NATIONAL ALUMINIUM COMPANY LIMITED - Rites
NATIONAL ALUMINIUM COMPANY LIMITED - Rites
NATIONAL ALUMINIUM COMPANY LIMITED - Rites
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<strong>NATIONAL</strong> <strong>ALUMINIUM</strong> <strong>COMPANY</strong> <strong>LIMITED</strong><br />
BID DOCUMENT No No. :OT/05/2012-13/WT/RITES-BBSR/NALCO<br />
TENDER DOCUMENT FORDESIGN, MANUFACTURE, SUPPLY, ERECTION,<br />
TESTING AND COMMISSIONING OF WAGON TIPPLER AND CONVEYOR<br />
SYSTEM FOR M/S. NALCO AT ANGUL.<br />
CONTENTS<br />
1. GENERAL<br />
2. INTENT OF SPECIFICATIONS<br />
3. SPECIAL STIPULATIONS TO BIDDERS<br />
4. SYSTEM PARAMETERS, OPERATION AND CONTROL PHILOSOPHY<br />
5. GENERAL TECHNICAL REQUIREMENTS<br />
6. ELECTRICAL<br />
7. CIVIL<br />
8. CONDITION OF CONTRACT FOR FIELD SERVICES<br />
9. MISCELLANEOUS<br />
(A GOVERNMENT OF INDIAENTERPRISE)<br />
PROJECT OFFICE<br />
BHAGWANTOWER, 1 ST FLOOR<br />
CUTTACK ROAD,<br />
BHUBANESWAR – 751006<br />
Annexure – I-Technical Specification<br />
BBSR/NALCO-ANGUL<br />
1
INDEX<br />
SECTION DESCRIPTION PAGE NO<br />
1 GENERAL 1-5<br />
2 INTENT OF SPECIFICATIONS 1-17<br />
3 SPECIAL STIPULATIONS TO BIDDERS 1-11<br />
4 SYSTEM PARAMETERS, OPERATION AND<br />
CONTROL PHILOSOPHY<br />
1-64<br />
5 GENERAL TECHNICAL REQUIREMENTS 1-27<br />
6 ELECTRICAL 1-97<br />
7 CIVIL 1-21<br />
8 CONDITIONS OF CONTRACT FOR FIELD SERVICES 1-23<br />
9 MISCELLANEOUS 1-55<br />
2
1.0 GENERAL<br />
M/S. National Aluminium Company Ltd. (NALCO), Angul have undergone 2<br />
expansion of their Captive Power Plant (CPP).The 9th & 10th units are added in 2nd phase<br />
expansion of the Existing Captive Power Plant (CPP) by increasing the station capacity to<br />
1200MW. Facility for Storage and Handling of about 90,000 t additional<br />
been envisaged to be added in 2nd phase expansion of Captive Power Plant. The new<br />
uncrushed coal storage yard shall be equipped with stacker and reclaimer machines and<br />
shall have uncrushed coal supply connectivity to old and new coal bu<br />
nd phase<br />
expansion of their Captive Power Plant (CPP).The 9th & 10th units are added in 2nd phase<br />
expansion of the Existing Captive Power Plant (CPP) by increasing the station capacity to<br />
1200MW. Facility for Storage and Handling of about 90,000 t additional uncrushed Coal has<br />
been envisaged to be added in 2nd phase expansion of Captive Power Plant. The new<br />
uncrushed coal storage yard shall be equipped with stacker and reclaimer machines and<br />
shall have uncrushed coal supply connectivity to old and new coal bunkers through<br />
respective Crusherhouse. house.<br />
2.0 Basic Data<br />
Material to be handled - Uncrushed coal (Grade E / F / G)<br />
Feed size<br />
- (-) 300 mm<br />
Specific gravity of coal - 0.8 t/m3 for volume calculation<br />
1.1 t/m3 for strength calculation<br />
Moisture (%)<br />
- 6% to 10%<br />
No of working days / yr - 330<br />
No of working shift / day - 3 shift of 8 hrs per day<br />
3.0 DESCRIPTION OF EXISTING SYSTEM<br />
The salient features of existing coal handling facilities consist of following:<br />
3.1 ROM Coal of (-) 300mm mm size is brought from coalfields in Bottom Discharge Captive Railway<br />
Wagons.<br />
3.2 Coal from coalfield is received through a Merry Go Go-round round (MGR) system between the CHP<br />
and coalfield.<br />
3.3 There are two (2) nos. of existing Track Hopper Buildings with undergrou underground RCC hopper.<br />
3.4 Each TrackHopperBuilding has four (4) nos. of paddle feeders of travelling type at its bottom<br />
to scoop coal from the track hopper. Two paddle feeders are mounted on individual<br />
conveyor.<br />
3.5 There are two (2) underground conveyors at bottom of each track hopper. Both conveyors<br />
are running parallel at the bottom of the track hopper hopper–1. 1. The parallel conveyor installed at<br />
the bottom of track hopper hopper–2 run in opposite direction.<br />
3.6 There are two (2) Bunker Bays. The old BunkerBay meets the crushed coal requirement for<br />
Unit 1 – 6 whereas the new BunkerBay meets the crushed coal requirement for unit 7 to 10.<br />
Thus, there are two separate conveyor paths. Each path has two conveyor streams running<br />
in parallel.<br />
Technical Specification:Sec-1 General<br />
SECTION 1<br />
Page 1 of 5
3.7 Rated & designed capacity of each conveyor stream is 800 TPH & 960 TPH respectively.<br />
3.8 Two parallel conveyors with moving tripper are installed on the top of each BunkerBay. One<br />
moving tripper is provided on each conveyor installed on the top of Bun BunkerBay. Moving<br />
trippers feed the crushed coal in desired bunkers as per requirement.<br />
3.9 The CHP has two (2) Crusher Houses. The old Crusherhouse house is provided on conveyor path<br />
that is feeding crushed coal to Units 11-<br />
6. The new Crusherhouse house is provided on con conveyor<br />
path that is conveying crushed coal to Unit 7 to 10.<br />
3.10 Each Crusher house has two (2) Crusher& & associated equipment installed on parallel<br />
conveyor series. Thus, each Crusherseries series has been provided with dedicated Crusher and<br />
associated equipment.<br />
3.11 There are three uncrushed coal storage yards with stacker cum reclaimer machine (SCR) in<br />
present CHP. One SCR machine is provided on each storage yard.<br />
3.12 Storage yard 1 & 2 receive uncrushed coal from track hopper 1 & 2. Storage yard 3 receives<br />
uncrushed coal oal from track hopper 2 only.<br />
3.13 Scooped uncrushed coal from track hopper 1 is conveyed to old Crusher house and then to<br />
coal bunker bay of Units 11-6<br />
6 through conveyor path that is conveying crushed coal to coal<br />
bunkers Bay of Units 1-6. 6.<br />
Uncrushed coal l is conveyed to storage yard 1 & 2. Preparation of coal Stock Pile is carried<br />
out by installed Stacker-cum-Reclaimer<br />
Reclaimer (SCR) machine. Uncrushed coal is reclaimed by SCR<br />
machine and conveyed to either of boiler bunkers through dedicated conveyor paths which<br />
is operating for these two boiler bunker bays.<br />
It is conveyed to boiler bunker Bay of Units 7 to 10 through new Crusher Crusherhouse by conveyor<br />
path that is feeding crushed coal in boiler bunkers of Unit 7 & 8. SCR machine is positioned<br />
in by-pass mode while e conveying coal from track hopper 1.<br />
3.14 Scooped coal from track hopper 2 is conveyed to Crusher house and then to coal bunker bay<br />
of Units 7 to 10 through conveyor path that is conveying crushed coal to coal bunkers Bay of<br />
Units 7 to 10.<br />
OR,<br />
It is conveyed to boiler bunker Bay of Units 11-<br />
6 through conveyor path linked with track<br />
hopper 1. OR, It is conveyed to storage yard 3. Preparation of stockpile is made with the help<br />
of SCR machine. Coal from the Stock Pile is reclaimed by SCR machine and is fed on to yard<br />
conveyor. The yard conveyor discharges the coal on to the conveyor path linked with boiler<br />
bunker bay of Units 7 to 10.<br />
Technical Specification:Sec-1 General<br />
OR,<br />
OR,<br />
Page 2 of 5
It is conveyed to the storage Yard 1&2 through the conveyor paths linked with track hopper<br />
1.<br />
4.0 Additions to existing system currently under development:<br />
Presently an additional coal storage and handling system is being implemented<br />
under a separate contract to augment the coal handling system. The salient features<br />
of the new scheme are:<br />
4.1 The terminal points for Addition Additional al Coal Storage & Handling System of CHP in 2nd Phase<br />
Expansion commences from and consist of:<br />
4.2 Modification and shifting of discharge end of existing belt conveyor BC BC-115 in Junction<br />
House JH-7 7 with a provision of two way chute and flap gate to feed uncr uncrushed coal received<br />
from Track Hopper No. 2 to either the existing conveyor BC BC-116 116 or to new conveyor BC BC-118A<br />
under implementation.<br />
4.3 Modification of existing Junction House JH JH-7 7 to accommodate tail end of new conveyor BC-<br />
118A for receiving & conveying unc uncrushed rushed coal to the proposed Additional Coal Storage<br />
Yard.<br />
4.4 Provision of new Junction House JH JH-7A 7A adjacent to existing Junction House JH JH-7 to<br />
accommodate discharge / head end of new belt conveyor BC BC-122 122 from the proposed<br />
Additional Coal Storage Yard and ex extended tail end of conveyor BC-116 116 to receive uncrushed<br />
coal from new conveyor BC BC-122.<br />
4.5 Extension of tail end of existing conveyor BC BC-116 116 from existing Junction House JH JH-7 to new<br />
Junction House JH-7A 7A to receive reclaimed uncrushed coal from the Additional Coal Storage<br />
Yard through a new conveyor BC BC-122. 122. Uncrushed coal received on conveyor BC BC-116 will be<br />
conveyed to the new Crusher house through existing belt conveyor system for supplying the<br />
crushed coal to bunkers of unit 77-10.<br />
4.6 Extension of tail end of eexisting<br />
conveyor BC - 104 from existing Junction House JH JH-2 to new<br />
Junction House JH-13 13 to receive reclaimed uncrushed coal from the Additional Coal Storage<br />
Yard through a new conveyor BC BC-120 and BC-121.Uncrushed 121.Uncrushed coal received on the extended<br />
conveyor BC-104 04 shall be Conveyed to the old Crusherhouse house through the existing belt<br />
conveyor system for supplying crushed coal to the bunkers of unit # 11-6.<br />
6.<br />
4.7 For Receipt of uncrushed coal for the proposed Additional Coal Storage and Handling<br />
System, uncrushed coal con conveyed to JH-7 by existing conveyor BC-115 115 from Track Hopper<br />
No.2 can be diverted either to existing conveyor BC BC-116 116 or to new conveyor BC BC-118A at<br />
Junction House JH-7. 7. The new conveyor BC BC-118A 118A will convey material to the proposed<br />
Additional Coal Storage Yar Yard d through a new conveyor system under development. For this,<br />
the existing Junction House JH JH-7, 7, shall be modified to accommodate the tail end of new<br />
conveyor BC-118A. 118A. The discharge chute of the existing conveyor BC BC-115 115 shall be replaced<br />
Technical Specification:Sec-1 General<br />
OR,<br />
Page 3 of 5
with new chute arrangement gement having a two way chute with a flap gate. Two Two-way chute with<br />
flap gate will divert the material discharged from conveyor BC - 115 either to existing<br />
conveyor BC-116 116 or to the new conveyor BC BC-118A 118A depending on position of the gate.<br />
The discharge pulley of existing conveyor BC BC-115 115 will be relocated suitably to ensure the<br />
flow of uncrushed coal, either to conveyor BC BC-116 116 or to the new conveyor BC BC-118A is<br />
smooth through the new flap gate and chute arrangement. The rated capacity of conv conveying<br />
system is 800 t/hr.<br />
4.8 For storage of uncrushed coal in the Additional Coal Storage Yard under development, the<br />
coal received through conveyor BC BC-118A 118A will be conveyed to the Yard through conveyors BC BC-<br />
119 & BC-120 120 and new Junction Houses JH JH-10 & JH-11. 1. The conveyor BC BC-120 will be<br />
equipped with a Slew Stacker Machine. The Slew Stacker Machine will be capable of forming<br />
two identical stock piles of uncrushed coal on either side of its track. The length of each<br />
stock pile will be 275 m. The storage capac capacity ity of each Stock Pile will be 45,000 t of uncrushed<br />
coal. The rated capacity of stacking system is 800 t/hr<br />
4.9 For Reclaiming the uncrushed coal from Additional Coal Storage Yard, a Bucket Wheel<br />
Reclaimer will be provided. The Bucket Wheel Reclaimer will be installed on conveyor BC -<br />
120 such that its discharge is collected on the yard conveyor BC BC-120. 120. The BWR will be<br />
operating on the same track as that of the Slew Stacker Machine. Simultaneous operation of<br />
stacking and reclaiming is also proposed on the yard conveyor BC-120. 120. Uncrushed coal<br />
reclaimed on conveyor BC BC-120 120 will be conveyed to new Junction House JH JH-12. The rated<br />
capacity of the reclaiming system shall be 800 t/hr.<br />
4.10 Conveyor BC-120 120 will convey reclaimed material to new Junction House JH JH-12. Head/<br />
discharge scharge end of conveyor BC BC-120 120 will be provided with two way chute with flap gate<br />
arrangement. Depending on position of flap gate in the discharge chute, uncrushed coal<br />
reclaimed from the Additional Coal Storage Yard will be diverted either to conveyor BC BC-121<br />
or to conveyor BC-122 122 at new Junction House JH JH-12. Conveyor BC-121 121 will transport the<br />
material to new JH-13 13 and transfer material to the tail end of existing and extended<br />
conveyor BC-104, 104, Conveyor BC BC-122 122 will convey the material to new Junction House JJH-7A<br />
and transfer the material to tail end of existing and extended conveyor BC BC-116. The rated<br />
capacity of conveying system is 800 t/hr.<br />
4.11 Conveying of uncrushed coal to new Crusherhouse. . Uncrushed coal received on conveyor<br />
BC-122 122 will be conveyed to new Junction House JH JH-7A, 7A, located adjacent to existing JH JH-7. At<br />
Junction House JH-7A, 7A, conveyor BC BC-122 122 shall discharge the uncrushed coal at the extended<br />
tail end of existing conveyor BC BC-116. Uncrushed coal received on conveyor BC BC-116 will be<br />
conveyed to the new Crusher Crusherhouse house through the existing coal flow path. The rated capacity<br />
of conveying system is 800 t/hr.<br />
4.12 For Conveying the uncrushed coal to the old Crusher house, uncrushed coal received on<br />
conveyor BC-121 121 shall be conveyed to new Junction House JH JH-13. 13. At this new Junction<br />
House JH-13, 13, conveyor BC BC-121 121 will discharge the material to the extended tail end of the<br />
Technical Specification:Sec-1 General<br />
Page 4 of 5
existing conveyor BC-104. 104. Coal received on conveyor BC BC-104 104 will be conveyed to the old<br />
Crusherhouse house through existing coal flow path.<br />
The tail end of existing conveyor BC BC-104 at JH-2 2 will be extended up to the new Junction<br />
House JH-13 13 and a new conveyor gallery between existing Junction House JH JH-2 and the new<br />
Junction House JH-13 13 wi will ll be provided to house the extended length of existing conveyor BC BC-<br />
104. The system rated capacity is 800 t/hr.<br />
4.13 Dust Suppression System will be provided at all transfer points at various Junction Houses<br />
and uncrushed coal storage yard.<br />
4.14 Suitable ventilation on and air conditioning facilities will be provided in Switch gear cum MCC<br />
room, Battery room, Transformer rooms.<br />
4.15 PLC based operation & control system is being provided for additional coal storage &<br />
handling system. Controls are being suitably interfaced with existing conveyor system<br />
through limit switches.<br />
Technical Specification:Sec-1 General<br />
Page 5 of 5
1.0 INTENT OF SPECIFICATIONS<br />
1.1 This specification is intended to cover the following activities and services in respect of<br />
all the equipment of Wagon Tippler and Conveyor System Package to be installed for<br />
National Aluminium Company Limited (NALCO), Captive Power Project located in Angu Angul<br />
of Orissa State in India.<br />
(a.) The broad scope of work covers the following:<br />
i. Detailed design and engineering of all the equipment and equipment system(s).<br />
ii. Complete manufacture including shop testing/ type testing.<br />
iii. Providing engineering data, drawings, Commissioning procedures and O & M<br />
manuals, etc. for the Owner Owner/RITES’s ’s review, approval and records.<br />
iv. Packing and transportation from the manufacturer’s works to site.<br />
v. Receipt, unloading, storage, preservation and conservation of equipment at<br />
site.<br />
vi. Fabrication, tion, pre pre-assembly, assembly, (if any), erection, testing and satisfactory operation<br />
of all the equipment including successful completion of facilities.<br />
vii. All associated civil, structural structural,electrical and C&I works.<br />
viii. Commissioning and completion of facilities and Performance Guarantee Tests.<br />
ix. Furnishing of mandatory spares and handing over to NALCO stores.<br />
x. Supply of commissioning spares<br />
xi. Reconciliation (if any) with custom authorities authorities.<br />
xii. Satisfactory conclusion of the contract.<br />
(b.) The equipment and services to be furnished and installed as required in this Technical<br />
Specification shall also meet all the requirements as stated in other sections of bid<br />
documents which shall be considered as a part of this technical specification as bound<br />
herewith.<br />
(c.) The Contractor or shall be responsible for providing all materials, equipment and services,<br />
specified or otherwise (unless specifically excluded) which are required to fulfill the<br />
intent of ensuring operability and the reliability of the complete system covered under<br />
this specification.<br />
(d.) It is not the intent to specify completely herein, all aspects of design and construction of<br />
equipment. Nevertheless, the equipment shall conform in all respects to high standards<br />
of engineering, design and workmanship and shall be capable of performing in<br />
continuous commercial operation.<br />
(e.) Whenever a material or article is specified or described by the name of a particular brand,<br />
manufacturer or trade mark, the specific item shall be understood as establishing type,<br />
function and d quality desired. Other manufacturer’s products may also be considered<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
SECTION 2<br />
Page 1 of 17
provided sufficient information is furnished so as to enable the Owner Owner/consultant to<br />
determine that the products are equivalent or superior to those named.<br />
(f.) Bidder is requested tto<br />
o carefully examine and understand the specifications and seek<br />
clarifications, if required, to ensure that they have understood the specifications. Such<br />
clarifications should reach Owner Owner/consultant at least 15 days before the scheduled date of<br />
the opening of the bids. The Bidder’s offer should not carry any sections like clarifications,<br />
interpretations and/or assumptions.<br />
(g.) If the Bidder feels that, in his opinion, certain features brought out in his offer are superior<br />
to what has been specified, those may be highlighted separately. The Bidder may also<br />
make alternative offers provided such offers are superior in his opinion. In which case,<br />
adequate technical information, operating feedback, , etc. shall be enclosed with the offer,<br />
to enable the Owner/cons /consultant to assess the superiority and reliability of the alternatives<br />
offered. In case of each alternative offer, its implications on the performance, guaranteed<br />
efficiency, auxiliary power consumption etc. shall be clearly brought out for the<br />
Owner/consultant to make an overall assessment. In any case, the base offer shall<br />
necessarily be in line with the bidding documents/ specifications. Under no circumstances<br />
the equipment / system specification in Technical Specification shall be brought out as<br />
alternative offer.<br />
(h.) Any deviation or variation from the scope, requirement and/or intent of this specification<br />
shall be clearly defined by the Bidder in “Deviation to NIT Document” irrespective of the<br />
fact that such deviations/ variations may be standard practice or a possible interpretation<br />
of the specification by the Bidder. Except for those deviations/ variations covered under<br />
Deviation Schedules, which are accepted by the Owner before the award of the Contract, it<br />
will be the responsibility of the Bidder to fully meet the intent and the requirements of the<br />
specification within the quoted price. No other deviation whatsoever from this<br />
specification, except for the declared deviati deviations ons submitted by the Bidder with his proposal<br />
under “Deviations to NIT Document Document” ” shall be considered. Bids not complying with this<br />
requirement shall be treated as non non-responsive responsive and hence liable for rejection. The<br />
interpretation of the Owner Owner/consultant in respect of the scope, details and services to be<br />
performed by the Bidder shall be binding unless specifically clarified otherwise by the<br />
Owner/RITES in writing before the Award of the Contract.<br />
(i.) Before submitting his bid, the Bidder should inspect an and d examine the site and its<br />
surroundings and should satisfy himself as to the nature of the ground and subsoil, the<br />
quantities and nature of work, materials necessary for completion of the work and their<br />
availability, means of access to site and in general shall himself obtain all necessary<br />
information as to risks, contingencies and other circumstances which may influence or<br />
affect his offer. No consequent extra claims on any misunderstanding or otherwise shall be<br />
allowed by the Owner. The contractor shall, prior to commencement of design work, carry<br />
out the Geo-technical technical investigation in the area proposed for development of wagon tippler<br />
and conveyor system package. The number of bore holes shall be decided by the<br />
contractor to ensure adequate data to carry out the design and guaranteeing the<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 2 of 17
installation. The cost of such Geo Geo-technical technical investigation is deemed to be included in the<br />
bid submitted by the contractor.<br />
(j.) The sizes of various buildings/conveyor galleries indicated in the tender drawings and the<br />
parameters of equipment indicated in various sections of technical specifications are the<br />
minimum requirements of the Owner. Any increase in these sizes or the parameters, if<br />
required to meet the system/maintenance/operational requirement shall be supplie supplied by<br />
the contractor without any extra cost implication to the Owner.<br />
(k.) The works under the scope of this contract are to be executed in an operating power<br />
station. The contractor shall take all necessary precautions to protect all the existing<br />
equipment, nt, structures, facilities and buildings etc. from damage. In case any damage<br />
occurs due to the activities of the contractor on account of negligence, ignorance,<br />
accidental or any other reason whatsoever, the damage shall be immediately made good<br />
by the contractor ntractor at his own cost to the satisfaction of the Owner. The contractor shall also<br />
take all necessary safety measures, at his own cost, to avoid any harm or injury to his<br />
workers and staff from the equipment and facilities of the power plant.<br />
(l.) Contractor should note that the existing rail lines within the plant area are operational with<br />
rail traffic of coal and liquid fuel rakes. Contractor shall take all precautions to ensure the<br />
safety of existing rail tracks and other associated facilities as well as the safety of his men,<br />
material and equipment from the operating rail traffic. The contractor shall plan and make<br />
all arrangements to ensure that disruption to the existing rail traffic is minimum and shall<br />
follow the instructions of the Owner in this regard. Further, contractor shall plan and<br />
coordinate all his activities considering restrictions, if any, on free access to his work areas<br />
due to the rail traffic.<br />
(m.) After award of work and, before finalising his layout especially the layout / l llevels<br />
of<br />
conveyors, cable / pipe routes routes/transmission lines and other services, the contractor shall<br />
carry out a site survey to identify the location & details of existing facilities that may<br />
interfere with his proposed facilities. The contractor shall suit suitably ably modify his layout / levels<br />
to prevent dislocation of existing facilities and any cost / time implication arising out of<br />
such modifications shall be to his account. Contractor shall also be responsible to<br />
determine and obtain the necessary details at ssite<br />
ite as required for interfacing and<br />
interconnection with the existing system / facilities.<br />
(n) If during the execution of works it is found that there is interference with the existing<br />
facilities / structures, the contractor shall revise his design / deta detailed iled drawings to clear the<br />
interference and shall provide all necessary measures for the safety of existing structures.<br />
No claim in terms of cost or relaxation in time shall be entertained for any redesign, rework<br />
and for safety measures provided. If at an any y stage of work, any dismantling or modification<br />
or relocation of any existing facility is required to be done to complete the work in<br />
contractor’s scope and which has been agreed by the Owner, the same shall be done by<br />
the contractor at no extra cost or ttime<br />
ime implication to the Owner. All such changes will be as<br />
per drawings and work plan approved by the Owner.<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 3 of 17
Equipment and services covered under WAGON TIPPLER AND CONVEYOR SYSTEM PACKAGE<br />
are described in the subsequent sections:<br />
1.2 In addition to the specifications cifications of equipment / system indicated in various sections as above<br />
and General Technical Requirement and Erection Conditions of Contract attached of the<br />
Specification shall also form part of this Technical specification.<br />
1.3 TENDER DRAWINGS<br />
1.3.1 The drawings listed elsewhere, form part of the specification and shall supplement the<br />
requirements specified herein. The scope and terminal points for the equipment to be<br />
furnished under this package shall be as identified in these drawings and read in co conjunction<br />
with the text of these specifications. These drawings are preliminary drawings for bidding<br />
purpose only and subject to changes that may be necessary during the detailed engineering.<br />
1.3.2 In case of any conflicts / contradiction among various vol volumes umes / sections / annexures /<br />
chapters / appendices / tender drawings of bid documents, the same shall be referred to the<br />
Owner for clarifications whose decision shall be final and binding. No extra claims shall be<br />
allowed on this account.<br />
2.0 BRIEF DESCRIPTION IPTION OF PROJECT<br />
NALCO intends to augment the coal handling facilities at its Captive Power Plant by an<br />
additional annual volume of 2.0 Million tonnes.<br />
For this purpose, it intends to install a wagon tippler and connecting conveyor System to<br />
receive the above quantum of coal through rail mode. The wagon tippler system shall be<br />
suitable for handling all prevailing wagons in coal circuits such as BOX / BOX BOX-N / BOXNHA /<br />
BOX N.MKDII.<br />
The facility provided shall be suitable to accommodate locomotives of maxi maximum 140 T<br />
weight passing through the platform at a maximum speed of 8kmph.<br />
The Wagon Tippler System shall have an in built weighing mechanism (load cell type) below<br />
the platform for weighment of wagons prior to and after each tippling cycle to record the<br />
exact quantity of coal unloaded from each wagon.<br />
Coal received at the tippler hopper would be transported by belt conveyors and integrated<br />
to existing system for feeding the existing and the new stockpiles under development.<br />
2.1 BRIEF DESCRIPTION OF PRO PROPOSED POSED WAGON TIPPLER AND CONVEYOR PACKAGE<br />
(i) Indian Railway rakes consisting of Box Box-N N wagons shall transport coal to the power plant.<br />
These Box-N N wagons are proposed to be unloaded in underground RCC hopper by means of<br />
a Rota side Wagon Tippler Tippler/Rotary Wagon Tippler. . Wagon tippler hopper shall have a holding<br />
capacity of minimum 2 wagons loads of coal coal. One Rota side wagon tippler tippler/Rotary<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 4 of 17
WagonTippler(WT-1) 1) is to be utilised for unloading of IR coal rake. A Side arm charger is<br />
envisaged for placement of loaded wagon on the tippler table & retrieval of empty wagon<br />
from the tippler table after tippling. Clear access shall be provided for movement of pay<br />
loaders on the hopper side of Wagon tippler. Wagon tippler hopper grating is to be<br />
positioned and designed d accordingly.<br />
(ii) Apron feeder is proposed under the Wagon tippler for extracting coal from the Wagon<br />
tippler hopper and feed into the apron feeder which in turn discharges crushed coal on to<br />
the proposed receiving conveyor RC RC-1. Conveyor RC-1 will transfer sfer the coal to conveyor RC RC-2<br />
at the new transfer tower TP TP-1. Conveyor RC-2 2 shall feed coal on to existing Conveyor BC BC-<br />
103/BC-115 115 at the existing junction house (JH (JH-1). 1). The rated capacity of all the conveyors in<br />
this package shall be 1200 TPH.<br />
(iii) The existing CHP control and monitoring system is PLC based. It is proposed to provide<br />
an independent PLC based control for smooth, efficient & trouble free operations of Wagon<br />
Tippler and conveyor system package. The control and monitoring system for belt con conveyors<br />
covered under this Package shall be integrated with the existing control system such that the<br />
operation of existing CHP is not hampered. Necessary interlocks and software changes in the<br />
existing PLC logic are also envisaged in this package.<br />
3.0 SCOPE OF WORK<br />
3.1.1 The scope of Wagon Tippler and Conveyor System Package to be furnished, erected and<br />
commissioned under this specification shall be as detailed hereinafter. The Contractor shall<br />
be fully responsible for system and detailed design, engineer engineering, ing, manufacture, shop<br />
fabrication, assembly, testing and inspection at manufacturer’s works, packing, dispatch,<br />
transportation, transit insurance, custom clearance etc. as applicable, delivery to site,<br />
unloading, handling and storage at site, insurance du during ring storage, construction, erection,<br />
including erection supervision, testing, inspection, commissioning and handing over to<br />
Owner and Guarantee testing including all associated electrical, civil & structural works as<br />
specified, unless specifically exclude excluded as per Section-Terminal Terminal Points & Exclusions.<br />
3.1.2 The scope of the contractor shall be deemed to include all such items which although are<br />
not specifically mentioned in the bid documents and/or in Contractor’s proposal but are<br />
needed to make the system complete in all respects for its safe, reliable, efficient and<br />
trouble free operation and the same shall be furnished and erected unless otherwise<br />
specifically excluded in this document. The general description of the proposed system and<br />
the broad scope of f work under the specification shall include but not be limited to as<br />
detailed below.<br />
3.1.3 An underground RCC Wagon Tippler Hopper, machinery hatches with wagon tippler hopper,<br />
associated underground tunnel, transfer point and pent house complete with ci civil, structural<br />
and electrical works for Wagon Tippler hopper and machinery hatches, steel grating over<br />
hopper portion, removable chequered plate covers over openings in machinery hatches for<br />
handling underground equipment, equipment handling facilities fo for r apron feeder feederinside<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 5 of 17
elow wagon tippler hopper including the structural steel shed with E.O.T crane over the<br />
WT-1 1 and other equipment/systems such as Dust Suppression system, ventilation system,<br />
drainage system etc. as specified elsewhere in the specifica specification. tion. However, the track work is<br />
excluded from Contractor’s scope however rails over tippler table and the track for Side Arm<br />
Charger are included in Contractor’s scope.<br />
3.1.4 One (1) no. Rotaside Wagon Tippler Tippler/Rotary Wagon Tippler complete with clamping<br />
arrangements, all structural members, tippler platform, tippling mechanism, tippler drive<br />
along with necessary controls, associated electricals, civil / structural works and accessories.<br />
3.1.5 Side arm charger associated with the Wagon Tippler complete with travel rails, drive<br />
equipment along with necessary controls, associated electricals, civil/structural works &<br />
accessories.<br />
3.1.6 One (1) no. Apron feeder complete with drives, all mechanical, electrical accessories &<br />
supporting g structure etc.<br />
3.1.7 Receiving Belt Conveyors RC RC-1 1 complete with conveyor supporting structures, short<br />
supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units,<br />
pulleys, idlers, gravity take ups, take up structure upt upto o ground level, take take-up platforms at<br />
intermediate level, internal and external belt cleaners, pull chord switches, belt sway and<br />
zero speed switches, electro electro-hydraulic hydraulic thruster brakes, all electricals etc. including RCC<br />
tunnel for receiving Conveyor RC RC-1 and nd underground tunnel portion upto pent house of<br />
Conveyor RC-1 1 with all civil, structural and architectural works for conveyor gallery, gallery<br />
supporting trestles and their associated foundations.<br />
3.1.8 A new pent house along with over ground structures structures, for conveyor Rc-1<br />
complete with all<br />
civil structural, architectural and electrical works including chutes, monorails, hoists/chain<br />
pulley blocks, hoist maintenance platforms, RCC/steel floors, external staircases, hand rails<br />
etc.<br />
3.1.9 A transfer point TP-1 1 complete with civil, structural and electrical works and associated<br />
foundations for transfer of coal from conveyor RC RC-1 to conveyor RC-2.<br />
3.1.10 Complete chute work along with chute plug switches and actuator operated flap gates in all<br />
Transfer points, nts, maintenance platforms along with suitable approach.<br />
3.1.11 Adequate number of ventilation equipment for ventilating the wagon tippler hopper,<br />
underground conv. RC-1 1 upto Pent House, complete with all mechanical, electrical, civil and<br />
structural works.<br />
3.1.12 Pressurised Ventilation system for all Switchgear rooms, MCC rooms complete with all<br />
mechanical, electrical, accessories, civil and structural works.<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 6 of 17
3.1.13 Air conditioning of Wagon Tippler control room room, PLC room and battery room room, complete with<br />
all electrical, civil & structural works etc.<br />
3.1.14 Exhaust fans for all toilets complete with electrical, civil & structural works etc. Exhaust fans<br />
along with required ducting shall also be provided for all underground structures/Transfer<br />
Points.<br />
3.1.15 Minimum of four (4) Nos. sump pumps in Wagon Tippler house complete with motors, local<br />
control panel, level switches, individual discharge piping with fittings and valves to nearest<br />
plant drain etc.<br />
3.1.16 A complete dust suppression system for contr control ol of fugitive dust at Wagon tippler, apron<br />
feeder, transfer points, complete with enclosed pump houses, water tanks, pumps, drives,<br />
