub-assembly and sectional drawings of every equipment. 

c) Complete cabling drawing giving details of cables required, terminal details, layout of 

trenches etc. 

d) Detailed wiring diagrams and arrangements of conduits for wiring various controls and 

instruments up to the required points. 

e) Shop drawings of all parts of equipment requiring repairing or replacements. 

f) A complete list of special erection tools and tackles required for complete assembly. 

15.05 Complete spare part hand books with details and diagrams, separate recommendations shall be 

made for the parts required for first one year of operation of important equipment and sent to 

Engineer for approval. Parts requiring frequent replacement shall be listed separately from parts 

required for ensuring reliability in unforeseen emergencies. On finalization ten (10) set of such 

spare part hand books shall be furnished to the Engineer. 

15.06 Assembly and erection instruction within a reasonable time after signing of the contract but at least 

three (3) months before starting erection the Contractor shall furnish ten (10) sets of the following 

for the use of Purchaser’s field Engineers: 

a) Descriptive literature and drawings to illustrate the working principles, method of assembly 

and dismantling. 

b) Instruction book for proper erection and assembly of all equipment and necessary 

instructions for checking and recording proper assembly of the plant. 


. 

Erection schedule giving the sequence of erection with reference to package/ assembly/ 

sub-assembly identification. 

c) Instruction sheets for proper balancing, alignment, adjustment, checking and calibrations 

as may be necessary. 

15.07 All drawings and technical data are to be furnished in English language only. 

15.08 Final Drawings and Operation Maintenance Manuals 

Before completion of the work, the Contractor shall furnish fourteen (14) complete sets of prints 

and one (1) reproducible transparency of all detailed drawings of the equipment actually supplied 

and as erected and assembled at site. In addition ten (10) sets of comprehensive manuals for use 

in the operation and maintenance of the plant shall be supplied at least six (6) months before the 

actual commissioning date to the Engineer. 

15.09 Seven (7) copies of monthly fabrication progress report for all equipment and material shall be 

supplied to the Engineer. 

16.00 MISTAKES IN DRAWINGS 

The Contractor shall be responsible for and shall pay for any alterations of the work due to any 

discrepancies, errors or omissions in the drawings or other particulars supplied by him whether 

such drawings or particulars have been approved by the Engineer or not. 

If any dimensions figured upon a drawing or a plan differ from those obtained by scaling the 

drawing or plan the dimensions as figured upon the drawing or plan shall be taken as correct. 

17.00 MATERIALS AND WORKMANSHIP 

All materials used in the manufacture of the equipment shall be selected from the best available for 

the purpose, considering strength, durability and best engineering practice. Liberal factors of safety 

shall be used through out the design and specially in the design of all parts subject to alternating 

stresses or shocks. 

All the work shall be performed and completed in a thorough workmanship like manner and shall 

follow the best modern practice in the manufacture of high grade equipment notwithstanding any 

omissions in the specifications. 

Castings shall be free from holes, flaws, cracks or other defects and shall be smooth, close grained 

and of true forms and dimensions. No plugged or filled up holes or other defects will ordinarily be 

allowed. Such castings are liable to be rejected. 

However, the Contractor may rectify minor casting defects by welding or other method in 

accordance with the standard manufacturing practice provided such rectification does not affect the 


. 

strength of the casting or impair the efficient working of the plant and prior approval of the 

Purchaser is obtained for the same. 

18.00 SPARE PARTS AND SPECIAL MAINTENANCE TOOLS 

18.01 The spare parts as required for the equipment under supply are listed in respective specification. 

The list is not exhaustive but only indicative. 

The Contractor shall also supply list of Guaranteed Spares for two years normal operation 

indicating parts name, catalogue no., quantity and unit prices on project site delivery basis. If any 

short fall is noticed during 2 years from the date of commissioning the same shall be supplied free 

of cost by the Contractor. 

18.02 In case of machinery and plant, the Contractor shall include provision for such tools as he 

recommends to be absolutely essential for proper maintenance and repair of the plant. A detailed 

list of the tools along with the itemized prices shall be submitted along with the tender. In the 

absence of this list, the tender is liable to be rejected. One new set of all special tools for 

maintenance for each type of equipment shall be furnished by the Contractor at his own expense 

and shall be dispatched along with the equipment. 

18.03 The contractor shall also undertake that supplies of necessary maintenance equipment and spare 

parts will be made available for the life of the plant offered through his Agents on a continuous 

basis at reasonable price. 

19.00 COMPLETENESS OF EQUIPMENT 

The equipment shall be complete in every respect with all mountings, fixtures and standard 

accessories which are normally supplied even though not specifically detailed in the specification. 

The Contractor shall not be eligible for any extra payment in respect of such mountings, fittings, 

fixtures and accessories which are needed for safe operation of the equipment as required by 

applicable codes of the country though they may not have been included in the contract. 

All similar component parts of similar equipment supplied shall be interchangeable with one 

another. 

The various equipment supplied under this contract shall be subject to the Purchaser’s approval 

20.00 INSPECTION AND TESTING AT CONTRACTOR’S PREMISES 

The Engineer and his duly authorized representative shall have at all reasonable times access to 

the Contractor’s /Sub-contractor’s premises of works, and shall have the power at all reasonable 

times to inspect drawings of any portion of the work or examine the materials and workmanship of 

the plant during its manufacture there and if part of the plant is being manufactured on other 


. 

premises, the Contractor shall obtain for the Engineer and his duly authorized representative 

permission to inspect as if the plant is manufactured on the Contractor’s premises. 

The Engineer shall on giving seven (7) days notice in writing to the Contractor setting out any 

grounds of objections which he may have in respect of the work, be at liberty to reject any drawings 

& all or any part of workmanship if the subject of any of the said grounds of objection, which in his 

opinion are not in accordance with the contract. The Contractor shall give due consideration to 

such objections and shall either make the modifications that may be necessary to meet the said 

objections or shall confirm in writing to the Engineer giving therein that no modifications are 

necessary to comply with the contract. 

The Contractor shall give the Engineer and his duly authorized representatives notice of any 

material being ready for testing and the Engineer or the said representative shall (unless the 

inspection of tests is voluntarily waived), on giving twenty four (24) hours previous notice in writing 

to the Contractor, attend at the Contractor’s premises (as the case may be) within fifteen (15) days 

of the date on which the material is notified as being ready failing which visit, the Contractor may 

proceed with the tests which shall be deemed to have been made in the Engineer’s presence. All 

standard shop tests, physical and chemical tests required by the Standards or as may be 

prescribed or approved by the Engineer shall be conducted by the Contractor. The Engineer 

reserves the right to waive any of the above test requirement and to prescribe new test required if 

found necessary to expedite the work or to conform to the latest and best practice. Definitions, 

methods of measurement, calibration of instruments and required procedure as referred in the 

above standard and/or those approved by the Engineer as equivalent shall be followed. The 

Contractor shall forthwith forward to the Engineer duly certified copies of the test certificates in 

quadruplicate (one copy to the Purchaser and three copies to the consulting Engineer) for 

approval. Further ten (10) copies of the shop test certificate shall be bound with the instruction 

manuals referred to in clause “Contractor’s documents, drawings and instruction manuals”. 

In all cases where contract provides for tests, whether at the premises or works of the Contractor 

or any sub-contractor, the Contractor, except where otherwise specified shall provide free of 

charge to the Purchaser, such labor, materials, electricity, fuel, water, stores, apparatus and 

instruments as may reasonably be demanded to carry out efficiently such tests of the plant, in 

accordance with the contract and shall give facilities to the Engineer or his authorized 

representative to accomplish such testing. 

When the tests have been satisfactorily completed in the Contractor/Sub-contractor’s Works, the 

Engineer shall issue a certificate to that effect within fifteen (15) days after completion of test, but if 

the tests were not witnessed by the Engineer or his representative the certificate would be issued 

within fifteen (15) days of the receipt of the test certificates by the Engineer. No plant shall be 

transported before such a certificate has been issued. The satisfactory completion of these tests or 

the issue of this certificate shall not bind the Purchaser to accept the plant should it on further tests 

after erection, be found not to comply with the contract provisions. 


. 

21.00 TESTS ON COMPLETION AND TRIAL RUN AT SITE 

Where possible all tests shall be carried out before dispatch. Should, however, it become 

necessary for the final tests as to performance and guarantees to be held over until the plant is 

erected at site, they shall be carried out as per agreed procedure within two (2) months or such 

time as may be considered reasonable by the Purchaser after commissioning of the equipment. 

Inspection and test at site during erection and on completion of erection shall be carried out on any 

plant and equipment to satisfy the guaranteed performance of each equipment and the whole 

installation as set forth below: 

Individual equipment tests: 

(I) Inspection and checking of units 

(II) Placing in operation 

(II) Initial operation 

(IV) Reliability tests 

(V) Efficiency and consumption tests 

(VI) Load tests 

The sequence of tests for individual equipment shall be as mutually agreed to between the 

Contractor and the Engineer. 

Duration of the trial operation of the complete equipment shall be 30 continuous days with available 

wagon rakes during this period as mutually agreed and decided. The acceptance test shall be 

carried out within two (2) months after the trial run has been satisfactorily completed. Any delay for 

carrying out these works for force majeure reasons shall be given due consideration. Should the 

result of these tests not come within the margin specified, the test shall, if required, be repeated 

after necessary rectification measures recommended by the Contractor within one (1) month from 

the date of plant is ready for retest, and the Contractor shall repay to the Purchaser all reasonable 

expenses which he may be put to by such tests. 

The performance and acceptance tests of the complete installation shall be carried out to prove the 

guarantees specified for different equipment. These tests shall be made in accordance with 

established and approved procedures. The Contractor shall submit within reasonable time after the 

award of contract, detailed procedure for conductance of all tests for approval of the Engineer. The 

procedure shall include the following information for such test: 


. 

(I) Loads at which tests will be conducted. 

(II) Time and durations of each test. 

(II) Instrument locations shown by a schematic diagram for each test. (Calibration certificates 

for each instrument shall be furnished before commencement of test). 

(IV) All formulas, calculations, conversion factors, correction curves, etc. to be used for test 

conductance. 

(V) Sample test report forms, and data sheet that will be used to record test results and 

valuation of final results. 

On completion of all tests, the overall efficiency of the plant shall be determined in accordance with 

the procedure mutually agreed upon between the Contractor and the Engineer unless otherwise 

covered under the Standards and Specification. 

In all cases, where the contract provides for test at the site, the Purchaser, except where otherwise 

specified, shall provide, free of charge, such labor, materials, fuel, water, electricity, lubricants as 

may be required from time to time and as may reasonably be demanded to carry out such tests of 

the plant, material or workmanship in accordance with the contract. Any special apparatus and 

precision instruments required for site test shall be provided by the Contractor. 

If for any reason, other than the fault of the contractor performance and acceptance tests for any 

unit shall not be carried out within sixty (60) days of notice by the Contractor to the Purchaser of 

the unit being ready for tests, then the Purchaser will issue an acceptance certificate on the last 

day of such period and payments due to the Contractor on acceptance shall be made, but 

nevertheless the Contractor, shall if called upon to do so by the Purchaser, within a period twelve 

(12) months from the said last date, make the said tests on the same terms as provided in the 

contract. 

22.00 TAKING OVER 

Upon successful completion of all the tests to be performed at site on equipment and systems 

furnished and erected by the Contractor, the Engineer shall Issue to the Contractor a taking over 

certificate as a proof of the final acceptance of the equipment. Such certificate shall not relieve the 

Contractor of any of his obligations which otherwise survive by terms and conditions of the contract 

after issuance of such certificate. 

23.00 REJECTION OF DEFECTIVE PLANT 

If the completed plant or any portion thereof, it is taken over under the clause ‘Taking Over’, be 

found defective or fails to fulfill the requirements of the contract, the Engineer shall give the 

Contractor notice selling forth particulars of such defects or failure, and the Contractor shall forth 


. 

wile make the defective plant good or to make it comply with the requirements of the contract. 

Should he fail to do so within a reasonable time, the Purchaser may reject and, replace at the cost 

of the Contractor the whole or any portion of the plant as the case may be, which is defective or 

fails to fulfill the requirements of the Contract. Such replacement shall be carried out by the 

Purchaser within a reasonable time and at a reasonable price, and where reasonably possible to 

the same specification and under comparative condition. The Contractor’s full and extreme liability 

under the clause shall be satisfied by the payment to the purchaser of the original contract price 

including charges of erection and/or supervision of erection plus the difference if any between the 

replacement price of the equipment including charges for erection and /or supervision of erection 

and the original contract price including charges for erection and / or supervision of erection in 

respect of such defective plant. 

In the event of such rejection, the Purchaser shall have the right to operate any and all equipment 

as soon as and as long as it is in operating condition, whether or not, such equipment has been 

accepted as complete and satisfactory, to enable him to obtain necessary replacement, except that 

this shall not be construed to permit operation of any equipment which may become damaged by 

such operation before any required alternations or repairs and/or replacement have been made. All 

repairs or alternations or replacement required of the Contractor shall be made by the Contractor at 

such times as directed and in such manner as will cause the minimum interruption in the use of the 

equipment by the Purchaser. Should the Purchaser not so replace the rejected plant within a 

reasonable time, the Contractor’s full and extreme liability under his clause will be satisfied by the 

repayment of all money paid by the Purchaser to him in respect of such plant. 

Nothing in this clause shall be deemed to deprive the Purchaser or affect any rights under the 

contract which he may otherwise have in respect of such defects or deficiencies or in any way 

relieve the Contractor of his obligations under the contract. 

24.00 COMPLETION CERTIFICATE & FINAL CERTIFICATE 

24.01 Application for Completion Certificate 

When the contractor fulfils his obligation under the contract he shall be eligible to apply for 

completion certificate in respect of the work by submitting the completion documents along with 

such application for completion certificate. 

The owner or his representative shall normally issue to the Contractor the completion certificate 

within one month after receiving an application from the Contractor after verifying from the 

completion documents and satisfying himself that the work has been completed in accordance with 

and as set out in the construction and erection drawings, and the contract documents. 

The contractor, after obtaining the completion certificate, is eligible to present the final bill for the 

work executed by him under the terms of contract. 


. 

24.02 Completion Certificate 

Within one month of the completion of work in all respects the Contractor, shall be furnished with a 

certificate by the owner or his representative of such completion but no completion certificate shall 

be give nor shall the work be deemed to have been executed until all scaffoldings surplus material 

and rubbish is cleared off the site completely nor until the work shall have been measured by the 

Engineer, whose measurement shall be binding and conclusive. The work will not be considered as 

complete and taken over by the Owner, until all the temporary works, labor and staff colonies etc. 

constructed are removed and work site cleared to the satisfaction of the Engineer. 

If the Contractor shall fall to comply with the requirements of this clause on or before the date fixed 

for the completion of the work, the Engineer may at the expenses of the Contractor remove such 

scaffoldings, surplus materials and rubbish and dispose off the same as he thinks fit and clean off 

such dirt as aforesaid, and the Contractor shall forthwith pay the amount of all expenses so 

incurred and shall have not claim in respect of any such scaffolding or surplus materials as 

aforesaid except for any sum actually realized by the sale thereof. 

Completion Certificate shall be in 3 parts as follows: 

1) Physical/Mechanical completion work. 

2) Satisfactory completion of commissioning of equipment with load. 

3) Satisfactory completion of guarantee. 

The Contractor shall clearly indicate the 3 dates separately. 

24.03 Completion Documents 

For the purpose of clause 24, the following documents will be deemed to form the completion 

documents: 

(i) The technical documents according to which the work was carried out. 

(ii) Three sets of construction drawings showing therein the modification and corrections 

made during the course of execution and signed by the Engineer. 

(ii) Completion Certificate for embedded and ‘Covered-up’ works. 

(iv) Certificates of final levels as set out for various works. 

(v) Certificates of test performed for various works. 

(vi) Materials appropriation statement for the materials issued by the owner for the works and 

list of surplus materials returned to the owner’s store duly supported by necessary 

documents. 


. 

(vi) Physical / Mechanical completion work. 

(viii) Satisfactory completion of commissioning of equipments with load. 

(ix) Satisfactory completion of guarantee. 

The contractor shall clearly indicate the 3 dates separately. 

24.04 Final Decision and Final Certificate 

Upon the expiration of the period of liability and subject to the Engineer being satisfied that the 

works have been duly maintained by the Contractors during monsoon or such period as herein 

provided in clause 8.00 and that the Contractor has in all respect duly made up all subsidence and 

performed all his obligations under the contract, the Engineer shall (without prejudice to the right of 

the Owner to retain the provision of relevant clause hereof) otherwise give a certificate, herein 

referred to as the final certificate, to that effect and the Contractor shall not be considered to have 

fulfilled the whole of his obligations under the contract until Final Certificate shall have been given 

by the Engineer not withstanding any previous entry upon the work and taking possession, working 

or using of the same or any part thereof by the Owner. 

24.05 Certificate and Payments No Evidence of Completion 

Except the final certificate, no other certificates or payment against a certificate or on general 

account shall be taken to be an admission by the Owner of the due performance of the Contract or 

any part thereof or of occupancy or validity of any claim by the Contractor. 

25.00 ENGINEER’S DECISION 

In respect of all matters which are left to the decision of the Engineer the Engineer shall, if so 

required to do so by the Contractor give in writing a decision there on to the Contractor. All 

decisions of the Engineer shall be binding on the Contract. 

26.00 CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE PURCHASER OR THE CONTRACTOR 

No Certificate of the Engineer on account, nor any sum paid on account by the Purchaser, nor any 

extension of time for the execution of the works by the Contractor shall affect or prejudice the rights 

of the Purchaser against the Contractor or relieve the Contractor of his obligations of the materials 

supplied and no certificate shall create liability for the Purchaser to pay for alterations, 

amendments, variations of additional work, not ordered in writing by the Engineer or discharge the 

liability of the Contractor for payment of damages, whether due, ascertained or certified or not to 

any sum against the payment of which he is bound to Indemnify the Purchaser, nor shall any such 

certificate nor the acceptance by him or any sum paid on account or otherwise, affect or prejudice 

the rights of the Contractor against the Purchaser. 


. 

27.00 MAINTENANCE AND GUARANTEE – WARRANTY PERIOD 

The Contractor shall guarantee in respect of the plant and materials to be furnished by him the 

following: 

(a) All equipment shall be free from any defect due to faulty design, materials and/or 

workmanship. 

(b) The equipment shall operate satisfactorily and the performance and efficiencies of the 

equipments shall not be less than the respective guaranteed values. 

(c) The efficiencies, temperature rises and other performance data furnished for the 

equipment. 

The guarantees have to be furnished on forms approved by the Engineer and shall be signed by 

the Contractor and / or his sub-contractor. 