hoisting arrangements, piping, valves etc. electrical, accessories, civil and structural works as<br />
briefly specified below:<br />
a) Plain water dust suppression through fogging nozzles for control of dust during Wagon<br />
Tippler operation.<br />
b) Dry fog type dust suppression system at all Transfer Points both at discharge and<br />
loading points including all electrical and accessories.<br />
c) Compressor units, Pump houses & water tanks for dust suppression, service water and<br />
cooling water system.<br />
3.1.17 Cooling water system for scoop coupling, Service water system for Wagon Tippler Package<br />
System shall be taken from nearest header located at new track ho hopper pper area.<br />
3.1.18 An E.O.T crane for installation & maintenance of equipment in wagon tippler complex<br />
complete with all electrical and control including the covered structural steel shed.<br />
3.1.19 Monorails and electrically operated hoist blocks as well aas<br />
s hand operated chain pulley blocks<br />
for servicing/installation/easy replacement of drive machinery, different types of pulleys for<br />
all conveyors, GTU and other equipment.<br />
3.1.20All All buildings in contractor’s scope shall be complete with all electrical, civ civil, structural,<br />
architectural works, cable trenches, fire safety walls, foundation / fencing / earthing earthingfor all<br />
equipments, structures, transformers etc. . All cables / duct banks, trenches, cable trestles<br />
shall be complete with associated civil/ structural wwork<br />
ork and necessary civil foundations.<br />
3.1.21 Drainage of Wagon Tippler hoppers, tunnels, conveyor galleries, TPs, upto nearest existing<br />
CHP drain including all civil & structural works.<br />
3.1.22 All equipment/fittings, supporting structure, along with inser insert t plates, bolts, accessories, MS<br />
sleeves, base plates, grouting as may be required and proper alignment etc.<br />
3.1.23 A complete set of all special tools and tackles, which are necessary or convenient for<br />
erection, commissioning and overhauling of any equipment, covered under the scope.<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 7 of 17
3.1.24 First fill of all consumables e.g.; oils and lubricants for one year toppings r rrequirements.<br />
3.1.25 Preservative shop coating, final painting of all structures and equipment under the scope.<br />
3.1.26 (a) Adequate fire alarm & detection of coal conveyor gallery area, Junction unction houses, Wagon<br />
tippler area, Electrical switch gear rooms, Co Control ntrol rooms, Battery rooms, Transformer<br />
rooms, cable spreader rooms etc. consisting of heat detectors detectors(both (both ceiling mounted &<br />
Canopy mounted type), smoke detectors, LHS cables, manual call points, fire alarm panels at<br />
main control room of Wagon Tippler, rep repeater eater panel at CISF Fire control room near CPP<br />
main gate etc shall be considered. Fire alarm & de detection ction system shall be of Intelligent<br />
Addressable type of Notifire/Siemens make.<br />
(b) b) The successful bidder is to obtain necessary approval from TAC for the complete Fire<br />
protection System of Wagon Tippler Package.<br />
(c) c) Underground pipes will be M.S heavy duty with coating wrapping by 4mm thick coal tat<br />
tape conforming to IS15337 (latest version). Over ground pipes shall be of he heavy duty GI<br />
pipes with fittings etc. Suitable number of water actuated deluge valves shall be provided<br />
for the hydrant system. Hydrant line will be tapped suitably from the existing hydrant net<br />
work.<br />
(d) d) The coal conveyors shall also be provided with MVW (Medium Velocity Water) Spray<br />
System which h will be operating automatically for protection of conveyors.<br />
3.2 Electrical System / Equipment<br />
3.2.1 Unless specifically excluded, contractor’s scope of work shall include all electrical wor works as<br />
required for putting into successful operation of the Wagon Tipplers & Associated Conveyors<br />
covered under this specification.<br />
3.2.2 LT SWITCHGEAR<br />
415V Switchgear/motor control centers distribution boards, AC & DC fuse boards, local<br />
emergency stop push button stations for all drives and local motor starters as required for<br />
plant and equipment.<br />
3.2.3 MOTORS<br />
Motors along with couplings and coupling guards for all rotating auxiliaries are covered<br />
under this package. All motors shall be with cable glands & lugs.<br />
3.2.4 CABLES<br />
HT & LT Power cables, control cables, Instrumentation cables and any special cables required<br />
for connection between equipment / devices in Contractor’s scope and also cables between<br />
Owner’s equipment and Contractor's equipment.<br />
3.2.5 CABLING, EARTHING AND LIGHTNING PROTECTION<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 8 of 17
(a) All cabling with cable accessories, cable trays with supporting structure, terminations and<br />
jointing kits, trenches, overhead trestle, duct banks etc. as required for the cables to be<br />
supplied by the Contractor.<br />
(b) Grounding and lightning protection for the plant and equipment under Contractor’s<br />
scope along with its interconnection to the nearest Owner’s earth grid at two points.<br />
3.2.6 ILLUMINATION SYSTEM<br />
Complete illumination system as required for complete internal and external lighting of<br />
associated plant, equipment and buildings covered under Contractor’s scope including 2<br />
Nos. of Lighting Masts for area lighting in W.T. area.<br />
3.2.7 CONTROL SYSTEM<br />
An independent Control desk, PLC panels, II/O<br />
/O racks, UPS, battery & battery chargers etc. for<br />
the control of Wagon Tipplers and other equipment.<br />
One (1) No. control building to be located near WT WT-1 1 . This building shall have two floors i.e.<br />
ground & first floors. The first floor of control room shall house PLC panels, control desks for<br />
operation of WT-1. 1. One office room (5m x 5m) at the first floor. There shall be a projected<br />
viewing balcony at a suitable location to have clear view of the Wagon Tipp Tipplers during<br />
operation. The ground floor shall house the MCC, DBS, Battery DBS etc.<br />
3.3 CIVIL WORKS<br />
3.3.1 The work to be performed under this specification consists of providing all labor, materials,<br />
construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental<br />
items not shown or specified, but reasonably implied or necessary for successful completion<br />
of the work including Contractor’s supervision and in strict accordance with the drawings<br />
and specifications. The nature of work shall generally involve earthwork in excavation<br />
including very deep underground excavation, de de-watering, watering, shoring and strutting, sheet<br />
piling, back filling around completed structures and plinth protection, area paving, disposal<br />
of surplus excavated materials, aterials, piling, concreting including reinforcement and form work,<br />
brick work, fabrication and erection of structural / miscellaneous steel works, inserts,<br />
architectural items & finishes such as plastering, painting, flooring, doors, windows &<br />
ventilators, , glass and glazing, rolling shutters etc., permanently colour coated profiled steel<br />
sheeting,, Aluminum industrial troughed sheets sheets, anchor bolts, R. C. C. trenches with covers,<br />
drainage, damp proofing, water proofing and other ancillary items. Supply of cement,<br />
reinforcement steel, structural steel sections ,MS rounds, chequered plates, flats etc will be<br />
within the scope of the bidder bidder.<br />
3.3.2 The work shall have to be carried out both below and above ground level and shall be<br />
involving, basements, equipme equipment nt foundations, grounding, slabs, beams, columns, footings,<br />
rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 9 of 17
galleries, trestles, penthouses, Wagon tippler hopper, underground tunnels, transfer points,<br />
finishes, hes, complete architectural aspects, drainage and all other civil, architectural and<br />
structural works associated with the complete Wagon Tippler and conveyor system<br />
Package.<br />
3.3.3 Scope of work shall also include dismantling and modifications of the exi existing<br />
structures/facilities, which may be required to facilitate, inter connection between the<br />
existing and the new structures or facilities and making good the dismantled/modified<br />
structures.<br />
4.0 TERMINAL POINTS<br />
Terminal point for Wagon Tippler and conveyor system commences from wagon tippler<br />
complex upto feeding points at conveyors BC BC-103 & BC-115, 115, in Junction House (JH (JH-1)<br />
including the modification necessary to the Junction Houseand and interconnection with the<br />
existing system. Within these terminal points, all equipment and services, civil, structural<br />
and architectural works, electrical distribution, piping network etc. as required for wagon<br />
tippler and conveyor system package will be furnished and erected by the co contractor unless<br />
specifically excluded.<br />
4.1 Contractor's Scope responsibilities shall include but not be limited to the following:<br />
4.1.1 Wherever Contractor is permitted by Owner to take support from any of the Owner’s<br />
Structures, the Contractor shall ensure that no damage is done, to the Owner’s Structures<br />
including Painting thereof. In case of any damage to the Owners Structure and/or Painting,<br />
then the Contractor shall rectify the same to the complete satisfaction of the Owner.<br />
4.1.2 The contractor shall carry out the redesign of JH JH-1 1 and shall ensure that the proposed<br />
modifications are adequate to support the discharge point of the conveyor RC RC-2 as well.<br />
4.1.3 Regarding erection of transfer point on existing junction house house-1, 1, contractor shall ensur ensure<br />
that opening on existing building and erection of conveyor chutes/skirts & platform are done<br />
in a manner to minimize shut down of existing conv. BC BC-103 & BC-115. 115. As work is to be<br />
executed in operating project, extra care must be taken by the Contractor.<br />
4.1.4 Water supply connections for dust suppression, service water system & cooling water shall<br />
be provided by the Owner, details of which are given elsewhere in the specification. Further<br />
network of piping including all compressors, pumps, tanks, necessa necessary ry accessories, supports<br />
and fittings etc. for distribution of water for dust suppression and service water system in all<br />
transfer points, control rooms, MCC rooms, toilets, Machinery hatches of the Wagon tippler<br />
etc. shall be under the scope of the contra contractor.<br />
4.1.5 Road lighting in wagon tippler area, for the roads, is included in the scope of Contractor.<br />
4.2 EXCLUSIONS<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
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<br />
scope of this Contract. However, supply, laying and fixing of rail over Wagon Tippler table<br />
and for side arm charger is included in the scope of this Contract. Contract.The The approaches of wagon<br />
tippler where track is to be laid on concrete base( to the extent required) equired) and aligning with<br />
the inhaul/outhaul haul/outhaul track junctions is also included in the scope of this contract the cost of<br />
which is deemed to be included in the quoted rate of relevant items items.<br />
5.0 SYSTEM DESIGN BASIS<br />
5.1 The rated capacity of the Conveyors shall be 1200 TPH. . The design capacity of the conveyors<br />
shall be 1320 TPH. . The mechanical and structural / civil system shall be designed for 1320<br />
TPH capacity and round the clock operation with both the streams operatin operating simultaneously.<br />
5.2 Following shall be considered while designing the Conveyors :<br />
a. The Coal delivered to the power station shall be of size 300 mm & below. However<br />
occasionally coal of higher lump size may also be encountered.<br />
b. HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary<br />
between 6% to 10%. However for design purposes, moisture content of 10% shall be<br />
considered.<br />
c. The coal “as received” shall contain varying percentage of fines. Coal with such fines may<br />
tend to form orm adhesive lumps, particularly during monsoon when surface moisture is at its<br />
maximum value.<br />
d. The sizing and selection of the vital equipment viz. apron feeder covered under the system<br />
shall be based on the above characteristic of coal and operating cond conditions. itions. Contractor shall<br />
ensure that equipment/ system efficiency shall not be effected particularly during monsoon<br />
when surface moisture is at its maximum value.<br />
5.3 For the purpose of volumetric computation, the bulk density of the coal shall be taken a aas<br />
800 kg/m3. Therefore for calculation of belt conveyor capacity, for their drives & drive<br />
motors kW requirement, and sizing (volume calculations) of chute, hoppers etc. the above<br />
bulk density shall be considered. For all other purposes viz. for stresses/ load on structures,<br />
loading on Apron Feeder tables, sizing of actuators for flap gates, calculations of plugged<br />
chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3.<br />
5.4 Coal Flow paths<br />
5.4.1 For the purpose of conducting guarantee test coal, the following flow path would be<br />
assessed.<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
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<br />
transferred to RC-2 2 through Transfer point feeding on to existing Conveyors (either BC BC-103<br />
or BC-115) in JH-1.<br />
5.4.2 Contractor shall also demonstrate that all intermediate equipments can perform as per<br />
specification and design requirement during PG Test.<br />
5.4.3 Performance and Guarantee tests have been elaborated elsewhere in the specification.<br />
6.0 ENGINEERING NG SCHEDULES<br />
6.1 Within one month of acceptance of Award Letter, Contractor shall submit, for review and<br />
approval, detailed engineering schedules, based on Master Network (as per requirement of<br />
bid documents), to the Owner / Consultant, showing the logic & duration of activities in the<br />
following areas :<br />
a) Detailed engineering, including submission and approval of quality plans and PG test<br />
procedure.<br />
b) Inputs required from Owner for smooth and timely execution of contract.<br />
6.2 The Contractor shall submit within 30 days of letter of award a master list of drawings<br />
incorporating the scheduled dates of submissions. The schedule date of submissions should<br />
match with the manufacturing and erection programme submitted in the detailed Master<br />
Network Schedule. The list shall be updated every month reflecting the additions / deletions<br />
during the period.<br />
6.3 The network schedule shall be updated at a frequency mutually agreed upon for the<br />
purposes of progress monitoring. However, for the purpose of identification of Contractor's<br />
Contractual Liability the agreed Master Network shall only be applicable.<br />
7.0 GUARANTEE AND LIQUIDATED DAMAGES<br />
7.1 Guarantee<br />
The Bidder shall guarantee that equipment offered shall meet the rating, performance and<br />
functional requirement sti stipulated pulated for various equipment covered in this specification. The<br />
Bidder shall also furnish a declaration in the manner prescribed and included in the Bid<br />
Proposal Sheets and other Schedules for certain guaranteed parameters which shall attract<br />
levy of liquidated uidated damages for shortfall in performance.<br />
7.2 Performance Requirement<br />
Guaranteed parameters of the major equipments shall be as follows:<br />
7.2.1 Flow Path Capacity<br />
Flow path capacity including the intermediate equipment for conveyor streams to be teste tested<br />
for 1200 TPH<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 12 of 17
7.2.2 Equipment Capacity<br />
Capacity of individual equipment shall be tested separately:<br />
(i) Each Wagon Tippler : 20 tips/hour (Guaranteed)<br />
(ii) Each Apron feeder : 1200 TPH (Guaranteed)<br />
7.2.3 Contractor shall also demonstrate that all intermediate equipments viz. Gates, Dust<br />
suppression, Ventilation System etc. can perform as per specification and design<br />
requirement.<br />
7.2.4 Performance and guarantee requirement of various other equipments have been elaborated<br />
elsewhere.<br />
8.0 PERFORMANCE & GUARANTEE TEST PROCEDURE<br />
In accordance with GTR the plant shall be subjected to performance and Guarantee Tests on<br />
successful completion of trial operations. Further, the performance and Guarantee Tests<br />
shall be conducted as per the guideline procedure indicated elsewhere. However, detailed<br />
procedure shall be submitted by vendor as per the guidelines for Owner Owner/RITES's approval.<br />
The P&G Test procedure shall be submitted by the bidder.<br />
8.1 Liquidated Damages for Shortfall in Performance<br />
Should the results s of the performance and guarantee tests show that the equipments /<br />
system have failed to meet the guaranteed parameters, the Contractor shall carry out<br />
modifications, if considered necessary, within 90 days of the notification by Owner.<br />
If the equipment fails ails to meet the guarantee parameters at the end of the above specified<br />
period of 90 days, Owner may at his discretion, reject the equipment or accept it after<br />
assessing the liquidated damages at rates specified herein, to be payable by the Contractor.<br />
8.2 The following equipments/streams shall be subjected to performance and guarantee test in<br />
line with the specification to prove the performance guarantee for all intermediate<br />
equipment.<br />
Liquidated Damages towards shortfall in guaranteed performance shall be imposed as % of<br />
the order value limiting to 5% against following parameters.<br />
Sl.<br />
No.<br />
Equipment<br />
1 Wagon Tippler<br />
2 Apron Feeder<br />
3 Conveyors (R1 & R2)<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Guaranteed<br />
parameter<br />
Short fall LD amount to be<br />
imposed<br />
20 Tips /Hour By One tip per hour 1% of order value<br />
By two tips per Hour 2% of order value<br />
Beyond two tips per hour Rejected<br />
1200TPH By 0.5% 1% of order value<br />
By 1.0% 1.5 1.5% of order value<br />
Beyond 1.0% Rejected<br />
1200TPH By 0.5% 1% of order value<br />
By 1.0% 1’5 1’5% of order value<br />
Beyond 1.0% Rejected<br />
Page 13 of 17
The LD shall be assessed on the basis of conveyor equipment having the poorest<br />
performance.<br />
9.0 COMMISSIONING (SYSTEM TRIAL OPERATION)<br />
Duration of the trial operation of the he complete equipment shall be 30 continuous days with<br />
available no of loaded rakes during the period or as to be mutually agreed agreed.<br />
10.0 TYPE TESTS AND TYPE TEST CHARGES<br />
10.1 All equipment / systems to be supplied shall conform to type tests as per re relevant standards<br />
and proven type.<br />
10.2 The Bidder / Contractor shall furnish the reports of all the type tests carried out within five<br />
years of the date of bid opening as per specification and relevant standards for all<br />
components / equipments / systems. These reports should be for the tests conducted on<br />
identical / similar components / equipments / systems to those offered / proposed to be<br />
supplied under this contract.<br />
10.3 In case contractor is not able to submit report of type test(s) conducted in last five years, or<br />
in case type test report(s) are not found to be meeting the specification / relevant standard<br />
requirements, then all such tests shall be conducted under this contract by the Contractor<br />
free of cost to Owner, and reports shall be submitted ffor<br />
approval.<br />
10.4 All acceptance and routine tests as per relevant standard and specification shall be carried<br />
out. Charges for these shall be deemed to be included in the bid price.<br />
11.0 SPARES<br />
11.1 GENERAL<br />
The Contractor shall include in his scope of supply all the necessary Mandatory spares, start<br />
up and commissioning spares and recommended spares and indicates these in the relevant<br />
schedules of the Bid Form and Price Schedules. The general requirements pertaining to the<br />
supply of these spares have bbeen<br />
described in the following paras.<br />
11.2 MANDATORY SPARES<br />
11.2.1 The list of mandatory spares considered essential by the Owner Owner/RITES /RITES is included in this<br />
specification. The Bidder shall indicate the prices for each and every item (except for items<br />
not applicable to the Bidders design) in th the e ‘Schedule of mandatory Spares . If the Bidder<br />
fails to comply with the above or fails to quote the price of any spare item, the cost of such<br />
spares shall be deemed to be included in the bid price unless the bidder specifies "not<br />
applicable" for the type of equipment/system offered by hi him. m. However during execution if<br />
such spares are found to be applicable, the Contractor shall supply them without extra cost<br />
to the Owner. The Bidder shall furnish the population per unit of each item in the relevant<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 14 of 17
Schedules. Whenever the quantity is menti mentioned oned in “sets” the Bidder has to give the item<br />
details and prices of each item.<br />
11.2.2 Whenever the quantity is indicated as a percentage, it shall mean percentage of total<br />
population of that item in the Package, unless specified otherwise, and the fraction will be<br />
rounded off to the next higher whole number. Wherever the requirement has been specified<br />
as a ‘set’ it will include the total requirement of the item for a unit, module or the station or<br />
as specified. Where it is not specified a ‘set’ it will include tthe<br />
he total requirement of the item<br />
for a unit, module or the station or as specified. Where it is not specified a ‘set’ would mean<br />
the requirement for the single equipment/system as the case may be. Also one set for the<br />
particular equipment. e.g. ‘set’ of be bearings arings for a pump would include the total number of<br />
bearings in a pump. Also the ‘set’ would include all components required to replace the<br />
item; for example, a set of bearings shall include all hardware normally required while<br />
replacing the bearings.<br />
11.2.3 The Owner reserves the right to buy any or all the mandatory spare parts.<br />
11.2.4 The prices of mandatory spares indicated by the Bidder in the Price Schedules shall be used<br />
for bid evaluation purposes.<br />
11.2.5 All mandatory spares shall be delivered at site at least two mmonths<br />
onths before scheduled date of<br />
initial operation. However, spares shall not be dispatched before dispatch of corresponding<br />
main equipments.<br />
11.2.6 Wherever quantity is specified both as a percentage and a value, the Contractor has to<br />
supply the higher quantity uuntil<br />
and unless specified otherwise.<br />
12.0 RECOMMENDED SPARES<br />
12.1 In addition to the spare parts mentioned above, the contractor shall also provide a list of<br />
recommended spares for 1 year of normal operation of the plant and indicate the list and<br />
total prices in relevant schedule of the Bid Form and Price Schedules. This list shall take into<br />
consideration the mandatory spares specified in this Volume, and should be independent of<br />
the list of the mandatory spares. The Owner reserves the right to buy any or all of the<br />
recommended spares. The recommended spares shall be delivered at project site at least<br />
two months before the scheduled date of initial operation. However, the spares shall not be<br />
dispatched before the dispatch of the main equipment.<br />
12.2 Price of recommended spares will not be used for evaluation of the bids. The price of these<br />
spares will remain valid upto 6 months after placement of Notification of Award for the main<br />
equipment during which the Contractor shall provide necessary justification for the quoted<br />
prices for these spares. However, if the Contractor fails to provide the aforesaid justification<br />
of the quoted prices, the prices of recommended spare shall remain valid for 2 months from<br />
the last date of providing such justification to the sati satisfaction sfaction of the Owner.<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 15 of 17
13.0 START-UP UP & COMMISSIONING SPARES<br />
Start-up up and commissioning spares are those spares which may be required during the startup<br />
and commissioning of the equipment/system. All spares used till the plant is handed over<br />
to the Owner shall come under this category. The Contractor shall provide for an adequate<br />
stock of such start up and commissioning spares to be brought by him to the site for the<br />
plant erection and commissioning. They must be available at site before the equipments are<br />
energized. The unused spares, if any, should be removed from there only after the issue of<br />
Taking Over certificate. All start up spares which remain unused at the time shall remain the<br />
property of the Purchase Purchaser.<br />
14.0 COMMON REQUIREMENTS<br />
14.1 The Contractor shall include in his scope of supply all the necessary Man Mandatory spares, start<br />
up and commissioning spares and recommended spares and indicate these in the relevant<br />
schedules of the Bid Form and Price Schedules. The general requirements pertaining to the<br />
supply of these spares is given below.<br />
14.2 The Contractor shall indicate the service expectancy period for the spares parts (both<br />
mandatory and recommended) under normal operating conditions before replacement is<br />
necessary.<br />
14.3 All spares supplied under this contract shall be strictly inter changeable with the parts for<br />
which they are intended for replacements. The spares shall be treated and packed for long<br />
storage under the climatic conditions prevailing at the site e.g. small items shall be packed in<br />
sealed transparent plastic with desecrator packs as necess necessary.<br />
14.4 All the spares (both recommended and mandatory) shall be manufactured along with the<br />
main equipment components as a continuous operation as per same specification and<br />
quality plan.<br />
14.5 The contractor will provide Owner with cross cross-sectional drawings, wings, catalogues, assembly<br />
drawings and other relevant documents so as to enable the Owner to identify and finalise<br />
order for recommended spares.<br />
14.6 Each spare part shall be clearly marked or labeled on the outside of the packing with its<br />
description. When more than one spares part is packed in a single case, a general<br />
description of the content shall be shown on the outside of such case and a detailed list<br />
enclosed. All cases, containers and other packages must be suitably marked and numbered<br />
for the purposes urposes of identification.<br />
14.7 All cases, containers or other packages are to be opened for such examination as may be<br />
considered necessary by the Owner.<br />
14.8 The contractor will provide the Owner with all the addresses and particulars of his sub<br />
suppliers ers while placing the order on vendors for items/components/equipments covered<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 16 of 17
under the contract and will further ensure with his vendors that the Owner, if so desires, will<br />
have the right to place order for spares directly on them on mutually agreed term terms based on<br />
offers of such Contractors.<br />
14.9 The Contractor shall warrant that all spares supplied will be new and in accordance with the<br />
contract Documents and will be free from defects in design, material and workmanship.<br />
14.10 In addition to the recomm recommended ended spares listed by the contractor, if the Owner further<br />
identifies certain particular items of spares, the contractor shall submit the prices and<br />
delivery quotation for such spares within 30 days of receipt of such request with a validity<br />
period of 6 months onths for consideration by the Owner and placement of order for additional<br />
spares if the Owner so desires.<br />
14.11 The Contractor shall guarantee the long term availability of spares to the Owner for the full<br />
life of the equipment covered under the contract. The Contractor shall guarantee that<br />
before going out of production of spares parts of the equipment covered unde under the<br />
Contract, he shall give the Owner at least 2 years advance notice so that the latter may order<br />
his bulk requirement of spares, if he so desires. The same provision will also be applicable to<br />
sub-contractors. contractors. Further, in case of discontinuance of manu manufacture facture of any spares by the<br />
Contractor and/or his sub contractors, Contractor will provide the Owner, two years in<br />
advance, with full manufacturing drawings, material specifications and technical information<br />
including information on alternative equivalent makes required by the Owner for the<br />
purpose of manufacture/procurement of such items.<br />
14.12 In case of equipment supplied with grease/lubricants from imported origin, the supplier shall<br />
clearly indicate the indigenous equivalent of the grease/lubricant aand<br />
nd source of supply so as<br />
to enable the Owner to procure these items from indigenous sources.<br />
Technical Specification Sec-2,:Intent :Intent of Specifications<br />
Page 17 of 17
1.1. GENERAL<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
SECTION 3<br />
(SPECIAL STIPULATIONS TO BIDDERS)<br />
1.1.1 This Technical Specification shall be read in conjunction with Commercial, General Condition<br />
of Contract and other project requirement mentioned in this specification.<br />
1.1.2 The Bidder shall quote for complete scope of work as covered in this specification.<br />
1.1.3 This Technical Specification is for turnkey supply of the plant & equipment and related<br />
structures including execution of structural steel works and civil works as specified in<br />
subsequent chapters, along with necessary modification, as detailed in the Scope of Work<br />
and Technical Specification.<br />
1.1.4 Instructions to Bidders idders / Special Instruction specified in other chapters shall be read in<br />
conjunction with stipulation stated in this chapter.<br />
1.1.5 The Bidder shall submit the drawings / documents, technical data / information as<br />
mentioned in various sections and annexure without which the Bid shall be considered as<br />
incomplete and may not be considered further.<br />
1.1.6 The Bidder shall submit along with the bid a work schedule in the form of a bar chart<br />
indicating the commencement and completion dates of each acti activity vity such as preparation of<br />
design, approval of design & drawings, preparation & approval of fabrication drawings,<br />
procurement of steel and other material, ordering of bought out items, their delivery to<br />
shop, major shop activities like fabrication of stru structures/ ctures/ manufacture of equipment,<br />
assembly, shop testing, inspection, shop painting &&dispatch<br />
to the site, schedule of erection,<br />
final painting after erection at site, testing and commissioning of Plant and Equipment,<br />
without which the bid may not be consi considered.<br />
1.1.7 The Bidder shall clearly indicate the clause wise compliance to the specification. Non<br />
compliance with this and generalized statements like. "The equipment shall be<br />
manufactured as per IS standard / our specification etc" may result in reje rejection of the Bid.<br />
The deviation, if any, shall be clearly specified clause clause-wise wise in the format enclosed with this<br />
technical specification. In absence of deviation indicated, it will be presumed that the Bidder<br />
has no deviations.<br />
1.1.8 One copy of the Tender er document and drawings shall be duly signed by the Bidder as a<br />
token of acceptance of all clauses / parameters / data mentioned therein and returned along<br />
with the Bid without which the Bid is liable to be rejected. In case the Bidder intends to<br />
change any ny data / parameter given in Technical Specifications the same shall be clearly<br />
mentioned in the deviation list, with reasons thereof.<br />
Page 1 of 11
1.1.9 If the Bidder feels that any information/ data described in the technical specification needs<br />
to be modified, he shall indicate the same specifically and submit an alternative proposal, on<br />
the basis of the design data, that he considers suitable and capable of meeting the<br />
requirement of this specification.<br />
1.1.10 All the materials used and equipment supplied shal shall l be new and the best of their kind and<br />
shall comply with the statutory requirements of the Govt. of Orissa, Govt. of India and the<br />
latest revision of the Indian Standards/ Indian Electricity Rules. Where the equipment/<br />
material supplied is not according tto<br />
o Indian Standards or regulations to which the equipment<br />
/ material conform, the Bidder shall submit relevant document along with the Bid.<br />
1.1.11 The Bidder shall visit the plant / site, and satisfy himself fully about the existing plant /site<br />
conditions s etc. The successful Bidder shall bear full responsibility for inferences and<br />
conclusions as to the nature and conditions under which the work is to be executed,<br />
including effect of climate, rainfall etc. Failure to do so shall not absolve the Bidder of h hhis<br />
responsibilities about the proper execution of the job. No claim for extra payments due to<br />
any special site conditions and ignorance about the site conditions shall be considered after<br />
acceptance of his Bid. For the site visit, the Bidder shall contact the Purchaser and take prior<br />
appointment from them.<br />
1.1.12 The drawings of the existing coal handling plant, available with the Purchaser, can be made<br />
available to the successful Bidder for reference. However, for the areas of the plant for<br />
which drawings s are not available, the Bidder shall make site measurements and work<br />
accordingly.<br />
1.1.13 The Bidder as far as practicable ensure that major equipments are brought to site in pre<br />
assembled condition to minimize site work and to achieve an early commissi commissioning of the<br />
equipment after delivery. Site welding shall be avoided as far as possible. The Successful<br />
Bidder before proceeding with design details shall satisfy himself about the site condition so<br />
as to avoid any difficulty in erection arising out of des design.<br />
1.1.14 The equipment shall be inspected during different stages of its manufacture (starting from<br />
raw material till the completion of manufacture) by the Purchaser / his authorized<br />
representative at the Bidder's or his sub Successful Bidder's works as per the inspection<br />
procedure mutually agreed between the Purchaser or his authorized representative and the<br />
successful Bidder. Inspection shall be regarded as a check up and shall be in no way binding<br />