If the Contractor finds, after his tender is accepted, that a variation in work, construction technique 

or the quality of materials is necessary to fulfill the guarantees called for, such variations may be 

made with the approval of the Engineer, provided the request for changes is made before signing 

the contract the changes are to be made without any increase in the contract price. 

The above guarantees shall be valid for a period of twelve (12) calendar months commencing 

immediately on the satisfactory completion of the final tests at site or thirty six (36) months after 

the last consignment to complete the plant is received at site,, whichever may be earlier. This 

period of the guarantee shall be called the ‘Warranty period’. During this period, the contractor’s 

liability shall be limited to the replacement of any defective parts that may develop in plant of his 

own manufacture of those of his sub-contractor’s under the conditions provided for by the contract 

under proper use and arising solely from faulty design, materials or workmanship provided always 

that such defective parts as are not repairable at site, and are not essential in the meantime in the 

commercial use of the plant, are promptly returned to the Contractors Works unless otherwise 

arranged. All such replacements of defective parts mentioned above shall be made free of costs at 

site by the Contractor and the return of the defective parts to the Contractor’s works shall be the 

Contractor’s responsibility and shall be made at his expense. The Purchaser will, however, render 

such assistance in this matter as well expedite the same. In the case of defective parts not 

repairable at site but essential in the meantime for the commercial use of the plant, the Contractor 

shall replace at site free of cost to the Purchaser the said defective parts before the defective parts 

are removed to his Works. 

If for rectification or replacement of any part of equipment or work due to defective materials, 

manufacture or design, the services of the Contractor personnel are requisitioned within the 

guarantee period, these services shall be made available free of any cost to the Purchaser. 


. 

If it becomes necessary for the contractor to replace or renew any defective portions of the plant 

under this clause, the provisions of this clause will apply to the portions of the plants so replaced or 

renewed until the expiration of six (6) months from the date of such replacement or renewal or until 

the end of the above mentioned period of twelve (12) months, whichever may be later. If any defect 

be not remedied within a reasonable time, the Purchaser may proceed to do the work at the 

Contractor’s risk and expenses but without prejudice to any other rights which the Purchaser may 

have against the Contractor in respect of such defects. 

If the replacement or renewals are of such character as may affect the efficiency of the plant, the 

Purchaser shall have the right to give the Contractor within one month of such replacement or 

renewal, notice in writing that ‘tests’ on completion be made in which case such tests be carriedout 

as provided in clause “tests a completion” and trial run at site hereof. Should such test show 

that the plant sustains the guarantee given in the Contract; the cost of the tests will be borne by the 

Purchaser. Should the guarantee be not sustained, the cost of the test shall be borne by the 

Contractor. 

All replacement or renewals to be carried out by contractor during the maintenance period shall be 

subject to such clauses of these general conditions as may be considered reasonable by the 

Engineer. 

Until the final certificate has been issued, the Contractor shall have the right of entry, at his own 

risk and expenses by himself or his duly authorized representatives whose names shall previously 

have been communicated in writing to the Engineer, at all reasonable working hours upon all 

necessary parts of the works, for the purpose of inspecting the working and the records of the plant 

and taking notes there from and, if he desires, at his own expense making any tests, subject to the 

approval of the Engineer that work will not be unreasonably withheld. 

The issue of the Engineer’s Certificate referred to in clause ‘Certificate of Engineer’ shall in no way 

expect the contractor from the provision of this clause. 

At the end of the maintenance period, the liability ceases. In respect of goods not covered by the 

first paragraph of this clause, the Purchaser shall be entitled to the benefit of any guarantee given 

to the Contractor by the original supplier or manufacturer of such goods. 

28.00 NEGLIGENCE 

If the Contractor neglects to execute the work with due diligence and expedition or refuses or 

neglect to comply with any reasonable orders given to him in writing by the Engineer in connection 

with the work, or contravene the provisions of the contract, the Purchaser may give notice in writing 

to the Contractor calling upon him to make good the failure, neglect or contravention complained or 

should the Contractor fail to comply with such notice within a period considered reasonable by the 

Purchaser from the date of service thereof, in the case of failure, neglect or contravention capable 

of being made good within that time or otherwise within such time as may in the opinion or the 

Purchaser be reasonably necessary for making it good, then and in such case the Purchaser shall 


. 

have the option and be at liberty to take the work wholly or in part, out of the Contractor’s hand and 

may carry on the work envisaged in the contract at a price with any other person or persons to 

execute the same or any part thereof and provide any other materials, tools, tackle or labor for the 

purpose of completing the works or part thereof. In such event the Purchaser shall without being 

responsible to the Contractor for fair wear and tear of the same be entitled to seize and take 

possession and have free use of all materials, tools, tackle or other things which may be on the 

site, for use at any time in connection with the work to the exclusion of any right of the Contractor 

over the same and the Purchaser shall be entitled to retain and apply and balance sum which may 

otherwise be then due on the contract by him to the Contractor or such part thereof as may be 

necessary, to the payment of the cost of execution of such work as aforesaid. 

If the cost of executing the work as aforesaid shall exceed the balance due to the Contractor and 

the Contractor fails to make good the deficit, the said materials, tools, tackle, construction plant or 

other things, the property of the Contractor as may not have been used up in the completion of the 

works, may be sold by the Purchaser and the proceeds applied towards the payment of such 

difference and the cost of an incidental to such sale. Any outstanding balance existing after 

crediting the proceeds of such sale shall be paid by the Contractor on the certificate of the 

Engineer. But when all expenses cost and charges incurred in the completion of the work are paid 

by the Contractor, all such materials, tools, tackle, construction plant or other things not used up in 

the completion of the works and remaining unsold shall be removed by the Contractor. If the 

proceeds of the above sale of the Contractor’s materials, tools, tackle, construction plant etc. are 

insufficient to cover the executing the aforesaid work, the balance remaining after crediting the 

proceeds of such sale shall be recoverable from the Contractor by encashing the Bank 

Guarantee/available/ any other money payable by Purchaser or by action of law. 

Not withstanding anything contained above, the Purchaser may determine the contract due to any 

breach or failure of the Contractor, without notice before determining the contract as above, if in the 

opinion of the Purchaser, the default or defaults committed by the Contractor is/are curable and 

can be cured by the Contractor if an opportunity is given to him, then the owner may issue a notice 

in writing calling upon the Contractor to cure the default within such time as may be specified in the 

notice. 

In the event of termination, the security deposit will be forfeited without reference to the Contractor 

and if no amount is available towards Security Deposit, an identical amount is recoverable from the 

contractor. 

29.00 POWER TO VARY OR OMIT WORK 

No alternations, amendments, omissions, additions, suspensions or variations of the work 

hereinafter referred to as ‘Variations’, under the contract shall be made by the Contractor except as 

directed in writing by the Engineer, but the Engineer shall have full power, subject to the provision 

hereinafter contained from time to time during the execution of the contract by notice in writing, to 

instruct the Contractor to make such variation without prejudice to the contract and the Contractor 


. 

shall carry out such variation and be bound by the same conditions as far as applicable, as though 

the said variation occurred in the contract. 

If any suggested variations would, in the opinion of the Contractor, if carried out prevent him from 

fulfilling any of his obligations or guarantees under the contract, he shall notify the Engineer thereof 

within 10 days in writing and the Engineer shall decide forthwith whether or not the same shall be 

carried out and if the Engineer confirms his instructions, the contractor’s obligations and 

guarantees shall be modified to such and extent as may be justified. In the absence of any such 

notification, the Contractor shall be bound to carry out the suggested variations without any 

additional financial implication to Purchaser and it will amount to an absolute waiver of any claim 

whatsoever. 

30.00 SETTLEMENT OF DISPUTE 

30.01 Except as otherwise specifically provided in the Contract all disputes concerning question of fact 

arising under the Contract s hall be decided by the Engineer subject to a written appeal by the 

Contractor to the Engineer, whose decision shall be final to the parties hereto. 

30.02 Any disputes or differences including those considered as such by only one of the parties arising 

out of or in connection with the Contract shall be to the extent possible settled amicably between 

the parties. 

30.03 If amicable settlement can not be reached then unresolved disputed issues may be settled by 

arbitration as provided subsequently. 

31.00 TERMINATION OF CONTRACT 

Notwithstanding anything contained elsewhere in this contract, if at any time during the term of this 

contract the plans of the Government of India and/ or the State Government change for any 

reason, the Purchaser shall have the right to terminate the Contract by notice to the Contractor by 

a registered letter. In respect of such changes the material that is complete as ready for 

transportation within thirty (30) days after such notice, Purchaser agrees to accept delivery thereof 

at the contract price and terms. In the case of the remainder of the undeliverable material, the 

Purchaser may elect (a) to have any part thereof completed and take delivery thereof at the 

contract price and (b) to cancel the residue (if any) and pay to the Contractor aprorated amount of 

the contract price based upon the state of completion to be certified by him. The Contractor shall 

deliver all such material in process of manufacture to the Purchaser and shall return to the 

Purchaser any funds remaining to the Purchaser’s credit. No payment shall be made by the 

Purchaser for any material not yet in process of manufacture on the date of notice of cancellation is 

received. 

32.00 DEDUCTION FROM CONTRACT PRICE 

All costs, damages or expenses which the Purchaser may have paid, for which under the contract 

Contractor is liable, may be deducted by the Purchaser from any money due or be coming due by 


. 

him to the Contractor under the contract, or may be recovered by action of law or otherwise from 

the Contractor. Further all legal and statutory deductions will be made and the Contractor is not 

entitled to any reimbursement or claim what-so-ever except only a tax deduction certificate. 

In the event of recovery to the necessary extent becoming impossible owing to insufficiency of the 

performance bond and withheld amounts, the balance due to the purchaser, may be recovered in 

any way the Purchaser may deem fit. 

33.00 CO-OPERATION WITH OTHER CONTRACTORS AND CONSULTING ENGINEERS 

The Contractor shall agree to co-operate with the Purchaser’s other contractors and Consulting 

Engineers for associated equipment and freely exchange with them such technical Information as 

is necessary to obtain the most efficient and economical design and to avoid unnecessary 

duplication of equipment. No remuneration shall be claimed from the Purchaser for such technical 

cooperation. The Purchaser and consulting Engineer shall be provided with two (2) copies each of 

all correspondence addressed by the Contractor to other Contractors in respect to such exchange 

of technical information. 

If any part of the Contractor’s work depends for proper execution or results upon the work of any 

other Contractor, the Contractor shall inspect and promptly report in writing to the engineer any 

defects; in such works that render it unsuitable for such proper execution and results. His failure to 

so inspect and report shall constitute an acceptance of the other Contractor’s work as fit and 

proper for the reception of his work, except as to defects which may develop in the other 

Contractor’s work after the proper execution of his work. 

34.00 ASSIGNMENT OF CONTRACT 

Any assignment of the contract or any part thereof or any rights or obligations there under, by the 

Contractor without the prior written consent of the Purchaser shall be void. 

The purchaser shall be at liberty to transfer and assign the contract only to Government Company 

as defined in the Indian Companies Act-I of 1956, and such Company shall exercise all the rights 

and be liable for all obligations of the Purchaser contained herein in the same manner as if the 

agreement had been entered into between the said Company and the Purchaser. The purchaser 

shall be also at liberty to entrust the carrying out of the agreement only to a Government Institution 

and upon the Instructions of the purchaser, the Contractor undertakes to do all things necessary to 

carry out of his obligations under the agreement with such institution as may be entrusted by the 

purchaser as agent or otherwise. The Purchaser, however, shall not be in either case relieved or 

discharged from any of his obligations and liabilities under the contract. 

The contractors shall be advised in writing of the date of any such substitution. 


. 

35.0 SUBLETING OF CONTRACT 

The Contractor shall not without the consent in writing of the Purchaser, which shall not be 

unreasonably withheld, assign or sublet his contract or any substantial part thereof other than for 

raw materials, for minor details, or for any part of the works of which the makers are named in the 

contract, provided that any such consent shall not relieve the Contractor from any obligation, duty 

or responsibility under the contract. 

For components/equipments procured by the Contractors for the purpose of the Contract; after 

obtaining the written approval of the Owner, the Contractor’s purchase specifications and enquiries 

shall call for quality plans to be submitted by the suppliers along with their proposals. The quality 

plans called for from the vendors shall set out, during the various stages of manufacture and 

installation, the quality practices and procedures followed by the Vendor’s quality control 

organization, the relevant reference documents/standards used, acceptance level, inspection of 

documentation raised, etc. Such quality plans of the successful vendors shall be discussed and 

finalized in consultation with the Engineer and shall form a part of the purchase order/contract 

between the Contractor and the vendor. Within 3 weeks of the release of the same purchase 

order/contracts for such bought out items/components, a copy of the same without price details but 

together with detailed purchase specifications, quality plants and delivery conditions shall be 

furnished to the Engineer by the Contractor. 

36.00 SUSPENSION OF WORK 

The owner reserves the right to suspend and reinstate execution of the whole or any part of the 

works without invalidating the provisions of the contract. Orders for suspension or reinstatement of 

the works will be issued by the Engineer to the Contractor in writing. The time for completion of the 

works will be extended for a period equal to duration of the suspensions. Any necessary and 

demonstrable costs incurred by the contractors as a result of such suspension of works other than 

force majeure conditions will be paid by the owner, provided such costs are substantiated to the 

satisfaction of the Engineer. The owner shall not be responsible for any liabilities if suspension or 

delay is due to some default on the part of the Contractor or his sub- Contractor. 

37.00 FORCE MAJEURE 

37.01 Any delays in or failure of the performance of either parties thereto shall not constitute default here 

under or give rise to any claims for damages, if any, to the extent such delays or failure of 

performance caused by occurrences such as acts of God or the public enemy, expropriation or 

confiscation of facilities by Government authority, compliance with any order or request of any 

Government authorities, act of war rebellion, sabotage, fire, floods, explosions, riots or illegal 

strikes, provided always that such occurrence result in impossibility of performances of the 

contract. 

37.02 Only events of Force Majeure which impedes the execution of the contract at the time of its 

occurrence shall be taken into cognizance. 


. 

38.00 PROGRESS REPORTS AND PHOTOGRAPHS 

The Contractor shall furnish six (6) prints each of progress reports and photographs of the work 

done in his shop. Photographs shall be taken when the where indicated by the Engineer or his 

representative. Photographs shall be approximately 100 mm x 125 mm in size including a margin 

of 5 mm side of fixing. Adequate number of photographs shall be submitted indicating various 

stages of manufacture. Each photograph shall contain the date the name of the Contractor and the 

title of the view taken. 

Monthly progress reports shall be submitted. These shall detail the status of design, procurement 

of raw materials and manufacture of the equipment. The Engineer shall advise the Contractor 

about the number of copies of progress schedule and photographs he has to submit each month 

together with the names and address of persons to whom they are to be sent. 

39.00 PATENT RIGHTS 

Royalties and fees for patents covering materials, articles, apparatus devices, equipment and 

processes used in the plant and equipment shall be deem to have been included in the Contract 

Price. The Contractor shall defend any claims which alleged in a suit or proceeding against the 

Purchaser that the equipment or any part thereof constitutes an infringement of any patent, it 

notified promptly in writing and given authority, Information and assistance for the defense and the 

Contractor shall pay all damages and costs awarded against the Purchaser in such suit or 

proceeding for the patent infringement. In case the equipment in such suit or proceeding is held to 

constitute infringement and the use of the equipment or part is prohibited, the Contractor shall, at 

his own expenses, either procure for the Purchaser the right to continue using the equipment or 

replace same with a non-infringing equipment or modify it so it become non-infringing or remove 

the equipment and refund the purchase price plus the transportation and installation costs thereof. 

The foregoing states entire liability of the Contractor for patent infringement and the Purchaser 

shall be kept indemnified in this regard. 

Notwithstanding any dispute regarding patents Purchaser will have a right to the use of materials, 

articles, apparatus, devices, equipment and process till final adjudication of such dispute. 

40.00 TRAINING OF ENGINEERS 

It so desired by the Purchaser, the Contractor shall undertake to train Engineers to be nominated 

by the Purchaser in the manufacture, testing, erection and operation of similar equipment as 

covered by the contract. The period of training, number of engineers to be trained, program of 

training will be mutually agreed upon. Cost of to and fro traveling for each engineer to the 

manufacturer’s factory and their living expenses shall be borne by the Purchaser. 


. 

41.00 EFFECT & JURISDICTION OF CONTRACT 

41.01 The contract shall be considered as having come into force from the date of the acceptance of 

Letter of Intent. 

41.02 The laws applicable to this contract shall be in the laws in force in India. The courts of Orissa shall 

have exclusive jurisdiction in all matters arising under the contract. 

42.00 TIME IS THE ESSENCE OF CONTRACT 

42.01 The time and the date of completion of the works as stipulated in the contractor’s proposal and 

accepted by the owner without or with modifications, if any, and so incorporated in the Letter of 

Intent, shall be deemed to be the essence of the contract. The Contract shall so organize his 

resources and perform his work as to complete it not later than the date agreed to. 

42.02 The Contractor shall submit a detailed PERT Network within the time frame agreed above covering 

various key phases of the works such as design, procurement, manufacturing, shipment and field 

erection activities within thirty (30) days after the date of Letter of Intent. This network shall also 

indicate the interface facilities to be provided by the Owner and the dates by which such facilities 

are needed. 

Contractor shall discuss the network so submitted with the owner. The agreed network which may 

be in the form as submitted or in revised form in line with the outcome of discussions shall form 

part of the Contract to be signed within sixty (60) days from the date of acceptance of Letter of 

Intent. During the performance of the contract, if in the opinion of the Engineer proper progress is 

not maintained suitable changes shall be made in the contractor’s operations to ensure proper 

progress. 

42.03 The above PERT network shall be reviewed and periodic review reports shall be submitted by the 

Contractor as directed by the Engineer. 

42.04 Within a month of the award of the contract, the Contractor shall make available to the Engineer, a 

detailed manufacturing programme, in line with the agreed contract network. Such manufacturing 

program shall be reviewed, updated and submitted to the Engineer once every two months 

thereafter. 

43.00 ERECTION SUPERVISION SERVICES 

The Contractor, if required by the Purchaser, shall furnish the services of one or more supervisors, 

to render technical advice, assistance and guidance to the Purchaser in connection with the 

erection and/or commissioning of equipment subject to the provisions herein after set forth. In case 

of complete erection of plant and materials such services shall automatically be included in the 

scope of the Contractor and no extra charges shall be applicable. 


. 

The Purchaser; shall pay the Contractor for the service of each supervisor as follows: 

(a) As agreed rate; per-calendar day from the date on which supervisor leave his 

headquarters up to and including the date of his return thereto. This rate is based up on a 

normal 48 hours work-week of six (6) eight-hour workdays, Monday through Saturday. 