on the Purchaser. However, general terms and condit conditions ions of inspection and testing is<br />
indicated in the subsequent chapter of this specification.<br />
1.1.15 Documents of all electrical and mechanical equipment supplied with equipment shall be put<br />
up for inspection along with the equipment. After inspection, aan<br />
n endorsement would be<br />
made in the inspection certificate about the availability of the documents.<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 2 of 11
1.1.16 The offer shall be complete in all respects and any additional equipment, accessories,<br />
auxiliaries, services, work etc. which are not specifically mentioned in the specification but<br />
are required for smooth and trouble free operation and to achieve performance required to<br />
be guaranteed in terms of the Bid Document, shall be included by the Bidder in the offer.<br />
1.1.17 The make of all bought out items shall be as per” List of preferred makes” of supplies and<br />
equipment mentioned in tender document.<br />
1.1.18 Metric systems & English language shall only be used throughout the Bid and in the<br />
drawings.<br />
1.1.19 The Bidder shall satisfy himself about his ability for completing the work as per the time<br />
schedule before submitting his offer. In case the Bidder is unable to adhere to the schedule<br />
indicated in this specification, the Bidder need not submit their offer against this Bid Bid.<br />
1.1.20 A complete list of exclusions from Bidder's scope of work shall be clearly indicated in the Bid.<br />
1.1.21 In case of any contradiction between Instructions to Bidder and Technical Specifications,<br />
stipulation in the Technical Specification shall prevail.<br />
1.1.22 The Bidder has to carry out the work is such a manner that it does not affect the plant<br />
operations. If other Contractors are also engaged at the same work site for other jobs, the<br />
Bidder shall work in co-ordination ordination with them such that tthe<br />
he work of other Contractor is not<br />
affected. For integration of new facilities & the existing one, shutdowns period in phases, as<br />
per the schedule mutually agreed between “Purchaser” and successful Bidder would be<br />
provided. Hence, Bidder shall indicate in their offer, the stages at which the shut downs are<br />
required and their respective duration.<br />
1.1.23 All parts of equipment requiring replacement or inspection or lubrication shall be so<br />
arranged/ assembled that they are easily accessible without the need of dismantling of other<br />
equipment or structures. All electrical cables shall be so laid that they are not liable to be<br />
damaged and can be easily inspected and maintained and when necessary any damaged<br />
cable can be accessed & replaced individually.<br />
1.1.24 All equipment shall be complete with adequate safety devices wherever a potential hazard<br />
to personnel exists. Provision for safe access of personnel working to and around equipment<br />
for operation and maintenance, shall be provided.<br />
1.1.25 The Bidder shall train the Purchaser’s personnel in all disciplines of the operation &<br />
maintenance of the plant & equipment being provided by them under the contract.<br />
1.1.26 Standardization of components and assemblies shall be carried out to the maximu maximum possible<br />
extent to ensure interchangeability/as well as to minimize inventory levels.<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 3 of 11
1.1.27 Bidders shall furnish drive ratings of all equipments including conveyors along with the offer.<br />
Conveyor profiles enclosed with this specification are indicat indicative only.<br />
1.1.28 The Bidder shall include in his scope of supply, a complete set of new and unused special<br />
tools and tackles required for operation and maintenance of the plant and equipment. The<br />
list of tools & tackles considered in the bid shall also be submitted.<br />
1.1.29 The Bidder shall include in his scope, the requirement of initial fill of oils, lubricants, grease,<br />
and all other consumables required for start start- up, testing, commissioning and performance<br />
guarantee uarantee tests of the unit/equipment. A list of such consumables shall also be furnished by<br />
the successful Bidder for Purchaser’s use.<br />
1.1.30 The Bidder shall include in his scope the supply of spares required for successful<br />
commissioning of plant & equ equipment. ipment. The list of commissioning spares considered in the bid<br />
shall also be furnished along with the bid.<br />
1.1.31 The Bidder shall quote separately for the spares required for the normal operation and<br />
maintenance of the plant and equipment for a period of 24 months to be reckoned from the<br />
date of taking over of the plant and equipment. A list of the spare parts shall also be<br />
furnished along with item wise price.<br />
1.1.32 The successful Bidder shall not offload the contract or part thereof to any subcont subcontractor<br />
without written permission of the purchaser. In the event of subletting of any part of the<br />
work with due permission by the purchaser, the fact that such permission has been<br />
accorded shall not absolve the successful Bidder from any of his obligations and liabilities<br />
under the contract.<br />
1.1.33 Subject to availability and at the request of the successful Bidder, water for construction<br />
purpose will be made available by the Purchaser at one mutually agreed point at site. The<br />
successful Bidder shall mak make e his own arrangement for any further distribution at his own<br />
cost. Water supply shall be free of cost and shall be provided as specified under clause no.<br />
54.13 b) of the GCC.<br />
1.1.34 Power Supply<br />
Subject to availability and at the request of the succes successful sful Bidder, Electric Power will be<br />
made available at one point only at a distance not more than 500 meters away from the<br />
Contractor’s premises. The power will be supplied at 400/440 Volt and shall be metered and<br />
charged at the rate as specified in the GCC GCC. . The successful Bidder should have sufficient<br />
number & capacity of DG sets to meet the emergency power requirements in the event of<br />
failure in power supply.<br />
1.1.35 Civil and structural steel works<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 4 of 11
The supply of conveyor galleries, trestles, Junction ttowers,<br />
owers, buildings & civil work are in the<br />
scope of this tender including the Design of Civil & Structural works , shall be within the<br />
scope of successful bidder.<br />
1.1.36 Fire hydrant system<br />
The Bidder shall include in his scope the extension & rerouting of fire hydrant system to the<br />
wagon tippler & conveyor system. The hydrant line should be laid as per IS specification.<br />
1.1.37 Exclusions: : Following items are excluded from the scope of work<br />
1. Railway track system.<br />
1.2 ERECTION<br />
1.2.1 The successful l Bidder shall be responsible and perform the following with respect to the<br />
erection of the Plant and supplies.<br />
1.2.2 The scope of work of the successful Bidder shall be complete erection of the Plant and<br />
Equipment etc. as specified in the Technical Spe Specification. cification. The Bidder shall make all<br />
arrangements to deliver the equipment at their site stores by wagons / truck / trailers, build<br />
his own stores (covered, uncovered and air air-conditioned, conditioned, if necessary) for the proper storage<br />
of equipment, maintain the st stores ores and all related documents and records, transport the<br />
equipment to site for erection purpose and take an Erection Erection- cum- Storage insurance policy<br />
covering all the risks including third party liability for all supplies as well as human life. All<br />
security arrangements also shall be made by the successful Bidder. Space only for stores and<br />
site office shall be made available to the Bidder by the Purchaser.<br />
1.2.3 The successful Bidder shall take the equipment from their site stores and transport the same<br />
to erection site.<br />
1.2.4 The successful Bidder shall unpack and do visual checking against physical damages to the<br />
equipment / cases, cleaning of equipment before start of erection. Damage / shortage if any,<br />
will be reported to the Purchaser / consultant and shall be rectified / replaced expeditiously,<br />
free of charge to Purchaser so as not to upset the erection and commissioning schedule.<br />
Delay on account of settlement of insurance claims by the successful Bidder shall not be<br />
considered an excuse for delay in completion.<br />
1.2.5 The successful Bidder shall lay and maintain properly all the temporary supply lines in the<br />
erection site for temporary power and water required for storage and erection purposes<br />
from a single point to be provided by the Purchaser. Drinking water shall also be made<br />
available at one central point at site. The successful Bidder shall make his own arrangement<br />
for any further distribution.<br />
1.2.6 The successful Bidder shall arrange all necessary construct construction ion machinery/ equipment, tools<br />
& tackles, instruments, compressors, small hand tools, welding equipment, all<br />
commissioning instruments, erection & service bolts, nuts, jigs and fixtures, winches,<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 5 of 11
alignment tools, precision levels etc., Crane/ hoists and oother<br />
ther equipment which may be<br />
required for carrying out the erection work efficiently within the time schedule provided<br />
herein the specification. Unless otherwise specified, the above construction materials shall<br />
be the property of the successful Bidder. How However ever Purchaser's prior permission shall be<br />
required for removal of these construction materials from the site. Successful Bidder shall<br />
ensure that proper documentation is maintained for such items, which are required to be<br />
carried back by successful Bidder after the completion of work.<br />
1.2.7 The successful Bidder shall provide all temporary ladders, scaffolding materials, platforms,<br />
supports and other necessary facilities required for handling, erection, testing and visual<br />
inspection of supplies at the ppoint<br />
oint of installation and shall also provide necessary packing<br />
plates, wedges, shims, levelling screws etc. required for erection of equipment and<br />
technological structures.<br />
1.2.8 The successful Bidder shall provide erection consumables like oxygen and acetylene gas,<br />
welding rods, solder lugs, oil, grease, kerosene, cotton waste, etc. required for erection of<br />
equipment and technological structures.<br />
1.2.9 The successful Bidder sh shall all erect and maintain his own site offices, main stores and site<br />
temporary stores as required for the work and arrange for maintaining in neat manner of<br />
the area placed at the Successful Bidder's disposal.<br />
1.2.10 The successful Bidder shall provide suf sufficient ficient fencing, notice boards and lights to protect and<br />
warn others as may be considered necessary by the purchaser / consultant. All materials<br />
used for providing these facilities shall be properties of the successful Bidder.<br />
1.2.11 The equipment and technological echnological structures will be erected as per the instructions of the<br />
suppliers & under the supervision of the supervisory staffs to be deployed by the successful<br />
Bidder at site and only with the approval of Purchaser / Consultant. The successful Bidder<br />
shall use pre-assembly assembly and mechanisation to the maximum extent in order to fulfill erection<br />
& construction targets.<br />
1.2.12 The Successful Bidder shall align, level, couple and securely fix all equipment, appurtenances<br />
and accessories in accordance with ddrawings<br />
rawings and / or instructions of Purchaser/ Consultant.<br />
1.2.13 Laying and termination of cables, bus bars, bus ducts, lightening protection and earthing<br />
shall be done by the Successful Bidder.<br />
1.2.14 The successful Bidder shall be responsible for prot protection ection and / or diversion of all existing<br />
underground and over ground services, wherever required. The terms and conditions for<br />
protection / diversion of services not shown on drawing / indicated in the specifications shall<br />
be mutually agreed.<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 6 of 11
1.2.15 Installation stallation and connection of all piping and fittings within the scope of work shall be<br />
responsibility of the successful Bidder.<br />
1.2.16 The successful Bidder shall be responsible for checking the correctness of erection of<br />
mechanical equipment, technolog technological ical structures and auxiliary systems, electrical equipment<br />
etc. as per the specification.<br />
1.2.17 The successful bidder has to carry out the work in such a manner that it does not affect the<br />
operation of other plant/ shop. If other Contractors are also eengaged<br />
ngaged in the same work site<br />
for other jobs the bidder shall work with them in a co co-ordinated ordinated manner.<br />
1.2.18 The successful Bidder shall be responsible for the management of erection work with proper<br />
and adequate supervision for ensuring progress of ere erection ction work and quality of<br />
workmanship.<br />
1.2.19 The successful Bidder shall deploy required number of supervisory, skilled, unskilled and<br />
auxiliary labour as required for the erection work: as per detail mobilisation schedule (to be<br />
furnished with Bid by successful Bidder) and comply with such reasonabl reasonable instructions of the<br />
Purchaser / Consultant in the interest of satisfactory progress and completion of the work<br />
according to the schedule. The successful Bidder shall work in 3 shifts per day basis for<br />
meeting the completion target, if required within the contract price.<br />
1.2.20 The successful Bidder shall organise the work in a manner that other work at site is not<br />
impeded and the workmen therein not endangered and shall arrange temporary access at<br />
site, if required for the erection work.<br />
1.2.21 Successful essful Bidder shall return to the Purchaser all crates, packing cases and packing<br />
materials excess commissioning spares, oil and lubricants at a place designated by the<br />
Purchaser.<br />
1.2.22 The successful Bidder shall conduct all necessary tests / checks dduring<br />
uring erection.<br />
1.2.23 The successful Bidder shall attend to the rectification of erection defects, if any,<br />
expeditiously. The successful Bidder shall arrange all testing instruments for such testing at<br />
site.<br />
1.2.24 The successful Bidder shall carry out final painting of the Plant & Equipment and<br />
technological Structures etc. erected as per the instructions stipulated in the Technical<br />
Specification.<br />
1.2.25 The successful Bidder shall be responsible for total commissioning of the Plant and<br />
equipment including cold trial run and demonstration of Performance Guarantee Test. The<br />
Purchaser's supervisory and skilled operating personnel shall, however, be available to work<br />
under the guidance and supervision of the Bidder. Necessary raw materials, auxiliari auxiliaries,<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 7 of 11
utilities, electricity and operating personnel shall be made available by the Purchaser<br />
covering 3 shifts operation as per the programme agreed to in advance.<br />
1.2.26 The Successful Bidder shall supervise running of the Plant for satisfactory, reliabl reliable and<br />
regular operation and performance after its successful commissioning for establishing<br />
performance guarantees.<br />
1.2.27 Electrical energy and construction water shall be supplied by Purchaser to the successful<br />
Bidder during erection, at one point.<br />
1.2.28 All safety measures required to be adopted as per the Statutory Regulations & the Safety<br />
Rules of the Plant shall be strictly followed by the successful Bidder during the execution of<br />
the Contract. The successful Bidder shall depute safety engineer engineers s for strictly compliance of<br />
safety rules & regulations.<br />
1.2.29 The successful Bidder shall intimate the Plant authorities in writing well in advance about<br />
the requirement of shut down of any of the existing units / facilities for inter connection /<br />
incorporation orporation of additional facilities. The shut down period shall be mutually discussed and<br />
finalised. The work to be undertaken during the shutdown period shall be planned<br />
meticulously to reduce the shut down period to the minimum.<br />
1.2.30 The successful Bidder shall comply with all statutory Rules, Regulations with respect to the<br />
employment of labour at site.<br />
1.2.31 The successful Bidder shall carry out any and all such works, as may be required, to build a<br />
Plant complete in all respect as per the Technical Specification and achieve the Performance<br />
Guarantees and other parameters as given in the subsequent chapter of this specification.<br />
1.2.32 Any loss of plant and equipment due to imprudence, negligence and / or inequitable<br />
treatment and handling shall be replaced by the Successful Bidder / his sub sub-contractor at his<br />
own cost.<br />
1.3 PAINTING<br />
All parts of the equipment ipment shall be thoroughly cleaned of loose mill scales, rust or foreign<br />
matters.<br />
All parts excepting motors, resistors, gears etc. shall be painted at shop and at site with two<br />
coats of epoxy zinc based on zinc dust.<br />
Interior of all gear housing shall be painted with oil resistant paint. All machine pads,<br />
bearings surface or structures or housing shall be painted with white lead. All parts,<br />
inaccessible after assembly, shall be painted and assembled while the paint is wet.<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 8 of 11
After erection, the damaged portion of the painted surface shall be retouched and an<br />
intermediate coat / final coat of PVC copolymer alkyd resin with micaceaus iron oxide (MIO)<br />
shall be applied. The colour shall be as per the choice of the Purchaser.<br />
The subsequent one final coat of paint of PVC copolymer alkyd with weather resistant<br />
pigment (approved by the Purchaser) and glossy finish shall be applied.<br />
The details of the dry film thickness (DFT) of the different coats shall be as follows:<br />
a) Primary coat : 30 –40 micron per coat<br />
b) Intermediate coat : 70 –80 micron per coat<br />
c) Final coat<br />
: 40 –50 micron per coat<br />
The painting scheme & colour code shall be approved by the Purchaser. The successful<br />
Bidder shall refer to Section 8 for further detail of f painting scheme & colour codes.<br />
1.4 OPERATING / PERFORMANCE PARAMETERS<br />
All the equipment covered in this specification shall fulfill the operating and performance<br />
requirement covered under this Technical Specification and indicated in the approved<br />
drawings.<br />
The successful Bidder shall study the specification and satisfy himself thoroughly regarding<br />
the workability and suitability of the equipment offered by him. He shall take full<br />
responsibility for the guaranteed and satisfactory operation of the eequipment<br />
quipment as regards to<br />
its performance and smooth and reliable working.<br />
1.5 PRELIMINARY ACCEPTANCE<br />
After completing the erection of a unit or agreed portion thereof, the successful Bidder shall<br />
give a notice in writing stating that the job is complete in all respects and ready for<br />
preliminary acceptance. The job shall be visually inspected by representa representatives of the<br />
Successful Bidder and Purchaser / Consultant to ascertain whether supply, fabrication and<br />
erection are as per contract drawings and Technical Specification. All observed defects,<br />
deficiencies and omissions shall be noted down. If the defects, deficiencies and omissions<br />
are not major in the opinion of the Purchaser / Consultant, the successful Bidder shall be<br />
issued a preliminary acceptance certificate mentioning the defects, deficiencies and<br />
omissions. The noted defects, deficiencies and omissi omissions ons shall be made good by the<br />
successful Bidder within a period of 3 to 4 weeks.<br />
1.6 FINAL ACCEPTANCE<br />
Before commencement of final acceptance test of the building or unit, the successful Bidder<br />
shall make available required numbers of complete sets of ordinary prints of drawings,<br />
required numbers of set of DOD list for the drawings and one set of reproducible film of all<br />
Technical Specification: Sec-3,Special 3,Special Stipulation To The Bidders<br />
Page 9 of 11
drawings, all representing As As-Built Built condition (i.e. all additions and alterations done during<br />
fabrication and erection shall be incorp incorporated in the drawings).<br />
The successful Bidder shall attend to all defects, deficiencies and omissions noted down<br />
during preliminary acceptance and after rectifying or making good the above in all respects,<br />
shall inform 10 days in advance the Purchaser / Consultant for conducting final acceptance.<br />
During Final Acceptance all defects, deficiencies and omissions noted earlier shall be<br />
checked. The successful Bidder shall also make good any defect, deficiency or omission not<br />
notified during earlier prelimina preliminary ry acceptance, but pointed out during final acceptance. Final<br />
Acceptance certificate shall be issued by the Purchaser after all defects, deficiencies and<br />
omissions noted under preliminary or final acceptance have been rectified.<br />
1.7 SCOPE OF WORK<br />
1.7.1 The broad turnkey scope of work shall be as per the following:<br />
• Design, manufacture, inspection, shop & primary coat of paint & supply of complete<br />
plant & equipment, fabrication (shop & site) of building structures & technological<br />
structures, civil construction materials, power distribution, electrics, instrumentation &<br />
automation, illumination, all utilities & services, in in-plant plant road networks, drainage<br />
systems, landscaping, fire detection & alarm system, fire fighting pump house, as<br />
required, for complete mplete & trouble free operation of Coal Handling System in an<br />
integrated manner.<br />
• Basic engineering, detail engineering and reference category of drawings, operating<br />
software and documents, in requisite copies, for approval of NALCO/ RITES. Further, the<br />
Tenderer nderer will furnish final basic & detail engineering drawings, manufacturing drawings<br />
of fast wearing items and non non-standard standard items, as built drawings, erection<br />
drawings/documents, operating software, operation and maintenance manuals in soft<br />
editable format.<br />
• Receipt of material, loading / unloading, storage, civil construction, complete erection,<br />
testing, commissioning, handing over of Wagon Tippler Complex to Purchaser,<br />
demonstration of performance guarantee and post commissioning services . Preparation<br />
and nd approval of erection survey / alignment schemes, grouting clearances, painting<br />
clearances, testing of welds, pressure testing protocols and other related site protocols.<br />
• Deputation of representatives of equipment suppliers and technology suppliers to site<br />
for supervision of erection, testing and commissioning.<br />
• Applying final finish coat of paint as per approved procedure & shades before handing<br />
over, first fill of lubricant & oil, special tools & tackles, mobile equipment, handling &<br />
hoisting equipment t etc.<br />
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• Supply of all commissioning spares. A list of such commissioning spares shall be<br />
indicated separately separately. Tenderer shall quote separately for one year recommended spares<br />
with the main offer.<br />
• Progress reporting as per agreed formats, providing documen documentary tary evidence of purchase<br />
orders on sub vendors with addresses of contact persons, attending all site progress<br />
review / engineering review meetings at NALCO, Angul or at RITES, Gurgaon /<br />
Bhubaneswar, opening an equipped site office with coordinator oversee overseeing all activities.<br />
• Arrangement of all erection equipment viz. cranes, hoists, winches, etc, and safety<br />
appliances as required for erection of plant & equipment. Appointment of safety officer<br />
by the contractor shall be included.<br />
• Specialized training of Purchaser’s personnel for operation, maintenance, for smooth<br />
handing over the plant.<br />
• Testing and cold trial run of systems/ sub - systems and integrated testing shall be<br />
carried out by the successful Tenderer on continuous basis for complete Coal Handling<br />
System along with associated facilities followed by commissioning. On successful<br />
commissioning of the various sub sub-systems systems of the Wagon Tippler complex, PG test of the<br />
entire Tippler House shall be carried out as elaborated in the relevant chapter.<br />
• Receiving g delivery of items at site, their proper storage, and handling at site, watch and<br />
ward services, removal of debris to a location specified by the Purchaser etc. Site shall<br />
be handed over to the Purchaser in clean and orderly manner to the satisfaction of the<br />
site engineers after commissioning of the project.<br />
• Getting Purchaser’s/ consultant’s approval for the drawings prepared by the successful<br />
Tenderer, obtaining required approval from statutory authorities, providing adequate<br />
personnel, equipment, tools & tackles for timely completion of the project.<br />
• For detailed scope of work and design parameters on various subsystems & facilities, the<br />
Tender Specification shall be referred to.<br />
1.7.2 This is a turnkey project for Installation of Wagon Tippler and convey conveyor or system and all the<br />
facilities required for proper functioning of the wagon tippler and achieving the rated<br />
capacity shall be deemed to be covered in the tender specification, unless specifically<br />
excluded from the Tenderer’s scope.<br />
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1.0 SYSTEM PARAMETERS, OPERATION & CONTROL PHILOSOPHY<br />
1.1 The specifications as brought out in various Sub Sub-sections sections for mechanical equipment shall be<br />
applicable for the proposed wagon tippler and conveyor system and specifically to all<br />
mechanical including their operation & control philosophy. However, some specific<br />
parameters of the entire system as a whole and the major equipment are brought out as<br />
under.<br />
2.0 PARAMETERS<br />
2. 1 Conveyor System<br />
i. Rated Capacity (Guaranteed) : 1200 TPH<br />
ii. Design capacity : 1320 TPH<br />
iii. Belt width : 1200 MM<br />
iv. Belt speed : 3.5 m/sec. (approx.)<br />
2.1.1 Belting and Pulleys<br />
Belts of conveyors shall be provided with latest belt weighing system to measure/record the<br />
quantum of coal falling on the belt and being carried by the conve conveyor yor system. The weighing system<br />
shall have adequate no of load cell., digitizer and intelligent terminal with printer facility for<br />
computerized zed print out of the weight.<br />
(a) Belt ratings with appropriate ratings shall be selected.<br />
(b) Minimum number of plies for belting shall be four (4) if possible, can be standardized<br />
with the type of belting available with NALCO.<br />
(c) For Pulley, following minimum parameters shall be adopted:<br />
(1.) Shell thickness : 16 mm (Min.)<br />
(2.) End disc plate thickness : 24 mm(Min.)<br />
(3.) Maximum allowable deflection of shaft at hubs : 5 Minutes<br />
(4.) Diameter for all drive pulleys shall be minimum 800 mm. Di Diameter of all other<br />
pulleys shall be minimum 630 mm<br />
The contractor shall obtain confirmation from belt manufacturers regarding the adequacy of<br />
the pulley diameters.<br />
2.1.2 Wagon Tipplers<br />
(a) No. required: 1 (One)<br />
(b) Guaranteed tips per hour per tippler: 20<br />
2.1.3 Side Arm charger<br />
(a) Nos. required :1 (one)<br />
(b) Guaranteed haulage : 60 fully loaded coal wagons (Box –N)<br />
2.1.4 Apron Feeder<br />
(a) No. required : One (1)<br />
SECTION 4<br />
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(b) Guaranteed (rated) capacity: 1200 TPH Apron Feeder<br />
2.1.5 E.O.T Crane<br />
(a) No. of unit : One (1)<br />
(b) Guaranteed (rated) capacity (Main/Aux.) : 25 T /5 T<br />
2.1.7 Dust Control System<br />
The parameters for the dust control system specified hereinafter are intended for<br />
Contractor’s guidance only. Contractor shall provide adequately sized and effective dust<br />
control system, the performance of which shall be guaranteed by the Contractor as required<br />
in the Technical specifications. The performance guarantee test procedure is to be<br />
submitted by the Contractor. However, the capacity of the offered ssystem<br />
ystem shall not be less<br />
than that specified below.<br />
(a.) Area Dust Suppression System at Wagon Tippler<br />
(1) Location<br />
: Wagon Tippler Top<br />
(2) Capacity of each nozzle : 2.0 lpm at 2.5 kg/ cm<br />
(3) Nozzle spacing.<br />
All nozzles to operate simultaneously in each wagon tippler area.<br />
2<br />
(3) Nozzle spacing. : 500 mm<br />
simultaneously in each wagon tippler area.<br />
(b) Dust Suppression System for other areas<br />
(1) Operation<br />
: Water sprayed with fogging nozzle<br />
(2) Location of spray : All coal loading and discharge point on the<br />
conveyor<br />
(3) Capacity / Pressure : 2.0 lpm / 2.5 kg/cm 2 Water sprayed with fogging nozzle<br />
: All coal loading and discharge point on the<br />
inlet of spray head<br />
2.1.8 Service Water System<br />
Service water connections are to be provided in conveyor galleries & tunnels at 50 meter<br />
interval and one (1) no. on each floor of Transfer Point.<br />
(a.) Flow at each valve : 5 cub . m/hr<br />
(b.) Minimum discharge Pressure at tap point : 2 kg/sq.cm<br />
(c.) No of pumps : 2 nos.<br />
(d) No. of valves operated : 6 nos. simultaneously<br />
2.1.9 Ventilation System<br />
A Mechanical Ventilation System<br />
2.1.10 Chutes<br />
• For Underground Areas a Minimum of 15 supply air changes and minimum 7 exhaust<br />
air changes per hour.<br />
• For other Areas a Minimum of 10 supply air changes per hour.<br />
B. Pressurized Ventilation System System: : Minimum 15 supply air changes per hour<br />
C. Air Conditioning System :<br />
• Adequate number of air changes to Maint Maintain ain uniform temp. & humidity.<br />
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Minimum clear cross section of chute shall be 1200 mm x 1000 mm (inside both ways).<br />
2.1.11 Hoists<br />
Suitable hoists as specified elsewhere shall be provided for erection & servicing of all major<br />
equipment. The equipment to be covered shall include (but not limit to) all conveyor drive<br />
units, all pulleys, Apron feeder, sump pumps, various DS/service water/potable water pumps,<br />
gravity take up units, removal of equipment from tunnels, lifting of belt drum at all tr transfer<br />
houses.<br />
2.1.12 All other equipment under the scope shall be suitable to the system capacities parameters<br />
as specified above.<br />
3.0 OPERATION AND CONTROLS<br />
3.1 This section is intended to cover design, engineering manufacture, supply, erection, tes testing<br />
and commissioning of the complete control and instrument panel/desk with annunciation<br />
panel, etc. as specified hereinafter complete in all respects, required for the system.<br />
3.2 General Requirements<br />
The instruments and controls to be furnished and er erected ected under this specification are as<br />
required for safe and satisfactory operation of the plant & equipment under Wagon Tippler<br />
and Conveyor System Package, as outlined under mechanical section and as specified<br />
elsewhere in the specification. For the equip equipment ment and materials procured by the Contractor<br />
from his sub-vendors, vendors, the Contractor shall study the specification, safety requirements,<br />
interface drawings for such equipment and material in detail and shall coordinate his work<br />
with his subvendors and supply instrumentation and control to ensure suitability of the<br />
system.<br />
3.2.1 Standards / Codes<br />
All construction, installation, workmanship, design & equipment shall conform to acts, rules<br />
& regulations of the jurisdiction within which the project is to be located, and to the current<br />
edition of the following or equivalent standards or codes, in so far as they apply:<br />
• American Iron & Steel Institute (AISI)<br />
• American Society for Mech. Engineers (ASME)<br />
• American Society for Testing & Materials (ASTM)<br />
• American Wire Gauge (AWG)<br />
• Institute of Electrical & Electronic Engineers (IEEE)<br />
• Instrument society of America (ISA)<br />
• National Electrical Code (NEC)<br />
• National Electrical Manufacturers Association (NEMA)<br />
• Bureau of Indian Standards (BIS)<br />
• Conveyor Equipment Manufacturers Ass Association (CEMA)<br />
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• Guideline for wagon tipplers issued by RDSO – G33 (Rev. 1) of May 2010 with latest<br />
amendments if any.<br />
3.2.2 This Sub-section section shall be read in conjunction with Electrical Sub Sub-sections. sections.<br />
3.3 Construction and Design<br />
3.3.1 Construction<br />
Control desks/panels and annunciation system shall be provided as per the requirement of<br />
electrical Section. Annunciation’s, indications, electrical meters and instrumentation shall be<br />
provided as specified. Ammeters shall be provided on control desk for a aall<br />
motors rated 30<br />
kW and above and for all equipment.<br />
3.3.2 Design<br />
The Contractor shall provide a comprehensive control indication and annunciation scheme<br />
for the plant & equipment under wagon tippler and conveyor system package and integrate<br />
the same with the existing control & monitoring scheme of the CHP. Contractor shall furnish<br />
a block diagram and write write-up up on the scheme proposed. The final scheme will be approved by<br />
the Owner/RITES and the Contractor shall be required to execute the approved scheme scheme. In<br />
general, interlocking shall be achieved through feed feed-back back signals from field equipment. A<br />
comprehensive Annunciation and Indication scheme shall be provided such that, it will be<br />
possible for the operator to locate and identify the fault from the disp display ace of Control<br />
desk. The scheme shall include the basic remote control instrumentation, indication and<br />
annunciation requirements as per various technical specification requirements. However,<br />
the Contractor may offer any alternative proposal which he co considers nsiders to be equal, superior<br />
to the scheme as described in subsequent clauses below for achieving reliable and trouble<br />
free operation of the plant, for consideration of the Owner.<br />
4.0 OPERATION AND CONTROL PHILOSOPHY<br />
4.1 The Wagon Tippler control room sh shall all be located by the side of Wagon Tippler to<br />
accommodate control & monitoring equipment of wagon tipplers. It shall also have a battery<br />
room.<br />
4.2 The existing coal handling system is being controlled from the following control points. The<br />
existing control ol philosophy of the coal handling plant is being described below for the<br />
contractor to understand the existing system and suitably plan integration of the controls<br />
and interlocks of the proposed control system of the wagon tippler package with the existin existing<br />
system.<br />
4.2.1 Owner’s Existing Coal Handling Plant Control Room<br />
Operation of the CHP equipment is being controlled from the Owner’s CHP control room.<br />
(a.) Conveyors, feeders, flap gates, hydraulic couplings etc.<br />
(b.) Complete Dust Suppression system & sservice<br />
water system.<br />
(c.) Ventilation system (group/individual control as required).<br />
(d.) In line Magnetic separators and Suspended Magnet (ON/OFF control with indication).<br />
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(e.) Metal Detectors (ON/OFF control with indication).<br />
(f.) Belt weigher (ON/OFF co control with indication)<br />
4.2.2 Local Control Panels<br />
Local control stations for following equipment shall be provided for<br />
(a) All conveyors<br />
(b) All gates<br />
(c) Electric hoist - wall mounted control box with pendent push button controls.<br />
(d) Wagon Tippler<br />
(e) Apron feeder<br />
(f) Sump Pump<br />
(g) ) Dust suppression system for wagon unloading<br />
(h) ) Hydraulic scoop coupling, if any.<br />
All the above local control panels shall be accessible and located near their respective<br />
equipment and shall be complete with all the required controls, interlocks, annunciation’s<br />
etc. Necessary controls, indications and annunciation’s for all the above equipment shall also<br />
be provided at main CHP Control Room.<br />
4.2.3 In addition to the remote control of various equipments, local stop push butto button stations<br />
shall be provided for all equipment.<br />
4.3 SYSTEM OPERATION<br />
4.3.1 Typical Operation philosophy of the plant, in general, as elaborated below is for the<br />
information of the contractor to facilitate development of the control & monitoring scheme<br />
of wagon tippler and conveyor system package and integration with the existing control &<br />
monitoring system of existing CHP.<br />
(a.) Coal flow path selection shall be done from Owner’s existing control desk to select<br />
conveying paths.<br />
(b.) The coal handling system oper operator ator will select any one of the paths from the main control<br />
desk. The flow stream path is then selected by positioning different flap gates at desired<br />
positions. Once the system is in the operation, the gates can not be moved from their<br />
positions and path. Flap gates which do not fform<br />
rm the stream in which coal flow is taking<br />
place, can be operated at any time.<br />
(c.) The Control system will be designed for both “Auto” & “Manual” operation of the<br />
conveyors in the selected path. Auto/Manual Selection shall be done ffrom<br />
rom Owner’s existing<br />
control desk.<br />
Auto Mode : In the “Auto” mode, the conveyors and related equipment will start<br />
sequentially when the “System Start” is activated. During stopping, when the “System Stop”<br />
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is activated, all conveyors will also stop sequent sequentially ially (in the reverse sequence) allowing time<br />
delays for clearing the belts.<br />
Manual Mode : In Manual Mode, the operator will start the conveyor system, in the same<br />
sequence as in Auto mode from control desk. The operator will also stop the conveyor<br />
system, , by pressing "System stop" or individual “Stop” push buttons/command from control<br />
desk in the reverse sequence. System Start and System Stop PB’s and located on the<br />
Owner’s Control Desk.<br />
4.3.2 Conveyor System<br />
(a) Normally the operation of the apron feeder and the reclaim conveyor shall be controlled<br />
from main control room for evacuating coal from tippler hopper.<br />
(b) The approach of a Railway wagon rake to the plant shall be signaled (visual and audible) in<br />
the wagon tippler Control room as well as to the main coal handling plant control room, as<br />
soon as the rake come within 100 meters distances from the wagon tippler.<br />
(c) Each conveyor shall be protected against damage to the edge of the belt due to excessive<br />
sideways movement by providing adequate number of belt sway switches. In addition, each<br />
conveyor shall be provided with one (1) No. speed detection device (zero speed switch). The<br />
zero speed switches shall be designed to sense belt speed.<br />
(d) All the conveyors shall be protected from roll back due to power failur failure by providing<br />
mechanical / or electrical locking system.<br />
(e) The starting sequence of the conveyors shall follow a direction opposite to that of flow of<br />
material. The details of Coal flow diagram of the existing stage stage-I I CHP shall be furnished to<br />
the successful bidder.<br />
(f) Any individual equipment (belt conveyor etc.) should not be allowed to start unless the<br />
equipment immediately following the same in the direction of flow of material is already in<br />
operation.<br />
(g) Pull-cord cord switches shall be provided along the length of each belt conveyor, which shall<br />
enable the respective conveyor to be stopped immediately. Each pull operated chord switch<br />
and belt sway switch shall be tagged and shall be identifiable in the main control room.<br />
(h) Siren shall be provided to fore fore-warn personnel sonnel working nearby when starting any conveyor.<br />
(i) Interlocking of various conveyors shall be achieved with Flap Gate, limit switches and zero<br />
speed switches.<br />
(j) Motors shall start only when the brake/rail clamp if if-provided, provided, is in “open” condition. This<br />
signal al shall be obtained from limit switch provided for that purpose.<br />
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(k) Once a conveyor trips, flap gate directing coal from this conveyor shall change over its<br />
position with a time delay and shall come back to the original position again, to prevent<br />
jamming of gate.<br />
(l) Where ever scoop type coupling provided for HT motors, the coasting time of respective<br />
conveyor, thruster brake, actuator selection and the chute size shall be so selected such that<br />
there is no spillage of coal from any downstream conveyors.<br />
4.3.3 Interlocking<br />
a) The following conveyors / equipment are considered under interlock scheme : :-<br />
(1.) All conveyors<br />
(2.) All gates<br />
(3.) Wagon tippler<br />
(4.) Apron Feeder<br />
b) The following equipment will not come under interlock of the conveyor scheme.<br />
(1.) All dust suppression systems & service water system.<br />
(2.) Ventilation systems<br />
c) All conveyors and equipment have local push button stations each consist of :<br />
(1.) Pos - I, Pos - II & stop button for flap gate<br />
(2.) Emergency stop push button (Red) for other equipment<br />
d) Belt scale is started when relevant conveyors are started.<br />
e) The dust suppression systems will be energized as soon as the conveyors are energized.<br />
f) Coal Handling plant shall be tripped in case of detection of fire. Necessary input contact<br />
shall be made available lable to the Contractor in the Owner’s main control room.<br />
g) Interlock for H.T. Motor : H.T. motors used will continue to run on no load by<br />
disengaging the fluid coupling in case of failure of any process interlock. The H.T.<br />
motors will however be tripped in case of any motor fault like O/L, high motor winding<br />
temperature etc. In addition, in case of normal stop command, after running of the<br />
system, motors will stop.<br />
h) The following are the various safety interlocks for the conveyors and other equipment.<br />
This list st is indicative only and the Contractor shall develop a comprehensive interlocking<br />
scheme.<br />
Conveyors<br />
a). Pull - Chord switch - not operated<br />
b). Belt sway switch - not operated<br />
c). Underspeed switch - closed at 90% speed of the conveyor within designed<br />
accelerating time.<br />
d). Motor protection - not tripped<br />
e). Local stop PB – reset<br />
f). Chute Block switch - not operated.<br />
g). Brakes for conveyor – not operated.<br />
h). Trip circuits healthy.<br />
i). Temp. of fluid coupling oil - not high<br />
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Wagon Tippler<br />
a). Motor O/L - not tripped<br />
b). Local E-Stop PB - reset<br />
c). Stop PB in main CHP control room - reset<br />
d). All Limit Switches – reset<br />
e). All limit switches – not tripped<br />
Apron Feeder<br />
a). Motor O/L - not tripped.<br />
b). Local stop PB - reset.<br />
Flap Gates<br />
a). End of travel vel limit switches - reset.<br />
b). Torque limit switches - reset.<br />
c). Local stop - reset.<br />
4.3.4 The lists of indications and audio audio-visual visual annunciation given in subsequent clauses are<br />
indicative only and the same shall be finalised during detail engineering.<br />
4.3.5 Status indications in Mimic.<br />
Following individual status indications shall be provided in mimic with individual ON/ OFF<br />
/TRIP indications on HMI of PLC.<br />
(a.) Conveyor 'ON'<br />
(b.) Flap Gate/Rack and Pinion position.<br />
(c.) Belt scale flow rate indicati indication and totalizer.<br />
(d.) Belt sway switch operated for each conveyor (individual switch indication on CRT).<br />
(e.) Pull cord switch operated for each conveyor (Individual switches indication on CRT).<br />
(f.) Zero speed switch operated for each conveyor<br />
(g.) Wagon Tippler ‘ON'<br />
(h.) Apron Feeder ‘ON'<br />
(i.) .) DS/ SW/ VentON (System wise)<br />
Further Mimic lamps and Controls for HT and LT Breakers shall be provided on the control<br />
desk.<br />
4.3.6 Annunication System:<br />
The Control desk shall be provided with adequate number of facia type annunciation<br />
windows for the following audio audio-visual visual fault annunciation purposes. Wherever group<br />
annunciation is provided, alarm status of individual equipment shall be provided on mimic.<br />
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All audio visual annunciation of following parameters should be incorporated in the HMI of<br />
PLC.<br />
(a) 33 kV Breaker Trip (Group wise for each board)<br />
(b) 415 V MCC Breaker Trip (MCC wise)<br />
(c) Bus under voltage for each LT MCC<br />
(d) Following group wise annunci annunciation ation shall be provided for transformers :<br />
(i) Buchholz alarm<br />
(ii) Winding/oil temperature high alarm<br />
(iii) Oil level low alarm<br />
(iv) Buchholz trip<br />
(v) Winding/oil temperature high trip<br />
(e) A.C Control Supply failure.<br />
(f) D.C. Control Supply failure.<br />
(g) Annunciation supply failure.<br />
(h) Both CPU fail<br />
(i) Stand by CPU in service<br />
(j) LT motor overload tripped (Group).<br />
(k) ) Belt sway switch operated (Group)<br />
(l) ) Pull cord switch operated (Group)<br />
(m) ) Zero speed switch operated. (Group)<br />
(n) ) Chute plugged (Group)<br />
(o) Wagon rake arrival.<br />
(p) ) Wagon Tippler tripped (group)<br />
(q) Apron feeder.<br />
(r)Dust Dust suppression/service water system faults and trips (system wise)<br />
(s) ) Water level low in tanks (group)<br />
(t) ) Oil temperature of fluid coupling high<br />
(u) 20% spare windows<br />
For identification of the fault for a particular conveyor or equipment, status indication<br />
against that conveyor / equipment in the mimic will start fast flickering and the annunciation<br />
window will be blinking against that particular fault. In addition, a buzzer (alarm) will also<br />
start tart sounding. After acknowledgement of the fault, the buzzer will stop, but the fast<br />
flickering on the mimic and the steady glow on the annunciation window will continue until<br />
the fault is cleared and the Reset push button is pressed. When the fault is cl cleared and the<br />
Reset push button is pressed, the status indication of that conveyor / equipment on the<br />
mimic will start slow blinking if it is on selected path otherwise it will go off and the steady<br />
glow in the annunciation window will go off. However, pre pressing ssing of the Reset push button<br />
before clearance of the fault, will have no effect on the lamps.<br />
At the time of a fault, the faulty conveyor / equipment, as well as the preceding conveyors /<br />
equipment in the interlock sequence, will stop except H.T. motors for which only scoop<br />
coupling will be disengaged and motor will continue to run for process fault. In case of<br />
motor fault, H.T. motor will trip but the succeeding conveyors / equipment will continue to<br />
run. The status indication against the preceding conv conveyors eyors / equipment will start slow<br />
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linking while the faulty conveyor / equipment will be fast blinking. Start command shall not<br />
be initiated unless reset button in pressed after clearance offault.<br />
The sequence of operation of the annunciation system shall be as follows: follows:-<br />
Condition<br />
Status<br />
Normal : Ann. Window : Off.<br />
Status indication : Steady glow<br />
Buzzer<br />
: Off.<br />
Fault : Ann. Window : Blinking.<br />
Status indication : Fast blinking<br />
Buzzer<br />
: Sounding.<br />
Press Accept PB.<br />
Ann. Window : Steady glow.<br />
Status indication : Fast blinking<br />
Buzzer<br />
: Off.<br />
Press Reset PB (When fault is cleared):<br />
Ann. Window : Off.<br />
Status indication : i) Steady blinking (if on selected path)<br />
ii) Off (if not on selected path)<br />
Buzzer.<br />
: Off.<br />
4.3.7 Dust Suppression System<br />
(a.) Conveyors / Equipment<br />
1. It shall be possible to spray the water on to coal stream only when corresponding<br />
conveyors/equipment’s are running with material at spray application points.<br />
2. If a running pump trips stand stand-by pump shall start automatically. lly. It shall be possible to select<br />
any of the pumps as auto standby from main CHP control room.<br />
3. Pump/pumps shall trip with a time delay, if discharge valves fail to open. Suitable<br />
pressure/flow switch shall be provided to sense this condition.<br />
4. Pumps shall trip in case of low level of water in tank.<br />
5. All feeding pumps to tank shall trip in case of high high-high level in tank.<br />
6. All the controls shall be through control desk.<br />
(b.) Wagon unloading<br />
1. System shall be operated from local control panel.<br />
2. Dust suppression system shall be provided to cover the WT Hopper.<br />
3. Pumps shall be started manually or from control panel. . If any of the pump/pumps trips,<br />
stand-by by pump/pumps shall start automatically. It shall be possible to select any of the<br />
pumps as auto stand - by.<br />
4. Pumps shall trip in case of low level of water in tank.<br />
5. Following annunciation’s shall be provided at local control panel.<br />
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(i) Motor electrical protection operated (Group)<br />
(ii) Discharge water pressure low (Group)<br />
(iii) Water level low in tank (Individual)<br />
6. Following individual indications shall be provided at local control panel.<br />
(i.) Motor ON/OFF/TRIP<br />
(ii.) Discharge pressure healthy<br />
(iii.) Water level high in tank.<br />
4.3.8 Sump Pumps<br />
(a) Sump Pumps shall start and stop by the level switches in the sump automatically.<br />
Further manual override start / stop push button shall be provided locally on ground<br />
level.<br />
(b) Any of the pumps can be selected as auto auto-standby.<br />
(c) If the sump level continues to be high even after the first pump is under operation<br />
second pump shall ll start automatically.<br />
(d) The following indications for sump pumps shall be provided on local Control Panel.<br />
(1.) Water level high<br />
(2.) Motor ON/OFF/TRIP.<br />
4.3.9 Wagon Tippler<br />
Wagon Tippler shall be controlled from the local control panel suitably placed. Require Requirement<br />
of operation as described elsewhere in the specification shall be complied with. Following<br />
indications shall also be provided on the local control panel:<br />
(a.) Motor ON/OFF<br />
(b.) Motor O/L protection operated<br />
(c.) Brakes applied (if provided)<br />
(d.) Hydraulic power pack indications as applicable.<br />
4.3.10 Flap Gates<br />
All flap gates shall be motorised and remote controlled from the main control desk. Their<br />
position shall be indicated on the mimic of main control room.<br />
4.3.11 Service water and Cooling Wa Water<br />
(a) These pumps shall be started from main CHP control room<br />
(b) Pump shall trip in case of low water level in tank.<br />
(c) Following individual inputs shall also be provided to PLC system for alarms/indications :<br />
(1.) Motor ON/OFF/TRIP<br />
(2.) Discharge water er pressure low<br />
(3.) Water level low in tank<br />
(4.) Water level high in tank<br />
5.0 WAGON TIPPLER<br />
GENERAL<br />
Rotaside / Rotary wagon tippler shall be furnished complete with all structural members,<br />
tippler platform, tipping mechanism, tippler drive motors, brakes, couplings, shafting and all<br />
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automatic controls for positioning, tipping and discharging the entire ccontents<br />
ontents of the wagons<br />
into the hopper.<br />
5.1 Wagon Unloading System<br />
5.1.1 The rake comprising of specified maximum maximum60number number of wagons shall be pushed into the<br />
reach of in-haul haul equipment by a locomotive. Further placing of wagons over tippler<br />
platforms and carrying aw away ay the empty wagons shall be accomplished with the help of a side<br />
arm charger under scope of bidder.<br />
5.1.2 Wagon unloading equipment shall be suitable to handle any type of wagons being used by<br />
Indian Railways for transportation of coal. Thus side arm charger aand<br />
nd wagon tippler shall be<br />
suitable to handle all standard broad gauge (1676 mm) wagons of RDSO design used by<br />
Indian Railways conforming to latest revision of IS: 10095.<br />
5.1.3 Maximum moving dimensions of locomotive & wagon as per Indian Railway norms shall be<br />
adopted for providing clearances with respect to structures, equipment and tippler<br />
arrangement.<br />
5.1.4 Complete wagon tippler and accessories shall have the approval of concerned Indian Railway<br />
Authorities and RDSO. Further, the contractor shall submit to the Owner detailed drawings<br />
of wagon tippler and accessories including civil and structural drawing only after getting the<br />
same approved from the concerned Railway authorities.<br />
5.1.5 The bidder shall obtain all statutory approvals from the relevant Railway authorit authorities, before<br />
the wagon tippler complex is put into operation. Any statutory payment charges, to be made<br />
to the concerned authorities shall be to Bidder’s account. It is the responsibility of the<br />
Contractor to carry out any modifications as required by the RRailway<br />
ailway authorities, at no extra<br />
cost to the Owner.<br />
5.2 Wagon Tippler Hopper<br />
5.2.1 The wagon tippler hopper shall be of RCC construction and adequately sized to<br />
accommodate the coal load for atleast two (2) nos. 8 wheeled wagons of RDSO design used<br />
by Indian ian Railways. For effective volumetric capacity computation of the hopper, the angle<br />
of repose of coal shall be considered as 37°. The minimum valley angle of the hopper shall<br />
be considered as 60°. The hopper shall have opening below which apron feeders sh shall be<br />
provided to evacuate coal from the hopper and feed onto associated belt conveyors below.<br />
Complete inside surfaces of the hopper shall be provided with 50 mm thick guniting. Further<br />
it shall be possible to empty out all the coal, without any dead sto stock ck from the hopper.<br />
5.2.2 Steel gratings of mesh size 30 300 mm x 300 mm over wagon tippler hopper shall be provided.<br />
The gratings shall be built of minimum 200 mm x 36 mm thick flats. The hopper and gratings<br />
shall be designed for movement of ffront<br />
end loader/bulldozer over them. Bull Bull-dozer weight<br />
shall be considered as about 35 T.<br />
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5.3 CODES AND STANDRDS<br />
The design, manufacture, inspection and testing of Wagon Tippler shall comply with all the<br />
currently applicable statutes, regulations and safety codes in the locality where the<br />
equipment is to be installed. The Wagon Tippler shall conform to the latest edition of the<br />
standards and codes. Other internationally acceptable standards/codes, which ensure equal<br />
or higher performance than those specified, shal shall l also be accepted. Nothing in this<br />
specification shall be constructed to relieve the contractor of the required statutory<br />
responsibility. In case of any conflict in the standard and this specification, the decision so<br />
the Engineer shall be final and bindi binding.<br />
5.4 DESIGN REQUIREMENT<br />
Keeping in view Technical guideline issued by RDSO (Research & design services organization<br />
)G 33 Rev.01 issued on May’10 & effective from Dec’10, the specification of wagon tippler<br />
along with apron feeder to be designed as under:<br />
a) Wagon tippler capacity : 25 Tips per Hour<br />
b) Load handling capacity of wagon tippler : 140 Ton<br />
5.4.1 The wagon tippler shall be suitable to unloa unload a coal wagon.<br />
5.4.2 During each cycle of operation, the tippler shall be capable of holding, completely unloading<br />
and replacing the wagon to its original position without damage to the tippler or the wagon<br />
or the track.<br />
5.4.3 The tippler shall be suitable for continuous operation, 24 hours a day, round the clock.<br />
5.4.4 The wagon tippler structure shall be designed to conform to the requirements of Indian<br />
Railway’s “Research, Design and Standards Organisation, (RDSO) - G 33 Rev.1 ” with regard<br />
to the nature of loading, impact factor and allowable stresses. It shall be the sole<br />
responsibility of the contractor to ensure that each and every component of the wagon<br />
tippler is adequate in rigidity, strength and of heavy duty construction of first class quality to<br />
guarantee against failure or major damage, assuming proper maintenance and usage. The<br />
tippler shall be designed to allow passage of all standard broad gauge (1676 mm) Indian<br />
Railways diesel locomotives over tippler table at restricted speed.<br />
5.4.5 The wagon tippler shall be suitably counter balanced at each stage of operation so as to<br />
require minimum driving power.<br />
5.5 WAGON TIPPLER WEIGHING SYSTEM<br />
5.5.1 This specification calls for an electronic static weighing system to measure / record the<br />
quantum of coal, wagon wise on the wagon tippler table before & after tippling. The<br />
weighbridge with adequate no. of load cells shall be provided beneath the wagon ti tippler<br />
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platform with a minimum accuracy of 1% of the gross weight of the wagon. The platform<br />
shall be freely supported on the weigh bridge before and after tipping for accurate weighing.<br />
The wagon tippler weighbridge shall be designed to statically weigh th the wagons in an<br />
uncoupled condition. The system shall comprise of a weighbridge, a tippler table, load cells,<br />
weight digitizer and an intelligent terminal with printer with the facility for computerized<br />
printed output of data gross weight, tare weight, wago wagon n no., time, date etc. the weighbridge<br />
shall be chosen to accommodate all types of wagons as per RDSO guidelines to move coal.<br />
The weighbridge shall be supported on minimum 4 nos. compression type load cells<br />
mounted on free motion structural unit assembly.<br />
Alternatively, in-motion motion weigh scales in both in in-haul and out-haul haul tracks shall be provided<br />
for the purpose. The load cells shall be suitable for dusty environmental conditions. The<br />
calibration of the weigh bridge shall be the scope of the bidder. The bbidder<br />
idder shall co co-ordinate<br />
with statutory authority to get the necessary stamping & other requirements.<br />
6.0 CONSTRUCTION REQUIREMENT<br />
6.1 Cradle<br />
6.1.1 The cradle shall consist of a pair of heavy welded steel plate sections reinforced with<br />
stiffeners and connected cted by side bearer beams pivotally attached, each section being fitted<br />
with a massive trunion shaft carried in bronze bushed cast steel bearings on each side,<br />
bolted to steel pedestal carried on concrete pedestals. Circumferential driving rack shall be<br />
rigidly gidly bolted to the peripheries of the sectors. The sectors shall be made of cast steel.<br />
Necessary features of safety against coming down of wagon tippler in the event of failure of<br />
one of the drive pinions and / or gear racks shall be provided and the sam same shall be clearly<br />
indicated in the bid.<br />
6.2 Rail Table<br />
6.2.1 The rail table shall be constructed of rolled steel joints with standard steel rails (52<br />
kg/metre) mounted on it. The table shall be pivoted from arms extended from the sectors.<br />
The table shall be covered with chequered plates between the rails.<br />
6.3 Feeders and Clamps<br />
6.3.1 The wagon shall be clamped automatically by hydraulic system and firmly on the cradle<br />
during the tipping without any damage or undue pressure on any part of the wagon and no<br />
hand adjustment of any sort shall be necessary. Sliding side stop pads shall be of resilient<br />
material to prevent damage to either the wagon or the stops.<br />
6.4 Spill Plate<br />
6.4.1 Fixed to the cradle of the tippler shall be a plain steel spill plate for deflecting material into<br />
the tippler hopper.<br />
6.5 Driving Gear<br />
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6.5.1 Multiple pinions meshing with cast steel racks bolted to the end sectors shall impart drive<br />
through hydraulic drive with each pinion drive through slow speed high torque hydr hydraulic<br />
motors using gear boxes as applicable. Suitable oil coolers shall be provided for hydraulic<br />
power pack. Suitable dust protective cover shall be provided.<br />
6.6 Brake<br />
6.6.1 An automatic electro hydraulic brake shall be furnished to hold the tippler in any position<br />
with the load and against any movement except that provided by drive.<br />
6.7 Limit Switches<br />
6.7.1 Limit switches of suitable type which can be readily adjusted to give the desired tippling<br />
angle shall be provided. An emergency over tip lim limit it switch operated by a striker on the<br />
tippler trunnion shaft shall be furnished.<br />
6.8 Ballast<br />
6.8.1 Ballast necessary for counter weight and balancing the tippler shall be provided as per the<br />
requirement.<br />
6.9 Lubrication<br />
6.9.1 All bearings shall be properly lubricated. Grease nipples and reservoirs shall be furnished<br />
where necessary.<br />
6.10 Guards<br />
6.10.1 All gears inside machinery pits and other moving parts shall be securely guarded.<br />
6.10.2 All necessary base plates, guide plates, chequered plate covering for drive pit and any other<br />
pits, all required fixing materials, inserts and sleeves shall be furnished.<br />
7.0 DATA SHEET<br />
7.1 GENERAL<br />
Wagon Type<br />
: All types of wagons in coal transport used by Indian<br />
Railways to move coal (as per latest test RDSO guidelines)<br />
Moving Profile<br />
: As per IR norms.<br />
No. of tips (guaranteed) : 20 per hour.<br />
Designed : 25 Tips per Hour<br />
Rail Gauge<br />
: 1676 mm.<br />
Weigh bridge<br />
: Load cell type<br />
Duty<br />
: Continuous 24 hrs.<br />
7.2 DESIGN & CONSTRUCTION<br />
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A. Wagon Tippler Hopper<br />
Construction<br />
: RCC Construction.<br />
Size<br />
: To accommodate atleast 2 nos. 8 wheeled wagons wagons.<br />
No. of openings : One (1)<br />
Angle of repose of coal for<br />
wagon tippler hopper sizing : 37°<br />
Lining<br />
Steel Grating<br />
: 50 mm thick guniting.<br />
(i) Mesh size : 300 mm x 300 mm<br />
(ii) Grating Section : 200 mm x 36 mm thick flats.<br />
B Wagon Tippler<br />
Type<br />
: Rotaside / Rotary type (As per latest RDSO guidelines)<br />
Tipping angle : The Wagon Tippler shall be suitable to unload Coa Coal wagons.<br />
The angle of tippling shall conform to RDSO GG-33<br />
(Rev – 1)<br />
Technical pamphlet for requirement of tippler installation<br />
for approval by RDSO.<br />
Duty Requirement : Continuous operation<br />
Counter balancing : Suitable to keep power requirement at minimum.<br />
Cradle<br />
: Heavy welded steel plate construction trunion mounted.<br />
Driving Gear<br />
(i) Racks<br />
: Cast steel rack sections bolted to end sectors.<br />
(ii) Pinion<br />
: Multiple pinions meshing with rack.<br />
8.0 SIDE ARM CHARGER<br />
8.1 GENERAL<br />
Rail Table<br />
: Rolled steel joists with ith steel rails mounted on it.<br />
Drive<br />
: Hydraulic motors.<br />
Brake<br />
: Electro hydraulic thruster operated.<br />
Clamping<br />
: Hydraulically operated<br />
Top & side stops : Self aligning type made of resilient material.<br />
8.1.1 Side Arm Charger shall be furnished complete with travel rails, drive equipments and<br />
associated accessories.<br />
8.1.2 The rake comprising of specified maximum number of wagons shall be pushed into the<br />
reach of inhaul equipment by a locomotive. Further placing of wagons over tippler platform<br />
and moving out the empty wagons shall be accomplished with the help of side arm c ccharger.<br />
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8.2 CODES & STANDARDS<br />
The design, manufacture, inspection and testing of Side Arm Charger shall comply with all<br />
the currently applicable statutes, regulations and safety codes in the locality where the<br />
equipment is to be installed and all nor norms stipulated by RDSO- G 33 Rev.1. The Side Arm<br />
Charger shall conform to the latest edition of the standards and codes. Other internationally<br />
acceptable standards/codes, which ensure equal or higher performance than those<br />
specified, shall also be accepted. Nothing in this specification shall be construed to relieve<br />
the contractor of the required statutory responsibility. In case of any conflict in the standard<br />
and this specification, the decision of the Engineer shall be final and binding.<br />
8.3 DESIGN REQUIREMENT<br />
8.3.1 A single module of side arm charger shall be used for inhaul and outhaul operations. Thus,<br />
side arm charger shall be used for indexing forward the rake of 60 nos loaded wagons,<br />
placing decoupled wagons on the tippler table and out hauli hauling ng the empty wagons.<br />
8.3.2 The rake of 60 loaded wagons will be brought by locomotive and placed on the retipping<br />
line such that the leading wagon will be within the reach of the side arm charger. Now the<br />
side arm charger will be coupled to the leading wwagon,<br />
agon, pull the rake of 60 nos. loaded<br />
wagons towards tippler table. The first wagon will be decoupled manually from the rake and<br />
signal will be given to the side arm charger operator that the wagon is de de-coupled. Now the<br />
leading wagon will be placed centra centrally lly onto the tippler table by side arm charger,<br />
(simultaneously ejecting the empty wagon from the tippler table). After the loaded wagon is<br />
placed on the tippler table, the arm is de de-coupled coupled from the loaded wagon. Adequate<br />
clearance between tippler table aand<br />
nd empty wagon shall be ensured. The side arm charger<br />
will stop at the end of its strokes, the arm will be swung vertically vertically-up up and the machine will<br />
move towards in-haul haul direction and occupies the initial position. In the meantime, the<br />
tippler will tip the loaded wagon placed on the tippler table and return to its original<br />
position. Before tippling operation of wagon tippler is completed, the arm of the side arm<br />
charger will be swung to horizontal position and will be coupled to the rake of remaining<br />
loaded wagons at waiting position just before the tippler table and is now ready for the next<br />
cycle to start. After the tippling operation of wagon tippler is completed the cycle will be<br />
repeated.<br />
8.4 TECHNICAL REQUIREMENTS<br />
8.4.0 CONSTRUCTION REQUIREMENT<br />
8.4.1 The Side Arm Charger shall be suitable to handle handle60 number of loaded wagons wagons. The pusher<br />
arm shall be vertically rotatable arm mounted on a carriage running back and forth parallel<br />
to the train track.<br />
8.4.2 The arm shall be raised to clear the movement of wwagons<br />
agons and locomotives during reversing<br />
back of positioner carriage and shall be lowered for engaging the head of the arm with the<br />
wagon coupler for index strokes.<br />
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8.4.3 The arm shall be raised and lowered by means of hydraulic cylinder mounted on the<br />
carriage. iage. Suitable means shall be provided to prevent damage to the arms should the arm be<br />
accidentally lowered into the side of wagon.<br />
8.4.4 The arm shall be of robust construction either of cast steel or of heavy duty fabricated steel<br />
for the required duty.<br />
8.4.5 The construction of the head assembly of the push arm shall be such that no damage is<br />
suffered by the couplers of wagons and engagement of arm over the coupling assembly as<br />
well as transmittance of indexing forces to accelerate, run and decelerate the train during<br />
the positioning cycle shall be very smooth.<br />
8.4.6 The carriage frame shall be a suitable fabrication assembly of large proportions massive<br />
enough in strength and rigidity for the required duty.<br />
8.5 Travel Carriage Drive System<br />
8.5.1 The travel carriage with push arm shall be propelled to and fro, parallel to train track<br />
through hydraulic motor driving through a gear box and EHT brake.<br />
8.5.2 The rating of the drive equipment and its characteristics shall match with indexing forces<br />
required quired to be exerted in varying amounts depending upon train dynamics and to suit<br />
haulage of 60 wagon loaded rake.<br />
8.5.3 The travel carriage shall ride on vertical bearing wheels and will be guided by horizontal<br />
bearing wheels by suitably transmitting the thrust load from the positioned arm to the<br />
foundation. The wheels/rollers shall be of forged steel and shall run on the rails supported<br />
over the RCC pedestal.<br />
8.5.4 Cushioned emergency bumpers (buffers) shall be provided at the forward and return end of<br />
carriage travel run for protection. These shall be designed to arrest the machine without<br />
undue shock in case the machine exceeds its extremities because of any mal mal-operation.<br />