Sunday will be normally a holiday but any other day of the week may be made a normal 

holiday depending upon working conditions. 

(b) The Purchaser shall in addition to the charge specified in paragraph above, pay the 

Contractor for any overtime work authorized by the Purchaser and performed by the 

supervisor at an agreed overtime rate per hour for hours worked in excess of 8 hours per 

day and all hours worked on the seventh day. There will be no overtime charge for work 

performed on locally recognized or national holiday or time spent in traveling to and from 

the supervisors headquarters. 

(c) Hours during which the supervisor is ready, willing and able to work up to 48 hours per 

week shall be regarded as having actually been worked by him even though his services 

are not in fact utilized. 

The Purchaser shall secure any labor permit or any other authorization which may be required to 

permit the Erection Supervisor to perform the services and any loss of the supervisor’s services 

pending the procurement of any such permit or authorization shall be to the Purchaser’s account 

and shall be paid for by the Purchaser. 

The Purchaser shall furnish, at his own expenses, and assume responsibility for all labor and labor 

supervision and shall make available all necessary installation to tools, except such special tools 

as may be supplied by the Contractor pursuant to written agreement between the parties. The 

supervisor may elect to bring certain personal tools which tools are to remain his property at all 

times. The Purchaser shall assist the Supervisor in arranging entry and exit permit for such tools. 

If any portion of the work of supervision by the Contractor proves to be defective within one (1) 

year from the date of completion of supervision, the Contractor, if promptly notified thereof in 

writing, will at his own expense, and at his option, with make repairs or supply replacement parts 

directly to or for the equipment and necessary to correct any defect or defects in such equipment 

directly resulting from such defective work of supervision on the part of the Contractor and will at 

his own expenses, furnish the necessary supervision for such corrections. The contractors liability 

in connection with his furnishing a supervisor hereunder shall in no event exceed the cost of 

correcting any such defective work of supervision in the manner herein provided and upon the 

expiration of the said one (1) year, all such liability shall terminate. In no event shall the Contractor 

be liable for special, indirect or consequential damages. 

The Contractor shall not be liable for loss of damage due to delays in furnishing the services or in 

the work resulting form any cause beyond the Contractor’s reasonable control including 

compliance with any Government regulations, orders or instructions, acts of God, acts of omission 


. 

of Purchaser, acts of civil or military authority, fires, strikes, war earthquake, storm, volcanic 

eruptions, landslide, riot or delays in transportation. The Purchaser shall advise the Contractor in 

writing reasonably in advance of the date that the supervisor shall be required to start performance 

of the services. 

44.00 ERECTION OF PLANT AND MATERIALS 

44.01 General 

Unless otherwise mutually agreed to the provisions of this clause shall apply where the services for 

erection of plant & material supplied by the contractor are included in the scope of work. 

If so desired by the Purchaser, the Contractor shall receive the imported equipment, if any, at the 

port of entry, clear them through Customs and make damage report through port broker. The 

Contractor shall arrange for payment at prescribed rate of Customs Duty which will be reimbursed 

by the Purchaser against Contractor’s valid documents. 

The Contractor shall transport all imported equipment from port of entry to the site and unload all 

Imported/Indigenous equipment at site. Escort service shall be provided, if necessary and called 

for. All storage at port of entry or at railway station will be at Contractor’s charge. 

The Contractor shall be responsible for complete installation of the equipment start-up and testing 

at site. 

All equipment and tools for transportation and erection shall be provided by the Contractor. 

All materials and /or equipment, after receipt at site, shall be checked and verified against shipping 

documents and all claims against loss or damage in transit shall be intimated to the purchaser. The 

materials and/or equipment shall remain under the custody of the Contractor until the plant as a 

whole is taken over by the Purchaser upon completion of the work. The Contractor shall take 

adequate steps to ensure safety of such materials and / or equipment. Necessary stores receipt 

certificates shall be issued to the Purchaser after the stores are checked and certified. No materials 

and/or equipment pertaining to the Contract shall be removed from site without the consent in 

writing of the Purchaser. 

The Contractor shall be responsible for obtaining the correct reference lines for purposes of fixing 

the alignment of various equipment. 

44.02 Regulation of Local Authorities and Statues 

The Contractor shall comply with the rules and regulations of local authorities during the 

performance of his field activities. He shall also comply with the minimum wages Act, 1948 and the 

payment of wages act (both of the Government of India) and the rules made there under in respect 

of any employee or workmen employed or engaged by him or his sub-Contractor. 


. 

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 Purchaser, shall be to the account of the Purchaser. 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 of such inspection and/or registration shall be borne by the 

Contractor. 

44.03 Work at Site 

In the execution of work, no persons other than the Contractor or his appointed representative, 

sub-Contractor and workmen shall be allowed to do work at site, except by the special permission 

in writing of the Engineer or his representative, but access to the Works at all times shall be 

accorded to the Engineer and his representative and other authorized officials or representatives of 

the Purchaser. 

Nevertheless, the Contractor shall not object to the execution of work by other Contractors or 

tradesmen whose names shall have been previously communicated in writing to the Contractor by 

the Engineer and afford them every facility for the execution of their several works simultaneously 

with his own. 

The Contractor shall at all times provide sufficient fencing, notice boards, lights and watchmen to 

protect and warn the public and guard the works, and in default thereof the Purchaser may 

provided such fencing, notice boards, lights and watchmen as he may deem necessary and charge 

the cost thereof to the Contractor. 

The work so far as it is carried out on the Purchaser’s premises shall be carried out at such time as 

the Purchaser may approve and so as not to interfere unnecessarily with the conduct of the 

Purchaser’s business but the Purchaser shall give the Contractor all reasonable facilities for 

carrying out the work. No female labor shall be employed during dark hours. 

The Contractor shall not employ for the purpose of the contract any person who is below the age of 

eighteen years and shall pay to each laborer, for the work done by such laborer, wages not less 

then the wages paid for similar work in the neighborhood. The Engineer shall have the right to 

enquire into and decide any complaint alleging that the wages paid by the Contractor to any laborer 

for the work done by such laborer is less than the wages paid for similar work in the neighborhood, 

and to refuse appointment of labor less than eighteen years of age. 

The Contractor shall make regular and prompt payment of wages to the laborers engaged on the 

work and in not case the payment shall be delayed more than seven (7) days following the period 

for which the wages are due. If it is found the workers are not paid regularly the contract is liable to 

be rescinded. The Contractor shall comply strictly with the provisions of Labor Laws in this behalf. 


. 

44.04 Manufacturer’s Supervision 

The Contractor may be required to work under the supervision of the manufacturer’s Engineers, 

where the Contractor is not the manufacturer. However, this will not relieve the Contractor of his 

responsibility of the correctness of quality of workmanship. 

44.05 Engineer’s Supervision 

All the works shall be carried out under the direction and to the satisfaction of the Engineer. The 

Contractor shall be responsible for the correctness of the positions, levels and dimensions of the 

works according to the drawings, notwithstanding that he may have been assisted by the Engineer 

in setting out the same. 

44.06 Contractor’s Representative 

The Contractor shall employ at least one competent representative, whose name or names shall 

have previously been communicated in writing to the Engineer by the Contractor for approval to 

superintend the erection of the plant and carrying our of the work. The said representative, or if 

more than one be employed, one of the representative, shall be present at the site, during working 

hours, and any written orders or instructions which the Engineer or his authorized representative 

may give to the said representative of the Contractor, shall be deemed to have been given to the 

Contractor. 

The Engineer shall be at liberty to object to any representative or person employed by the 

Contractor in the execution of or otherwise of the work who shall misconduct himself or be 

incompetent, or negligent, and Contractor shall remove the person so objected to, upon receipt 

from the Engineer or notice in writing requiring him to do so and shall provide; in his place a 

competent representative at the Contractor’s expenses. The Contractor’s representatives to be 

employed for the purpose of the work at site shall be made available when the Purchaser shall 

inform the Contractor in writing to the effect. The services of the Contractor’s representative shall 

be made available for such period as the Engineer may require and they shall work at all 

reasonable times as may be necessary to complete the work within the period specified in the 

Contract. 

44.07 Program of work and Progress Reports 

The Contractor shall submit at such times as may be required by the Engineer, schedules showing 

the program and order in which the Contractor proposes to carry out the work, with dates and 

estimated completion times of various parts of the work. Such schedules shall be approved by the 

Engineer, prior to starting the erection. Such times shall be binding on the Contractor for purpose 

of assessing the penalty as called for under subsequent clause. The Engineer may not allow the 

Contractor to start work for non-submission of the time schedule of the erection program. 


. 

During the progress of work the Contractor shall submit monthly progress reports and photographs 

and such other reports on the erection work and organization, as the Engineer may direct. The 

progress indicated be arrived by agreement between the Contractor and the Engineer. The 

Contractor shall also submit an anticipated one (1) month progress schedule at the beginning of 

each month describing in detail the anticipated progress for the following month. The Contractor 

shall also submit every week a list of various categories of men working under him. Monthly 

progress reports shall be submitted within the tenth day of the month following the reporting month. 

44.08 Man - Power Report 

The Contractor shall submit to Engineer, on the first day of every month, a man hour schedule for 

the month, detailing the man hours scheduled for the month, skill wise and are wise. 

The Contractor shall also submit to the Engineer on the first day of every month, a man power 

report of the previous month detailing the number of persons scheduled to have been employed 

and actually employed, skill wise and the areas of employment of such labor. 

44.09 Extension of Time 

The application for extension of time is to be given to owner/purchaser through the Engineer and 

the owner/purchase may authorize extension of time after considering the due merits. 

Whenever extension of time is granted by the owner/purchaser, the same shall be on the existing 

terms and conditions of the contract and without any additional financial liability to the Owner. The 

Contractor in any case shall have no claim whatsoever for any type of compensation on account of 

any delay attributable to any one. 

44.10 Liability for Accident and Damage 

The Contractor shall Indemnify the Purchaser against any claims which may be made under the 

workman’s Compensation Act, 1923, or any statutory modification thereof or otherwise for or in 

respect of any damages or compensation payable in consequence of any accident or injury 

sustained by any workman or other person whether in the employment of the Contractor or not. In 

every case in which by virtue of the provisions of sub-section (1) of Section 12 of the Workman’s 

compensation Act, 1923, the Purchaser is obliged to pay compensation to a workman employed by 

the Contractor in execution of the works, the Purchaser will recover from the Contractor the amount 

of the compensation so paid and without prejudice to the rights of the Purchaser under sub-section 

(2) of Section 12 of the said Act. The Purchaser shall be at liberty to recover such amount or any 

part thereof by deducting it from the Performance Bond or from any sum due by the Purchaser to 

the Contractor whether under the contract or otherwise. 

The Purchaser shall not be bound to contest any claim made against it under Section 12, subsection 

(1) of the said Act, except on the written request of the Contractor and upon his giving to 

the Purchaser full security for all costs for which the Purchaser might become liable in 

consequence of contesting such claim. In the event of claim being made or action brought against 


. 

the Purchaser involving the Contractor and arising out of the matters referred to and in respect of 

which the Contractor is liable under this clause, the Contractor shall be immediately notified thereof 

and he shall with the assistance, if so required by the Purchaser, but at the sole expense of the 

Contractor, conduct all negotiations for the settlement of the same, or of any litigation that may 

arise there from. In such case the Purchaser, at the expenses of the Contractor, afford all available 

assistance for any such purpose. 

The Contractor shall be responsible for all loss, damage or depreciation to the plant until the plant 

is taken over in accordance with clause ‘Taking Over’. The Contractor shall, during the progress 

other work, properly cover up and protect the plant from injury by exposure to weather and; shall 

take every reasonable, proper, timely and useful precaution against accident or injury to the same 

from any cause shall be and remain answerable and liable for all accidents or injuries thereto 

which, until the same be or be deemed to be taken over under clause ‘Taking Over’ may arise or 

be occasioned by the acts or omissions or the Contractor of his workmen or sub- Contractors, and 

all losses and damage to the Plant arising from such accidents or injuries as aforesaid shall be 

made good in the most complete and substantial manner by and at the sole cost of the Contractor 

and to the reasonable satisfaction of the Engineer. 

Until the plant shall be or deemed to be taken over as aforesaid the Contractor shall also be liable 

for and shall be deemed to have agreed to indemnity the Purchaser in respect of all damage to any 

property of the Purchaser or of others occasioned by the negligence or fault of the Contractor or 

sub-contractor or his or their workmen or representatives or by defective design, work or material 

or otherwise. 

The Contractor shall pay all taxes due in India for the personnel employed by the Contractor work 

arising out of their services in connection with the contract and obtaining at his (Contractor’s) own 

cost ‘work permits’ from competent authorities to enable any foreign personnel to work in India. 

The Contractor shall be responsible for all formalities in connection with the passport, obtaining of 

visas, police permits, and expenses for customs duties related to personal goods of foreign 

personnel to be employed in the erection work. However, the Purchaser shall If requested, assist 

the Contractor in obtaining visas and “work permits’ for the foreign personnel to be deputed for the 

erection work. 

44.11 Cleanliness 

During erection, the Contractor shall, without any additional payment, at all times keep the working 

and storage areas used by him free from accumulation of waste materials or rubbish. If the 

Contractor fails to remove the rubbish, within forty eight (48) hours, after being requested by the 

Engineer, the rubbish will be removed by others and cost back charged to the Contractor. Any 

inflammable material should be removed forthwith on request by the Engineer. 


. 

Before completion of erection, the Contractor shall remove or dispose of in a satisfactory manner 

all temporary structures, packing cases, waste and debris and leave the premises in a condition 

satisfactory to the Engineer. 

Similarly the labor colony, the offices and the residential areas of the Contractor’s employees and 

workmen shall be kept clean & neat to the entire satisfaction of the Engineer. Proper sanitary 

arrangements shall be provided by the Contractor, in the work areas office and residential areas of 

the Contractors. 

44.12 Co-ordination with the Purchaser’s Engineers 

The Contractor shall at all times work in co-ordination with the Purchaser’s Engineers and afford 

them every facility to become familiar with the erection and maintenance of the equipment. 

In respect of observance of local rules, administrative matters, co-ordination with other Contractors 

and the like, the Contractor and his personnel shall work under the Purchaser’s Engineer in charge 

of the work. 

44.13 Work and Services to be provided by the Purchaser 

Unless otherwise agreed upon, the following works and services shall be provided by the 

Purchaser for carrying out complete erection work: 

(a) Water Supply 

Water supply for construction purpose will be provided by the Purchaser at one mutually 

agreed point at site. Drinking water will also be made available at one central point at site. 

The Contractor shall make his own arrangement for any further distribution. Such 

distribution pipe network shall have the prior approval of the Engineer at site so as not to 

interfere with the layout and progress of other construction works. The water supply shall 

be free of cost. Contractor shall ensure that there is no wastage of water. On completion of 

the work, the Contractor shall remove all such work and shall reinstate and make good any 

work disturbed to the satisfaction of the Engineer. 

(b) Power Supply 

(I) Electric power will be supplied at 400/440 V and shall be metered and charged at 

applicable rates. 

(II) Supply for execution of work will be made available at one point only. This point 

will not be more than 500 meters away from the Contractor’s premises. The 

Contractor shall make his own arrangement at his own cost for distribution of 


. 

power to different worksites. This arrangement shall however, be coordinated and 

laid with approval of the Engineer. Any change in the alignment of the Contractor’s 

distribution lines necessitated by his work or another work must be done at 

Contractor’s cost. The Engineer also reserves the right to change the location of 

point of supply whether necessitated by his work or another work and the 

Contractor shall make his own arrangement at his own cost for extending his 

distribution line to the new location of supply point. A 3 phase armored cable shall 

be used by the Contractor for connecting their equipment to Purchaser’s point 

supply. 

(III) The Purchaser shall not however, guarantee the supply of electricity and no 

compensation for any failure or short supply of electricity will be entertained and 

this does not relieve the Contractor of his responsibility for timely completion of the 

work as stipulated in the Contract. 

(IV) It shall be the responsibility of the Contractor to provide and maintain the complete 

installation on the load site of the supply with due regard to safety requirement at 

site. All cabling, equipment, installations etc. shall comply in all respects with the 

latest statutory requirements and safety provisions, i.e. as per given in the 

Central/State Electricity Acts and Rules etc. The Contractor will ensure that his 

equipment and Electricity wiring etc. are installed, modified and maintained by a 

licensed Electrician / Supervisor and before power is supplied, a test certificate is 

to be produced to the Engineer for his approval. 

(V) At all times, IEA Regulations shall be followed failing which the Purchaser has a 

right to disconnect the power supply without any reference to the Contractor. No 

claim shall be entertained for such disconnection by the Engineer. Power supply 

will be reconnected only after production of fresh certificate from authorized 

electrical supervisors. 

(VI) The Purchaser will not liable for any loss or damage to the Contractor’s equipment 

as a result of variation in voltage or frequency or interruption of power supply or 

other loss to the Contractor arising there from. 

(VII) The Contractor shall ensure that the Electrical equipment installed by him are such 

that average power factor does not fall below 0.9 at this premises. In case P.F. 

falls below 0.9 in any month, he will reimburse to the purchaser at the rate same 

as OSEB’s rate for per unit fall of P.F. determined from time to time by Purchaser 

all units consumed during the month. 

(VIII) The power supply required for Contractor’s colony near the plant site will be 

determined by the Purchaser and shall be provided as per State Electricity Board’s 

Rules and other Statutory provisions applicable for such installations from time to 

time. In case of power supply to Contractor’s colony, the power will be made 

available at a single point and the Contractor shall make his own arrangement at 


. 

his own cost for distribution to the occupants of the colony as per Electricity Rules 

& Acts. The site area and colony shall be sufficiently lighted to avoid accidents. 

(IX) The Contractor will have to provide and install his own light and power meters 

which will be governed as per Central/State Govt. Electricity Rules. The meters 

shall be sealed by the Purchaser. 

(X) In case of damage to any of the Purchaser’s equipment on account of fault, 

intentional or unintentional on the part of the Contractor, the purchaser reserves 

the right to recover the cost of such damage from the contractor’s bill. 

(XI) After completion of work, the Contractor shall promptly dismantle, at his own cost 

distribution and other facilities that he may have erected and shall also remove the 

same within a reasonable time fixed by the Engineer and on his failure to do so the 

Purchaser will be entitled to realize from his reasonable compensation fixed by the 

Engineer and also to remove them at the cost of the Contractor. 