9.0 DATA SHEETS<br />
9.1 GENERAL<br />
Quantity<br />
No. of wagons to be handled By<br />
: 1 (One) no<br />
each side arm charger at a time : 60<br />
No. of tips by wagon tippler<br />
: 25 per Hour (designed)<br />
: 20 (min.) per hour (guaranteed)<br />
9.2 DESIGN & CONSTRUCTION REQUIREMENTS<br />
Arm : Robust construction either of cast steel or heavy duty fabricated<br />
steel.<br />
Arm Drive : Hydraulic cylinder<br />
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Carriage Frame<br />
Travel Carriage drive<br />
: Single fabrication assembly.<br />
Motor : Hydraulic<br />
Travel brake : Integral part of hydraulic motor<br />
Bearings for sheaves : Anti friction bearings.<br />
10.0 APRON FEEDER<br />
10.1 GENERAL<br />
Apron feeders complete with all accessories shall be furnished for wagon tippler hoppers as<br />
specified.<br />
10.2 CODES & STANDARDS<br />
The design, manufacture, inspection and testing of apron feeders shall comply with all the<br />
currently applicable statutes, regulations and safety codes in the locality where the<br />
equipment is to be installed. The apron feeders shall conform to the latest edition of the<br />
standards and codes. Other internationally acceptable standards/codes, which ensure equal<br />
or higher performance e than those specified, shall also be accepted. Nothing in this<br />
specification shall be constructed to relieve the contractor of the required statutory<br />
responsibility. In case of any conflict in the standard and this specification, the decision of<br />
the Engineer eer shall be final and binding.<br />
10.3 DESIGN REQUIRMENTS<br />
Apron feeders shall be of robust construction & designed for handling ROM coal as specified<br />
and without any choking particularly during rainy season when coal is sticking. A drible<br />
conveyor shall be provided for proper clean up. The pan and chain shall be of proven design<br />
and shall be with adequate factor of safety.<br />
10.4 CONSTRUCTION REQUIREMENT<br />
The frame shall be manufactured from rolled steel section welded and bolted together to<br />
form a rigid structure. cture. The roller shall be life time lubricated and shall be manufactured from<br />
alloy steel.<br />
The chain Link shall be forged steel. Pins and rollers shall be of hardened steel. The chain link<br />
shall be bolted to the pans. Apron/pan shall be of suitable thickn thickness which shall be<br />
constructed out of fabricated MS with wear resistant liner plate or special alloy steel without<br />
any liner plate for the duty requirement. The pan would be fitted directly to the chain<br />
attachment. The head and tail end shall be of sturdy steel construction suitably stiffened.<br />
The sprocket shall be made of cast alloy steel with case hardened teeth or forged steel. The<br />
traction wheel shall be made of cast steel with case hardened surface. Tensioning<br />
arrangement with sufficient travel shall bbe<br />
e provided for the tensioning of the chain chain.<br />
Complete dribble belt system consisting of head pulley, tail pulley, drive, motor, stringers,<br />
deck plates etc. shall be provided.<br />
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10.5 DATA SHEET<br />
Capacity (TPH) : 1500 MTPH ( Design)<br />
1200 MTPH ( Rated )<br />
Angle of Installation : Horizontal<br />
Chain Link : Forged alloy Steel<br />
Apron pan : MS fabricated with wear resistant plate or special alloy steel .<br />
Traction wheel : Cast Steel<br />
Rollers : Forged Alloy Steel<br />
11.0 No sizer or crusher is required.<br />
12.0 DRIVE EQUIPMENT<br />
GENERAL<br />
Suitable Drive Chain Equipment’s like electric motors, gearboxes (where applicable), fluid<br />
couplings (where applicable), flexible couplings and other accessories shall be provided for<br />
all the belt conveyor systems, wagon tippler tippler, , side arm charger, apron feeders, various<br />
pumps of dust suppression system, fans for ventilation system, monorail electrical hoists and<br />
other equipment’s specified in this specifications. Various requirements as spelt out in the<br />
Technical Specifications ffor<br />
or individual equipment’s shall be taken into consideration while<br />
designing the associated drive chain equipment’s.<br />
12.1 CODES AND STANDARDS<br />
The design, manufacture, inspection and testing of Drive Equipment shall comply with all the<br />
currently applicable statutes, regulations and safety codes in the locality where the<br />
equipment in to be installed. The Drive Equipment’s shall conform to the latest edition of<br />
the following standards and codes. Other internationally acceptable standards/codes, whic which<br />
ensure equal or higher performance than those, specified, shall also be accepted. Nothing in<br />
this specification shall be construed to relieve the contractor of the required statutory<br />
responsibility. In case of any conflict in the standard and this specif specification, ication, the decision of<br />
the Owner shall be final and binding.<br />
IS:3688 : Dimensions for shaft ends<br />
IS:3681: General plan for spur & helical gears<br />
IS:7403 : Code of practice for selection of standard worm and helical gear boxes<br />
12.2 DESIGN AND CONSTRUCTION REQUIREMENTS<br />
12.2.1 GEAR BOXES<br />
12.2.2 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces.<br />
12.2.3 The gearboxes shall be designed for 24 hours continuous duty and gear boxes shall have<br />
appropriate thermal rating.<br />
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12.2.4 The e gears used shall be helical conforming to IS:3681 (latest revision) or worm reduction<br />
units or spiral bevel speed reduction units conforming to suitable Indian Standards. The<br />
dimensions of the shaft end shall conform to IS:3688 or its latest revision. Ab Above 40 kW drive<br />
rating, all gearboxes shall be helical or bevel helical type only.<br />
12.2.5 Recommended oil grade shall be compatible with gear internals like material of bearing,<br />
cages. Further, all gearboxes shall have suitable breather plugs, dipstick, drain plug etc.<br />
12.3 COUPLINGS<br />
12.3.1 Flexible / Rigid Couplings<br />
Approved type of couplings shall be used for power transmission depending upon duty<br />
requirements. The design of the coupling shall be such that it can take shock and<br />
misalignment without sacrificing its efficiency. Geared type flexible coupling shall be used on<br />
low speed side ide for all conveyors and other drive chains where gear box is provided. Other<br />
couplings in the drive chains shall be either rigid or flexible type, depending upon the<br />
requirement of equipment design and shall be finalized during detailed engineering.<br />
12.3.2 Fluid Couplings<br />
Fluid couplings shall be provided in all the drive machinery for wagon tipplers & associated<br />
belt conveyor systems if the actual power requirement at motor output shaft is more than<br />
40 kW. The fluid coupling for LT motors shall be of tr traction action type. Cooling water coils for<br />
traction type fluid coupling shall not be accepted. Scoop tube type fluid coupling shall be<br />
provided for conveyors with HT motors. Suitable electrically operated actuators shall be<br />
provided for scoop tube operation from local as well as remote. Suitable provision for<br />
alternate manual operation shall also be kept. Separate pump with motor shall necessarily<br />
be provided for circulating the fluid coupling oil through oil cooler. Independent<br />
arrangement for forced cooling wat water er supply using 2X100% capacity pumps to oil cooler<br />
shall be provided by Contractor. Suitable interlock using flow switches shall be provided in<br />
both oil as well as water lines to trip the drive motor in the event of flow in either lines<br />
falling below/ acceptable eptable levels. Suitable pressure indicators and flow indicators shall be<br />
provided in the cooling water lines along with all all-relevant relevant valves, strainers and accessories.<br />
Necessary isolation valves shall be provided in the oil / water line for maintenance of any<br />
equipment in the line. Necessary interlock shall also be provided so that the HT motor<br />
cannot be started from remote / local unless position of scoop tube permits no load start of<br />
the motor. Tripping of downstream equipment while the system is under n nnormal<br />
operation<br />
shall result in scoop tube re re-positioning positioning to permit no load run of the concerned HT motor.<br />
Temperature switch shall be provided in the oil circuit and shall trip the system in case of<br />
high oil temperature. Selection of rating & speed of act actuator uator for scoop type fluid coupling<br />
shall be made taking into consideration the coasting time of downstream and upstream<br />
conveyors and the engagement/disengagement time achievable. The scoop tube operation<br />
must be such so to ensure quick draining out of oi oil l from the operating circuit, by providing a<br />
double speed motor.<br />
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12.4 DATA SHEET: DRIVE EQUIPMENT<br />
GENERAL<br />
12.4.1 Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for<br />
Electric Motors<br />
a) For conveyors of belt conveyor systems and belt for In line magnetic separator:<br />
*120% 120% of actual power at drive motor output shaft at specified design capacity<br />
b) WT, SAC, apron feeders: *110% 110% of actual power requirement at drive motor output<br />
shaft at guaranteed (rated) capacity.<br />
c) Mono-rail rail hoists (travel and hoisting), various pumps of DS systems, service water<br />
systems, cooling water system, potable water system and sump pumps: *110% of<br />
actual power requirement at drive motor output shaft at guaranteed (rated)<br />
capacity.<br />
d) Ventilation Fans: *110% 110% of actual power requirement at drive motor output shaft at<br />
guaranteed (rated) capacity. In case of belt drive, the efficiency of transmission shall<br />
be considered as 95%.<br />
*The The actual power at drive motor output shaf shaft t shall be calculated after considering all the<br />
losses of down the line equipment’s of the drive train.<br />
1.0 Drive Equipment Rating<br />
a) For Conveyors : 120% of actual design requirement<br />
b) Other Equipment 1 x 100 % duty: 120% of actual design requirement<br />
c) ) Other Equipment 2 x 50 % duty: 110 % of actual design requirement<br />
2.0 DESIGN & CONSTRUCTION REQUIREMENT<br />
2.1.0 Gear Box<br />
2.1.1 Type<br />
(a) Below 40 KW: Helical, worm, bevel as per requirement without cooling coil<br />
(b) Above 40 KW: Helical / bevel helical wwithout<br />
cooling coil<br />
2.1.2 Service Factor: As per accepted engineering practice / manufacturer's<br />
recommendations<br />
2.1.3 Ambient temperature for Thermal rating: 50<br />
2.1.4 Mounting: On Machined/Ground Surfaces<br />
2.1.5 Output Rating:<br />
a) For belt conveyor systems<br />
requirement at drive pulley shaft at design capacity}<br />
b) For other equipment<br />
of the driven equipment }<br />
@ Service factor shall include all the components considered by the supplier and should be<br />
clearly indicated in manufacturer’s gear box selection catalogues.<br />
o 2.1.2 Service Factor: As per accepted engineering practice / manufacturer's<br />
C Minimum<br />
2.1.4 Mounting: On Machined/Ground Surfaces<br />
a) For belt conveyor systems @ Service factor X {1.2 times the actual power<br />
requirement at drive pulley shaft at design capacity}<br />
b) For other equipment @ Service factor X {1.2 times the actual power requirement<br />
of the driven equipment }<br />
shall include all the components considered by the supplier and should be<br />
clearly indicated in manufacturer’s gear box selection catalogues.<br />
2.1.6 Duty: 24 Hrs. Continuous<br />
2.2.0 Flexible Couplings:<br />
2.2.1 Type: Geared capacity.<br />
2.2.2 Rating: Not less than han motor rating.<br />
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2.3.0 Fluid Couplings: For all motors having rating more than 40 KW.<br />
2.3.1 Type<br />
(a) L.T. Motors: Traction type<br />
(b) H.T. motors: Scoop tube type.<br />
2.3.2 Rating: Not less than motor rating<br />
13.0 EOT CRANE<br />
13.1 GENERAL<br />
An E. O. T. crane complete with all accessories shall be furnished for maintenance at wagon<br />
tippler house.<br />
The design, manufacture, supply erection and commissioning of EOT crane complying with<br />
all the currently applicable statutes, regulations and safety codes in the loca locality where the<br />
equipment is to be installed. The EOT crane shall conform to the latest edition of the<br />
standards and codes. Other internationally acceptable standards/codes, which insure equal<br />
or higher performance than those specified, shall also be accept accepted. ed. Nothing in this<br />
specification shall be construed to relieve the contractor of the required statutory<br />
responsibility. In case of any conflict in the standard and this specification, the decision of<br />
the Engineer shall be final and binding.<br />
13.2 DESIGN REQUIREMENTS EQUIREMENTS AND CONSTRUCTION REQUIREMENTS<br />
The crane shall be generally of box type double girder construction and shall designed for<br />
appropriate class of duty in accordance with BSS: 466/1960 and or IS:3177 to meet the<br />
installation and maintenance of wag wagon on tippler and the associated equipment.<br />
The bridge should comprise of two main girders with two out riggers and the end carriage<br />
built up from mild steel channel with adequate diaphragms or stiffing plates. Each bridge<br />
girder shall be fabricated and dis dispatched without any spliced joints.<br />
Box Girder & End carriage joints shall preferably have fit bolts. For all bolted joints the holes<br />
are to be drilled and reamed and bolts are to be force fitted.<br />
Hand railing shall be fitted on both sides of the end carriages and throughout the length of<br />
the platform (height of 1.1m) parallel to girder. Size of the hand rail shall be not less than 25<br />
mm bore heavy gauge steel pipe. The vertical pipes shall have flanges at the bottom for<br />
proper support. Suitable hand rrailing<br />
ailing should be provided on Cross Travel Trolley also.<br />
All Rotating parts & Overhang parts shall be provided with suitable guard.<br />
The end carriages shall be of approved design, with L type Brackets of substantial<br />
construction and ample stiffness built up of mild steel sections securely welded.<br />
The end carriages of the crane are to be mounted on double flanged wheels of approved<br />
diameter in accordance with IS: 3177. Number of wheels on each side of the crane shall be 2<br />
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Nos (Total 4 Nos in the Crane ffor<br />
or Long Travel motion) The Wheel shall be of forged steel<br />
having composition as Cr 55 Mn 75 (EN 9) hardened to 300 300-350 350 BHN with minimum depth<br />
10mm confirming SAE 1055 / IS 1570 & shall be fitted with roller bearings with dust proof<br />
seals. For lubrication, Grease nipples shall be provided at convenient points.<br />
Twin drive system to be adopted for Long Travel of E. O. T. in the bay.<br />
One wheel in each carriage is to be driven by forged steel gears through a motor mounted<br />
on or adjacent to the carriage.<br />
Long travel mechanism shall be provided with, a thruster brake on each individual drive of<br />
the track wheels. These brakes shall be such that it can be operated from both the control<br />
desk as well as remote control. The brakes shall be of post type with hing hinged shoes, lined<br />
with good quality reinforced bonded brake lining and suitable for easy of adjustment of the<br />
wear on lining.<br />
An independent additional mech. / electrical operating brake are to be provided with LT<br />
motion to stop the crane immediately in ca case of power failure.<br />
13.3 DATA SHEET<br />
13.3.0 CAPACITY AND LEADING DIMENSION<br />
13.3.1 Safe Working Load: Main Hoist - 25T<br />
13.3.2 Safe Working Load: Aux. Hoist - 5T<br />
13.3.3 Duty as per I.S.3177 (Latest Amendment)<br />
13.3.4 SPEED OF MECHANISMS:<br />
(a) Main hoist Hoisting / Lowering - 6 M/Min<br />
(b) Aux. Hoist Hoisting / Lowering - 8 M/Min<br />
(c) Cross Traverse (CT) Forward/ reverse - 10 M/Min<br />
(d) Long Travel (LT) Left / Right - 30 M/Min<br />
13.3.5 (a) Normal Span: Actual span & other dimensions as required as per structural steel<br />
shed of wagon tippler shall be evaluated by the bidder and confirmed in the bid.<br />
13.3.6 (b) RailCenter to Center: Bidder to confirm<br />
13.3.7 Gantry Rail heights above floor level: Bidder to confirm<br />
13.3.8 Hook lift above flo floor or level to be provided: Bidder to confirm depending upon actual<br />
site condition<br />
13.3.9 Type of Hook - Shank type<br />
13.3.10 Available head height above rail top: to be confirmed by Bidder<br />
13.3.11 Available side clearance from gantry rail center: Bidder to confirm<br />
13.3.12 Location<br />
Wagon tippler shed, Bay Length & Width: Bidder to confirm<br />
13.3.13 Electric power supply - 415 Volt, 3 Phase, 50 HZ A.C. Supply<br />
13.3.14 Gantry rail size - Bidder to confirm.<br />
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14.0 MONORAILS AND HOISTS<br />
14.1 GENERAL<br />
Suitable handling arrangements shall be provided for all equipment’s included in<br />
Contractor’s scope to transfer the equipment to maintenance area within the building<br />
and/or to transfer the equipment outside the building upto ground level for further<br />
transportation by the Owner. For this purpose Contractor shall provide monorails and hoist<br />
blocks with cross travel facility.<br />
14.1.1 CODES AND STANDARDS<br />
The design, manufacture, inspection and testing of Monorails and Hoists shall comply with<br />
all the currently applicable statutes, regulations and safety codes in the locality where the<br />
equipment is to be installed. The Monorails & Hoists shall conform to the latest edition of<br />
the following standards & codes. Other internationally acceptable standards/codes, which<br />
ensure equal al or higher performance than those specified, shall also be accepted. Nothing in<br />
this specification shall be construed to relieve the contractor of the required statutory<br />
responsibility. In case of any conflict in the standard and this specification, the decision of<br />
the Owner/RITES shall be final and binding.<br />
14.2 DESIGN REQUIREMENTS<br />
• IS:3938 : Specification for Electric Wire Rope Hoist<br />
• IS:3832 : Chain pulley blocks<br />
• IS:2429 : Round steel short link chain<br />
• IS:6216 :Short link chain grade 80<br />
• IS:8610 :Points hooks with shank for gener general al engineering purposes<br />
• IS:210 : Cast Iron Castings<br />
14.2.1 For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with the<br />
exception of hoists for GTU and bend pulleys motor operated hoist blocks for both long<br />
travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both<br />
travel and lift. For hoists for GTU’s and bend pulleys clause no. 1.02.18 shall be referred to.<br />
All monorails coming out of the buildings shall be provi provided ded with electric hoist blocks,<br />
irrespective of load and lift. Minimum 3 meter length of Cantilever shall be provided in<br />
monorails coming out of the building to lower the equipment to ground level clearing the<br />
building sidewalls and any other facilities be beneath neath the floor upto ground level.<br />
14.2.2 The exact lift/travel and the number of the hoisting mechanisms and the mode of lifting<br />
equipment’s to various floors of the buildings shall be as decided by the Owner Owner/RITES at the<br />
time of detailed engineering. Us Use e of single hoist shall be avoided for handling more than one<br />
equipment. Clear height shall be maintained when handling one equipment over other, in<br />
such case dismantling of any equipment shall not be permitted. The center line of monorail<br />
shall not deviate e by more than 500 mm from the center of gravity of any equipment that is<br />
to be lifted. Contractor shall take clear note of the fact that the number and monorail<br />
hoisting systems shall also be decided considering the movement of the equipment being<br />
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lifted over/by the side of other equipment’s without removing the later. The necessary<br />
levels of floors in various buildings shall be decided considering the above requirement.<br />
14.2.3 Monorails shall be extended outside the building to handle the equipment to g gground<br />
level.<br />
For monorail/hoist routed inside the buildings, suitable machinery well and removable<br />
handrailing and grating shall be provided on various floors of buildings, as necessary, to<br />
handle the equipment.<br />
14.2.4 Electrically operated monogirder typ type e hoists shall consist of following major components.<br />
a) Electrically operated trolley complete with drive motor (Trolley travel speed maximum 15<br />
m/min.).<br />
b) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting speed<br />
maximum 6m/min.).<br />
c) Limit switch to prevent overhoisting, over lowering and over travel.<br />
d) Festoon arrangement of feeding power to trolley assembly.<br />
e) Erection hardware.<br />
f) Pendent control station suspended from hoist.<br />
g) Control Panel mounted on wall.<br />
14.2.5 The electric hoist shall be de designed signed and constructed in accordance with the latest revision of<br />
IS:3938 and shall be suitable for duty class 2.<br />
14.2.6 For electric hoists, trolley movement and hoisting shall be effected by using two separate<br />
motors. Motors shall be as per technical re requirements quirements discussed elsewhere. However the<br />
motors shall be suitable for 150 starts per hour at 40% CDF.<br />
14.2.7 Trolley for motorized / manual cross travel shall be designed to accommodate a wide range<br />
of I beams and shall be capable of travelling on straight as well as curved monorails with the<br />
design being such to maintain uniform distribution of pressure on the flanges.<br />
14.2.8 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which shall be<br />
driven through motor.<br />
14.2.9 Wire rope shall be of pre pre-formed formed type, hemp cored, regular lay 6/36 construction with a<br />
breaking strength of 160 -175 175 kgf/ sq. mm. Reverse bend of ropes is not acceptable.<br />
Minimum number of falls of rope shall be four (4).<br />
14.2.10 All gears and pinions shall be of hardened and tempered steel with machine cut teeth in<br />
metric modules. Surface hardening of steel is not acceptable.<br />
14.2.11 All running shafts and wheels shall be fitted with roller bearings with a rated life not less<br />
than 20 years based on eq equivalent running time as per IS:3938.<br />
14.2.12 An electromechanical brake shall provided for hoisting as well as cross travel. Brake lining<br />
shall be of asbestos.<br />
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14.2.13 Cast iron parts, wherever used, shall be of minimum grade 30, IS:210.<br />
14.2.14All chain n pulley blocks shall be designed to IS:3832, the operating hand chain shall conform to<br />
IS:2429 grade 30 pitched and polished and the load chain to IS:6216 grade 80. The chain<br />
pulley block shall be suitable for duty class 2. Hooks shall be as per IS: 8610 & with<br />
antifriction bearing for bottom look.<br />
14.2.15 All hoists/chain pulley blocks shall be selected to have minimum headroom and shall be<br />
selected to lift heaviest piece of equipment. Further, it shall be possible to handle any<br />
equipment without disturb disturbing other equipment.<br />
14.2.16 The hand chain wheels shall be of cast steel, the wheels shall be with flanges and designed<br />
to ensure effective operation of hand chain. Further, suitable local brake shall be provided as<br />
per IS:3832 to arrest and sustain load loads in all working positions.<br />
14.2.17 The velocity rates, effort on chain required to raise the safe working load and travel and<br />
speed shall be within the limit specified in IS:3832. Proof load test shall be carried out as per<br />
IS:3832. Balance requirements shall be as discussed in earlier clauses pertaining to electric<br />
hoists.<br />
14.2.18 Hoist for Gravity Take up arrangement and bend pulley.<br />
For handling bend pulley, take take-up up pulley and counter weights following hoisting<br />
arrangement shall be provided:<br />
(1) For handling bend pulleys, hooks of adequate capacity shall be provided at the top of gallery.<br />
Further minimum four (4) nos. manually operated chain pulley blocks of adequate capacity<br />
shall also be provided for the entire coal handling plant for handling bend pulleys.<br />
(2) For handling take-up up pulleys, manual hoist along with mono rail beam of adequate capacity<br />
having cross travel, arrangement shall be provided at bottom of gallery to handle take take-up<br />
pulley only of conveyors.<br />
(3) For handling take-up up weight, a separate mmanual<br />
anual hoist with mono rail beam of adequate<br />
capacity shall be provided to hold complete counter weight (inclusive of all counter weight<br />
blocks). This hoist shall be provided for holding the counter weight and shall be located in<br />
the zone of counter weight travel.<br />
14.3 CONSTRUCTION REQUIREMENT<br />
14.3.1 The hoist mechanism shall consist of a grooved rope drum driven by electric motor through<br />
gears. Each end of the rope shall be anchored to the drum in such a way as the anchorage is<br />
readily available for mai maintenance. ntenance. Each rope shall have not more than two (2) full turns of<br />
the drum when the hook is at its lowest position and one (1) spare groove when the hook is<br />
at its highest position. The leading rope taken by the drum should not slope sideways when<br />
slack and nd it should not be caught between the gear wheel.<br />
14.3.2 Rope drum, gear box, block etc. should be fabricated out of weldable quality steel.<br />
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14.3.3 Trolley wheels shall be of single flange type in the taper treads. The wheels shall be mounted<br />
on antifriction iction bearings and shall be easily removable for repair/replacement.<br />
14.3.4 The load hook shall be swiveling type forged circular shank section and shall confirm to<br />
IS:8610.<br />
14.3.5 All gears and bearings shall be lubricated by grease. All lubricating po points ints shall be grouped<br />
together in easily accessible position.<br />
14.3.6 The bottom block shall be of enclosed type and shall have guard against rope jamming in<br />
normal use. It shall have standard forged swivel shank hook fitted on antifriction thrust<br />
bearing. . Lock to prevent hook from rotation and locking arrangement to prevent accidental<br />
unlocking shall be provided. Pulley of the bottom block shall be provided with antifriction<br />
bearings.<br />
14.3.7 All parts requiring replacement/inspection/lubrication shall be accessible without need for<br />
dismantling of other parts/structures.<br />
14.3.8 All components of hoists of identical capacity and duty shall be interchangeable.<br />
14.3.9 Hoists shall have permanent inscription in English on each side readily recognizable from<br />
floor level stating safe working load.<br />
14.3.10 Pendant shall be provided with flourscent up/down/forward/reverse travel push buttons<br />
and indicating lamps. Its power supply shall be limited to 24V AC.<br />
14.3.11 The control panel shall be wall mounted type & easily approachable from the floor by a<br />
standing man.<br />
14.3.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 1.5m) with<br />
ladder shall be provided for each hoist.<br />
14.3.13 Each inline magnetic separator shall have in independent dependent motorised hoist for its handling /<br />
maintenance purpose. Each suspended magnet shall also be provided with a dedicated<br />
electric hoist.<br />
14.4 DATA SHEET : MONORAILS AND HOISTS<br />
1.0 GENERAL<br />
1.1 Functional Requirement : To transfer equipment’s to maintenance a aarea<br />
or outside<br />
the building.<br />
2.0 DESIGN & CONSTRUCTION REQUIREMENT<br />
2.1.0 Hoists<br />
2.1.1 Drive<br />
(i) More than 2.0 tonne or more than 10.0 m lift or hoists coming out out-side the<br />
buildings: Motor driven for both travel & lift.<br />
(ii) Other hoists including the hoists for handling takeup pulley and takeup<br />
weight: Manual for both travel & lift.<br />
2.1.2 Maximum trolley travel speed for electric hoists: 15m/min<br />
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2.1.3 Maximum Hoisting speed for electric hoists: 6 m/min<br />
2.1.4 Drive Motors: SQIM, Separate for travel & lift<br />
2.1.5 No. of starts for drive motor: 150 starts/hr at 40% CDF<br />
2.1.6 Wire Rope<br />
(i) Type/Construction: Pre Pre-formed formed type, hemp cored, regular lay 6/36 construction<br />
(ii) Breaking Strength: 160 160-175 kgf/sq. mm<br />
2.1.7 Bearing<br />
(i) Type: Ball/Roller bearing<br />
(ii) Life: 20 years<br />
2.1.8 Brake: Electro Mechanical type with asbestos lining.<br />
2.1.9 Load Hook: Swiveling type forged circular shank section.<br />
2.1.10 Duty: Class –2<br />
2.2.0 Monorail location/layout<br />
2.2.1 Cross section I beam<br />
2.2.2 Distance between CC/L<br />
/L of monorail & C.G. of equipment to be lifted Maximum 500<br />
mm<br />
2.2.3 Power Cables Support Festoon type arrangement<br />
2.3.0 Manual Hoists<br />
2.3.1 Maximum manual effort for operation. 30 Kg<br />
15.0 CHUTES AND HOPPERS<br />
15.1 GENERAL<br />
Chutes & Hoppers, flap gates and shall be furnished integral with coal handling system being<br />
supplied. All necessary accessories, electricals etc. shall be provided to ensure proper<br />
flow/storage/bifurcation of coal as per system requirements.<br />
15.1.1 CODES AND STANDARDS<br />
The design, gn, manufacture, inspection and testing of Chutes & Hoppers shall comply with all<br />
the currently applicable statutes, regulations and safety codes in the locality where the<br />
equipment is to be installed. The chutes, hoppers shall conform to the latest editio edition of the<br />
following standards and codes. Other internationally acceptable standards/codes, which<br />
ensure equal or higher performance than those specified, shall also be accepted. Nothing in<br />
this specification shall be construed to relieve the,contractor of tthe<br />
he required statutory<br />
responsibility. In case of any conflict in the standard and this specification, the decision of<br />
the Owner/RITES shall be final and binding.<br />
• IS:4682 :Code of practice for lining of vessels and equipment for chemical<br />
processes.<br />
• IS:226 : Structural Steel (Standard Quality)<br />
• IS:11592 : Code of practice for selection and design of Belt Conveyors.<br />
15.2 DESIGN AND CONSTRUCTION<br />
15.2.1 Chutes, Hoppers<br />
15.2.2 The minimum valley angle of chutes shall be 60 degrees from horizontal.<br />
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15.2.3 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without<br />
any accumulation anywhere.<br />
15.2.4 Complete chute work above the drive floor for conveyors provided with ‘In ‘In-line belt<br />
magnetic separators’ shall be of 10 mm thick SS - 304 in the zone of magnetic field.<br />
15.2.5 Direct impact of material on conveyor belt shall be avoided by providing an inclined surface<br />
at 60 degrees valley angle at the feeding point to guide the material in the direction of belt<br />
travel. Further, chute ute construction below flap gate shaft shall be such that there will not be<br />
any accumulation of coal dust between chute and flap gate in that zone.<br />
15.2.6 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL or equivalent material.<br />
However, Contractor ntractor to submit test certificates stating composition of material and<br />
mechanical properties of these wear resistant steel to the Owner during detail engineering.<br />
Long chutes guiding flow from considerable height shall be provided with impact plates<br />
wherever ever change in direction of flow takes place. Hinged inspection doors (generously sized)<br />
of leak proof construction shall be provided for access/ maintenance purpose, at<br />
approachable heights for chutes and flap gates. All chutes should have one inspection door<br />
at every floor and for the ones in between the floors (more then 1.5 meter above the<br />
operating floor level) suitable access for trouble free maintenance shall be provided.<br />
Maximum distance between two inspection doors in a chute shall be 2 mtrs. For s ssealing<br />
of<br />
inspection doors labyrinth type arrangement (with rubber inserted in grooves) to be<br />
provided. In addition to positive locking arrangement, mounting bolts, to tighten the door<br />
further against rubber shall also be provided.<br />
15.2.7 Bottom side of the chutes on which the coal slides shall be welded to the side plates to form<br />
a trough. Bottom sides along with its adjacent sides shall be flanged and made from TISCRAL<br />
or equivalent material of 20 mm thickness. The non non-striking striking surface i.e. the covers oof<br />
the<br />
trough shall be of 10 mm thick mild steel and bolted to the flange provided on the trough.<br />
Inside welding shall be provided in the corners for permanent sealing. Further, the chute<br />
boxes not more than 1.5 m in length shall be joined through bolted fl flange connection to<br />
form the chute legs. Adequate care shall be taken to locate the flange joint away from floor<br />
level for easy maintenance. Bolted flange joints shall be of dust tight construction and<br />
necessary sealing material shall be provided in all the flange connections for adequate<br />
sealing. Complete chute work in the region of flap gates shall be fabricated from 20 thk<br />
TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree) complete<br />
chute, work shall be of 20 mm thick TISCR TISCRAL AL or equivalent material. While finalising the<br />
chute work inside the building, arrangement for shifting and replacing chute legs, proper<br />
handling arrangement/wall openings, trolleys, hoists shall also be provided. While<br />
fabricating the chute, the constitu constituent ent plates used shall be in one piece. No welds in between<br />
shall be allowed. In the zones of direct impact due to Coal trajectory, wear resistant backing<br />
plate with stiffners shall be provided in coal flow chutes. Similar backing plates & stiffening<br />
arrangement ement shall also be provided on the chute surfaces having direct coal fall.<br />
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15.2.8 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 4 mm<br />
M.S. Plates and shall be provided with hinged and gasketed inspection doors with suit suitable<br />
access to them. Further, serrated rubber seal shall also be provided at the very inlet of head<br />
chute to minimise dust nuisance.<br />
15.2.9 Separate maintenance sealed door shall be provided for access to belt cleaners in head<br />
pulley hood impact plates, flap gates for maintenance and inspection doors shall be of<br />
hinged with positive locking facility.<br />