(XII) Only motors up to 3HP will be allowed to be started direct on line. For motors 

above 3 HP and up to 100 HP suitable starting devices approved by the Purchaser 

Engineer, shall be provided by the Contractor. For Motors above 100 HP slip ring 

induction motors with suitable starting devices as approved by the Engineer shall 

be provided by the Contractor. 

(XIII) The single line distribution system with loadings and specifications shall be 

submitted to the Engineer for his approval before the system is installed. The 

system shall conform to Central/State Statutory provisions Act, with latest 

amendments and to the Approved specifications of the company. The installations 

have to be inspected and approved by the Electrical Inspector, Govt. of Orissa 

before energisation. 

(XIV) The total requirement of power shall be indicated by the tenderer in his tender and 

confirmed within thirty days from the date of Letter of Intent. 

(d) Land for Contractor’s Use 

(I) The Purchaser will at his own discretion and convenience and for the duration of 

the execution of the work make available near the site, land for construction of 

Contractor’s field office, godowns, workshops and assembly yard required for the 

execution of the contract. The Contractor shall at his own cost construct all these 

temporary buildings and provide suitable water supply and sanitary arrangement 

approved by the Engineer. 

(II) On completion of the works undertaken by the Contractor, he shall remove all 

temporary works erected by him and have the site cleared as directed by 

Engineer. If the Contractor fails to comply with these requirements, the Engineer at 


. 

the expenses of the Contractor will remove such surplus and rubbish materials 

and dispose off the same as he deems fit and get the site cleared as aforesaid, 

and the contractor shall forthwith pay the amount of all expenses so incurred and 

shall have no claim in respect of any such surplus materials disposed off as 

aforesaid. But the Purchaser reserves the right to ask the Contractor any time 

during the pendency of the contract to vacate the land by giving 7 days notice on 

security reasons on national interest or otherwise. A token rent of Rs. 100/- 

(Rupees one hundred only) per hectare or part thereof per annum or part thereof 

shall be charged for the land so occupied. 

(III) Land for residential accommodation for staff and labor will be made available at 

the discretion of the Engineer and rent for the same will be as decided by the 

Engineer according to location and area taken by the Contractor. 

(e) Electricity and drinking water at normal charges for labor quarters at a central point within 

the land provided by the Purchaser. The cost of distribution, if any, shall be borne by the 

Contractor. 

(f) Assistance to the Contractor in obtaining Indian visas, residential or working permits for the 

permits for the personnel, if necessary. 

(g) Water and electricity as may be required for the initial starting up of the equipment free of 

charge to Contractor. 

(h) Necessary Engineers, operators and other personnel for start – up commissioning and 

acceptance tests of the equipment free of charge to Contractor. 

(i) Assistance in obtaining priorities for transportation, customs permit etc. 

(J) Suitable access to site and possession of the site shall be afforded to the Contractor by the 

Purchaser. 

44.14 Work and Services to be provided by the Contractor 

Unless otherwise agreed upon, the following work and services shall also be provided under the 

erection contract. 

(i) Clearing, unloading the equipment from the rail or road transport to Contractor’s 

transport/vehicle and delivery the same to storage area. Demurrage charges, if incurred at 

rail head or at site for default of the Contractor shall be paid by him 

(ii) Opening of packing cases, Inspection and checking of materials. Repair and replacement 

of contract material damaged or lost in transit or at site. 


. 

(iii) Final adjustment of foundation levels by chipping and dressing, checking location, 

elevation etc. of anchor bolts and grouting or anchor bolts and base plates. 

(iv) Complete erection of the equipment covered under the contract, final preparation for 

testing, commissioning, final run and acceptance tests and putting the plant into 

commercial operation. 

(v) All consumable stores required for the above work, except those mentioned under Clause 

44.13 (i). 

(vi) Watch and ward to ensure security and safety of materials under the custody. 

(vii) Furnishing of residential accommodation to erection labor and other personnel. 

(viii) Daily transport for his erection personnel to and fro between residence and site. 

(ix) All erection tools and lifting tackles, also all equipment, tools and tackles for transportation 

of all equipment to site. A list of such tools and tackle and equipment shall be submitted to 

the purchaser before commencement of site work. These tools and tackle shall not be 

removed from the site without written permission of the Engineer. 

(x) All ladders, platforms, temporary supports and facilities required for handing of heavy 

packages at site required for erection. 

(xi) Necessary clerical staff, supervisory personnel skilled and unskilled labor. 

(xii) Third Party Insurance at site and insurance of Contractor’s personnel employed at site as 

required under Workmen’s Compensation Act. 

(xiii) Site offices and covered storage as required. 

(xiv) Postage, telephone and telegraph expenses. 

(xv) Cleaning up of site during and after erection. 

(xvi) Applying final paint to all equipment, piping, hanger etc. covered under the contract. 

(xvii) Necessary supervisory personnel with approved license as per provisions of Indian 

Electricity rules. 

(xviii) If the Contractor uses his own crane, he must have a skilled crane operator. 

(xix) Contractor must take all safety precautions during work and the workmen must use safety 

belts, tested gloves, masks and other devices as necessary for safety of personnel 


. 

(xx) Contractor should provide identity badges for his employees. These should be properly 

displayed during working hours. 

(xxi) The Contractor shall employ only competent and skilled workmen fully experienced and 

capable of performing duties assigned for them. When local laws required the employee 

shall be required to acquire certificate of competency for his work from the competent 

authority. 

(xxii) Communication 

The Contractor will make his own arrangement for all his communications needs such as 

telephone, telex etc. at his site office and his residential area. Purchaser will assist in 

getting the above facilities, in case he finds and difficulty. 

(xxiii) First – Aid 

The Contractor shall provide necessary first-aid facilities for all his employees, 

representatives and workmen working at site. Enough number of contractor’s personnel 

shall be trained in administering first-aid. 

(xxiv) Welfare facilities 

44.15 Lines and Grades 

Contractor shall provide in his labor colony all necessary standard welfare facilities like 

canteen, shopping facility etc. 

All the works shall be performed to the lines/alignments, grades and elevations indicated on the 

drawing. The Contractor shall be responsible to locate and layout the works area. Basic horizontal 

and vertical control points will be established and marked by the Engineer at site at suitable points. 

These points shall be used as datum/reference points for the works under the contract. The 

Contractor shall inform the Engineer 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 reference points may be established and 

checked by the Engineer to enable the Contractor to proceed with his works. Any work done 

without being properly located may be removed and/or dismantled by the Engineer at Contractor’s 

expenses. 

44.16 Fire Protection 


. 

(a) The work procedures that are to be used during the erection shall be those which minimize 

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, oil and 

volatile or flammable materials shall be stored away from the construction and equipment 

and materials storage area in safe containers. Adequate precaution shall be taken in 

handling and storage of flammable gas. Care shall be taken to avoid and reduce hazards 

from electrical short circuits and faults. 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 

area of storage. 

(b) Similar 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 combustible resulting from welding sparks, cutting flames and other 

similar fire sources. 

(c) All the Contractor’s supervisory personnel and sufficient number of workers shall be 

trained for fire - fighting and shall be assigned specific fire protection duties. Enough of 

such trained personnel must be available at site during the entire period of the Contract. 

(d) The contractor shall provide enough fire protection equipment of the types and number for 

the ware - houses, office, temporary structures, labor colony area etc. Access to such fire 

protection equipments shall be easy & kept open at all times. 

44.17 Materials Handling & Storages 

(a) All the equipments furnished under the Contract and arriving at site shall be promptly 

received, unloaded and transported and stored in the storage spaces by the contractor. 

(b) The Contractor shall be responsible for examining all the shipment and notify the engineer 

immediately of any damages, shortages; discrepancy etc. for the purpose of Engineer’s 

information only. The Contractor shall submit to the Engineer 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 storage & erection of the equipment 

at site. Any demurrage, wharfage and other charges claimed by the transporters, railways 

etc. shall be to the account of Contractor. 


. 

(c) The Contractor shall maintain an accurate & exhaustive record detailing out the list of all 

equipment received by him for the purpose of erection & keep such record open for the 

inspection of the Engineer at any time. 

(d) All equipments shall be handled very carefully to prevent any damages or loss. No bare 

wire, rope, slings etc. shall be used for unloading and/ or handling of the equipment 

without the specific written permission of the Engineer. The equipment stored shall be 

properly protected to prevent damages 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. 

(e) All electrical panels, control 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. 

(f) All the electrical equipment such as motors, generators, 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 Engineer. 

(g) The Contractor shall ensure that all the packing materials and protection devices used for 

the various equipment during transit and storage are removed before the equipment are 

installed. 

(h) The consumables and other supplies likely to deteriorate to storage must be thoroughly 

protected and stored in a suitable manner to prevent damage or deterioration in quality by 

storage. 

(i) All the materials stored in the open or dusty location must be covered with suitable 

weatherproof and flame-proof covering material wherever applicable. 

(j) If the materials belonging to the Contractor are stored in areas other than those earmarked 

for him the Engineer will have the right to get it moved to the area earmarked for the 

Contractor at the Contractor’s cost. 

(k) The Contractor shall be responsible for making suitable indoor storage facilities to store all 

equipment which required indoor storage. Normally, all the electrical equipment such as 

motors, control gear, generators, exciters and consumables like electrodes, lubricants etc. 

shall be stored in the closed storage space. The Engineer, in addition, may direct the 

Contractor to move certain other materials which in his opinion will require indoor storage 

areas which the Contractor shall strictly comply with. 


. 

44.18 Construction Management 

(a) The field activities of the Contractors working at site will be coordinated by the Engineer 

and the Engineer’s decision shall be final in resolving any disputes or conflicts between the 

contractors and tradesmen of the Purchaser regarding scheduling and co-ordination of 

work. Such decision by the Engineer shall not be a cause for extra compensation or 

extension of time for the Contractor. 

(b) The Engineer shall hold weekly meetings of all the Contractors working at site, at a time 

and a place to be designated by the Engineer. The Contractor shall attend such meetings 

and take notes of discussions during the meeting and the decisions of the Engineer and 

shall strictly adhere to those decisions in performing his works. In addition to the above 

weekly meetings, the Engineer may call for other meetings either with individual 

contractors or with selected number of contractors and in such a case the Contractor, if 

called, will also attend such meetings. 

(c) Time is the essence of the Contract and Contractor shall be responsible for performance of 

his woks in accordance with the specified construction schedule. If at anytime, the 

Contractor is falling behind the schedule, he shall take necessary action to make good for 

such delays by increasing his work to comply with the schedule and shall communicate 

such actions in writing to the Engineer, satisfying that his action will compensate for the 

delay. The Contractor shall note be allowed any extra compensation for such action. 

(d) The Engineer shall however not be responsible for provision of additional labor and/ or 

materials or supply or any other services to the Contractor except for the co-ordination 

work between various entities as set out earlier. 

44.19 Safety Regulations 

(a) Without prejudice to the general obligation under the statutes the Contractor shall ensure 

the safety of all the workmen, materials and equipment either belonging to his or to others 

working at site. 

b) The Contractor will notify the Engineer of his intention to bring on to site any equipment or 

any container, with liquid or gaseous fuel or other substance which may create hazard. 

The Engineer shall have the right to prescribe the conditions under which such equipment 

or container may be handled and used during the performance of the works and the 

Contractor shall strictly adhere to such instructions. The Engineer shall have the right to 

inspect any construction plant and to forbid its use, if in his opinion it is unsafe. No claim 

due to such prohibition shall be entertained by the Purchaser. 


. 

c) 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, 

Explosive Act 1948 published by the Chief Inspector of Explosives of India. All such 

storage shall have prior approvals of the Engineer. In case any approvals are necessary 

from the Chief Inspector of Explosives or any statutory authorities, the Contractor shall be 

responsible for obtaining the same. 

d) The Contractor shall be responsible for provisions of all safety notices and safety 

equipment required both by the relevant legislations and the Engineer as he may deem 

necessary. 

e) The Contractor shall be responsible for the safe storage of his and his sub - contractor’s 

radioactive sources, if any. 

f) In no circumstances will the Contractor interfere with fuses and electrical equipment 

belonging to the Purchaser or other Contractors. 

g) Before the Contractor connects any electrical appliances to and plug or socket belonging 

to the other Contractor or Purchaser, he shall - 

i) Satisfy the Engineer that the appliance is in good working condition; 

ii) Inform the engineer of the maximum current rating, voltage and phases of the 

appliances; 

iii) Obtain permission of the Engineer detailing the sockets to which the appliances 

may be connected. 

h) The Engineer will not grant permission to connect until he is satisfied that - 

i) The appliance is in good condition and fitting with a suitable plug; 

ii) The appliance is fitting with a suitable cable having two earth conductors, one of 

which shall be an earthed metal sheath surrounding the cores. 

i) No electric cable in use by the Contractor/Purchaser will be distributed without prior 

permission. No weight of any description will be imposed on any such cable and no ladder 

or similar equipment will rest against or he attached to it. 

j) No work shall be carried out on any live equipment. The equipment must be made safe by 

the Engineer and permit - to - work issued before any work is carried out. 

k) The Contactor employs the necessary number of qualified, full time electricians to maintain 

his temporary electrical installation. 


. 

45.00 FOREIGN PERSONNEL 

45.01 The Contractor shall submit to the purchaser data on all personnel he proposes to bring into India 

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 work to be performed by him. 

45.02 Any person unsuitable and unacceptable by the purchaser shall not be brought to India. Any 

person brought to India, if found unsuitable or unacceptable by the purchaser, the Contractor shall 

within a reasonable time make alternative arrangements for providing a suitable replacement and 

repatriation of such unsuitable personnel. 

45.03 No person brought to India for the purposes of the works shall be repatriated without any consent 

of the purchaser in writing, based on a written request from the Contractor for such repatriation 

giving reasons for such an action to the Engineer. The purchaser may give permission for such 

repatriation that the progress of work will not suffer due to such repatriation. 

45.04 The Contractor and his expatriate personnel shall respect all India 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 the Government of India, the purchaser and the 

Engineer may establish from time to time, on them. 

The Contractor expatriate personnel shall work and living in close coordination and coordination 

with their co workers and the community and shall not engage themselves in any other 

employment either part - time or full - time nor shall they take part in any local politics. 

45.05 The purchaser 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 DEATH, BANKRUPTCY ETC. 

If the Contractor shall die or dissolve or commit any act of bankruptcy or being a Corporation, 

commence to be wound up except for reconstruction purposes or carry on its business under a 

receiver, the executors, successors or other representatives in law of the estate of the Contractor 

or any such receiver, liquidator or any person in whom the contract may become vested, shall 

forthwith give notice thereof in writing to the purchaser and shall for one month, during which he 

shall take all reasonable steps to prevent a stoppage of the work, have the option of carrying out 

the contract subject of the approval of Purchaser and subject to his or their providing such 

guarantee as may be required by the Purchaser but not exceeding the value of works for the time 

being remaining unexecuted, provided however that nothing above said shall be deemed to relieve 

the Contractor or his successors of his or their obligations under the contract under any 


. 

circumstances. In the event of stoppage of the works the period of the option under this clause 

shall be fourteen (14) days only, provided that should be above option be not exercised, the 

contract may be terminated by the purchaser by notice in writing and the same power and 

provisions reserved to the Purchaser in clause `Negligence’ in the event of taking the work out of 

the Contractor’s hands shall immediately become operative. 

47.00 GRAFTS AND COMMISSION ETC. 

Any graft, commission, gift or advantage given promised or offered by or on behalf of the 

Contractor or his partner, agent, officers, director, employee or servant or any one on his or their 

behalf in relation to the obtaining or to the execution of this or any other contract with purchaser, 

shall in addition to any criminal liability which it may incur, subject the contractor to the cancellation 

of this and other contracts and also to payment of any loss or damage to the purchaser resulting 

from any cancellation. The purchaser shall then be entitled to deduct the amounts so payable from 

any money otherwise due to the Contractor under the contract. 

48.00 COMPLETION OF CONTRACT 

Unless otherwise terminated under the provisions of any other relevant clause, this contract shall 

be deemed to have been completed all the expiration of the guarantee period as provided for under 

the clause entitled `Guarantee Period’ as provided for under the clause entitled `Guarantee’ and 

only on issue of a certificate to that effect and not otherwise. 

49.00 DEFENCE OF SUITS 

In any action in court is brought against the purchaser or Engineer or an officer or agent of the 

purchaser, for the failure or neglect on the part of the contractor to perform any acts, matters, 

convenants or things under the contract, or for damage or injury caused by the alleged omission or 

negligence on the part of the Contractor, his agents, representatives or his sub-contractors, 

workmen, suppliers, or employees, the Contractor shall in all such cases indemnify and keep the 

purchaser, and the Engineer and / or his representative harmless from all losses, damages, 

expenses or decrees arising of such action. 

50.00 ARBITRATION 

All disputes or differences arising under the contract whether during or after completion of the 

contractor or whether before or after determination, for closure or breach of the contract (other than 

those in respect of which the decision of any person is by the contract expressed to the final and 

binding) shall after written notice by either party to the contract to the other of them and to the 

Appointing Authority hereinafter mentioned be referred for adjudication to a sole Arbitrator to be 

appointed as hereinafter provided. 


. 

For the purpose of appointing the sole Arbitrator referred to above, the CMD NALCO who shall be 

Appointing Authority will send within thirty days of receipt of the notice to the Contractor a panel of 

three names of persons. 

The Contractor shall on receipt of the names as referred select any one of the person names to be 

appointed as a sole Arbitrator and communicate his name to the Appointing authority within thirty 

days of receipt of the names. The Appointing Authority shall there upon appoint the said person as 

the sole Arbitrator. If the Contractor fails to communicate such selection as provided above within 

the period specified, the Appointing Authority shall make the selection and appoint the selected 

person as the Sole Arbitrator. 

If the Arbitrator so appointed is unable to / unwilling to act or resigns his appointment or vacates his 

office due to any reason whatsoever sole arbitrator or shall be appointed as aforesaid. The work 

under the contract shall not be stopped during the arbitration proceedings. 

The Arbitrator shall be deemed to have entered on the reference on the date he issues notices to 

both the parties fixing the date of first hearing. 

The Arbitrator may, from time to time, with the consent of the parties, enlarge the time for making 

and publishing the awards. 

The Arbitrator shall give a separate award in respect of each dis pute or difference and shall give a 

reasoned and speaking award / awards. 

The venue of arbitration shall be at Bhubaneswar. However, if the situation so warrants, it may as 

and when required, he held at the place where the site of work is situated. 

The fees, if any, of the Arbitrator shall, if required to be paid before award is made and published, 

be paid half and half by each of the parties. The cost of the reference and of the award including 

the fees, if any, of the Arbitrator shall be in the discretion of the Arbitrator who may direct to and by 

whom and in what manner, such costs or any part thereof shall be paid and may fix or settle the 

amount of costs to be so paid. 