15.3. Skirt Boards<br />
15.3.1 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable<br />
‘Skirt Plates’ of minimum 3.0 meters length shall be provided at each feeding point of<br />
conveyor. The width of the Skirt Boards shall be two two-third third the conveyor belt width width. In the<br />
beltswhere coal of appreciable lump size (250 mm) is being conveyed conveyed, , the gap between the<br />
bottom of the skirt board and the belt shall be made to increase uniformly in the direction of<br />
belt travel. The height of the skirt boards shall be sufficient to contain the material volume<br />
as it is loaded on the belt and shall not be less than 750 mm. The skirt plates shall be fitted<br />
with modular segmented and replaceable rubber skirting pads having facility of adjusting the<br />
pressure on the belt conveyor and shall have provision of on line removal for the purpose of<br />
easy maintenance. Such segmented rubber pads with its holdi holding ng down adjustment<br />
arrangements shall be of proven design. The edges of segmented pads shall be installed at<br />
an angle for providing a better seal. All care shall be taken while designing, to combine good<br />
sealing with minimum belt wear.<br />
15.4 Flap Gates<br />
15.4.1 The motor operated 2 position flap gates shall be provided in transfer chutes as specified<br />
and shall be complete with electrically operated actuators. The gates shall be of robust<br />
construction and suitable for trouble free operation. The face of the flap gate shall be made<br />
out of 20 mm thick TISCRAL or equivalent material.<br />
15.4.2 The equipment shall be capable of being operated for at least 15 switchings per hour at<br />
rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at r rrated<br />
load<br />
and thrust. The equipment shall be shop tested to prove this requirement.<br />
15.4.3 The motor rating for the actuator shall be so selected as to provide sufficient thrust for<br />
operation of the flop gates against the moving weight of coal and/or fla flap p gate. The flap gate<br />
travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight.<br />
15.4.4 Lever arm shall be provided between actuator and flap gate shaft for obtaining required<br />
thrust. The linkage mechanism proposed shall be indicated in the Bid.<br />
15.4.5 The actuators shall be capable of preventing any over travel. Suitable travel dependent limit<br />
switches controlling the travel of the flop gates on either direction shall be furnished. These<br />
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shall be placed internal to the drive unit and shall be completely dust dust-proof. The limit<br />
switches shall be capable of adjustments to vary the total length of travel of the gates.<br />
15.4.6 Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip<br />
off the e actuator motor in case of excessive thrust due to jamming of the gates during its<br />
travel in either direction. The same shall also be integral to the drive unit and shall be dust<br />
proof.<br />
15.4.7 Provision for alternative manual operation shall also be mad made e using declutchable<br />
handwheel. The diameter of handwheel shall be selected considering convenient force to be<br />
applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm.<br />
Limit switch for safety of person operating the hand wheel shall be provided.<br />
15.4.8 All the two way chutes, one way of which is leading towards the future conveyor, shall be<br />
provided with blind flange and flap gate with a provision to mount an actuator in future.<br />
15.4.9 The Contractor shall furnish calculations for selection of actuator for each location for<br />
approval of Owner/RITES /RITES.<br />
15.4.10 Suitable stiffening arrangement shall be provided between the two faces of the gate plate.<br />
At the end of the travel the total length of edge of the flap gate sh shall all rest on a suitable<br />
projected surface from chute to prevent leakage of coal dust through the available clearance<br />
between chute and flap gate.<br />
15.4.11 Maximum feasible counterweights shall be provided for better utilisation of system.<br />
However, for calculation lation of thrust required, the benefit of counterweight shall not be taken<br />
into considerations.<br />
15.4.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft.<br />
Suitable provision for re--greasing<br />
shall be provided.<br />
15.4.13 For standardisation purposes, only one standard type of actuator for flap gates shall be<br />
provided. The standard type actuator shall be selected for maximum thrust as calculated for<br />
various locations. Flap gate actuator as a whole and individual co component mponent wise shall be<br />
completely interchangeable for all locations.<br />
15.4.14 The material of shaft shall be EN EN-8 8 or equivalent. The diameter of the shaft shall be suitable<br />
for motor stalled condition and associated twisting.<br />
15.4.15 Approach/maintenance platforms complete with the chequered plate floor, hand rails,<br />
ladders etc. shall be provided for all flap gates.<br />
15.4.16 Shaft & flap gate shall be tightly fitted to each other.<br />
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15.4.17 On both faces of flap gate main plate, 20mm thick TISCRAL liner pla plate te or equivalent material<br />
shall be provided.<br />
15.5 DATA SHEET : CHUTES AND HOPPERS<br />
1.0 GENERAL<br />
1.1 Coal Parameters As specified elsewhere<br />
2.0 DESIGN & CONSTRUCTION<br />
2.1.0 Chutes & Hoppers<br />
2.1.1 MinimumValley Angle: 60 degrees<br />
2.1.2 Material :<br />
(a) Chute work<br />
Sliding zones & adjacent sides : 20 mm thk. TISCRAL / equivalent<br />
No striking/ Non sliding zones : 10 mm thk MS<br />
Chute with valley angle 80 degree and above : All four sides of 20 mm thk.<br />
TISCRAL/equivalent material<br />
In the zone of magnetic field of ILMS (chute above floor level) : SS-304 304 10 mm thk.<br />
In the zone of flap gates<br />
: 20 thk TISCRAL/ equivalent material<br />
Discharge Hoods over head pulleys : 4 mm thk M.S. with rubber curtain<br />
2.1.3 Size of Chutes<br />
: Minimum 1200mm X 1000mm (inside both way ways)<br />
2.1.4 Inspection Doors<br />
2.1.5 Chute Construction<br />
:Hinged & leak proof construction (min. size 35 x 45 cm)<br />
(a) Corners: One face of removable bolted flange connection<br />
(b) Joints Bolted: flange joints of dust tight construction<br />
(c) Bolt size: Min. MM-16<br />
(d) Bolts spacing: Not more than 125 mm C/C<br />
(e) Fixing Arrangement: Bolts with plain spring washers<br />
2.2.0 Skirt Boards<br />
2.2.1 Length : Min. 3 m for each feeding point<br />
2.2.2 Height : Not less than 750 mm<br />
2.2.3 Width : 2/3 of belt width<br />
Side plate : Min. 10 thk TISCRAL/equivalent<br />
Top cover : 6 mm thk M.S.<br />
2.3.0 Flap Gate<br />
2.3.1 Type: Linear actuator operated, 2 position<br />
2.3.2 Travel: 60 to 70 deg. (with limit switches on both sides).<br />
2.3.3 Automatic operation<br />
(i) Drive: Dust tight motor driven wit with suitable linkages<br />
(ii) Minimum Actuator Rating: 2500 kg with 1 m lever arm<br />
(iii) No. of Operation / Hr: 15 (with 10 consecutive switchings)<br />
(iv) Protection: Travel and Thrust dependent limit Switches.<br />
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2.3.4 Manual Operation<br />
(a)<br />
(b)<br />
2.3.5 Flap gate shaft<br />
(i) Diameter: minimum 130 mm<br />
(ii) Material: EN-8<br />
16.0 DUST CONTROL AND MISCELLANEOUS SYSTEM<br />
16.1 GENERAL<br />
INTENT OF SPECIFICATION<br />
16.1.1 The specification is intended to cover design, engineering, manufacture, supply, erection,<br />
testing and commissioning of the complete, Dust Control and Miscellaneous Systems as<br />
specified hereinafter required for the Wagon Tippler Package. The Contractor shall refer to<br />
the other sections and scheme indicated in the tender drawings to appraise himself of the<br />
work and scope of supply of the other Contractors/Owner's and shall coordinate his work<br />
with the work of other Contractors.<br />
16. 1.2 Dust Control System<br />
The dust control system to be furnished under this specification is required for control of<br />
fugitive dust emissions from dust generation points such as transfer points, feeders etc. Dust<br />
control is achieved by dust suppression sys system. tem. Contractor shall guarantee and offer dust<br />
control system which shall not allow a dust concentration in the ambient air inside the<br />
buildings more than acceptable limits as per Owner Owner/RITES approved guidelines or any<br />
internationally recognized hygienic SStandards/Codes.<br />
tandards/Codes. The Capacity of dust control system<br />
specified elsewhere is for Contractor’s guidance only. Contractor shall provide adequately<br />
sized fool proof dust control systems the performance of which should be guaranteed by the<br />
Contractor. However, the he capacity of the offered system shall not be less than the specified<br />
values. Further, for computation of design capacity of the pumps, permanent recirculation<br />
lines as shown in tender drawings shall also be considered. Water scheme dust suppression<br />
shall be provided as indicated in tender drawings. Clarified water shall be used for Service<br />
water system, Plain water dust suppression system shall be used for all receipt and discharge<br />
points in Transfer.<br />
16.1.3 Miscellaneous Systems<br />
Maximum effort : Convenient for single<br />
operator by declutchable hand wheel regardless<br />
of electrical power.<br />
Minimum Handwheel : Diameter 500 mm<br />
Service water system, p otable water system, cooling water system & sump pumps shall be<br />
provided as specified elsewhere in this specification and as indicated in tender drawings.<br />
16.2 Scope<br />
16.2.1 Plain Water Dust Suppression System<br />
Complete with water supply system, piping, sp spray ray heads, pumps, drive motors with canopy<br />
(wherever required), couplings with enclosure, electricals, supporting structures,<br />
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approach/maintenance platforms, handling for equipment, civil and structural works and<br />
necessary accessories shall be provided for WT hopper top & all transfer points, etc.<br />
16.2.2 Sump Pump<br />
4x100% sump pumps alongwith level switches and piping up to nearest Owner's drain (max.<br />
up to 50.0 meters from outside the building) shall be provided at all locations wherever<br />
natural drainage is not possible. Sump pumps along with drain pits shall be provided at other<br />
locations also, if required, during detailed engineering stage. Sealing pumps with valves,<br />
piping fittings and other accessories for sealing of sump pumps shall be provided.<br />
16.2.3 Service Water System<br />
Service water distribution system complete with water supply system, valves, quick<br />
couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy, couplings with<br />
enclosure, electricals, including supporting structures, handling for equipment’s, civil and<br />
structural works and necessary accessories shall be provided throughout the coal handling<br />
plant area in Contractor’s scope.<br />
16.2.4 Pipings, Fittings, Valves and Specialities<br />
The material to be supplied for completing the pipe work shall include but not be limited to<br />
the following :<br />
(1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing unions,<br />
couplings, caps, blank flanges, saddles etc. necessary for making reliable piping system.<br />
(2) Gaskets, ring joints, ints, jointing material etc. as required.<br />
(3) Instrument tapping connections, stubs.<br />
(4) Gate, globe and check valves to start/stop, regulate and to prevent back flow.<br />
(5) Duplex Strainers.<br />
(6) Anchors, hangers and supports as required including secondary steel embedments etc.<br />
(7) Bolts, nuts, fasteners as required for interconnection piping, valves and fittings as well<br />
as for terminal points.<br />
(8) The entire water piping of DS/SW/PW/CW shall be routed/supported on concrete<br />
pedestal and conveyor galleries. Whereever the layout does not permit the pipes to be<br />
routed over ground, the same shall be buried in conformity to the relevant standards &<br />
shall be provided with necessary protective coating as per relevant standards.<br />
(9) Painting, anti-corrosive corrosive coatings etc. inside and outside pipe pipes s as necessary.<br />
(10) Welding electrodes and welding rods.<br />
(11) The area around storage tanks strainers, two valves etc. (located out side pump house)<br />
shall be paved with drains.<br />
16.3 Terminal Points<br />
Owner shall provide supply of water for dust suppression system, service water, potable<br />
water at one terminal point as elaborated elsewhere. Beyond the terminal point, the<br />
complete pipe work along with associated valves, specialities, instruments, fittings and<br />
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supports, pumps, tanks, etc. as required for the satisfactory operation of dust control,<br />
service water & potable water systems shall be furnished by the Contractor.<br />
16.4 Codes and Standards<br />
The design, manufacture, inspection and testing of Dust Co Control ntrol & Miscellaneous Systems<br />
shall comply with all the currently applicable statutes, regulations and safety codes in the<br />
locality where the equipment is to be installed. The Dust Control & Miscellaneous Systems<br />
shall conform to the latest edition of the following standards and codes. Other<br />
internationally acceptable standards/codes, which ensure equal or higher performance than<br />
those specified, shall also be accepted. Nothing in this specification shall be construed to<br />
relieve the contractor of the requir required ed statutory responsibility. In case of any conflict in the<br />
standard and this specification, the decision of the Owner Owner/RITES shall be final and binding.<br />
• IS:778 : Gun Metal gate, globe & check valves for general purpose.<br />
• IS:780 :Sluice valves for water work works purposes (50 to 300 mm)<br />
• IS:1239 : Mild Steel tubes & fittings.<br />
• IS:2379 :Colour for the identification of pipe line.<br />
• IS:2906 :Sluice valves for water work purposes.<br />
• IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm)<br />
• IS:5312 : Swing check type reflux (non return) valves.<br />
• IS:1520 : Horizontal centrifugal pump for clean, cold fresh water.<br />
• IS:5120 :Centrifugal pump for clean, cold & fresh water.<br />
• ANSI B 31.1:Code for pressure piping.<br />
• Hydraulic institute Standards of U.S.A.<br />
16.5 DESIGN REQUIREMENT<br />
Plain Water Dust Suppression<br />
16.5.1 At specified locations dust suppression system shall be provided which comprises spray<br />
nozzles discharging plain water in a fine spray to capture air borne dust particles and direct<br />
them into the main in coal flow. Water shall be discharged via a pipe work system through<br />
spray heads at the dust suppression zones.<br />
16.5.2 Water shall be drawn from the water storage tank by 2x100% electric motor driven pumps<br />
and discharged into tank from where 2x100% dut duty y electric motor driven pumps shall<br />
discharge the water via a pipe network system through spray heads at the dust suppression<br />
zones. Solenoid valves shall be provided for open/close control of water line to each spray<br />
head. Each spray head shall consist of minimum 4 nos. nozzles. Spray heads shall be<br />
provided at coal loading and receipt zone. Pressure at inlet to spray head shall not be less<br />
than 2.5 Kg/sq.cm(g).<br />
16.5.3 The dust suppression system over the WT hopper shall have a canopy on which fogging<br />
nozzles zzles are fixed at specified distance. Each nozzle header shall be provided with adequate<br />
number of spray nozzles spaced at 500 mm interval so that the entire length & width of the<br />
wagon tippler hopper are covered by a grid of nozzles. Further, the water s sspray<br />
shall be of<br />
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fogging type with a minimum pressure of 2.5 kg/sq.cm(g) at spray nozzle inlet. It should be<br />
possible to operate any number of zones simultaneously. The operation of wagon tippler<br />
dust suppression system shall be automatic so that the foggi fogging ng water spray shall get<br />
activated only when the tippling is in operation.<br />
16.5.4 Each spray head shall have a provision for installing a pressure gauge whenever required.<br />
Further, pressure gauges shall be provided at least at two locations.<br />
16.5.5 Sump Pumps<br />
Sump pumps shall be vertical centrifugal type with separate discharge pipe and shall be<br />
capable of developing required head at rated capacity for continuous operation. Sump<br />
pumps shall be suitable for handling coal slurry & sludge. Head capacit capacity y curve of the pump<br />
shall be rising type up to the shut off condition. Sump pumps alongwith level switches &<br />
piping upto nearest Owner's drain (max upto 50.0 mtrs. from outside the building) shall be<br />
provided at all locations wherever natural drainage is nnot<br />
ot possible. Further sump pumps<br />
alongwith drain pits shall be provided at other locations also, if required, during detailed<br />
engineering stage. The capacity of each pump shall not be less than 50 cub. M/hr.<br />
Continuous motor rating (name plate rating) at 50 deg. C. for sump pump shall have at least<br />
10% margin above the maximum load demand of the equipment in the entire operating<br />
range (including run out condition of pumps in case of parallel operation). The maximum<br />
load demand shall include the drive losses in the transmission system. Size of the sump pit<br />
shall not be less than 2.0 meters x 2.0 meters x 2.5 meters. One no. of settling pit, of<br />
adequate size, before the sump pit shall also be provided so that water without heavy coal<br />
particles goes into sump pu pump mp pit. High and low level switches shall be provided in the sump<br />
pump pit.<br />
16.5.6 Service Water (SW) System<br />
Service water connections are to be provided in conveyor galleries and tunnels at 50 meter<br />
intervals. Adequate number of these connections shall be provided in all transfer houses<br />
with minimum one no. at each floor. Each connection shall be provided with one (1) no. 32<br />
NB globe valve and quick coupling. One (1) No. Hose pipe with nozzle shall be provided in<br />
each building. Service water distributio distribution n system shall be designed considering the water<br />
scheme and water requirement indicated in tender drawings.<br />
16.6 CONSTRUCTION REQUIREMENT<br />
16.6.1 Water Supply Pumps<br />
16.6.1.1 Water supply pumps shall be provided as required.<br />
16.6.1.2 The pumps shall be complete with drive motors, baseplate and other accessories. The<br />
constructional features of the pump shall be as follows:<br />
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a. Pump casing may be axially or radially split. The casing shall be of robust construction.<br />
Casing drain and vent connections shall be provided.<br />
b. Impeller shall be made in one piece and securely keyed to the shaft. Locking device shall<br />
be provided to prevent its loosening during all conditions of operation.<br />
c. Wearing rings shall be of renewable type. Opposed wearing surface shall be of h hhardened<br />
material and shall have a hardness difference of at least 50 BHN.<br />
d. Replaceable shaft sleeves shall be provided to protect the shaft where it passes through<br />
bearings and stuffing boxes. The end of the shaft sleeve assembly shall extend through<br />
the packing acking gland. Shaft sleeve shall be securely locked or keyed to the shaft to prevent<br />
loosening or rotation. Shaft and shaft sleeves shall be machined and assembled for<br />
concentric rotation.<br />
e. The design of the shaft shall take into consideration the critical speed, which shall be at<br />
least 20% away from operating speed.<br />
f. Pump bearings shall be of antifriction type. Bearings shall be readily accessible without<br />
disturbing the alignment of pump.<br />
g. Packed stuffing boxes shall be of sufficient length to prevent leak leakage age along the shaft and<br />
shall be complete with all packing and lantern rings required.<br />
h. Pumps shall be furnished complete with an approved type of flexible --coupling.<br />
i. Couplings guards made of expanded metal and bolted to the base plate shall be<br />
furnished.<br />
j. The common base plate for pumps and motor shall be in one piece and shall be made of<br />
fabricated steel.<br />
k. Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 cum cum/hr.<br />
16.6.1.3 The power, head and flow characteristics of each pump shall be suitable for parallel<br />
operation. The Power characteristics of the pumps shall be of non overloading type.<br />
16.6.1.4 All rotating parts of the pumps shall be statically and dynamically balanced.<br />
16.6.1.5 The motor shall be rated for continuo continuous us operation and confirm to companion electrical<br />
specification. However, motor rating shall not be less than the max. power demand<br />
throughout the entire range of operation of pump.<br />
16.6.1.6 Design duty point of pump shall match with the average value oof<br />
f maximum and minimum<br />
flow rates of the pump in the stable operation zone.<br />
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16.6.1.7 Materials of construction of pump components shall be as stated in data data-sheet to this<br />
section.<br />
16.6.2 Sump Pumps<br />
16.6.2.1 The column pipe shall serve as a housing for the line shaft and bearing and support for<br />
bowl (casing). The line shaft bearing shall be supported from the pump column pipe.<br />
Individual sections of column pipe shall be coupled by flanged joints. The flange outside<br />
diameter shall not exceed the bowl outside diameter.<br />
16.6.2.2 Casing shall house the impeller and shall be hydraulically designed to minimize radial<br />
thrust. Further suitable sealing arrangement shall be provided to prevent the leakage of<br />
pumped liquid into the column pipe.<br />
16.6.2.3 The impeller shall be semi open or open (non clogging) as per standard design of the<br />
Manufacturer. All rotating parts including the impeller shall be statically and dynamically<br />
balanced. Impeller shall be securely fastened to the impeller shaft with keys taper<br />
bushings or locknuts and shall be specifically designed to pass large solids or unscreened<br />
liquids. The clearances between stationary and moving part shall be such as to allow<br />
sustained performance without excessive maintenance.<br />
16.6.2.4 The discharge pipe ipe should be terminated above the base plate or mounting channel.<br />
Type of end connection shall be as specified in data sheets. No support shall be provided<br />
for the bottom elbow (near pump bowl) to facilitate easy removal of line pump from top<br />
without the necessary to go down to the sump for removal of bottom support, if<br />
provided.<br />
16.6.2.5 The design of the bunt shaft shall also take into consideration the critical speed of the<br />
shall which shall be minimum 20% higher than any operating or run away speed.<br />
16.6.2.6 Individual sections of the shaft shall be interchangeable.<br />
16.6.2.7 The type of couplings for the line shaft shall be such to prevent loosening during reserve<br />
rotation.<br />
16.6.2.8 Line shaft bearings shall be water lubricated. Line shaft bearin bearings gs shall be spaced not more<br />
than 1.5 meters apart. For lubrication purpose clarified water shall be used.<br />
16.6.2.9 For meeting the sealing/lubricating water requirement, Contractor to provide seal water<br />
pumps (2x100% capacity).<br />
16.6.2.10 Replaceable shaft aft sleeves shall be furnished. The shaft sleeve shall be securely locked to<br />
shaft to prevent loosening while in operation.<br />
16.6.2.11 Replaceable type wear rings shall be provided for casing and/or impellers wherever<br />
applicable.<br />
16.6.2.12 For the following accessories shall be provided for sump pumps<br />
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(i) Base plates together with foundation bolts and nuts. The base plate shall<br />
accommodate the discharge pipe, which is to be terminated above the floor level.<br />
(ii) Motor stool.<br />
(iii) Non-return return valves and gate vvalves<br />
alves on pump discharge lines (unless otherwise<br />
specifically excluded).<br />
(iv) Lifting lugs, eye bolts etc.<br />
(v) Pre-lubricating lubricating tank with accessories (if necessary).<br />
(vi) Sleeves and inserts to be embedded in concrete.<br />
(vii) Coupling guard, if necessary<br />
16.6.2.13 The pump shaft shall be connected to motor shaft by a heavy duty rigid/flexible coupling<br />
or the pump shall be VV-belt<br />
driven.<br />
16.6.3 PIPING, FITTINGS, VALVES AND SPECIALTIES<br />
16.6.3.1 Piping & Fittings<br />
(a) Material of construction of piping and fittings shall not be inferior to those given in data<br />
sheet of this section.<br />
(b) All piping shall be capable of withstanding the maximum pressure in the corresponding<br />
line at the relevant temperature.<br />
(c) In general pipe sizes 65 mm NB and larger are to be joined by butt welding and pipe work<br />
of size 50 mm NB and below by socket welding/screwed connections. Joints at valves or<br />
specialities shall be flanged for sizes 65 mm NB or large and screwed for sizes 50 mm NB<br />
and below. All galvanized piping shall be joined by screwed connec connections. tions. Minimum pipe<br />
diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall<br />
be 32 NB.<br />
(d) End preparation for butt welding shall be done by machine/flame cutting. Socket weld<br />
and preparation shall be saw/machine cut.<br />
(e) Hangers and supports ports shall be capable of carrying the sum of all concurrently acting<br />
loads. They shall be designed to provide the required supporting effects and allow pipe<br />
line movements as necessary. All guides, anchors, braces, dampers, expansion joints and<br />
structural steel to be attached to the building/structure, trenches etc. shall be provided.<br />
The type of hangers and components for all piping shall be selected and approval<br />
obtained from the Owner Owner/RITES.<br />
(f) All piping shall be routed on ground on concrete pedestals and at road crossings, these<br />
shall be laid through hume pipes.<br />
16.6.3.2 Valves and Specialties<br />
(a) Valves & Specialties shall be used to start, stop or regulate the flow. All valves/specialities<br />
below 50 mm size (for isolation purpose) in service water/dust suppression/potable water<br />
lines should be plug type of proven make.<br />
(b) All valves shall be suitable for most stringent service conditions i.e. flow, temperature and<br />
pressure under which they may be required to operate.<br />
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(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above 50 NB and Globe<br />
valves shall be used for regulating the flow.<br />
(d) Valves shall be provided with back seating bush to facilitate gland renewal during full open<br />
operation.<br />
(e) All gate and globe valves of size 65 NB and large shall be bolted bonnet, outside screw, rising<br />
type with flanged ends. Valves of size 50 NB and smaller shall be with screwed ends.<br />
(f) Valves shall be provided with the following as necessary:<br />
i. Hand wheel<br />
ii. Position indicator<br />
iii. By-pass pass valve and spur gear reductio reduction unit for larger valves.<br />
iv. Draining arrangement.<br />
(g) Material of construction of valves shall not be inferior to those given in data sheet of this<br />
section.<br />
(h) Globe valves shall be provided with contoured plug to have well controllability.<br />
(i) Non-return valves shall be swing check type. These valves will have a permanent ‘arrow’<br />
inscription on its body to indicate direction of motion of the fluid.<br />
(j) All valves shall be provided with hand wheel, chain operated, extension spindle and floor<br />
stand wherever required so that they can be easily operated either at a lower or higher<br />
elevation as the case may be.<br />
(k) Strainer shall be of duplex type designed with 3 way valves so that one filter can be cleaned<br />
while the other is in operation. Suitable vent and drain valves shall also be provided. Screen<br />
opening area shall be at least four times the pipe cross sectional area. Pressure drop in clean<br />
conditions shall not exceed 1.5 MWC at full flow.<br />
(l) Bib cocks provided for potable water system shall be made of stainless steel<br />
16.6.4 Special cleaning, protection and painting<br />
16.6.4.1 Piping & Fittings<br />
(a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire<br />
brushing.<br />
(b) For over ground exposed steel pipes, one shop and one site coat of red oxide zinc p pphosphate<br />
and two coats of synthetic enamel finishing paints unless specified otherwise shall be<br />
applied. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall<br />
be ensured.<br />
(c) For steel buried pipeline, three (3) coats of heavy du duty ty bitumastic paint shall be applied on<br />
the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen<br />
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impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty<br />
bitumastic paint.<br />
16.7 DATA SHEET : DUST CONTROL & MISCELLANEOUS SYSTEM<br />
1.0 GENERAL<br />
1.1 Dust Control: Plain water dust suppression<br />
1.2 Miscellaneous systems: Service water system, Potable water system, Cooling water<br />
system & Sump pumps.<br />
2.0 DESIGN REQUIREMENT<br />
2.1 Dust Suppression<br />
2.1.1 Operation: ration: Water sprayed through nozzles.<br />
2.1.2 Pumps: 2x100% for water<br />
2.1.3 Spray Head<br />
(i) Minimum No. of nozzles per spray head: 4 (Four)<br />
(ii) Pressure at inlet: Minimum 2.5 kg/sq. cm<br />
2.2.0 Plain Water Dust Suppression<br />
2.2.1 Pumps: 2x100% electric motor driven<br />
2.2.2 Minimum Pressure at inlet of spray nozzles: 2.5 kg/sq. cm<br />
2.2.3 Nozzle spacing on WT Top: 500 mm<br />
2.2.4 Nozzles: Fogging type<br />
2.2.5 Flow from each nozzle: 2.0 Lpm<br />
2.3.0 Sumps Pumps<br />
(i) Type: 2x100% electric motor driven<br />
(ii) Capacity: 50 cub.m/hr minimum with 10% margin<br />
(iii) Head: 20% margin on computed head<br />
2.3.1 Drain Pits: Minimum 2x2x2.5 mts. and 1 No. settling pit for slurry & high/low level<br />
switches in drain pit.<br />
2.3.2 Piping: To nearest plant drain<br />
2.4.0 Service ice Water System<br />
2.4.1 Water connections<br />
(a) Conveyor Galleries and tunnels: every 50 m<br />
(b) Transfer points: Min. 1 no. at every floor<br />
2.4.2 Connection details: 1 No. 32 NB globe valve & quick coupling<br />
2.4.3 Hose pipes with hose reel: One in each building of 25 mtr. Length with nozzle<br />
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3.0 CONSTRUCTION REQUIREMENTS<br />
3.1 Water Supply Pumps for DS/SW/PW/CW<br />
3.1.1 Casing Axial or radially split with drain & vent connection<br />
3.1.2 Impeller One piece, keyed to shaft along with locking device<br />
3.1.3 Shaft Critical speed atleast 20% away from operating speed<br />
3.1.4 Shaft sleeves at bearings & stuffing boxes.<br />
3.1.5 Bearings Antifriction type<br />
3.1.6 Wearing rings Renewable type (preferable)<br />
3.1.7 Pump speed Below 1500 rpm for capacity more than 10 cub. m/hr.<br />
3.1.8 Head flow characteristics Suitable for parallel operation.<br />
3.1.9 Materials<br />
(a) Casing: Cast Iron to IS:210, FG 260<br />
(b) Impeller: Bronze conforming to Gr.I of IS:318<br />
(c) Impeller Wearing ring: Bronze conforming to Gr.I of IS:318<br />
(d) Casing Wearing ring: Bronze conforming to Gr.I of IS:318<br />
(e) Shaft: Medium carbon steel<br />
(f) Shaft sleeve: Stainless steel conforming to AISI AISI-416 hardened.<br />
(g) Gland packing: Impregnated Teflon<br />
3.2.0 Sump Pumps<br />
3.2.1 Type: Vertical, centrifugal, single st stage, age, semi open or open (non clogging) type impeller.<br />
3.2.2 Duty: Intermittent. However, to be designed for contineous operation.<br />
3.2.3 Fluid to be Pumped: Sludge/Coal slurry<br />
3.2.4 Suction Condition: Submerged<br />
3.2.5 Pump speed (maximum): 1000 RPM<br />
3.2.6 Type of coupling between pump and motor: Directly driven through flexible or rigid<br />
coupling/V-Belt<br />
3.2.7 Location of pump thrust bearing: In motor stool<br />
3.2.8 Materials<br />
(a) Casing: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.)<br />
(b) Impeller: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.)<br />
(c) Impeller: Shaft Stainless steel<br />
(d) Line Shaft: EN-8 8 to BS; 970<br />
(e) Column pipe and discharge pipe: Fabricated steel to IS: 226 (min. 6mm thick).<br />
(f) Shaft sleeve: Hardened stainless steel to 400 BHN<br />
(g) Base Plate: Steel to IS: 226 up to 20mm thickness and IS: 2062 over 20mm thickness.<br />
3.2.9 Accessories Provided with the Pump<br />
i. Lubrication and sealing water system: Yes<br />
ii. Common base plate for Pumps and Motor and Motor stool: Yes<br />
iii. Anchor Bolts, nuts, sleeves and inserts (which will be embedded in concrete): Yes<br />
iv. Coupling, guards lifting lug, eye bolt, positioning Dove: Yes<br />
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3.3.0 Pipings & Fittings<br />
3.3.1 Joints<br />
(i) Pipe to pipe<br />
Pipe size < 50 NB: Socket welding/screwed Butt<br />
Pipe size > 65 NB: welding<br />
(ii) Pipe to valves<br />
Pipe size ≤ 50 0 NB: Screwed<br />
Pipe size ≥ 65 NB: Flanged<br />
3.3.2 Isolation of flow: Plug / Gate / Sluice valves<br />
3.3.3 Regulation of flow: Globe Valve<br />
3.3.4 Valves<br />
i. Size > 65 NB: Bolted bonnet outside screw rising type.<br />
ii. Size < 50 NB: Union bonnet with screwed ends for Globe valves & screwed<br />
ends for plug valves.<br />
3.3.5 Materials for Pipework<br />
(a) For sizes 200 NB and Larger: ERW carbon steel pipes to API API-5LGr.B minimum<br />
thick 6.35 mm or plate fabricated and welded pipes to IS:3589, Class Class-2.<br />
(b) For sizes 150 NB to 65 NB: ERW carbon steel black pipes to IS:1239 (Part (Part-I, Heavy<br />
Class).<br />
(c) For sizes upto 50 NB: ERW carbon steel galvanized pipes to IS:1239 (Part (Part-I) Heavy<br />
class.<br />
3.3.6 Materials for Valves & Specialities<br />
(a) Cast Iron Valves: (65 NB & above)<br />
i. Body and bonnet: Cast Iron to IS:210, Gr.FG-200<br />
ii. Disc for non non- return: Cast Iron to IS:210, Gr.FG-200 200 valves<br />
iii. Seating surfaces and rings: 13% chromium steel<br />
iv. Hinge pin for non return valves: Stainless steel type AISI AISI--316<br />
v. Stem for gate and globe valves: 13% chromium steel<br />
vi. Back seat bush: 13% chromium steel<br />
(b) Gun metal valves (50 NB & below and upto a working pressure of 10 kg/cm2)<br />
(i) Body: Gun metal to IS:318, Gr Gr-2.<br />
(ii) Trim: Gun metal to IS:318, Gr Gr-2.<br />
(c) Duplex Strainer<br />
(i) Body: MS fabricated<br />
(ii) Strainer: Stainless steel type element AISI-316<br />
(d) Pressure Gauge/Switch (to be provided with isolating valves, gauge cock, snubber and<br />
syphon)<br />
(i) Dial size : 150 mm<br />
(ii) Accuracy : (+/-) 1% of range span<br />