The award of the arbitrator shall be final and binding on both the parties. 

Subject to aforesaid the provisions of the Arbitration Act 1940 or any statutory modification or reenactment 

thereof and the rules made there under, and for the time being in force, shall apply to 

the arbitration proceeding under this clause. 

For Public Sector Enterprises guidelines as per circular of BPE No. 15.9.86 - BPE (FIN) dtd. 

30.03.1989 as amended from time to time will be applicable for resolving any disputes. 

51.00 CORRESPONDENCE 

The Purchaser shall ordinarily correspond with the Contractor at the address furnished by the 

Contractor. 


. 

The Contractor shall ordinarily forward two (2) copies of all correspondence relating to this contract 

to the Purchaser and two (2) copies to the Consulting Engineer or his representative as may be 

requested. 

Two (2) copies of all correspondence from the Contractor to Purchaser’s other Contractors for 

associated plants shall be forwarded to the Purchaser and the Consulting Engineer. 

All drawings and correspondence to the Purchaser and the Consulting Engineer shall be 

transmitted by the Contractor via Air Mail or alternatively by means involving the minimum time of 

transit. 

52.00 CONTRACT AGREEMENT 

If so desired by the Purchaser, a formal Agreement shall be entered into by the Contractor with the 

Purchaser for the proper fulfillment of the Contract. 

The expenses of completing and stamping the Agreement shall be paid by the Contractor, and the 

Purchaser shall be furnished free of charge with an executed stamped counterpart of the 

Agreement as also copies of the Agreement as may be required by the purchaser. 

Any tender drawing, technical data and / or correspondence which forms the basis of an order or a 

contract aforesaid, or which may be furnished by the Contractor for the Purchaser’s approval or 

information as provided under the said order or contract, shall be in English and it is in any other 

language, a complete translation in English shall have to be duly furnished. The Purchaser shall 

not be bound to consider any tender drawing, technical data or correspondence which is not 

furnished in English. 

53.00 PAYMENTS 

53.01 The payment to the Contractor for the performance of the works under the contract will be made by 

the purchaser as per the guidelines and conditions specified herein. All payments made during the 

contract shall be on account of payments only. The final payment will be made on completion of all 

the works and on fulfillment by the Contractor of all his liabilities under the contract. 

53.02 Currency of Payment 

The payments for the foreign currency potion of the contract price will be made in the currency of 

the bid. If the bid is in a currency other than that of the country of origin of goods, payment may be 

made in an amount equivalent to the bid price in the currency of the country of origin. The Indian 

Rupees portion of contract price stated in the contractor’s bid will be paid in Indian Rupees. 

53.03 Payment Schedule 


. 

The Contractor shall prepare and submit to the Engineer for approval, break-up of the contract 

price. The contract price break-up shall be interlinked with the agreed detailed PERT Network of 

the Contractor setting forth his starting and completion dates for the various key phases of works. 

Any payment under the contract shall be made only after the contractor’s price break-up is 

approved by the Engineer. The aggregate sum of the contractor’s price break down shall be equal 

to the lump sum contract price. 

53.04 Application for Payments 

The Contractor shall submit application for the payments in the prescribed proforma of the 

purchaser. 

The foreign contractor shall submit to the Engineer separate applications for payment in different 

currencies whenever payment is to be made in more than one currency. 

Each such application shall state the amount claimed and shall set forth in details, in the order for 

the payment schedule particulars of the works including the works executed at site and of the 

equipment shipped/brought on to the site pursuant to the contract up to the date mentioned in the 

application and for the period covered since the last preceding certificate, if any. 

Every interim payment certificate shall certify the contract value of the works executed up to the 

date mentioned in the application of the payment certificate, provided that no sum shall be included 

in any interim payment certificate in respect of the works that, according to the decision of the 

Engineer, does not comply with the contract, or has been performed, at the date of certificate 

prematurely. 

53.05 Terms of Payment 

Subject to any deduction which the Purchaser may be authorized to make under the contract, the 

Contractor shall, on the certificate of the Engineer be entitled to payments generally as follows: 

A) Supply 

- 80% shall be paid for each consignment dispatched pro-rata against presentation 

of each invoices and evidence of shipment/dispatch. 

- 10% shall be paid after completion of erection. 

- 10% shall be paid after completion of satisfactory commissioning and performance 

guarantee tests. 


. 

B) Marine Freight and Insurance 

The ocean freight wherever payable shall be paid on production of invoices, evidence of 

shipment and other supporting documents for ocean freight and marine insurance 

components. In case of contracts inclusive of ocean freight and marine insurance total of 

the payments shall not exceed the total amount quoted by the Contractor in his bid. 

C) Inland Transportation and Inland Insurance 

Inland transportation (including port handling) shall be paid after the equipment has been 

received at site on production of invoices for such charges. Wherever this is included in the 

contract the aggregate of all such invoices shall not exceed the total amount indicated by 

the Contractor in his proposal. 

D) Erection Services 

54.00 MISCELLANEOUS 

54.01 Entire Agreement 

- 80% shall be paid for the progress made during the month on monthly progress 

bills against certification by the Engineer. 

- 10% shall be paid on completion of erection and Tests on Completion. 

- 10% shall be paid on completion of the successful commissioning and guarantee 

tests. 

These General Conditions together with the specification, tender drawing and guaranteed technical 

particulars, tender data with subsequent agreed modification thereof shall constitute the entire 

Agreement between the parties in respect of the subject matter hereof. No variation or modification 

of the contract or waiver of any of the terms and conditions thereof shall be deemed valid unless in 

writing and signed by the parties hereto. 

54.02 General Conditions of Contract, the tender specifications and other contract / tender documents 

are to be taken as mutually explanatory to one another. However, in case of conflict between these 

documents, the technical specification, special conditions of the contract and general conditions of 

the contract shall have precedence in that order. 

54.03 Endorsement of Terms 

The failure of either party to endorse at any time any of the provisions of the contract or any rights 

in respect thereto or to exercise an option herein provided shall in no way be construed to be a 


. 

waiver of such provisions, rights or option or in way to effect the validity of the Contractor. The 

exercise by either party of any of his rights here in shall not preclude or prejudice either party from 

exercising the same or any other right it may have hereunder. 

54.04 Contract Labor Regulation & Abolition 

The Contractor shall be responsible for all statutory obligations under Contract Labor (Regulation & 

Abolition) Act 1970. E.S.I. and Provident Fund Acts, as applicable, for their labor and staff engaged 

in executing this work. The Contractor will also keep the Purchaser indemnified against all claims 

and disputes arising out of death or injury to their workmen and staff. It will be necessary for the 

contractor to ensure that proper safety measures are followed by their workmen to avoid 

accident/damage/loss to life and property. Approved safety belts must be used by their workmen 

when working at any height. Charges for above are deemed included in the quoted rates and 

accepted amount. 

54.05 Recover of Damages 

Nothing contained in the conditions or in any other part of this Contract shall be construed as 

preventing the Purchaser from the Contractor any damages to which the purchaser may be entitled 

in law as a consequence of any breach by the Contractor of any of the terms of this Contract. 


Tender Notice No. - …………….............. 

1.0 SCOPE 

ADDENDUM TO TENDER DOCUMENT (COMMERCIAL) 

Page 1 of 11 

ANNEXURE - IV 

1.1 The subject enquiry is being issued on turnkey basis with entire responsibility of design, 

engineering up to Commissioning and handing over of plant / equipment / system to the Owner. 

Owner intends to enter into two separate contracts (if placed) as follows to rationalize tax liability as 

per legal provision of country and also for operational convenience. 

(a) Basic design, engineering, supply of equipments and materials including all necessary 

accessories, Spares at Site 

(b) Unloading, storage, handling of equipments at site, complete Construction, Erection, Testing and 

Commissioning services, Supervision and Training Services 

1.2 The Contract-cum-Performance Bank Guarantee for 10% of Total Order Value for both the 

contracts shall be furnished by the vendor to the Owner. 

2.0 PAYMENT TERMS 

2.1 Following Payment Terms will be applicable: 

(i) For Supply (including Design & Engineering): 

(i) 80% payment on prorate basis against presentation of dispatch documents. 

(ii) 10% payment shall be made after completion of erection. 

(iii) Balance 10% payment shall be made after final handing over of equipments to the Owner 

at site. 

(ii) Inland Transportation 

Charges for inland transportation shall be paid after the equipment is received at Site against 

invoices. 

(iii) Site Work 

(i) 90% against monthly progressive billing duly certified by Site In- charge. 

(ii) 10% within 30 days of final handing over of the equipment to Owner at site. 

2.2 Invoices should be submitted along with certificate stating “It is certified that Cenvatable/ VAT 

Invoices have been issued in the name of consignee, for full amount of Excise Duty/ Sales Tax/ 

Service Tax charged in the Invoice, as per rules in force. Vendor agrees to reimburse Excise Duty/

Tender Notice No. - ………….............. 

2.3 NOTE: 

Sales Tax/ Service Tax, if documents are not found to be in order for claiming Cenvat/ VAT 

benefits.” 

(i) Final Handing Over: 

Final Handing Over shall mean Commissioning including acceptance of PG Tests. However, in 

case PG Test could not be conducted within 6 months from commissioning, for reasons not 

attributable to vendor, last 10% payment will be released against a Bank Guarantee of equal 

amount valid for 12 months initially and extendable thereafter. 

(ii) Payment for indigenous supply shall be through Bank against dispatch documents. Payment 

through bank shall be as per normal banking procedure. 

Direct Payment can be made through e-payment mode through SBI as well as NEFT/RTGS mode 

through designated enabled branches. In case of Direct Payment, duly filled Bank Mandate form in 

duplicate should be furnished with due authentication from bidder’s Banker 

3.0 TAXES & DUTIES 

3.1 All taxes and duties including Excise Duty and concessional CST/ VAT but excluding Sales Tax on 

Works Contract will be paid against Documentary Evidence at actuals limited to amount quoted in 

price bids. However, statutory variations (on finished products) will be allowed against 

documentary evidence. Vendor shall provide break up along with billing schedule subject to ceiling 

limit quoted in price bid. 

3.2 Service Tax and E-cess applicable should be clearly indicated with ceiling limit to be paid against 

documentary evidence and invoice raised in line with Service Tax Rule to enable NALCO to avail 

Cenvat. 

3.3 Vendors are required to quote prices inclusive of Works Contract Tax and no variation is payable 

on this account. In case vendor insists on WCT variation, rate of WCT and amount should be 

mentioned in the bid, without which statutory variation will not be admissible. 

3.4 It is to be noted that the Contractor shall be required to submit the documentary evidence(s) for 

Excise Duty paid by them to concerned authorities for Owner to claim CENVAT benefit. 

3.5 Necessary Cenvatable documents such as Transporter’s copy of Challan / Bill of Entry Triplicate 

Copy for availing Cenvat benefit to be given in NALCO’s name indicating consignee as NALCO for 

availing Excise Duty, Copy of Registration with Central Excise Authority and any other document 

required by the Owner shall be furnished by Contractor to enable Owner to claim CENVAT. 

3.6 The classification of goods as per Central Excise Customs Tariffs should be correctly done to 

ensure that CENVAT benefits is not lost by the Owner on account of any error on the part of the 

Contractor. The Owner shall be at liberty to withhold the payment of cenvatable duties (viz. Central 

Page 2 of 11


Excise Duties, Countervailing Duties of Customs etc.) If the requirements as specified in the clause 

are not fulfilled by the Contractor. The price of materials shall stand reduced accordingly. 

3.7 The Contractor shall furnish the details of Excise Duty and CD/CVD component included his price 

for the purpose of cenvat benefit. 

The amount of ED and CVD indicated as part of Quoted Price is for information only. Contractor is 

required to pay all taxes & duties nevertheless and must furnish Cenvatable documents for the 

amount of ED and CVD paid by him, subject to minimum of the amount of ED and CVD indicated 

by him in his bid. 

3.8 Entry Tax shall be paid by NALCO for consignments coming from outside Orissa. For supplies to 

be made from Orissa, Entry Tax shall be paid by Seller and should be mentioned in the Invoices for 

reimbursement by NALCO. 

4.0 INSURANCE 

4.1 The Owner will arrange for insurance of equipment and material under the scope of the Contract as 

detailed in Tender Documents - Commercial. 

4.2 The Contractor shall deal directly with the Insurance Company. The Contractor will be required to 

lodge all the claims of his part of the contract directly and arrange settlement as expeditiously as 

possible by complying with the required formalities and proper follow ups. 

4.3 The contractor shall bear the entire cost of corresponding with the Insurer and arrange all 

documents/informations facilitating inspection/discussions by the officials/surveyors deputed by the 

Insurer. The Contractor shall make all efforts to get settlement of claim at the earliest and no time 

extension for completion of work will be given for delay on this account. 

4.4 In respect of equipment damaged in transit or during erection & commissioning, the contractor shall 

arrange for replacement/ repair expeditiously. The replacement cost payable by the owner shall be 

limited to the invoice cost of damaged equipment. The cost payable for repair shall be mutually 

settled. 

4.5 Contractor shall be liable solely to adhere to the requirements of the insurer for settlement of 

claims without prejudice to the rights of Contractor / NALCO / Insurer. Following steps are listed, 

however not exhaustively, for the information of contractor. 

(a) Timely information for conducting survey. 

(b) Protecting the rights of insurer while issuing acknowledgments. 

(c) Lodging of monitory claims in time and furnishing of requisite documents to surveyors / 

insurers. 

(d) Taking necessary precautions so that the loss/damage is not aggravated further. 

(e) Damaged goods to be protected fully. 

Page 3 of 11


4.6 Employees State Insurance Act 

(i) The Contractor agrees to and does hereby accept full and exclusive liability for the compliance with 

all obligations imposed by the Employee State Insurance Act 1948 and the Contractor further 

agrees to defend, indemnify and hold Owner harmless for any liability or penalty which may be 

imposed by the Central, State or Local authority by reasons of any asserted violation by Contractor 

or his Sub-contractor of the Employees’ State Insurance Act, 1948 and also from all claims, suits or 

proceeding that may be brought against the Owner arising under, growing out of or by reasons of 

the work provided for by this Contractor, whether brought by employees of the contractor, by third 

parties or by Central or State Government authority or any political sub-division thereof. 

(ii) The Contractor agrees to fill in with the Employee’s State Insurance Corporation, the Declaration 

forms, and all forms which may be required in respect of the Contractor’s or his Sub-contractor’s 

employees, who are employed in the WORK provided for or those covered by ESI from time to 

time under the Agreement. The Contractor shall deduct and secure the agreement of his subcontractor 

to deduct the employee’s contribution as per the first schedule of the Employee’s State 

Insurance Act from wages and affix the Employees Contribution Card at wages payment intervals. 

The contractor shall remit and secure the agreement of his sub-contractor to remit the State Bank 

of India, Employee’s State Insurance Corporation account the Employees contribution as required 

by the Act. The Contractor agrees to maintain all Cards and Records as required under the Act in 

respect of employees and payments and the contractor shall secure the agreement of his subcontractor 

to maintain such records. Any expenses incurred for the contributions; making 

contributions or maintaining records shall be to the Contractor’s or his Sub-contractor’s account. 

(iii) Owner shall retain such sum as may be necessary from the total value of contract until the 

Contractor shall furnish satisfactory proof that all contributions as required by the Employees State 

Insurance Act, 1948 have been paid. This will be pending on the Contractor when the ESI Act is 

extended to the place of work. 

4.7 Workmen’s Compensation & Employer’s Liability Insurance 

Insurance shall be effected by Contractor for all their employees engaged in the performance of 

this Contract. If any of the work is sublet, the Contractor shall require his sub-contractor to provide 

workman’s Compensation and employer’s liability insurance for the later’s employees if such 

employees are not covered under the Contractor’s insurance. 

4.8 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 Owner’s men and damage to the 

property of others arising from the use of motor vehicles, during on or off the Site Operations, 

irrespective of the ownership of such vehicles. 

4.9 Comprehensive General Liability Insurance 

This insurance shall protect the Contractor against all claims arising from inuries, disabilities, 

disease or death of members of public or damage to property of others, due to any act or omission 

Page 4 of 11


on the part of the Contractor, his agents, his employees, his representative and Sub-Contractors or 

from riots, strikes and civil commotion. This insurance shall cover all the liabilities of the contractor 

arising out of the relevant clauses of enquiry documents. 

The hazards to be covered will pertain to all the works which and areas where, the Contrctor, his 

Sub-Contractors, his agents and his employees have to perform work pursuant to the contract. 

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. 

4.10 Any other Insurance required under Law or Regulations or by Owner 

Contractor shall also carry and maintain any and all other Insurance(s) which he may be required 

under any law or regulation from time to time without any extra cost to Owner. He shall also carry 

and maintain any other insurance which may be required by the Owner. 

4.11 Accident or Injury to Workmen 

Owner shall not be liable for or in respect of any damages or compensation payable at law in 

respect or in consequence of any accident or injury to any workman or other person in the 

employment of the Contractor or his Sub-Contractor and the Contractor shall indemnify and keep 

indemnified the Owner against all such damages and compensation and against all claims, 

demands, proceedings, costs, charges and expenses, whatsoever in respect or in relation thereto. 

5.0 CONSTRUCTION, ERECTION OF PLANT AND MATERIAL 

5.1 Contractor’s Material brought on the Site 

The Contractor shall bring to Site all equipments, components, parts, materials, including 

construction equipment, tools and tackles for the purpose of the Works under intimation to the 

Owner. All such goods shall, from the time of their being brought vest in the Owner, 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 Owner. The Contractor shall nevertheless be 

solely liable and responsible for any loss or destruction thereof and damage thereto. 

5.2 Work & Services to be provided by the Owner 

Works and services which shall be provided by the Owner for carrying out complete work at Site 

shall be as defined in the technical part of the Enquiry Documents and its clarification up to award 

of Contract. 

(a) Water supply for construction purpose may be provided by the Owner at one mutually 

agreed point at Site. Drinking water will also be made available at one central point at 

Site. The Contractor shall make his own arrangement for any further distribution. Such 

distribution pipe network shall have the prior approval of the Engineer at Site so as not to 

Page 5 of 11


interfere with the layout and progress of other construction works. Supply of water shall be 

charged from Contractor at the rates prevailing at Site. 

Contractor shall ensure that there is no wastage of water. On completion of the work, the 

Contractor shall remove all such work and shall reinstate and make good any work 

disturbed to the satisfaction of the Engineer. 

(b) Cranes, if available, will be provided by Owner on payment of rent to the Owner. 

5.3 Work and Services to be provided by the Contractor 

The following work and services shall also be provided under the contract : 

(i) Material transportation to erection site at Contractor’s risk and cost. 

(ii) All construction activities to complete the plant as per the specifications agreed by the 

Owner. The activities shall be included but not limited to building structures, rooms, 

foundations for equipments and accessories and stack etc. 

(iii) Labor license for contractor and sub-contractor’s labor if required / applicable as per State 

Govt. 

5.4 Owner’s Lien on Equipments 

The Owner shall have lien on all equipments including those of the Contractor brought to the Site 

for the purpose of construction, erection, testing and commissioning of the plant. The Owner shall 

continue to hold the lien on all such equipments throughout the period of Contract. 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 Owner. 

5.5 Protection of Work 

The contractor shall have total responsibility for protecting his Works till it is finally taken over by 

the Owner. No claim will be entertained by the Owner or the Consultant for any damage or loss to 

the Contractor’s Works and the Contractor shall be responsible for the complete restoration of the 

damaged works to its original condition to comply with the specifications and drawings. Should any 

such damage to the Contractor’s Works occur because of other party not 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 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 clause 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 dispute. 

Page 6 of 11


5.6 Security 

The Contractor shall have total responsibility for all equipments and materials in his custody stored, 

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 Project Site only with the written permission of the Owner 

in the prescribed manner. 

Contractor’s employees shall wear identification badges while on the work at Site. 

5.7 Contractor’s Area Limits 

The Owner will mark-out the boundary limits of access road, 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 operation. In case of such a need for the Contractor’s 

personnel to work, out of the areas marked out for him, the same shall be done only with the 

written permission of the Owner. 

5.8 Contractor’s Co-operation with the Owner 

In cases where the performance of the Site Work by the Contractor affects the operation of the 

system facilities of the Owner such Site Work of the Contractor shall be scheduled to be performed 

only in the manner stipulated by the Owner and the same shall be acceptable at all times to the 

Contractor. The Owner may impose such restriction on the facilities provided to the Contractor 

such as electricity, water, etc. as he may think fit in the interest of the Owner and the Contractor 

shall strictly adhere to such restrictions and co-operate with the Owner. It will be 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 supplied and erected by him, so as to make such equipments ready for 

operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants 

unless otherwise specified elsewhere in these documents and specifications. 

5.9 Protection of Property and Contractor’s Liability 

5.9.1 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 Owner 

and the employees of other Contractors and Sub-Contractors and all public and private property 

including structurs, building, other plants and equipments and utilities either above or below the 

ground. 

5.9.2 The Contractor will ensure provisions of necessary safety equipment such as barriers, sign-boards, 

warning lights and lamps, etc. to provide adequate protection to persons and property. The 

Contractor shall be responsible to give reasonable notice to the Owner and the Owner of public or 

private property and utilities when such property and utilities are likely to get damaged or injured 

Page 7 of 11


during the performance of his works and shall make all necessary arrangements with Owners, 

related to removal and/or replacement of such property and utilities. 

5.10 Painting 

All exposed metal parts of the equipment including piping, structures railing, etc. wherever 

applicable, after installation unless otherwise surface protected, shall be first painted with at least 

one coat of suitable primer which matches the shop primer paint used, after thoroughly cleaning all 

such parts of all dirt, rust, scales, greases, oil and other foreign materials by wire brushing, 

scraping or sand blasting, and the same being inspected and approved by the Engineer for 

painting. Afterwards, the above parts shall be finished with two coats of a alloyed resin machinery 

enamel paints. The quality of the finish paint shall be as per the standards of ISI or equivalent and 

to be of the colour as approved by the Owner. 

5.11 Unfavorable 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 Consultant/Owner. Such unfavorable construction conditions will in no way relieve the 

contractor of his responsibility to perform the works as per the schedule. 

5.12 Protection of monuments and reference points 

The Contractor shall ensure that any finds such as relic, antiquity, coins, fossile, etc. which he may 

come across during the course of performance of his works either during excavation of elsewhere, 

are properly protected and handed over to the Owner. Similarly, the Contractor shall ensure that 

the bench marks, reference points, etc. which are marked out either with the help of Owner or by 

the Owner shall not be disturbed in any way during the performance of his works. If any work is to 

be performed which may disturb such reference, the same shall be done only after these are 

transferred to other suitable locations under the direction of the Owner. 

6.0 CONSTRUCTION 

6.1 Rules and Regulations 

6.2 Safety 

Contractor shall observe all national and local laws, ordinaces, rules and regulations pertaining to 

the work, and shall be responsible for extra costs arising from violations of same. 

Contractor shall take all necessary measures to protect the work and workmen against accidents 

and occupational disease. They shall observe and comply with all Government safety regulations 

as specified by the Owner. 

Page 8 of 11


The Contractor shall be responsible for following the proper procedures in reporting accidents or 

incident. 

The Owner’s Safety Engineer located in Site will be immediately notified by faster means possible 

of any accident which involves the following: 

(a) Death from any cause whatsoever. 

(b) A fractured skull, arm, thigh or spine, fore-arm or leg. 

(c) A dislocated shoulder. 

(d) The amputation of arm or hand, or of one or more fingers on the same hand, or of a leg or 

a foot. 

(e) The loss of sight of an eye. 

(f) Any other serious bodily injury, including internal bleeding or burns or asphyxia where such 

injury is likely to endanger life, cause permanent incapacity or temporary incapacity of 5 

days or more. 

6.3 In case of death, the Contractor shall be responsible for immediately notifying the nearest Indian 

Police so that they can make the proper investigation in accordance with the law. 

7.0 FOREIGN LIABILITY CLAUSE 

It is expressly understood and agreed by and between (the Corporation0 and M/s National 

Aluminium Company Limited (The Indian PSU) that M/s National Aluminium Co. Ltd. (the Indian 

PSU) is entering into this agreement solely on its own behalf and not on behalf of any other person 

or entity. In particular, it is expressly understood and agreed that the Government of India is not a 

party to this agreement and has no liabilities, obligations or rights hereunder. It is expressly 

understood and agreed that M/s National Aluminium Co. Ltd. (the Indian PSU) is an independent 

legal entity with power and authority to enter into contracts solely in its own behalf under the 

applicable Law of Indian and General Principles of Contract Law. The (Company) expressly 

agrees, acknowledges and understands that M/s National Aluminium Co. Ltd. (the Indian PSU) is 

not an agent, representative or delegate of the Government of India. It is further understood and 

agreed that the Government of India is not and shall not be liable for any acts, omissions, 

commissions, breaches or other wrongs arising out of the Contract. Accordingly (corporation) 

hereby expressly waives, releases and foregoes any and all actions or claims including cross 

claims, impleader claims or counter claims against the Government of India arising out of this 

contract and covenents not to sue the Government of India as to any manner, claim, cause of 

action or thing whatsoever arising of or under this agreement. 

8.0 CLAUSE 44.02: REGULATION OF LOCAL AUTHORITIES & STATUES (TENDER DOCUMENT 

COMMERCIAL - INDIGENOUS) 

8.1 The following is to be read along with Clause 44.02:- 

(a) The payment of minimum wages to Contract Labour shall be as per the rates notified by the 

central Government as per Minimum Wages Act,1948 and as adopted by the NALCO 

Management from time to time plus any additional element and statutory dues thereon. 

Page 9 of 11


(b) The Minimum wage as notified by the Chief Labour Commissioner (central) has a variable 

component as Special allowance which is linked to average AICPI for Industrial Workers, 

which keeps on changing every six months. The Contractor has to absorb all such variations 

due to increase in Minimum wage in their quoted price and no claim whatsoever on this 

account shall be entertained. 

(c) Where the Minimum wages notified by the concerned State Government are higher than the 

rates notified by the Central Government, the States Government rates should apply in 

concerned scheduled employment as long as the same remains higher than the Central 

Government rates. 

(d) The classification on workers in different categories will be as per the notification issued by the 

Central Government fixing the minimum wages for the above scheduled appointment. 

8.2 The classification of workers in different categories will be as per the notification issued by the 

Central government fixing the minimum wages for the above scheduled appointment. Where the 

minimum wages notified by the concerned State Government are higher than the rates notified by 

Central Government, the State Government rates should apply in concerned scheduled 

employments. 

9.0 GUARANTEE PERIOD 

Guarantee Period shall be 12 months from commissioning (including acceptance of 

Performance Guarantee Tests) or 24 months from completion of erection, whichever is earlier. 

All other provisions of the clause remain unaltered. 

10.0 CONTRACT PERFORMANCE GUARANTEE 

Supplier will be required to submit Contract - cum - Performance Bank Guarantee (CPBG) for 10% 

of Total Order Value (Supply + Transportation + Supervision + Site Work) for the complete 

package within 30 days of placement of order with validity up to 3 months beyond Guarantee 

Period. All payments shall be released after receipt of CPBG. 

11.0 CONSTRUCTION POWER 

Construction power rate indicated in Tender Documents Commercial is modified as “As applicable 

at Site” in place of Rs. 1/- per KWH. 

12.0 PRICE REDUCTION SCHEDULE 

(i) Liquidated Damages (LD) wherever mentioned in NIT documents, is to be read as Price Reduction 

Schedule (PRS). 

(ii) The Contractor’s liability for delay shall not in any case exceed five percent of the total contract 

price. 

All other provisions of these clauses remain unaltered. 

Page 10 of 11


13.0 POWER TO VARY OR OMIT WORK 

13.1 In partial modification to clause No. - 29 of GCC - Indigenous the last sentence of this clause is 

amended as follows: 

“In the absence of any such modification, the contractor shall bind to carry out the suggested 

variations. Any addition or deletion to price will be discussed between purchaser and contractor 

and settled.” 

13.2 All other provisions of this clause remain unaltered. 

Note: The terms and conditions mentioned herein will prevail over the terms mentioned in tender 

document commercial (indigenous). 

Page 11 of 11

IMPORTANT 

AGREED TERMS & CONDITIONS (INDIGENOUS) 

NALCO, SMELTER PLANT 

(FOR INDIGENOUS BIDDERS) 

Page 1 of 7 

ANNEXURE - V 

1. This questionnaire must be filled in against all Serial nos. & enclosed with the Un-priced offer. 

Non submission or submission of incomplete questionnaire may lead to rejection of the offer. 

2. All commercial terms except the deviations to Tender Documents - Commercial (Indigenous), 

Addendum to Tender Documents and other attachments of NIT must be given in this 

questionnaire itself and not elsewhere in the quotation. In case of contradiction, the terms 

given below shall prevail. The deviations to Tender Documents - Commercial (Indigenous), 

Addendum to Tender Documents and other attachments of NIT, if any must be listed in a 

separate Annexure. 

Sl. Descriptions Vendor’s confirmation 

No. with details 

(A) TECHNICAL: 

1. (i) Acceptance of Technical specifications and scope 

of supply as per attached Annexure - I - 

Technical Specification. 

(ii) In case of deviations, confirm that the same has 

been highlighted separately. 

2. Confirm that data sheets/ technical questionnaire 

duly filled in are attached, wherever required. 

3. Confirm Spare parts list, wherever required with 

item wise prices have been submitted for 

following categories of Spares. 

(a) Mandatory Spares 

(b) Commissioning Spares 

(c) Recommended Spares for One Year 

normal operation and maintenance 

(d) Special Tools & Tackles 

4. It is noted that deviations to terms & conditions 

shall lead to loading of prices or rejection of offer.



5. Confirm that the quoted prices are based on FOR/ 

FOT Despatch point including packing & 

forwarding. 

(i) If quoted on Ex- works basis, indicate P&F 

charges in terms of percentage. 

(ii) Indicate despatching station. 

6. Confirm you have quoted prices strictly in the 

price schedule format enclosed with NIT 

documents. 

7. Please confirm that firm freight charges inclusive 

of applicable Service Tax and E-cess up to Site is 

quoted in price bid. 

(a) In case you have not quoted the freight charges 

separately in the Price Schedule, please quote 

the same in terms of % of the quoted price. 

(b) Confirm that freight charges for Recommended 

Spares for One Year normal O&M have been 

quoted separately and the freight for all other 

supplies are included in freight of Main 

Equipment. 

8. Confirm Transit insurance is excluded from the 

quoted prices. If inclusive, indicate rebate for 

excluding the same. 

9. Indicate rate of Central Sales Tax/Orissa VAT 

payable extra. 

(i) CST without concessional Form. 

(ii) CST with concessional Form. 

(iii) Orissa VAT 

Page 2 of 7



10(a) Statutory increase in Excise Duty & Education 

cess beyond contractual delivery date shall be to 

vendor’s account but any reduction up to actual 

date of despatch shall be to owner’s account. 

(b) Indicate present rate of Excise Duty & Education 

Cess applicable on the supplies (including 

Spares) and whether the same is included/ 

excluded from quoted prices. 

(c) If there is any increase in ED & E-cess at the time 

of supplies for any reasons, other than statutory, 

including turnover, confirm the same will be borne 

by the vendor. 

(d) If ED & E-ces is presently not applicable, confirm 

whether the same will be borne by the vendor in 

case it becomes leviable later. 

(e) In case (c) or (d) is not acceptable, advise 

maximum rate of ED & E-cess chargeable. 

11. Entry Tax on supplied items shall be paid by 

Nalco directly to Tax Authorities. However, any 

Entry Tax applicable for items and consumables 

etc used for Erection/ Commissioning shall be to 

Seller’s account. 

12. Confirm submission of following documents with offer: 

1) Valid Excise Regn. Certificate. 

2) Valid Sales Tax Regn. Certificate. 

3) Valid Service Tax Regn. Certificate. 

4) TIN (Tax Identification No.) 

13. Confirm in case of delay on a/c of vendor, any 

new or additional taxes and duties imposed after 

contractual delivery shall be to vendor’s account. 

Page 3 of 7



14. Confirm acceptance to delivery/ Completion 

period as mentioned in NIT documents. 

15. Confirm acceptance to Price Reduction Schedule 

clause specified in Tender Documents. 

16. Confirm acceptance of relevant terms of payment 

as per the NIT documents attached. 

17. Confirm that the quoted prices are firm and fixed 

till complete execution. 

18. Confirm that Contract cum Performance/ 

Performance Bank Guarantee wherever required 

will be furnished for value and terms & conditions 

as per document attached with NIT. 

19. Confirm that Bank Guarantee for equivalent 

amount of Free Issue Materials, wherever 

applicable, shall be furnished. 

20. Confirm acceptance of Guarantee/ Warranty as 

per documents attached with NIT. 

21. Confirm that quoted prices are inclusive of all 

Testing charges as required in the NIT. 

22(i) All other Commercial terms & conditions shall be 

as per Tender Documents - Commercial 

(Indigenous), Addendum to Tender Documents - 

Commercial and other documents attached with 

the NIT. Confirm. 

(ii) In case of deviations, confirm clause wise 

comments have been specified in a separate 

Annexure. 

(iii) All the terms & conditions have been indicated in 

this format including Annexure and have not been 

repeated elsewhere. It is noted that terms & 

conditions indicated elsewhere shall be ignored. 

Page 4 of 7



23. Confirm that all taxes, duties and levies of any 

kind payable by Seller up to the stage of handing 

over of the system to Owner shall be borne by 

you. 

25. Import permit/ Licence, if required shall be the 

responsibility of the Seller and any expenditure 

towards the same shall be borne by you. Please 

confirm. 

26. In case of any Imported supply to be quoted in 

INR by Indian Associate, confirm that all 

variations in Customs Duty and Foreign 

Exchange till complete execution of the contract 

shall be to Seller’s account. 

27. The vendor is required to state whether any of the 

Directors of vendor is a relative of any of the 

Directors of Owner or the vendor is a firm in which 

any Director of Owner or his relative is a partner 

or the vendor is a Private Company in which any 

of the Directors of Owner is a member or Director. 

28. Confirm that the offer shall be valid up to 4 

months from the bid due date/ extended bid due 

date. 

29. Please furnish Annual Report containing Balance 

Sheet and Profit and Loss Account for the last 

three years. 

30. Confirm that net worth of your company during 

the last financial year is positive. 

31. As soon as shipment/ dispatch is made, the Seller 

shall intimate NALCO’s Underwriters the dispatch 

details t the address which shall be furnished 

later. 

32. The Vendor is required to state whether M/s AP/ 

ALCAN has any shareholding/ management 

control in your Company. 

Page 5 of 7



33. Please note that you have not been banned or 

de-listed by any Government or Quasi 

Government agencies or PSU. 

34. Confirm that in case of conflicting version of 

various terms & conditions at different places, 

Owner can choose any version. 

35. Please furnish name and address of the official to 

whom correspondence should be sent including 

telephone number/ fax number and e-mail id. If email 

id is not available, an undertaking is to be 

given that e-mail id is to be registered within 2 

weeks of bid submission 

Place: Signature: 

Date: Name : 

Page 6 of 7 

Designation : 

Seal :

SL. 

NO. 

REFERENCE OF NIT DOCUMENT 

DOCUMENT CLAUSE NO. 

DEVIATIONS TO NIT DOCUMENTS 

SUBJECT DEVIATIONS 

NOTE: This shall be submitted along with the Un - priced Offer. Deviation mentioned anywhere else in the 

offer shall not be considered. 

Page 7 of 7 

Signature: 

Date: Name : 

Designation : 

Seal :

Tender Notice No. - …………………............... 

ITEM: WAGON TIPPLER AND CONVEYOR SYSTEM 

IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT 

1.0 SUPPLY OF MAIN EQUIPMENT 

1.1 Design, Engineering, Manufacturing, Procurement, 

Inspection, Assembly, Painting, Testing at Supplier’s 

works, Packing & Forwarding and Supply of Wagon 

Tippler & Accessories including Commissioning & Start-up 

Spares, Tools & Tackles , first fill of oil & lubricants/ oil and 

consumables as per Annexure - I - Technical Specification 

of NIT on FOT Dispatch point basis including packing & 

forwarding (break - up of prices to be submitted as per 

Annexure - A attached herewith) 

1.2 Supply of Mandatory Spares, as per NIT (itemized prices to 

be furnished along with the price bid) on FOT dispatch 

point basis including packing & forwarding 

1.3 Others if any to complete the Scope (Pl specify) 

SUB TOTAL (1.0) 

2.0 FREIGHT, INSURANCE, TAXES & DUTIES ON ITEMS 

UNDER SUB HEADING 1.0 

2.1 Total & maximum Excise Duty & E-cess on ED (Amount 

payable against Cenvatable Invoices ) 

2.2 Total & maximum Central Sales Tax (Considering CST 

Declaration form to be furnished by NALCO, wherever 

applicable/ admissible) 

2.3 Total & Maximum Orissa VAT applicable for items to be 

supplied from within the state of Odisha 

PRICE SCHEDULE FORMAT 

INDIGENOUS SUPPLY (IN INDIAN 

Rs.) 