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(iii) Bourdon : AISI 316 SS<br />
(iv) Block : AISI 316 SS<br />
(v) Movement : AISI 316 SS<br />
(vi)<br />
Case and Bezel : Die cast Alum. Weather proof case stove<br />
enameled block with screwed type inner bezel of ABS plastic<br />
and glycerin filled.<br />
(vii) No. of contacts : 2 NO + 2 NC<br />
(viii) Type of contact : Adjustable throughout the range.<br />
(ix) Degree of protection : IP. 65<br />
(e) Solenoid valve (to be provided with isolating valve)<br />
(i) Type<br />
: 2/2 way Diaphragm type pilot operated<br />
(ii) Diaphragm : molded synthetic rubber<br />
(iii) Body<br />
: Forged brass / SS<br />
(iv) Pressure : 0.5 to 20 kg/cm2<br />
(v) Protection : Class IP 65<br />
(f) Flow Switch (to be provided with isolating valves)<br />
(i) Body<br />
: Forged steel<br />
(ii) Extension Rod/wire : SS-304<br />
(iii) Sleeve and Sleeve pipe: SS SS-304<br />
(iv) Cover<br />
: Die cast aluminum<br />
(v) Max. working pressure : 10 kg/sq.cm<br />
(vi) Repeatability : ± 0.5%<br />
(vii)No. of contacts : 2 NO + 2 NC<br />
(viii)Type of contact : Adjustable throughout the range.<br />
(ix) Protection : class IP – 65<br />
(g) Level Switch<br />
(i) Type : Displacer operated magnetic type<br />
(ii) Displacer: SS – 316<br />
(iii) Wire rope: SS – 316<br />
(iii) Spring Housing Spring and sleeve pipe: SS – 316<br />
(iv) Cover: Cast Aluminum<br />
(v) No. of Contacts: 2 NO + 2 NC<br />
(vi)Type of Contact: Adjustable throughout the range.<br />
(viii)Protection: class IP – 65<br />
(h) Level gauges<br />
(i) Type: Float type mechanical gauge wit with arrow scale<br />
(ii) Accuracy: (+/--)<br />
1% of full scale range<br />
(iii) Material of construction<br />
(a) Float & Guide wire: 316 SS<br />
(b) Elbows: Suitable grade of SS<br />
(c) Housing: Mild Steel<br />
(d) Cable fastener: SS 304<br />
(i) Nozzles<br />
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(j) Y Strainer<br />
17.0 VENTILATION SYSTEMS<br />
17.1 GENERAL<br />
17.1.1 INTENT OF SPECIFICATION<br />
(i) Type: Fogging, non non-clogging type<br />
(ii) Material: Stainless Steel<br />
(iii) Nozzle housing : To ensure protection of nozzle against damage.<br />
(a) Body: SS 304<br />
(b) Plug: SS 304<br />
(c) Filter Element: SS 316, 60 mesh<br />
The specification is intended to cover design, engineering, manufacture, supply, erection,<br />
testing and commissioning of the complete Ventilation & air conditioning systems as<br />
specified hereinafter for the smooth and trouble free operation of plant & equipment of<br />
Wagon tippler package.<br />
17.1.1.1 The Contractor shall refer to the other sections enclosed to appraise himself of the work<br />
and scope of supply of the other Contractors and shall coordinate his work with the work of<br />
other Contractors.<br />
17.2 GENERAL DESCRIPTION<br />
17.2.1 Mechanical Ventilation system<br />
The air quantity for mechanical ventilation system shall be estimated based on equipment<br />
and solar heat loads and the temperature rise inside the building. Necessary air filters shall<br />
be provided ided to supply only clean air into building. Exhaust air shall be discharged at a<br />
suitable height above building. Exhaust fans shall be provided for Toilets, Battery rooms. All<br />
underground structure shall be provided with supply air as well as exhaust air fans.<br />
17.2.2 Pressurised Ventilation System<br />
The pressurised ventilation system having adequate nos. of supply and exhaust air fans with<br />
washable metallic pre filters, HDPE fine filters, and exhaust fans with self closing flaps,<br />
ducting along with 3 phas phase e AC motor drives, electricals, supporting structures, access /<br />
maintenance platforms shall be provided in all MCC/switchgear room areas of coal handling<br />
plant to be furnished under this specification. The pressurized ventilation system shall be<br />
designed considering onsidering 20 air changes per hour to maintain these areas pressurized slightly<br />
above atmospheric pressure to prevent ingress of dust from outside.<br />
17.2.3 Air Conditioning System<br />
Air conditioning system shall be furnished for control room area of Wagon tippler control<br />
building, it shall be designed considering the equipment heat loads, solar heat loads, heat<br />
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17.3 SCOPE<br />
gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and<br />
relative humidity within the air conditioned areas.<br />
17.3.1 Mechanical Ventilation System<br />
The ventilation system generally consisting of adequate number of supply and exhaust air<br />
fans, air filters, ducting along with 3 phase AC motor drives, electricals, supporting<br />
structures, approach/maintenance platforms, civil and structural works and necessary<br />
accessories shall be furnished for ventilating the WT hopper, underground portion of<br />
transfer points, underground conveyor tunnel tunnels s and pent houses. Exhaust fans shall be<br />
provided for Toilets & Battery rooms.<br />
17.3.2 Pressurised Mechanical Ventilation System<br />
The ventilation system generally consisting of adequate number of supply and exhaust fans,<br />
metallic pre filters, HDPE fine fi filters, lters, ducting along with 3 phase AC motor drives, electricals,<br />
supporting structures, approach / maintenance platforms, necessary shed, civil & structural<br />
works and necessary accessories shall be furnished for all MCC/switchgear rooms.<br />
17.3.3 Air Conditioning ioning System<br />
17.3.4 2x100% capacity air conditioning units shall be provided for Wagon Tippler Control Room.<br />
17.3.5 Supply and return air distribution ducting complete with insulation, of resin bonded mineral<br />
wool equivalent of density at least 24 Kg/m Kg/m³ ³ and thermal conductivity of max. 0.49<br />
mw/cm°C conforming to IS:8183 including supporting structures, approach/ maintenance<br />
platforms, civil and structural works and necessary accessories shall be provided.<br />
17.3.6 Air cooled PAC shall be provided provided.<br />
17.3.7 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear<br />
surrounding.<br />
17.4 Codes & Standards<br />
The design, manufacture, inspection and testing of Ventilation & A/C System shall comply<br />
with all the currently applicable statutes, regulations and safety codes in the locality where<br />
the equipment is to be installed. The Ventilation & A/C System shall conform to the latest<br />
edition of the following standards and codes. Other internationally acceptable<br />
standards/codes, which eensure<br />
nsure equal or higher performance than those specified, shall also<br />
be accepted. Nothing in this specification shall be construed to relieve the contractor of the<br />
required statutory responsibility. In case of any conflict in the standard and this<br />
specification, ion, the decision of the Owner Owner/RITES shall be final and binding.<br />
• IS:3588 : Specification for electrical axial flow fans.<br />
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• IS:2312 :Propeller type AC Ventilation fans<br />
• IS:3963 :Specification for roof roof-extractor units<br />
• IS:4894 :Centrifugal Fans<br />
• IS:655 :Specification ation for Metal Air Duct<br />
• ARI:210 :Standard for Unitary air conditioning equipment.<br />
• ARI:270 :Standard for application, installation and servicing of unitary equipment.<br />
• IS:8183 :Specification for bonded mineral wool.<br />
• IS:661 :Thermal insulation for cold surfa surfaces.<br />
• IS:4671:Expanded polystyrene for thermal insulation purpose.<br />
• IS:8148 :Packaged Air conditioners.<br />
17.5 DESIGN REQUIREMENT<br />
17.5.1 Roof Ventilators & Accessories<br />
17.5.2 Roof ventilators & accessories shall be provided as required. Impeller shall be axial flow<br />
type.<br />
17.5.3 Design duty point of the fan shall match with the average value of maximum and minimum<br />
flow rates of the fan in stable operation zone.<br />
17.5.4 The speed of the roof ventilators shall not exceed 960 rpm for ventilators with impeller<br />
diameter above 450 mm & 1440 rpm for ventilators with impeller diameter 450 mm and<br />
less. The first critical speed of rotating assembly shall be at least 25% above operating speed.<br />
17.5.5 Motor shall be totally enclosed type suitable for vertical mounting mounting. . Motors shall comply with<br />
the companion electrical specifications.<br />
17.5.6 Axial Fans<br />
17.5.7 Design duty point of the fan shall match with the average value of maximum and minimum<br />
flow rates of the fan in the stable operation zone. The speed of the fan shall not exceed 960<br />
rpm for fan with impeller diameter above 450 mm and 1440 rpm for fan with impeller<br />
diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25%<br />
above operating speed.<br />
17.5.8 Impellers shall be axial flow low type single piece.<br />
17.5.9 Centrifugal Fans<br />
17.5.10 The fan units shall be centrifugal type with radial bladed impeller. For design purpose out<br />
door ambient temperature shall be taken as 50 deg.C.<br />
17.5.11 Fans shall be manufactured vibration free in operation and shall be designed to limit noise<br />
level within limits specified in Data Sheet.<br />
17.5.12 The motor shall be rated for continuous operation and conform to companion electrical<br />
specification. However, motor rating shall not be less than the m mmax.<br />
power demand<br />
throughout the entire range of operation of fan.<br />
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17.5.13 All fan mountings shall have adequate arrangement for vibration isolation.<br />
17.5.14 The reverse flow through non non-working working fan shall be prevented by dampers. The dampers<br />
shall be made out of 18 SWG MS sheets.<br />
17.5.15 Design duty point of the fans shall match with the average value of maximum and minimum<br />
flow rate of the fan in the stable oper operation zone.<br />
17.5.16 Filters<br />
17.5.16.1 Metallic Filters<br />
Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be<br />
2 m/sec.<br />
17.5.16.2 HDPE Filters<br />
HDPE filters should have an efficiency of 90% down to 5 microns. Vel Velocity ocity across the filter<br />
shall be limited to 2.5 m/sec.<br />
17.5.17 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99.9% down<br />
to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm<br />
w.c.<br />
17.5.18 Packaged Air-Conditioning Conditioning Unit<br />
PAC units shall be provided as required.<br />
17.5.19 PAC units shall be factory tested and assembled self contained units complete with<br />
refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units<br />
wherever required shall be insulated with expanded polyethylene conforming to IS:4671.<br />
17.5.20 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled<br />
condenser (outdoor air) section. Heavy gauge steel cabinet factory finished with two coats of<br />
epoxy paint of approved colour, shall be used to house components of PAC.<br />
17.5.21 The evaporator and condenser coils shall be arranged for direct expansion cooling and shall<br />
be formed of aluminum fins mechanically bonded to seamless copper tubes and electrically<br />
tinned. The inter-connecting connecting refrigerant circuits shall comprise of multiple cylinder hermetic<br />
compressor(s) and motor(s) with all necessary isolation valves, suction gas controlled<br />
thermal expansion valves, with adjustable set point, sight glass, copper tubing and pipeline<br />
ancillaries. The condenser coils shall be air cooled by propeller type fans complete with<br />
safety guards. The condensing coils shall be suitably arranged to avoid radiant heat pick pick-up<br />
from solar sources.<br />
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17.5.22 Condenser capacity control shall be provided by means of variable speed fans and ‘head<br />
pressure’ sensing.<br />
17.5.23 The evaporator air blower(s) shall be centrifugal forward curved type belt driven by<br />
individual motor(s) and suitable for the external static pressure. The fan assembly shall be<br />
isolated from the casing by anti anti-vibration vibration mounts. The fan/motor drive shall be capable of<br />
capacity adjustment by pulley changes within +15% of design duty.<br />
17.5.24 High efficiency filters shall be pprovided<br />
rovided in the main supply air duct and in the fresh air<br />
connection to return air duct.<br />
17.6 Construction Requirements<br />
17.6.1 General construction details of various equipment under Contractor’s scope shall be as<br />
elaborated in subsequent clauses below.<br />
17.6.2 Roof Ventilators and accessories<br />
Roof ventilators and accessories shall be provided as required.<br />
17.6.3 Impeller shall be axial flow type, cast in one piece finished all over and carefully dynamically<br />
balanced after final assembly. All impellers shall consist of high efficiency aerofoil blades.<br />
Impellers shall be mounted directly on the motor shaft.<br />
17.6.4 Casing shall be of heavy gauge construction and shall be properly reinforced for rigidity.<br />
Access door with suitable locking arrang arrangement shall be provided.<br />
17.6.5 Hood shall be of hinged type providing easy access to motor and impeller. It will also protect<br />
them from rain and any other contingencies. Weather Weather-proof proof lockable type disconnect switch<br />
shall be provided such that the hoods can be opened only when the disconnect switch is in<br />
‘OFF’ positions. On larger sizes of roof ventilators, hoods shall be of split construction. 15<br />
mm mesh galvanised bird screen shall be provided. The hoods will have low pressure drop<br />
across it.<br />
17.6.6 Suitable uitable arrangement shall be provided for mounting the roof ventilators such that ingress<br />
of rainwater into the building will be avoided completely.<br />
17.6.7 Axial Flow Fans<br />
Axial flow fans shall be provided as required.<br />
17.6.8 Impellers shall be axial fl flow ow type and single piece cast aluminum with aerofoil blades<br />
construction. It shall be finished all over and balanced dynamically. Impeller shall be<br />
mounted directly on the motor shaft.<br />
17.6.9 Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall be<br />
provided with suitable supports. Access door shall be provided in the casing for easy access<br />
to motor and impeller. Suitable arrangement for mounting of motor shall be provided.<br />
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17.6.10 Rain protection cowls will be de designed signed to suit wall exhausters/supply fans for protecting<br />
fans/motors from rain. It will be provided with bird screen.<br />
17.6.11 Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or<br />
M.S.<br />
17.6.12 Motor shall be of totally otally enclosed type complying with the companion electrical<br />
specification. Suitable rain/sun shade for motors shall also be provided.<br />
17.6.13 Centrifugal Fan<br />
Centrifugal fans shall be provided as required.<br />
17.6.14 The casing shall be of welded construction fabricated with heavy gauge material. It shall be<br />
rigidly reinforced and supported by structural angles. The seams shall be permanently sealed<br />
airtight. Split casing shall be provided on larger sizes of fans. Casing drain with valves shall be<br />
provided wherever required.<br />
17.6.15 The impeller shall have die formed curved blades fabricated out of MS heavy gauge welded<br />
to the rim and back plate to have a non overloading characteristics of the fan. Rim shall be<br />
spun to have ve a smooth contour. If required intermediate stiffening rings shall be required.<br />
The impeller, pulley and shaft sleeves shall be secured to the shaft by key and/or nuts. The<br />
impeller along with driven pulley shall be dynamically balanced. Fan shaft shall be of EN-8<br />
equivalent.<br />
17.6.16 The bearings shall be self self-aligning heavy-duty duty ball or roller bearings. They shall be<br />
adequately supported. They shall be easily accessible and lubricated properly from outside.<br />
17.6.17 Filters<br />
17.6.18 Metallic Filters<br />
Metallic allic cleanable filters shall consist of VV-fold<br />
fold galvanised wire mesh inter spaced with a flat<br />
layer of galvanised wire mesh. The density of the filter medium shall increase in the direction<br />
of airflow. Wire mesh edges shall be suitably hemmed to eliminate the danger of abrasion<br />
during handling. Filter medium shall be supported on either side by galvanised expanded<br />
metal casing. Filter frame shall be constructed from galvanised sheet of thickness not less<br />
than 18 gauge.<br />
17.6.19 HDPE Filters<br />
HDPE filters shall all be provided as required. This shall be constructed of HDPE fabric with<br />
continuous water spraying on it from a header for keeping it clean.<br />
17.6.20 High efficiency filter (for A/C purpose)<br />
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The media of the filter shall be made from either special synthetic non non-woven bond fiber<br />
design or made from micro fiber glass media. It shall be supported with GI wire mesh or<br />
aluminum mesh and shall be housed in an aluminum sheet frame. It shall be of washable<br />
type several times.<br />
17.6.21 Package A/C Unit<br />
17.6.22 .22 A separate cubicle shall be provided within the overall casing to house the thermostatic<br />
controls, which shall be electric/electronic solid state, prewired and tested. The refrigerant<br />
system shall be protected by pressure limiting devices, electric and thermal overloads and<br />
unloading facilities to provide the required control range tolerances. A low voltage room<br />
thermostat shall be provided for wall mounting. The casing shall be fitted with all necessary<br />
coil drains and service connections/<br />
entries.<br />
17. . 6.23 PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The units<br />
shall be fully packaged and incorporate integral room air sensing control thermostats and<br />
manufacturers work fitted safety interlocks. All controls shall be prewir prewired to unit mounted<br />
control/power terminal boxes.<br />
17.6.24 Ventilation and Air Conditioning system ducting<br />
17.6.25 All GI sheet metal ductwork required for ventilation and air conditioning system shall be<br />
furnished by the supplier. All ducts and plenums unless otherwise noted shall be constructed<br />
out of standard quality galvanised steel sheet. All sheet metal ducts shall be fabricated and<br />
installed in conformity to the requirements of IS:655. Steel supports for the ductwork shall<br />
be furnished as required. The thickness of ducting steel shall be 1 mm min. For ducting with<br />
large size exceeding 1300 mm it shall be 1.25 mm. The flexible connection between fan and<br />
ducting shall be on Teflon impregnated canvas. The zinc coating on GI sheet shall be 275<br />
gm/cm2.<br />
17.7 DATA SHEET : VENTILATION SYSTEM<br />
1.0 GENERAL<br />
1.1.0 Mech. Ventilation System: To provide ventilation using fans for specified areas.<br />
1.1.1 No. of air changes per hour<br />
(a) For overground building: Not less than 10 supply air changes & 7 Exhaust air<br />
changes<br />
(b) For underground areas: Not less than 15 supply air changes & 7 Exhaust air changes<br />
1.1.2 Equipment<br />
(1) Underground tunnel: Centrifugal fans/Axial Fans<br />
(2) All other places: Axial fans, roof ventilators<br />
1.2.0 Pressurised ventilati ventilation on system: To provide clean air to all MCC / Switchgear buildings<br />
1.2.1 No. of air changes per hour: Not less than 20<br />
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1.2.2 Equipment: Centrifugal fans/Axial Fans and exhaust air fan<br />
1.3.0 Air-conditioning conditioning system As specified<br />
1.3.1 Temperature to be maintained : 24 ± 1 deg. C<br />
1.3.2 Humidity to be maintained : 50 ± 5% relative humidity<br />
1.3.3 Fresh Air intake : More than 1.5 air changes per hour.<br />
1.3.4 Equipment: 2 x 100 % roof mounted package AC units along with ducting etc.<br />
and window AC<br />
1.4.0 Outside Ambient Conditions<br />
(i) Summer: As per weather data given in project synopsis.<br />
(ii) Monsoon: - Do –<br />
(iii) Winter: - Do<br />
2.0.0 DESIGN & CONSTRUCTION<br />
2.1.0 Roof Ventilators<br />
2.1.1 Capacity: 10% more of actual requirement<br />
2.1.2 Head: 20% more of actual requirement<br />
2.1.3 Speed<br />
(a) Impeller: dia above 450 mm Max. 960 rpm<br />
(b) Impeller: dia less than or equal to 450 mm Max. 1440 rpm<br />
(c) Critical speed: 25% above operating speed.<br />
2.2.0 Axial Fans<br />
2.2.1 Capacity: 10% more of actual requirement<br />
2.2.2 Head: 20% more of actual requirement<br />
2.2.3 Speed<br />
(a) Impeller: dia above 450 mm Max. 960 rpm<br />
(b) Impeller: dia less than or equal to 450 mm Max. 1440 rpm<br />
(c) Critical speed: 25% above operating speed.<br />
2.3.0 Centrifugal Fans<br />
2.3.1 Capacity: 10% more of actu actual requirement<br />
2.3.2 Head: 20% more than actual requirement<br />
2.3.3 Speed: Max. 1500 rpm<br />
2.3.4 Outdoor temperature: 50 deg.C.<br />
2.3.5 Rating: Continuous<br />
2.4.0 Packaged Air-Conditioning Conditioning Unit<br />
2.4.1 Type: Roof top mounting<br />
2.4.2 Service/application: Continuous, round the clock.<br />
2.4.3 Capacity<br />
(i) TR: Suitable<br />
(ii) CFM: Suitable<br />
2.4.4 Type of compressor: Multiple cylinder hermetic compressor.<br />
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2.4.5 Condenser: Air cooled type<br />
2.4.6 Fan: Forward curved centrifugal fan<br />
2.4.7 Filter: High efficiency filter<br />
2.4.8 Cooling Coil<br />
(a) Type: Direct Expansion<br />
(b) Material: Copper<br />
(c) Fins: Aluminum mechanically bonded.<br />
2.4.9 Refrigerant: Piping Copper<br />
2.4.10 Insulation for PAC parts: Expanded polyethylene of density at least 15 kg/cub.m.<br />
2.5.0 Filters<br />
2.5.1. Metallic Filters<br />
(1) Max. air velocity: 2m/sec.<br />
2.5.2 HDPE filters<br />
(1) Efficiency: 90% down to 5 microns<br />
(2) Max. velocity: 2.5 m/sec.<br />
(3) Testing: As per BS 2831 / Sqv.<br />
2.5.3 High Efficiency Filter<br />
(1) Efficiency: 99.9% down to 5 microns.<br />
(2) Pr. drop across: 10 mm W.C.<br />
(3) Testing: As per BS 2831 / Sqv.<br />
2.6.0 Insulation for A/C Ducting Resin Bonded Mineral wool as per IS:8183<br />
2.6.1 Density: 24 kg/cub.m<br />
2.6.2 Thermal conductivity: 0.49 mw/cm deg.C<br />
18.0 DESIGN OF CONVEYOR GALLERIES AND JUNCTION HOUSES<br />
18.1 Design Considerations<br />
a) The general parameters for conveyor galleries shall conform to the provision of IS : 11592 11592-<br />
1985 unless specified otherwise in Technical Specifications. The structures shall be designed<br />
so as to meet functional requirem requirements ents and shall provide space for operation, maintenance<br />
and removal of machinery and give the workers good and safe environment.<br />
b) Gallery floors shall be of chequered plates supported on steel beams.<br />
c) Steps shall be provided with (rise not exceeding 130 mmm<br />
m along the walkways if the gallery<br />
slope exceeds 12°. . In case the slope of gallery is between 66°<br />
to 12°, , suitable ribs (without any<br />
sharp edges) shall be provided on floor at 250 to 300 mm intervals.<br />
d) Roof and side walls of conveyor galleries shall be covered with Aluminium industrial<br />
troughed sheets. . with a provision of gap of 300 mm below roof and 150 mm from top of<br />
floor level on the side wall for ventilation.<br />
e) Adequate provision for natural light in inside side conveyor gallery shall be made through side walls<br />
by providing translucent sheets (FRP sheets as per IS: 12866 12866-1989). 1989). Every sixth sheet on side<br />
wall shall be FRP sheet and shall be staggered on opposite wall.<br />
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f) Roof slopes of conveyor galleries shall bbe<br />
1:5 (1 vertical, 5 Horizontal).<br />
g) The level of underside of the base plate of gallery supporting trestles shall be 300 mm above<br />
the average ground level of the surrounding area.<br />
h) Protective hand railing shall be provided along gallery walkways, open platf platform, stairways,<br />
landings, edges of walkways when the gallery is not enclosed, and around erection openings,<br />
if any, to ensure safety of operating personnel.<br />
i) Conveyor galleries longer than 150 m shall be provided with expansion joints with twin<br />
trestles/supports. pports. Each expansion block shall have fixed support/rigid trestle with adequate<br />
arrangement (provision of top chord and bottom chord bracing to gallery girder etc.) for<br />
transferring the transverse and longitudinal forces to the foundation.<br />
j) Gallery girders rs near junction house shall be preferably supported on trestle located as close<br />
to the junction house as possible, with part of gallery girder between junction house and<br />
trestle cantilevered from the trestle. Supporting gallery girders on junction house s sshall<br />
be<br />
generally avoided.<br />
k) The underside of the belt conveyor shall be fully covered with 3 mm sheet in case of<br />
conveyors located within the boundaries of the plant area. including the gallery crossing the<br />
roads / railway lines / areas of public gathering gatherings.<br />
l) When conveyor gallery crosses above or below H.T cables, a minimum clear distance of 1.0<br />
m between the structural elements/cladding and HT cables shall be maintained.<br />
m) When the conveyor bridge passes over plant roads, clearance between the road surface and<br />
the lowest points of the bridges shall not be less than 8.0 m or the height needed for the<br />
passage of the largest individual components of the plant equipment, whichever is the<br />
larger.<br />
n) The junction house shall be designed to suit the functional requirement. Number of floors,<br />
height of building etc. shall be decided accordingly.<br />
o) In general the junction house shall be designed as framed structures on shorter span side<br />
and vertically braced on longer side to achieve stability.<br />
p) Floor of junction houses ouses shall be of RCC slab / Chequered plate supported on steel beams,<br />
unless required otherwise from technological suitable lugs.<br />
q) Roof and side covering of junction houses shall be with Aluminium industrial troughed<br />
sheets as specified. Roof slope shall be 1: 5 ( 1 Vertical : 5 Horizontal).<br />
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) Suitable access staircase with safety hand railing shall be provided to all floors of junction<br />
houses.<br />
s) Wall sheeting shall generally start from the lowest working floor and extend up to roof level<br />
with louvers at each h floor level to ensure adequate natural ventilation.<br />
t) Monorails for maintenance hoists shall be provided for maintenance and repair of various<br />
equipments located on the floors.<br />
18.2 Components of structures<br />
a) Gallery Trusses and Roof<br />
Gallery truss shall be of latticed type construction. The trusses shall be adequately braced at<br />
top and bottom chord level to transfer the horizontal wind forces to end portals.<br />
b) Stringer Beam<br />
These beams shall be suitably spaced to support the conveyor stringer supports and shall<br />
transfer load to gallery. Walkways on either side of the conveyor shall also be supported on<br />
these stringer beams.<br />
c) Supporting Trestles<br />
Intermediate trestles shall be two legged and shall deliver loads from gallery trusses to the<br />
foundations. In addition, four legged trestles shall be provided which will act as fixed support<br />
to transmit all longitudinal forces between expansion block, in addition to other forces.<br />
d) Junction Houses<br />
i) Floors - Floor beam layout shall be arranged to suit equipment llayout<br />
ayout as well as equipment<br />
anchoring system.<br />
ii) Columns - In addition to loads from floor and roof, columns shall be designed to transmit<br />
horizontal load due to belt tension/snapping of belts to the foundation.<br />
e) Belt Tensioning Device<br />
Suitable structures shall be provided to accommodate belt belt-tensioning tensioning device which may be<br />
located either under the conveyor gallery or in the junction house itself.<br />
f) Wall Structures<br />
(i) Wall runners with necessary sag rods shall be provided to support wall sheeting in<br />
conveyor galleries and junction houses.<br />
(ii) Walls shall be provided with louvers and translucent sheeting at appropriate levels,<br />
to provide natural ventilation and lighting.<br />
g) Access stairs, walkways, platforms, ladders, hand railing etc.<br />
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(i) Wherever possible, access shall be provided by means of stairs.<br />
(ii) All walkways and stairs leading to working platforms shall have minimum 800 mm width<br />
of walkways/flight of stair.<br />
(iii) All other walkways and stairs leading to areas for maintenance purpose, or due to<br />
restriction iction of space, shall have a minimum width of 800 mm of walkway/flight of stair,<br />
unless required otherwise.<br />
(iv) Staircases shall be generally designed with slope of approximate 37.5 37.5° with the<br />
horizontal. (In no case the slope shall exceed 40 ° with the horizo horizontal). Intermediate<br />
landings shall be provided wherever required such that vertical rise of each flight does<br />
not exceed 3000mm. Risers in one flight shall be equally spaced.<br />
(v) Walkway floors and stair treads shall be designed with chequered plate (or non non-slip<br />
type plates). Ribbed floor/treads may be provided wherever the possibility of<br />
accumulation of dust exists, taking care that such provisions do not crate a nuisance to<br />
the operating personnel on the shop floor.<br />
(vi) Rise of treads in staircases shall not excee exceed 200 mm.<br />
(vii) A minimum headroom of 2200 mm shall be provided over operating platforms, visitor's<br />
galleries, or other areas with possibility of public gathering. In all other platforms,<br />
walkways and stairs, minimum headroom of 2000 mm shall be provided. Only i iin<br />
special<br />
cases, local headroom of 1800 mm may be allowed (i.e. at intersection with structural<br />
members etc.).<br />
(viii) Cat ladders shall be provided for access, wherever provision of staircase is impractical<br />
due to limitations of space, or the access is required vvery<br />
ery infrequently.<br />
(ix) Wherever the height of cat ladder exceeds 4.0 m, safety cage shall be provided.<br />
Intermediate landing shall be provided to cat ladders such that vertical height of single<br />
rise does not exceed 8.0 m.<br />
(x) Cat ladders shall be designed with follo following provisions:<br />
i. Width of rung = 500 mm<br />
ii. Minimum rise of rung = 250 mm; Maximum rise of rung = 300 mm<br />
iii. Minimum clearance from rung of ladder to back of cage (in case of caged<br />
ladders) = 700 mm<br />
iv. Minimum clearance from the centre of cage all round = 350 mm<br />
v. Slope of cat--ladders:<br />
I. For normal cat cat-ladders, ladders, slope shall be within the range of 75 75°-90° with the<br />
horizontal.<br />
II. For ship-type type ladders (i.e cat cat-ladders ladders with short side handrails) the slope shall be<br />
within the range of 65 65°-75° with the horizontal.<br />
(xi) All walkways, platforms and stairs shall be provided with safety handrails. All handrails<br />
shall be constructed with steel tubes / angles for posts, top and middle rail and<br />
plates/sheets for toe plates. In case of stairs, the toe guards need not be provided.<br />
(xii) The he vertical height of hand hand-railings railings on walkways and stairs shall be minimum 1000 mm<br />
above floor level.<br />
(xiii) Hand-railing railing along edge of roof and gutters shall have a minimum height of 600 mm<br />
over top edge of gutters/sheets. In such hand railings toe guards need not be provided.<br />
(Only top handrail and midrail shall be provided).<br />
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18.3 ADDITIONAL DESIGN CRITERIA<br />
a) Design of steel structures shall be done in accordance with IS:800 IS:800-1984. 1984.<br />
b) In absence of specified dynamic factor to be considered for the load from the belt<br />
conveyor, a dynamic factor of not less than 1.3 shall be considered for the design of<br />
floor beams and gallery girders.<br />
c) Gallery trusses and stringers as well as floor be beams ams of junction house shall be checked<br />
for obviating occurrence of resonance and shall be designed such that the ratio of<br />
applied frequency to natural frequency shall not lie within the range 0.7 to 1.5.<br />
d) As far as possible gallery structure shall be mmade<br />
ade independent of junction houses. A<br />
trestle shall be planned close to the junction house to avoid gallery span resting on the<br />
junction house.<br />
e) The contractor after the award of work shall submit design criteria to owner /<br />
consultant for approval befo before submission of design drawings.<br />
f) The design drawings shall be submitted in complete for a unit along with design<br />
calculations both in hard copy and soft copy. Design shall be done using STAAD.<br />
g) The effective ratio of utility of all main sections shall be limited to 0.85<br />
h) Structural schematic general arrangement with plans at various levels, elevations along<br />
each row and axes, sections, considered loads and load diagrams with location etc. and<br />
Structural design drawings with BOQ and Table of me members mbers containing design forces shall<br />
be submitted for Owner’s/Consultant’s approval. However the approval shall be limited<br />
to checking of overall dimensions, general stability of system, effective load transfer and<br />
deflection limits etc. The approval shall not relieve the contractor of his responsibility of<br />
correctness in design, adequacy of connections, accuracy etc.<br />
i) Submission of Stability certificate for all the steel structures is under the scope of the<br />
contractor.<br />
18.4 Description of loads and loading codes<br />
a) Unless specified otherwise hereinafter, all the live loads shall be considered in<br />
accordance with IS: 875 (Part (Part-2) -1987.<br />
b) Wind loads shall be considered in accordance with IS: 875 (Part (Part-3)-1987. 1987.<br />
c) Seismic loads shall be considered in accorda accordance nce with IS:1893(part1)<br />
IS:1893(part1)-2002 and<br />
1893(part 4)-2005<br />
d) Live loads from conveyor on the gallery floor shall be as per conveyor suppliers load<br />
data.<br />
e) While designing the fixed support/rigid trestles in an expansion block of conveyor<br />
gallery the following loads (in addition to wind load) shall be considered.<br />
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(i) Forces due to difference in frictional resistance of top and return idle rollers of<br />
conveyor.<br />
(ii) Forces due to inertia of rollers at the time of starting of conveyor belt.<br />
(iii) Break down load caused by snapping of bbelt<br />
elt (in case of multiple conveyors,<br />
snapping of one belt at a time) shall be considered.<br />
(iv) Special loads if any<br />
f) Gallery girders and floor shall be designed for the following live loads,inclusive of<br />