(M/s …………..) 

Page 1 of 7 

Annexure - VI 

ERECTION/ TESTING/ 

COMMISSIONING SERVICES AT 

SITE , SUPERVISION & TRAINING 

SERVICES (IN INDIAN Rs.) 

(M/s ……………….)



2.4 All other taxes & duties currently applicable (Please specify 

the nature of Tax/ Duty & its rate) 

2.5 Inland freight charges up to Site including Service Tax & Ecess 

on same 

2.6 Transit Insurance up to Site (Optional) inclusive of all 

taxes 


3.0 SUPPLY OF ONE YEARS O&M SPARES FOR 

3.1 

TROUBLE FREE OPERATION - OPTIONAL 

Supply of vendor recommended Spares for One year O&M 

on FOT dispatch point basis (itemized prices to be 

furnished along with the price bid, list of spares to be 

furnished along with un - priced bid) 

3.2 Total & maximum Excise Duty & E-cess on ED (Amount 

payable against Cenvatable Invoices ) 

3.3 Total & maximum Central Sales Tax (Considering CST 

Declaration form to be furnished by NALCO, wherever 

applicable/ admissible) 

3.4 Total & Maximum Orissa VAT applicable for items to be 

supplied from within Orissa 

3.5 All other taxes & duties currently applicable (Please specify 

the nature of Tax/ Duty & its rate) 

3.6 

Inland freight charges up to Site including applicable 

3.7 

Service Tax & E-cess 

Transit Insurance up to Site (Optional) inclusive of all 

taxes 

SUB TOTAL (3.0 ) 


Rs.) 

(M/s …………..) 

Page 2 of 7 





(M/s ……………….)



4.0 UNLOADING, STORAGE, HANDLING & 

TRANSPORTATION OF EQUIPMENT/ MATERIALS AT 

SITE 

4.1 For Main Equipment under Sl. No. - 1.0 above 

4.2 For One Year O&M Spares under Sl. No. - 3.0 above 

4.3 Total & Maximum Service Tax for 4.1 

4.4 Total & Maximum E-cess for 4.1 

4.5 Total & Maximum Service Tax for 4.2 

4.6 Total & Maximum E-cess for 4.2 


5.0 CONSTRUCTION, ERECTION, TESTING, 

COMMISSIONING AND PERFORMANCE GUARANTEE 

TESTS 

5.1 Civil & Structural Work as per NIT 

5.2 Erection - Mechanical 

5.3 Electrical and Instrumentation works 

5.4 Testing, Commissioning and Performance Guarantee 

Tests. 

5.5 All statutory/contingency insurance coverage e.g. third 

party liability, ESI, workmen compensation etc. 

5.6 Total for Construction, Erection, Testing, 

Commissioning and Performance Guarantee Tests 

5.7 Insurance coverage for storage erection & commissioning 

etc. (Optional) 

5.8 Orissa VAT on Works Contract (Works Contract Tax) as 

currently applicable 


Rs.) 

(M/s …………..) 

Page 3 of 7 





(M/s ……………….)



5.9 Any other Indian taxes/ duties currently applicable 

5.10 Total & maximum Service Tax. 

5.11 Total & maximum E- cess on Service Tax. 

5.12 Others, if any. 

NOTES: 


GRAND TOTAL ( SUM OF 1.0 T0 5.0 ) 


Rs.) 

(M/s …………..) 

Page 4 of 7 





(M/s ……………….) 

1. The Price Schedule shall be made available in Un-priced offer also with prices blanked out and written “Quoted/ Not Quoted/ Not Applicable”, as 

the case may be. 

2. In the Price Schedule no column should be left blank. 

3. The quoted prices shall include charges towards testing & all documentation required as per NIT. 

4. Any correction in the quotation shall be initialed by the bidder, otherwise the offer shall be rejected. 

5. Bidders are required to quote prices inclusive of Works Contract Tax or Orissa VAT on Works Contract and any variation is not payable on this 

account. Liability of Works Contract Tax on Erection/ Testing/ Commissioning for Service Contract i.e. Contract C shall be solely of Contractor. 

NALCO would deduct WCT in line with NIT provisions while releasing payment to Contractor and deposit the same with Sales Tax Authority and 

issue TDS to Contractor from time to time. Contractor will settle WCT directly with the Sales Tax Authority without any liability on the part of 

NALCO. Bidders are required to include the WCT into their price, as applicable, and it would be deemed that the same has been taken into 

consideration by them, irrespective of whether such WCT amount has been indicated separately or not. Accordingly, there would be no loading (i.e. 

there will be no like to like comparison) even if any agency does not indicate such amount or such percentage in their price bid. However, WCT 

mentioned in the price schedule by a bidder shall be considered for evaluation of his price. 

6. Applicable Service Tax & E-cess on Service Tax will be paid at actuals subject to documentary evidence limited to the maximum amount quoted.


7. Entry Tax on supplies against supply of items shall be paid by NALCO directly to Tax authorities. 

8. The sum of quoted prices for relevant divisible package (s) shall be treated as the Contract price(s) for concerned package(s) on lump sum basis. 

The contract vis-à- vis payment operations shall be done, however, as per approved Billing schedules only. 

9. The Contract (s) prices, will remain firm & unchanged until complete execution excepting for statutory variations, if any on the rates of taxes & 

duties included in the Contract price ( as per break ups specified in the Billing schedule) and also excepting for imposition of any fresh statutory 

levy/ tax. 

10. In case of award of work, the Contractor has to submit a Billing Schedule for approval of NALCO/RITES. The payment of bills involving Excise duty 

shall be made at actuals against submission of Cenvatable ED invoices but limited to the quoted ED & E-cess on ED. 

11. Optional prices shall not be considered for evaluation. However, the optional prices shall be valid during execution of Contract and could be 

exercised by NALCO, in case NALCO decides the same. 

12. Supply of spares parts for One Year normal operation and maintenance as per Sl. No. - 3.0 of Price Schedule shall not be considered for 

evaluation. However, the prices shall be valid and separate order shall be placed for such spares which are decided by NALCO. Sl. No. - 4.2, 4.5 & 

4.6 shall not be considered for evaluation. 

13. Bidder shall submit Price break - up along with quantity and unit price for the Spares for 1 year normal operation and maintenance in priced and un 

- priced format. 

14. Bidder shall submit Price break - up along with quantity and unit price for the following in Priced & Un-priced format: 

(a) Mandatory Spares 

(b) Commissioning & Start-up Spares 

(c) Tools & Tackles 

(d) Spares for One Year O&M 

Page 5 of 7 

Bidder’s Signature: 

Bidder’s Stamp: 

Date:


Description of Item 

ANNEXURE-A TO PRICE SCHEDULE FORMAT 

01. Design, Manufacture and Supply of Wagon Tippler System 25 tips / hour design 

capacity (20 tips per hour guaranteed output) complete with tippler platform with rails, 

cradle, top & side clamps, etc. including all electricals and instrumentation and required 

other connected accessories. 

02. Design, Manufacture and Supply of Side Arm charger (25 wagons per hour) 20 wagons 

per hour guaranteed capacity complete with all rails and travel mechanism. 

03. Design, Manufacture and Supply of Apron feeder (1200 TPH) complete with dribble 

conveyor, feeder pans, suitable for underground hopper of tippler complete with drives, 

base plates and accessories required for fixing in foundation and other connected 

accessories complete. 

04. Design, Manufacture and Supply of Receiving belt conveyor system 1200 TPH 

guaranteed capacity, 1200 mm belt width suitable for transport of coal received from 

apron feeder to existing conveyors BC-103 & BC-115 in plant including pent house, 

junction tower complete with stringers, supports, Idlers, Belt, Pulleys, chutes and safety 

devices, foundations, supports overhead gallery and trestle etc. with all electricals and 

plc control accessories. 

05. Design, Manufacture and Supply of Dust control system at Wagon Tippler House, 

transfer points of conveyor complete with all civil, mechanical and electricals works. 

06. Design, Manufacture and Supply of E.O.T. 

Crane 25T / 5T capacity suitable to handle the erection and Maintenance requirements 

of wagon tippler, apron feeder, etc. 

07. Design and supply of Mono rail hoists of appropriate capacity for equipments, drivers, 

pulley and Gear reducers, apron feeder at various location within the terminal points 

complete with all accessories. 

08. Design and supply of Fire hydrant system covering Wagon Tippler House, Conveyor 

Galleries, Transfer House etc. extending from existing fire water grid in the vicinity 

within Plant area with all necessary accessories complete. 

Page 6 of 7 

Unit of 

measurement 

Lump sum 1 

Lump sum 1 

Lump sum 1 

Lump sum 1 

Lump sum 1 

Lump sum 1 

Lump sum 1 

Lump sum 1 

Quantity Unit Price


Description of Item 

09. Design and supply of Service water connections at Transfer Towers, tippler house, at 

each floor level complete system extending from the existing header near the new track 

hopper with all accessories for complete system. 

10. Design and supply of Illumination and lighting system for Wagon Tippler House, 

Transfer Towers, Conveyor Galleries and control rooms etc. with all accessories. 

11. Design and supply of ACSR cables, rail poles, insulators, hardware fittings, 33KV/6.6KV 

transformer complete, breakers, isolators, CT, PT, LA, switch gear, etc. for HT system 

as per scope of work. 

12. Design and supply of cables, 6.6KV/415V transformer complete, switch gear, panels, 

etc. LT system as per scope of work. 

Page 7 of 7 

Unit of 

measurement 

Lump sum 1 

Lump sum 1 

Lump sum 1 

Lump sum 1 

13. Supply of all control cables, Panels, PLCs etc. complete for the system. Lump sum 1 

LUMP SUM PRICE TOTAL 

Quantity Unit Price

Page 1 of 2 

ANNEXURE - VII 

PROFORMA OF CONTRACT CUM PERFORMANCE GUARANTEE BY SELLER/CONTRACTOR 

(To be executed on non-Judicial stamped paper of appropriate value) 

B.G. No. - ……………… Date: ………………… 

WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its Office at 

Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter called "the Company/Owner") 

which expression shall unless repugnant to the subject or context includes its legal representatives, 

successors and assigns), has entered into a contract with M/s. ………………../ has placed a purchase 

order on M/s. ………………… (hereinafter referred to as “Contractor(s)/Seller(s)”) which expression shall 

unless repugnant to the subject or context includes their legal representatives, successors and assigns) for 

.............................. on the terms and conditions as set out inter alia, in the company Contract No/P.O. 

No.............................. dt............. and various documents forming part thereof herein after referred to as the 

“said contract” which expression include all amendments, modification and/or variation thereto and where 

as the Contractor/Seller has agreed for due execution of the entire contract and guarantees its performance 

including any parts executed through any others agencies/sub-contractors. 

AND WHEREAS one of the conditions of the “said contract” is that “contractor/seller shall furnish to the 

owner a Bank Guarantee from a bank for ......% (............. percent) of the total value of the “said contract” 

against due and faithful performance of the “said contract” including defects liability obligations and the 

performance guarantee obligations of the contractor/seller for execution/supplies made under the “said 

contract”. 

2. We ……………………….. Bank having its branch office at …………………. do hereby agree and undertake 

to pay the amount due and payable under this guarantee without any demur merely on a demand from the 

Company stating that in the opinion of the company which is final & binding, the amount claimed is due by 

reason of default made by the Contractor(s)/ Seller(s) in performing any of the terms and conditions of the 

said Contract including defects liability obligations, in fulfilling the performance Guarantee obligation or loss 

or damage caused to or would be caused to or suffered by the Company by reason of any breach by the 

said Contractor(s)/Seller(s) of any of the terms and conditions of the contract. Any such demand made on 

the Bank by the owner shall be conclusive as regards the amount due and payable by the Bank under this 

guarantee. However our liability under this guarantee shall be restricted to Rs.................. 

(Rupees........................... only) 

3. We undertake to pay to the Company any money so demanded not withstanding any dispute or disputes 

raised by the Contractor(s)/Supplier(s) in any suit or proceeding pending before any office, court or Tribunal 

relating thereto, our liability under this present being absolute and unequivocal. The payment so made by 

us under this bond shall be a valid discharge of our liability for payment there under. Our liability to pay is 

not dependent or conditional on the owner proceeding against the contractor(s)/seller(s). 

4. The guarantee herein contained shall not be determined or affected or suspended by the liquidation or 

winding up, dissolution or change of constitution or insolvency of the said Contractor(s)/ Seller(s) but shall 

in all respects and for all purposes be binding and operative until payment of all money due or liabilities 

under the said Contract(s)/Order(s) are fulfilled.

5. We ……………………… Bank further agree that the guarantee herein contained shall remain in full force 

and effect during the period that would be taken for the performance of the said Contract(s)/Order(s) and 

that it shall continue to be enforceable till all the dues of the Company under or by virtue of the said 

Contract(s)/Order(s) have been fully paid and its claims satisfied or discharged or till a duly authorised 

officer of the Company certifies that the terms and conditions of the said Contract(s)/Order(s) have been 

fully and properly carried out by the said Contractor(s) and accordingly discharge this guarantee. 

6. We ................................. Bank further agree with the Company that the Company shall have the fullest 

liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the 

terms and conditions of the said Contractor(s)/ Order(s) or to extend time of performance by the said 

Contractor(s)/Seller(s) from time to time or to postpone for any time or from time to time any of the powers 

exercisable by the Company against the said Contractor(s)/Seller(s) and to forbear or enforce any of the 

terms and conditions relating to the said Contractor(s)/Seller(s) and we shall not be relieved from our 

liability by reason of any such variation or extension being granted to the said Contractor(s)/Seller(s) or for 

any forbearance, act or omission on the part of the Company or any indulgence by the Company to the said 

Contractor(s)/Seller(s) or by any such matter or thing whatsoever which under the law relating to sureties 

would but for this provision have effect of so relieving us. 

7. Notwithstanding anything contained herein before, our liability shall not exceed Rs………………….. 

(Rupees ………………….. only) and shall remain in force till …………….. unless a demand or claim under 

this guarantee is made on us within three months from the date of expiry we shall be discharged from all 

the liabilities under this guarantee. 

8. We ………………… Bank, lastly undertake not to revoke this guarantee during its currency except with the 

previous consent of the Company in writing. We further undertake to keep this Guarantee renewed from 

time to time at the request of Contractor(s)/Seller(s). 

Date: ......................Bank 

Corporate Seal of the Bank By its constitutional Attorney 

Page 2 of 2 

Signature of duly 

Authorised person 

on behalf of the Bank 

With seal & signature code 

BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX.

Tender Notice No. - …………. 

PROFORMA FOR BANK GUARANTEE FOR EARNEST MONEY DEPOSIT 

(To be executed on non-Judicial stamped paper of appropriate value) 

B.G. No_____________ Date____________ 

Page 1 of 2 

ANNEXURE - VIII 

1. WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its 

Office at Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter referred as 

"The Owner/ Company" which expression shall unless repugnant to the subject or context includes 

its legal representatives, successors and assigns), has issued tender paper vide its Tender No. 

.............. for................................... (hereinafter called “the said tender”) to M/s............................ 

(hereinafter called “the said Tenderer(s)” which expression shall unless repugnant to the subject or 

context includes their legal representatives, successors and assigns) and as per terms and 

conditions of the said tender, the tenderer shall submit a Bank Guarantee for Rs.____________ 

(Rupees ___________________________ Only) towards earnest money in lieu of cash. 

2. We___________________ Bank having its branch office at _________________ do hereby 

undertake to pay the amounts due and payable under this guarantee without any demur merely on 

a demand from the Company stating that in the opinion of the company, which is final & binding, 

the amount claimed is due because of any withdrawal of the tender or any material alteration to the 

tender after the opening of the tender by way of any loss or damage caused or would be caused or 

suffered by the Company by reason of any breach by the said tenderer(s) of any terms and 

conditions contained in the said tender or failure to accept the letter of Intent/Agreement or that the 

amount covered under this Guarantee is forfeited. Any such demand made on the Bank by the 

owner shall be conclusive as regards the amount due and payable by the Bank under this 

Guarantee. However our liability under this guarantee shall be restricted to an amount not 

exceeding Rs........................... (Rupees……………. Only). 

3. We undertake to pay to the Company any money so demanded notwithstanding any dispute or 

disputes raised by the tenderer(s) in any suit or proceeding pending before any office, court or 

Tribunal relating thereto, our liability under this present guarantee being absolute and unequivocal. 

The payment so made by us under this bond shall be a valid discharge of our liability for payment 

there under. Our liability to pay is not dependant or conditional on the owner proceeding against 

the tenderer(s). 

4. The guarantee herein contained shall not be determined or affected or suspended by the 

liquidation or winding up, dissolution or change of constitution or insolvency of the said tenderer(s) 

but shall in all respects and for all purposes be binding and operative until payment of all money 

due or liabilities under the said tender are fulfilled. 

5. We _________________ Bank Ltd., further agree that the guarantee herein contained shall remain 

in full force and effect during the period that would be taken for the finalisation of the said tender 

and that it shall continue to be enforceable till the said tender is finally decided and order placed on

Tender Notice No. - …………. 

the successful tenderer(s) and/or till all the dues of the Company under/or by virtue of the said 

tender have been fully paid and its claims satisfied or discharged or till a duly authorised officer of 

the Company certifies that the terms and conditions of the said tender have been fully and properly 

carried out by the said tenderer(s) and accordingly discharges the guarantee. 

6. That the Owner/Company will have full liberty without reference to us and without affecting this 

guarantee to postpone for any time or from time to time, the exercise of any of the power of the 

owner under the tender. 

7. Notwithstanding anything contained herein before, our liability shall not exceed Rs.__________ 

(Rupees________________________________ Only) and shall remain in force till 

__________unless a demand or claim under this guarantee is made on us within three months 

from the date of expiry, we shall be discharged from all the liability under this guarantee. 

8. We __________________ Bank, lastly undertake not to revoke this guarantee during its currency 

except with the previous consent of the Company in writing. We further undertake to keep this 

Guarantee renewed from time to time on the request of the Tenderer(s). 

Date: ......................Bank 

Corporate Seal of the Bank By its constitutional Attorney 

BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX. 

Page 2 of 2 

Signature of duly 

Authorised person 

on behalf of the Bank 

With seal & signature code

Tender Notice No. - ………….. 

1. State Bank of India 

2. State Bank of Bikaner and Jaipur 

3. State Bank of Hyderabad 

4. State Bank of Mysore 

5. State Bank of Patiala 

6. State Bank of Travancore 

7. Allahabad Bank 

8. Andhra Bank 

9. Bank of Baroda 

10. Bank of India 

11. Bank of Maharashtra 

12. Canara Bank 

13. Central Bank of India 

14. Corporation Bank 

15. Dena Bank 

16. Indian Bank 

17. Oriental Bank of Commerce 

18. Punjab National Bank 

19. Punjab and Sind Bank 

20. Syndicate Bank 

21. Union Bank of India 

22. UCO Bank 

23. Vijaya Bank 

24 IDBI Bank 

(Twenty Four Banks) 

LIST OF STANDARDISED BANKS 

SCHEDULED PUBLIC SECTOR BANKS (INDIAN) 

Page 1 of 3 

ANNEXURE - IX


1. ING Vysya Bank 

2. Axis Bank 

3. SBI Commercial & International Bank Ltd. 

4. ICICI Bank 

5. HDFC Bank 

6. Yes Bank 

7. Indus Ind. Bank 

8. Kotak Mahindra Bank 

LIST OF STANDARDISED BANKS 

SCHEDULED PRIVATE SECTOR BANKS (INDIAN) 

(Eight Banks) 

SCHEDULED FOREIGN BANKS 

1. American Express Bank Ltd. 

2. Bank of American NT & SA 

3. Bank of Tokyo Ltd. 

4. BNP Paribas 

5. Barclays Bank Plc 

6. Citi Bank NA 

7. Deutsche Bank AG. 

8. Hongkong and Shanghai Banking Corporation 

9. Standard Chartered Bank 

10. JP Morgan Chase Bank NA 

(Ten Banks) 

Page 2 of 3


To 

National Aluminium Company Limited, 

NALCO Bhawan, 

Plot No. P/1, Nayapalli, 

Bhubaneswar - 751061 

Dear Sir, 

ECS MANDATE FORM 

ELECTRONIC CLEARING SERVICES/ELECTRONIC FUND TRANSFER/INTERNET 

BANKING MANDATE FORM 

Sub: Authorization for release of payment due from NALCO, Corporate Office, Bhubaneswar through Electronic Clearing Services (RBI)/ 

Electronic fund transfer (RBI/SBI)/ Internet Banking (SBI). 

Refer Order No……………..dt……………and/or Tender/Enquiry/Letter No……………..dt…………….. 

(Please fill in the information in CAPITAL LETTERS. Please TICK wherever it is applicable) 

1. Name of the Party : 

2. Address of the party :………………………………………… 

…………………………………………. 

………………………………………… 

City:……………. Pin Code:………….. 

E-mail Id: 

3. Particulars of Bank: 

Bank Name Branch Name 

Branch Place Branch City 

Pin Code Branch Code 

MICR No. 

(9 Digits code number appearing on the MICR Band of the cheque supplied by the Bank. Please attach Xerox copy of a cheque of 

your bank for ensuring accuracy of the bank name, branch name and code number) 

Account Type ? Savings ? Current ? Cash Credit ? 

Account Number(as appearing in the Cheque 

Book) 

4. Date from which the mandate should be effective: 

I hereby declare that the particulars given above are correct and complete. If any transaction is delayed or not effected for 

reasons of incomplete or incorrect information, I shall not hold National Aluminium Company Limited responsible. I also undertake to advise any 

change in the particulars of my account to facilitate updation of records for purpose of credit of amount through RBI ECS/RBI EFT/SBI NET. 

Place: 

Date: 

Signature of the party/Authorized 

Signatory 

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

Certified that particulars furnished above are correct as per our records. 

Bank’s Stamp: 

Date: 

(Signature of the Authorized Official from the Banks) 

Page 3 of 3


A. Basic information 

Name of the organization 

Address 

Telephone No 

Name of the Proprietor 

Nature of Business 

License Number and date of 

expiry 

Social Accountability 8000 Compliance Format 

Page 1 of 5 

Annexure - X 

Employees Staff (Total Number) Workmen (Total Number) 

Permanent 

Casual 

Badli 

Temporary 

Contracted 

B. Information regarding Social Accountability 

What is the minimum age required to join ___________ Years 

your organization? 

What types of certificates (Like mark sheet, Original Copy / Xerox 

birth certificate) you keep with you? 

Do you require to keep any kind of deposit Yes/No 

inform of cash at the time of employment? 

Do you provide safe & healthy work environment Yes/No 

as per statutory requirement? 

If directly not provided by you, do you get Yes/No 

health & safety benefits from NALCO?


Are you certified for SA 8000? Yes/No 

If Yes, please submit a copy of SA8000 Certificate along with this 

filled up questionnaire 

Have you undergone Code of Conduct Audit (COC Audit) Yes/No 

in last 2 years ? 

If yes, please submit a copy of Code of Conduct Audit Report 

along with this filled up questionnaire 

Have your sub-suppliers been certified for SA 8000? Yes/No 

Have your sub-suppliers undergone Code of Conduct Audit Yes/No 

(COC Audit) in last 2 years? 

Do you provide personal protective equipment(s) Yes/No 

to your employees free of cost? 

Do you provide safety training to your employees? Yes/No 

Do you ensure canteen facility for your employees? Yes/No 

If not, do you get the facilities from NALCO Yes/No 

What types of medical benefits you provide to your employees? 

Do you allow trade union and collective bargaining in 

your organization? Yes/No 

If no, how do you ensure freedom of expression? 

Page 2 of 5


Incase of non-performance of any employee, how do you deal with such situations? 

What are the procedures of hiring/promotion/ remuneration in your organization? 

Do you provide appointment letter to your employees? Yes/No 

Do you maintain a documented terms and conditions Yes/No 

of employment? 

Do you maintain a disciplinary procedure? Yes/No 

If no, how do you terminate your employee? 

How do you ensure that your employees are not discrimination on the basis of cast creed, gender, 

religion, age and dieses? 

Page 3 of 5


How many shift you have? _______ shifts 

What is the official working time? _______ hours 

Which day is off day in your organization? ____________ 

In case, a person works in off day or holiday, how is he/she compensated? 

Do you pay overtime to your employees as per law? Yes/No 

What is the lowest amount (salary/wage) you pay to Rs._______/- 

your employees? 

Is there any case of deduction in wage? Yes/No 

In case, it is yes, what are the general reasons for such deduction? 

Is there any apprentice period in your organization? Yes/No 

If yes, what is the apprentice period in your organization? ___________ 

Do you have any international certification Yes/No 

If yes, please specify 

Page 4 of 5


Do you receive, handle or promote goods and/or services Yes/No 

from supplier/subcontractors or sub-suppliers 

Do you receive, handle or promote goods and/or services Yes/No 

from supplier/subcontractors or sub-suppliers who are 

classified as home worker? 

If yes, what steps you have taken to ensure that they get similar level of protection as afforded to 

directly employed employees? 

Have you taken care to look into issues related to child labor Yes/No 

Forced labor, health & safety, working hours and remuneration 

of your suppliers 

We do hereby declare that our organization is committed to social accountability. We will promptly 

implement remedial/corrective actions identified against the requirement and promptly inform your 

organization. We also declare that the sub contractors/sub supplier’s performances are monitored 

by us. Moreover, we declare that if invited, we shall participate in awareness program as well as 

monitoring program organized by you. 

We declare that the above-mentioned information is correct. 

Signature: 

Designation: 

Date Seal of the organization 

Page 5 of 5

1.0 General 

PACKING, MARKING, SHIPPING AND DOCUMENTATION 

SPECIFICATIONS FOR INDIGENOUS MATERIALS 

NALCO 

ANNEXURE-XI 

1.1 This specification forms an integral part of the relevant PURCHASE ORDER, in addition to the 

specifications, drawings and instructions explicitly listed in the PURCHASE ORDER. 

1.2 Seller shall strictly comply with all applicable prescriptions in the specifications. Lack of relevant 

information and/or documents shall not absolve the SELLER of his responsibilities and any loss 

arising out of non -compliance shall be to supplier’s account. 

2.0 Project 

Name of OWNER, Project location and some other relevant information are as per Bid document. 

3.0 Packing 

3.1 The packing specifications incorporated herein are supplementary to the internal and external 

packing methods and standards as per current rules of IRCA goods tariff Part -I. All packing shall 

be done in such a manner so as to reduce volume as much as possible. Fragile articles should 

be packed with special packing materials depending on the type of materials. 

3.2 Items shipped in bundles must be securely tied with steel wire or strapping. Steel reinforcing 

rods, bars, pipes, structural materials, etc. shall be bundled in uniform lengths and the weight 

shall be within the breaking strength of the securing wire or strapping. 

3.3 All delicate surfaces on equipment/materials should be carefully protected and painted with 

protective paint/compound and wrapped to prevent rusting and damage. 

3.4 All mechanical and electrical equipment and other heavy articles shall be securely fastened to the 

case bottom and shall be blocked and braced to avoid any displacement/shifting during transit. 

3.5 Attachments and spare parts of equipment and all small pieces shall be packed separately in 

wooden cases with adequate protection inside the case and wherever possible should be sent 

along with main equipment. Each item shall be suitably tagged with identification of main 

equipment, item denomination and reference number of respective assembly drawing. Each item 

of steel structure and equipments shall be identified with two erection markings with minimum 

lettering height of 15 mm. Such marking will be followed by connection numbers in indelible 

ink/paint. A copy of the packing list shall accompany the material in each package. 

3.6 All protrusions shall be suitably protected by providing a cover comprising of tightly bolted 

wooden discs on the flanges. 

3.7 Wherever required, equipments/materials/instruments shall be enveloped in polyethylene bags 

containing silicagel or similar dehydrating compound. 

3.8 All pipes shall be packed as under: 

a) Upto 50mm NB in Wooden cases/crates. 

b) Above 50mm NB and upto 100mm NB in Bundles and the bundles should be strapped at 

minimum three places. 

c) Above 100mm NB in loose. 

Individual cases/bundles must contain the pipes of same size and length. Ends should be 

capped. 

Page 1 of 5



ANNEXURE-XI 

3.9 Pipes with threaded or flanged ends shall be protected with suitable caps/covers before packing. 

Line pipes shall be transported only on Flat bed trailers. Semi low bed/low bed trailer shall not be 

used. 

The trailers used for transportation of Line Pipes shall be equipped with adequate pipe supports, 

having as many round hollow beds as there are pipes to be placed on the bottom of the trailer 

bed. Total width of the supports shall be at least 10% of the pipe length. These supports shall be 

lined with a rubber protection and shall be spaced in a manner as to support equal load from the 

pipes. The rubber protection must be free from all nails and staples where pipes are in contact. 

The second layer and the following layers shall be separated from each other with adequate 

number of separating layers of protective materials such as straw in plastic covers or mineral 

wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of 

trailers used for transportation shall be covered by non -abrasive material like rubber belts or 

equivalent. Care shall be exercised to properly cover the top of the stanchions and other 

positions such as reinforcement of the trailer body rivets etc. to prevent damage to the coated 

surface. 

3.10 Detailed packing list in waterproof envelope shall be inserted in the package together with 

equipment/material. One copy of the detailed packing list shall be fastened outside the package 

in waterproof envelope and covered by metal cover. 

3.11 The Seller shall be held liable for all damages or breakages to the goods due to the defective or 

insufficient packing as well as for corrosion due to insufficient protection. 

3.12 Packaged equipment or material showing damage, defects or shortages resulting from improper 

packaging material or packing procedures or having concealed damage or shortages, at the time 

of unpacking shall be to the seller’s account. 

4.0 Marking 

4.1 Each package shall be marked on three sides with proper paints/indelible waterproof ink as 

follows: 

OWNER 

PROJECT 

DESTINATION 

Purchase Order No..................................................................................................... Net 

Wt.....................…………….... Kgs Gross Wt...................................... Kgs. 

Dimensions.......................................................X....................X...........................CM. 

Package No. (Sl. No. of total packages)......................................................................... 

Seller’s Name............................................................................................................. 

4.2 Additional marking such as ‘HANDLE WITH CARE’, ‘THIS SIDE UP’, ‘FRAGILE’ or any other 

additional indications for protection and safe handling shall be added depending on the type of 

material. 

4.3 Specific marking with paint for ‘SLINGING and ‘CENTRE OF GRAVITY’ should be provided for all 

heavy lifts weighing 5 Tons and above. 

Page 2 of 5



ANNEXURE-XI 

4.4 In case of bundles/bags or other packages, wherever marking cannot be stenciled, the same 

shall be embossed on metal or similar tag and wired securely at two convenient points. 

5.0 Shipment 

5.1 Despatch of materials shall be made in accordance with the relevant terms of the Purchase 

Order. Any change in mode of transport shall be resorted to only after prior approval in writing. 

Seller shall ensure despatch of equipments/materials immediately after they are inspected and 

released. All consignments shall be booked in the name of Owner and not under self-basis. 

5.2 Despatch by Road 

(a) The Seller shall be responsible for despatch of materials on DOOR-DELIVERY basis 

through a reliable Bank -Approved transport company unless otherwise the transport 

company is named by OWNER/CONSULTANT. 

(b) The SELLER shall ensure with Transport Company the delivery of materials within a 

reasonable transit period. SELLER shall also obtain from transporter, particulars of Lorry 

Number, Transporter’s Challan Number, destination of lorry (if transshipment is involved), 

Transporter’s Agent at destination, if any, etc. and intimate same to General 

Manager (Projects), CPP, Nalco, Angul with copy to Resident Construction Manager at 

RITES, (respective Project Site). 

5.3 Despatch by Rail 

5.3.1 The SELLER shall be responsible for: 

(a) Despatch by the shortest possible route. The Seller shall as far as possible, despatch 

the materials by the fastest goods train like QTS, Super Express Goods, etc. wherever 

such facilities exist. 

(b) Correct classification of goods and freight charges. 

(c) Obtaining clean Railway Receipts without any qualifying remarks. 

5.3.2 As “SMALLS” 

Should there be any restriction for movement by a particular route, the Railway 

authorities should be requested to move goods by the next alternative route, subject to 

prior consent of NALCO/RITES. 

When the materials that are ready do not make up a wagonload by weight/volume or for minimum 

freight payable for a wagon the despatch should be affected as “smalls”. 

SELLER should obtain from the Railway, the particulars of wagon in which the “Smalls” have 

been loaded, station at which sealed, train Number and date/time of movement and transmit the 

same to the Resident / Visiting Inspector, General Manager (Projects), CPP-Nalco , RCM-RITES 

(concerned Site) for monitoring their movement. 

5.3.3 As Wagon Loads 

Consignments, though of lesser weight, but otherwise constituting a “wagon load” by volume 

should be dispatched as “wagon load” paying the freight applicable to a minimum wagon load or 

at the smalls rate, whichever is advantageous, as per Rule-164 of IRCA Goods Tariff Part -I (Vol.I) 

When consignments call for full wagon(s), indents should be placed with the Railway Station 

concerned after predetermining accurately the type and number of wagons required. In case of 

Page 3 of 5



ANNEXURE-XI 

covered wagons, it should be ensured that the same are watertight. If a particular type of wagon 

is in short supply, request should be made to the Railway Authorities to supply the next suitable 

type of wagon. Suitable packing in the wagon shall be done, wherever necessary, to ensure 

maximum safety of the material in transit. 

When ODC packages are involved, the SELLER shall apply to the Railway Authorities with 

loading sketches showing overall dimensions and the wagon proposed to be utilized sufficiently in 

advance for obtaining movement sanction and to establish firm transportability. Copies of all 

such correspondence together with loading sketches should be sent to NALCO and Consultant 

RITES. ODC packages shall be loaded, packed and lashed strictly in accordance with the 

Railway Regulations. Should there be any delay/difficulty in obtaining the required wagon(s), the 

SELLER shall inform Resident Inspector and General Manager (Projects), CPP-Nalco , RCM- 

RITES immediately giving details of the required number of wagons, type, carrying capacity, etc. 

and indent number so that the matter may be taken up with the Railway Authorities concerned. 

After despatch, SELLER shall obtain from the Railway Authorities, particulars of the wagon/train 

number, date of movement and destination junction for the particular train and furnish the same to 

General Manager (Projects), CPP-Nalco , RCM-RITES for follow-up action on movement, as 

may be necessary. 

After despatch of the equipment from dispatching station, if movement of the wagon is held-up 

due to improper/loose lashing resulting in shifting of the load and consignment is required to be 

readjusted/refixed the vendor shall be responsible to arrange for the same as per Railway 

requirements. Similarly, in case some infringement in dimensions of the loaded consignment is 

detected by Railway Authorities after its movement from despatching station and if it is required to 

be corrected either by adjustment of the load or by cutting a few protrusions the same shall be 

arranged by vendor at their cost. 

5.4 Shipment by Air 

Wherever SELLER is instructed by OWNER/CONSULTANT to airfreight any material, the 

SELLER shall take prompt action for the same. Immediately after air shipment is effected, the 

Seller shall intimate by Fax / E-mail, the details of airway bill number and date, flight number, 

number of packages etc. to the Resident Inspector, Consultant RITES, General Manager 

(Projects), CPP-Nalco , Resident Construction Manager -RITES, (respective Project Site). 

5.5 Destination 

The consignments should be despatched as indicated in bid document/Purchase Order. 

5.6 Advance Information 

Immediately after a shipment is made, SELLER shall send advance information as to the 

particulars of materials, value, Purchase Order Number, date of despatch, railway receipt 

number, wagon number/goods consignment note number, truck number, name of transport 

company and their destination office/associate’s address etc./Airway Bill Number and flight details 

by way of Fax / E-Mail to Resident / Visiting Inspector, Consultant RITES, Resident 

Construction Manager- RITES, (respective Project Site) and NALCO. 

5.7 Transmission of Despatch Documents 

Seller shall, within 48 hours of the despatch of the material depending upon the payment terms of 

the Purchase Order, either negotiate through OWNER’s Bankers or forward direct by Registered 

Post, the railway receipt/consignment note/Airway Bill to the Owner at project site accompanied 

by the original invoices, packing lists and challans. 

Page 4 of 5



ANNEXURE-XI 

The SELLER shall be responsible for any delay in clearance of the consignment at destination 

and consequent wharfage/demurrage, if any, due to delay in transmittal of the Railway Receipt, 

Consignment Note/Air Way Bill. Copies of such despatch advise together with 2 copies of 

invoices and packing lists shall be simultaneously distributed to OWNER’s (HO & Site), 

Consultants (HO & Site) etc. 

6.0 Transit Risk Insurance 

All equipments/ materials will be insured for transit risk by OWNER unless otherwise specified. 

The Insurance cover will be provided from warehouse - to - warehouse. 

7.0 Despatch through Approved Transporters 

All materials must be despatched through OWNER/CONSULTANT approved transporters, list of 

which may be obtained from the OWNER’s/CONSULTANT’s nearest branch/regional office. 

--x-- 

Page 5 of 5

NATIONAL ALUMINIUM COMPANY LIMITED - Rites

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?