spillage loads on floors.<br />
i) Walkway/Supporting beams for floor - 4.0 KN/m²<br />
ii Under the conveyor belt - 0.75 KN/m²<br />
iii) Gallery girder, for floor load of - 3.0 KN/m²<br />
g) Dust load on roof of junction house and conveyor galleries shall be considered as<br />
follows:<br />
i. For building and structures located at a distance of 300m from the dust<br />
producing units - 0.5 KN/m²<br />
ii. At a distance of 300 m to 800 m from the dust producing unit - 0.25 KN/m²<br />
h) As per technological requirements, provision of supporting the following, and load<br />
arising thereof shall be considered in the design of conveyor gallery.<br />
i) Ventilation duct.<br />
ii) Electrical cables/cable racks.<br />
iii) Fire Fighting equipment.<br />
i) Junction house floors shall be designed for the following loads:<br />
i) Live load on floor - 5.0 KN/m²<br />
ii) Tension from conveyor belt<br />
ii) Load due e to equipment located on floor.<br />
iv) Load due to jamming of chutes.<br />
v) Erection loads anywhere on the floor.<br />
j) Combination of loads<br />
The various loads specified shall be combined in accordance with clause 8.0 of IS: 875<br />
(Part-5)-1987 1987 to give the most severe loading condition for design of structures.<br />
k) Stress enhancements<br />
Permissible limits of stress may be increased, wherever permissible, in accordance with<br />
IS:800-1984.<br />
18.5 Limiting deflection<br />
a. The deflection shall be limited in various elements of structures in accordance with<br />
clause 3.13 IS: 800-1984. 1984.<br />
b. In addition following limitation in deflection shall be observed in design:<br />
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i) Gallery Trusses<br />
Span / 400<br />
ii) Top of End portal of gallery truss H / 325 where H =Height of portal above beams<br />
iii) Traverse deflection of top of Trestle H/1000 where H = Height of trestle above foundation<br />
18.6 FABRICATION OF STEEL STRUCTURES<br />
18.6.1 Drawings<br />
The Contractor shall prepare fabrication drawings, erection drawings, bill of materials,<br />
drawing office despatch lists / shipping documents, schedule of bolts and nuts and as built<br />
drawings. All drawing work shall be in metric system and all writing work shall be in English.<br />
The work shall be carried out as described in General Technical Specifications for s sstructural<br />
works.<br />
18.6.2 Material of Construction<br />
18.6.2.1All steel and other materials used for steelwork and in association with steelwork shall<br />
conform to appropriate Indian standards. Only tested materials shall be used unless written<br />
authority is obtained for the use of untested materials for certain secondary structural<br />
members.<br />
Unless otherwise specified in the drawings<br />
i. All rolled sections and plates upto 20 mm thk. Shall conform to Grade Grade-E250 & quality<br />
A of IS: 2062-2006 2006 and shall generally be of tested quality.<br />
ii. Plates above 20 mm thk. and plated structures subjected to dynamic loading shall<br />
conform to Grade Grade-E 250 & quality B as per IS: 2062-2006.<br />
iii. For High Tensile steel requirements, material conforming to IS: 8500 or SAIL SAIL- MA<br />
(HYA or HYB) shall be used.<br />
18.6.2.2 Steel sheets shall conform to IS: 1079.<br />
18.6.2.3 Steel tubes for structural purpose shall conform to IS: 1161 (of Grade Yst 240)<br />
18.6.2.4 Corrugated Galvanised Sheets shall conform to IS: 277 with appropriate Zinc coating for<br />
the selected thickness of sheet on roof and sides. (1.0mm thk for roof and 0.8mm thk for<br />
sides)<br />
18.6.2.5 Aluminium industrial troughed sheets conforming to IS: 1254 shall be used as follows:<br />
i) On roof - 0.91mm thick ii) On side walls - 0.71mm thick<br />
18.6.2.6 Translucent sheets shall be fibre glass reinforced polyester sheets of matching profile as<br />
per IS: 12866.<br />
18.6.2.7 Colour coated sheets shall be as per appropriate standard.<br />
18.6.2.8 Gutters shall be of copper bearing steel conforming to Grade "A" as per IS:2062.<br />
18.6.2.9 Rails shall conform to IS: 3443.<br />
18.6.2.10 All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364 (for precision and<br />
semi precision hexagonal bolts) of property class 6.4unless otherwise specified. Washers<br />
shall conform to IS: 6610<br />
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18.6.2.11 All tapered washer shall be as per IS: 55372<br />
372 for channels, and IS: 5374 for Joists. Spring<br />
washers shall conform to IS: 3063.<br />
18.6.2.12 All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG bolts shall<br />
conform to IS: 4000. Nuts and washers for HSFG bolts shall be as per IS: 66 6623 & IS:6649<br />
respectively.<br />
18.6.2.13 Covered electrodes for arc welding shall conform to IS:814 IS:814–2004. 2004. Electrode to be used<br />
for submerged arc welding shall conform specification IS: 7280 7280-1974.<br />
Alternatively<br />
Covered electrodes for arc welding shall confirm to AWS Specifications and shall be as<br />
follows.<br />
- E 6013 for all fillet welds of IS 2062 steel dr E250 , quality A & B<br />
- E 7018 for all fillet welds of SAIL SAIL-MA 350 HYA steel<br />
- E 7018 for all but welds including site welds irrespective of the quality of ste steel.Viz. IS<br />
2062 gr E250 , quality A , B or SAILMA SAILMA-350 HYA steel.<br />
18.6.2.14 Certified mill test reports of materials used in the work shall be made available for<br />
inspection by the Owner / Consultant upon request.<br />
18.6.3 Fabrication<br />
18.6.3.1 Fabrication of all structural steelwork shall be in accordance with IS:800 or their equivalent<br />
foreign national standard of the country of origin of supply unless otherwise specified, and<br />
in conformity with various clauses of the Technical Specification.<br />
18.6.3.2 Wherever herever practicable and wherever perfect matching of parts is required at site, members<br />
shall be shop assembled before despatch to minimise site work. Parts not completely<br />
assembled in the shop shall be secured, to the extent possible, to prevent damage du during<br />
despatch.<br />
18.6.3.3 ERECTION OF STEEL STRUCTURES<br />
18.6.3.3.1 Scope<br />
The scope of work under erection includes in addition to provision of erection and transport<br />
equipments, tools and tackles, consumables, materials, labour and supervision, the<br />
following:<br />
a) Storing and stacking at site of erection of all fabricated structural components/<br />
units/assemblies till the time of erection.<br />
b) Transportation of structures at site.<br />
c) Receiving at site of structures including site handling /movement, unloading, storing and<br />
stacking at site of erection of technological structures such as bunkers and the related<br />
structures<br />
d) All minor rectification / modification such as :<br />
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i) Removal of bends, kinks, twists, etc. for parts damaged during transportation and<br />
handling;<br />
ii) Cutting chipping, filing, grinding, etc., if required, for preparation and finishing of site<br />
connections;<br />
iii) Reaming for use of next higher size bolt for holes which do not register or which are<br />
damaged.<br />
iv) Welding of connections in place of boltin bolting g for which holes are either not drilled at all or<br />
wrongly drilled during fabrication.<br />
e) Other rectification work such as<br />
i) Re-fabrication fabrication of parts, damaged beyond repair during transportation and handling or<br />
incorrectly fabricated.<br />
ii) Fabrication of parts s omitted during fabrication by oversight or subsequently found<br />
necessary.<br />
iii) Plug-welding and re-drilling drilling of holes which do not register and which cannot be reamed<br />
for use of next higher size bolt.<br />
f) Fabrication of minor items/missing items or such import important ant items as directed by the Owner /<br />
Consultant.<br />
g) Assembly at site of steel structural components wherever required including temporary<br />
supports and staging.<br />
h) Making arrangements for and providing all facilities for conducting ultrasonic X XX-ray<br />
or<br />
gamma ray tests on welds; getting the tests conducted by reputed testing laboratories,<br />
making available test films/ graphs,reports and interpretation.<br />
i) Rectifying at site, damaged portions of shop primer by cleaning and touchup paint.<br />
j) Erection of structures including making connections by bolts/high strength friction grip bolts<br />
/ welding.<br />
k) Alignment of all structures true to line, level plumb and dimensions within specified limits of<br />
tolerances as per IS :12843 “Tolerance for Erection of Steel Structures”.<br />
l) Application of second coat of primer paint and two coats of finishing paint at site after<br />
erection.<br />
m) Grouting of all column bases after proper alignment of columns and only after obtaining<br />
clearance from Owner / Consultant.<br />
n) Conducting preliminary acceptance and final aacceptance<br />
tests.<br />
o) Preparation of as built drawings, preparing of sketches/drawings to suit<br />
field engineering decisions, availability of material, convenience of fabrication,<br />
transportation and erection and changes during fabrication and erection.<br />
All such works are subject to approval by the Owner / Consultant.<br />
18.6.4 PAINTING OF BUILDING STEEL STRUCTURES<br />
18.6.4.1All steel structural work shall be painted as follows unless otherwise stated in the drawing /<br />
Technical Specification.<br />
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18.6.4.2 Surface preparation<br />
The steel surface which is to be painted shall be cleaned of dirt and grease, and the heavier<br />
layers of rust shall be removed by chipping prior to actual surface preparation to a specified<br />
grade.<br />
Following are the type and standards of surface preparation to be followed based on the<br />
requirement of a particular painting system or as specified in the design drawings.<br />
Manual/Power tool cleaning : :- Manual/Power tool cleaning shall be done as per Grade St St-2 or<br />
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<br />
- 1).<br />
Grade St-2 :- Thorough scraping and wire brushing, machine brushing, grinding etc. This grade<br />
of preparation shall remove loose mill scale, rust cleaner or with clean compressed air or clean<br />
brush. After preparation, the surface should have a faint metallic sheen. The appearance shall<br />
correspond to the prints designated St St-2. 2. If no grade of surface preparation is specified, St St-2<br />
grade of preparation as per Swedish Standard shall be followed.<br />
18.6.4.3 Paint System<br />
(i) Surface preparation : :- St-2<br />
(ii) Primer paint:- Two coats of zinc phosphate in phenolic alkyd medium<br />
(35microns/coat).<br />
(iii) Finishing paint:- Two coats of synthetic enamel (25 microns/coat) conforming to IS :<br />
2932 - 1974.<br />
All paints shall be of approved and shade as per Purchaser / Consultant's requirements.<br />
18.6.4.4 Paint and Painting<br />
Manufacture of paints, mixing of paints, etc. shall be generally according to the relevant IS<br />
codes of practice.<br />
Generally compatibility between primer intermediate and finishing paint shall be certified by<br />
the paint manufacturer supplying the paints.<br />
Guarantee period shall commerce from the date of completion of finishing coat of paint on<br />
entire structures. The guarantee period shall be indicated depending on the type of surface<br />
preparation and system of painting. To fulfill this obligations, the Contractor may obtain<br />
from the painting manufacturer, guarantee for the performance of paint/painted surfaces.<br />
Application of paint shall be by spraying or brushing as per IS : 486-1983 1983 and IS : 487 487-1985<br />
and in uniform layers of 50% overlapping strokes by skilled painters. Painting shall not be<br />
done when the temperature is less than 5 degree C or more than 45 degree C and relative<br />
humidity is more than 85 85% % unless manufacturer's recommendations permit. Also painting<br />
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Page 63 of 64
shall not be done in foggy weather. During application, paint agitation must be provided<br />
where such agitation is recommended by the manufacturer.<br />
Painting shall be applied at painting manufactu manufacturer's rer's recommended rates. The number of<br />
coats shall be such that minimum dry film thickness specified is achieved. The dry film<br />
thickness (DFT) of painted surfaces shall be checked with ELCOMETER or measuring gauges<br />
to ensure specified DFT.<br />
All structures shall receive one coats of primer paint at shop after fabrication before<br />
despatch after surface preparation has been done as per requirements.<br />
Unless otherwise specified all structures after erection shall be given one coat of primer and<br />
two coats of finishing shing paint of approved colour and quality. The under coat shall have<br />
different tint to distinguish the same from the finishing coat.<br />
The proposed make, quality and shade of paint shall have the approval of Purchaser /<br />
Consultant.<br />
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1.0 INTRODUCTION<br />
This part covers technical requirements which will form an integral part of the Contract. The<br />
following provisions shall supplement all the detailed technical requirements brought out in<br />
the Technical Specifications and the Technical Data Sheets.<br />
2.0 BRAND NAME<br />
Whenever a material or article is specified or described by the name of a particular b bbrand,<br />
manufacturer or vendor, the specific item mentioned shall be understood to be indicative of<br />
the function and quality desired, and not restrictive; other manufacturer's products may be<br />
considered provided sufficient information is furnished to enable the Employer to determine<br />
that the products proposed are equivalent to those named.<br />
3.0 COMPLETENESS OF FACILITIES<br />
3.1 Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in<br />
the specification. Each of the plant shal shall l be engineered and designed in accordance with the<br />
specification requirement. All engineering and associated services are required to ensure<br />
that a completely engineered plant is provided.<br />
3.2 All equipments furnished by the Contractor shall be complete in every respect, with all<br />
mountings, fittings, fixtures and standard accessories normally provided with such<br />
equipment and/or those needed for erection, completion and safe operation & maintenan maintenance<br />
of the equipment and for the safety of the operating personnel, as required by applicable<br />
codes, though they may not have been specifically detailed in the respective specifications,<br />
unless included in the list of exclusions. All similar standard compon components/ ents/ parts of similar<br />
standard equipment provided, shall be interchangeable with one another.<br />
4.0 CODES & STANDARDS<br />
4.1 In addition to the codes and standards specifically mentioned in the relevant technical<br />
specifications for the equipment / plant / sy system, stem, all equipment parts, systems and works<br />
covered under this specification shall comply with all currently applicable statutory<br />
regulations and safety codes, including the following:<br />
a. Bureau of Indian Standards (BIS)<br />
b. Indian electricity act<br />
c. Indian electricity city rules<br />
d. Indian Explosives Act<br />
e. Indian Factories Act and State Factories Act<br />
f. Indian Boiler Regulations (IBR)<br />
g. Regulations of the Central Pollution Control Board, India<br />
h. Regulations of the Ministry of Environment & Forest (MoEF), Government of India<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
SECTION 5<br />
Page 1 of 27
i. Pollution n Control Regulations of Department of Environment, Government of India<br />
j. State Pollution Control Board.<br />
k. Rules for Electrical installation by Tariff Advisory Committee (TAC).<br />
l. Guideline for wagon tippler – G33 Rev.01 of May 2010.<br />
m. Any other statutory codes / standards / regulations, as may be applicable.<br />
4.2 Unless covered otherwise by Indian codes & standards and in case nothing to the contrary is<br />
specifically mentioned elsewhere in the specifications, the latest editions (as applicable as<br />
on date of bid opening), pening), of the codes and standards given below shall also apply:<br />
(a.) Japanese Industrial Standards (JIS)<br />
(b.) American National Standards Institute (ANSI)<br />
(c.) American Society of Testing and Materials (ASTM)<br />
(d.) American Society of Mechanical Engineers (ASME)<br />
(e.) American Petroleum Institute (API)<br />
(f.) Standards of the Hydraulic Institute, U.S.A.<br />
(g.) International Organisation for Standardization (ISO)<br />
(h.) Tubular Exchanger Manufacturer's Association (TEMA)<br />
(i.) American Welding Society (AWS)<br />
(j.) National Electrical Manufacturers Association (NEMA)<br />
(k.) National Fire Protection Association (NFPA)<br />
(l.) International Electro Electro-Technical Commission (IEC)<br />
(m.) Expansion Joint Manufacturers Association (EJMA)<br />
(n.) Heat Exchange Institute (HEI)<br />
4.3 In the e event of any conflict between the codes and standards referred to in the above<br />
clauses and the requirement of this specification, the requirement of Technical Specification<br />
shall govern.<br />
4.4 In case of any change in codes, standards & regulations betwee between n the date of bid opening and<br />
the date when vendors proceed with fabrication, the Employer shall have the option to<br />
incorporate the changed requirements or to retain the original standard. It shall be the<br />
responsibility of the Contractor to bring to the no notice tice of the Employer such changes and<br />
advise Employer of the resulting effect.<br />
4.5 EQUIPMENT FUNCTIONAL GUARANTEE<br />
The functional guarantees of the equipment and the system under the scope of the Contract<br />
is given elsewhere in the technical specification. These guarantees shall supplement the<br />
general provisions covered under General Conditions of Contract.<br />
4.6 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS<br />
4.6.1 Design of Facilities<br />
All the e design procedures, systems and components proposed shall have already been<br />
adequately developed and shall have demonstrated good reliability under similar conditions<br />
elsewhere. The Contractor shall be responsible for the selection and design of appropria appropriate<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 2 of 27
equipments to provide the best co co-ordinated ordinated performance of the entire system. The basic<br />
requirements are detailed out in various clauses of the Technical Specifications. The design<br />
of various components, assemblies and subassemblies shall be done so tha that it facilitates easy<br />
field assembly and dismantling. All the rotating components shall be so selected that the<br />
natural frequency of the complete unit is not critical or close to the operating range of the<br />
unit.<br />
4.7 DOCUMENTS, DATA AND DRAWINGS TO BE FURN FURNISHED ISHED BY CONTRACTOR<br />
4.7.1 Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in<br />
the specification. Each of the plant and equipment shall be fully integrated, engineered and<br />
designed to perform in accordance with the technical specification. All engineering and<br />
technical services required ensuring a completely engineered plant shall be provided in<br />
respect of mechanical, electrical, control & instrumentation, civil & structural works as per<br />
the scope. The Contractor sh shall all furnish engineering data/drgs. in accordance with the<br />
schedule of information as specified in Technical Specification and data sheet.<br />
4.7.2 The number of copies/prints/CD<br />
copies/prints/CD-ROMs/manuals ROMs/manuals to be furnished for various types of<br />
documents is given in Section 5. . Distribution schedule shall be informed to successful<br />
Contractor.<br />
4.7.3 The documentation that shall be provided by the Contractor is indicated in the various<br />
sections of specification. This documentation shall include but not be limited to the<br />
following :<br />
4.8 INSTRUCTION MANUALS<br />
The Contractor shall submit to the Employer, Instruction Manuals for all the equipments<br />
covered under the Contract. The Instruction manuals shall contain full details required for<br />
erection, commissioning, operation and maintenance of each equipment. The ma manual shall<br />
be specifically compiled for this project. The Instruction Manuals shall comprise of the<br />
following.<br />
4.8.1 Erection Manuals<br />
The erection manuals shall be submitted prior to the commencement of erection activities<br />
of particular equipment/system<br />
equipment/system. . The erection manual should contain the following as a<br />
minimum.<br />
a) Erection strategy.<br />
b) Sequence of erection.<br />
c) Erection instructions.<br />
d) Critical checks and permissible deviation/tolerances.<br />
e) List of tool, tackles, heavy equipments like cranes, dozers, etc.<br />
f) Bill of Materials<br />
g) Procedure for erection.<br />
h) General safety procedures to followed during erection/installation.<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 3 of 27
i) Procedure for initial checking after erection.<br />
j) Procedure for testing and acceptance norms.<br />
k) Procedure / Check list ffor<br />
pre-commissioning activities.<br />
l) Procedure / Check list for commissioning of the system.<br />
m) Safety precautions to be followed in electrical supply distribution during erection<br />
4.8.2 Operation & Maintenance Manuals<br />
i. The operating and maintenance ins instructions tructions together with drawings (other than shop<br />
drawings) of the equipment, as completed, shall be in sufficient detail to enable the<br />
Employer to operate, maintain, dismantle, reassemble and adjust all parts of the<br />
equipment. They shall give a step by st step ep procedure for all operations likely to be carried<br />
out during the life of the plant / equipment including, operation, maintenance,<br />
dismantling and repair including periodical activities wherever required. Each manual<br />
shall also include a complete set of drawings of the equipment.<br />
ii. If after the commissioning and initial operation of the plant, the manuals require any<br />
modification / additions / changes, the same shall be incorporated and the updated final<br />
instruction manuals shall be submitted to the Emp Employer for records.<br />
iii. A separate section of the manual shall be for each size/ type of equipment and shall<br />
contain a detailed description of construction and operation, together with all relevant<br />
pamphlets and drawings.<br />
iv. The manuals shall include the following:<br />
a) List of spare parts along with their drawing and catalogues and procedure for<br />
ordering spares.<br />
b) Lubrication Schedule including charts showing lubrication checking, testing and<br />
replacement procedure to be carried daily, weekly, monthly & at longer intervals to<br />
ensure trouble free operation.<br />
c) Where applicable, fault location charts shall be included to facilitate finding the<br />
cause of mal-operation operation or break down.<br />
v. Detailed specifications for all the consumables including lubricant oils, greases, che chemicals<br />
etc. system/equipment/assembly/subassembly - wise required for the complete plant.<br />
vi. On completion of erection, a complete list of bearings / equipment giving their location,<br />
and identification marks etc. shall also be furnished to the Employer indicating lubrication<br />
method for each type/category of bearing.<br />
4.8.3 Project Completion Report<br />
The Contractor shall submit a Project Completion Report at the time of handing over the<br />
plant.<br />
4.8.4 DRAWINGS<br />
(a.) All documents submitted by the Contractor for Employer's review shall be in electronic<br />
form (soft copies) along with the number of hard copies. The soft copies to be supplied<br />
shall be either in CDs, or through direct transfer via EE-mail,<br />
mail, etc. depending upon the<br />
nature/volume/size of the document. The drawings submitted for approval could be in<br />
the Image form.<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 4 of 27
(b.) Final copies of the approved drawings shall be submitted in vector form on CDROM<br />
along with the requisite number of hard copies.<br />
(c.) All documents/text information shall be in latest version of MS Office.<br />
(d.) All drawings submitted by the Contractor including those submitted at the time of bid<br />
shall be in sufficient detail indicating the type, size, arrangement, weight of each<br />
component for packing and shipment, the external connection, fixing arrangeme arrangement<br />
required, the dimensions required for installation and interconnections with other<br />
equipments and materials, clearance and spaces required between various portions of<br />
equipment and any other information specifically requested in the drawing schedules.<br />
(e.) Each ach drawing submitted by the Contractor (including those of sub sub-vendors) vendors) shall bear a<br />
title block at the right hand bottom corner with clear mention of the name of the<br />
Employer, the system designation, the specifications title, the specification number, th the<br />
name of the Project, drawing number and revisions. If standard catalogue pages are<br />
submitted the applicable items shall be indicated therein. All titles, notings, markings<br />
and writings on the drawing shall be in English. All the dimensions should be in m mmetric<br />
units.<br />
(f.) The drawings submitted by the Contractor (or their sub sub-vendors) vendors) shall bear Employer’s<br />
drawing number in addition to contractor’s (their sub sub-vendor’s) vendor’s) own drawing number.<br />
Employer’s drawing numbering system shall be made available to the succe successful<br />
Contractor so as to enable him to assign Employer’s drawing numbers to the drawings<br />
to be submitted by him during the course of execution of the Contract.<br />
(g.) The Contractor shall also furnish a “Master Drawing List” which shall be a<br />
comprehensive list of all drawings/ documents/ calculations envisaged to be furnished<br />
by him during the detailed engineering to the Employer in line with engineering<br />
information flow schedule (to be tied up with successful Contractor). Such list should<br />
clearly indicate the ppurpose<br />
urpose of submission of these drawings i.e. “FOR APPROVAL” or<br />
“FOR INFORMATION ONLY”.<br />
(h.) Similarly, all the drawings/ documents submitted by the Contractor during detailed<br />
engineering stage shall be stamped “FOR APPROVAL” or “FOR INFORMATION” prior to<br />
submission.<br />
(i.) The furnishing of detailed engineering data and drawings by the Contractor shall be in<br />
accordance with the time schedule for the project. The review of these documents/<br />
data/ drawings by the Employer will cover only general conformance of the data/<br />
drawings/ awings/ documents to the specifications and contract, interfaces with the<br />
equipments provided by others and external connections & dimensions which might<br />
affect plant layout. The review by the Employer should not be construed to be a<br />
thorough review of all dimensions, quantities and details of the equipments, materials,<br />
any devices or items indicated or the accuracy of the information submitted. The<br />
review and/ or approval by the Employer / Project Manager shall not relieve the<br />
Contractor of any of his resp responsibilities onsibilities and liabilities under this contract.<br />
(j.) After the approval of the drawings, further work by the Contractor shall be in strict<br />
accordance with these approved drawings and no deviation shall be permitted without<br />
the written approval of the Employe Employer.<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 5 of 27
(k.) All manufacturing, fabrication and execution of work in connection with the equipment<br />
/ system, prior to the approval of the drawings, shall be at the Contractor’s risk. The<br />
Contractor is expected not to make any changes in the design of the equipment<br />
/system, system, once they are approved by the Employer. However, if some changes are<br />
necessitated in the design of the equipment/ system at a later date, the Contractor may<br />
do so, but such changes shall promptly be brought to the notice of the Employer<br />
indicating the reasons for the change and get the revised drawing approved again in<br />
strict conformance to the provisions of the Technical Specification.<br />
(l.) Drawings shall include all installations and detailed piping and wiring drawings.<br />
(m.) Assessing & anticipating the rrequirement<br />
equirement and supply of all piping and equipment shall<br />
be done by the contractor well in advance so as not to hinder the progress of piping &<br />
equipment erection, subsequent system charging and its effective draining & venting<br />
arrangement as per site suita suitability.<br />
(n.) Any software used by the contractor shall be given to the project manager and<br />
concerned engineer of employer. The contractor shall make the engineer of the<br />
employer aware of the programme. Any computer aided programme shall be approved<br />
subject to giving entire detail to the project manager.<br />
(o.) Drawings must be checked by the Contractor in terms of its completeness, data<br />
adequacy and relevance with respect to Engineering schedule prior to submission to<br />
the Employer. In case drawings are found to be su submitted bmitted without proper endorsement<br />
for checking by the Contractor, the same shall not be reviewed and returned to the<br />
Contractor for re-submission. submission. The contractor shall make a visit to site to see the existing<br />
facilities and understand the layout completel completely y and collect all necessary data /<br />
drawings at site which are needed as an input to the engineering. The contractor shall<br />
do the complete engineering including interfacing and integration of all his equipment,<br />
systems & facilities within his scope of work as well as interface engineering &<br />
integration of systems, facilities, equipment & works under Employer’s scope and<br />
submit all necessary drawings/ documents for the same.<br />
(p.) All drawings shall be reviewed and approved by Engineering coordinator, including the<br />
following drawings / data which require specific approval.<br />
1. Data sheets for various equipments / systems.<br />
2. Field testing procedures for various equipment and piping system.<br />
3. Pre commissioning / commissioning procedures including flushing, Chemical<br />
cleaning, g, steam blowing and hydro test etc. (Wherever applicable) O&M manual<br />
shall also be reviewed and approved by Employer. The content of O&M manual<br />
shall be as specified elsewhere in the specification.<br />
4. Guarantee test procedures.<br />
5. Any other drawings that may be required by the Engineer from time to time.)<br />
6. Data furnished in the bid shall be binding on the contractor even if superior to<br />
the technical specification requirement and any revision shall be done with the<br />
owner/RITES /RITES’s agreement.<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
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(q.) The Contractor shall submit adequate prints of drawing / data / document for<br />
Employer’s review and approval. The Employer shall review the drawings and return<br />
one (1) copy to the Contractor authorizing either to proceed with manufacture or<br />
fabrication, or marked to show change changes s desired. When changes are required, drawings<br />
shall be re-submitted submitted promptly, with revisions clearly marked, for final review. Any<br />
delays arising out of the failure of the Contractor to submit/rectify and resubmit in time<br />
shall not be accepted as a reason for delay in the contract schedule<br />
(r.) Upon review of each drawing, depending on the correctness and completeness of the<br />
drawing, the same will be categorised and approval accorded in one of the following<br />
categories :<br />
• CATEGORY I Approved<br />
• CATEGORY II Approved subject to incorporation of comments/ modification as<br />
noted. Resubmit revised drawing incorporating the Comments<br />
• CATEGORY III Not approved. Resubmit revised drawings for approval after<br />
incorporating comments/modification as noted.<br />
• CATEGORY IV For informat information and records.<br />
(s.) Vendor shall resubmit the drawings approved under Category II and III within three (3)<br />
weeks of receipt of comments on the drawings, incorporating all comments. Every<br />
revision of the drawing shall bear a revision index wherein such revisio revisions shall be<br />
highlighted in the form of description or marked up in the drawing identifying the same<br />
with relevant revision Number enclosed in a triangle (eg. 1, 2, 3 etc).<br />
• In case Vendor does not agree with any specific comment, he shall furnish the<br />
explanation for the same to owner / consultant for consideration. In all such cases<br />
vendor shall necessarily enclose explanations along with the revised drawing (taking<br />
care of balance comments) to avoid any delay and/or duplication in review work.<br />
• It is responsibility of the Vendor to get all the drawings approved in the Category I<br />
& IV (as the case may be) and complete engineering activities within the agreed<br />
schedule. Any delay arising out of submission and modification of drawings shall<br />
not alter the contract ontract completion schedule. Vendor shall not make any changes in<br />
the portions of the drawing other than those commented upon. If changes are<br />
required to be made in the portions already approved, the vendor shall resubmit<br />
the drawing identifying the change changes for owner/RITES’s ’s review and approval.<br />
(t.) If Vendor fails to resubmit the drawings as per the schedule, construction work at site<br />
will not be held up and work will be carried out on the basis of comments furnished on<br />
previous issues of the drawing. These ccomments<br />
omments will be taken care by the contractor<br />
while submitting the revised drawing.<br />
(u.) All engineering data submitted by the Contractor after final process including review<br />
and approval by the Project Manager/ Employer shall form part of the contract<br />
documents s and the entire works covered under these specification shall be performed<br />
in strict conformity with technical specifications unless otherwise expressly requested<br />
by the Project Manager in writing.<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 7 of 27
(v.) After final acceptance of individual equipment / system bby<br />
y the Employer, the<br />
Contractor will update all original drawings and documents for the equipment / system<br />
to “as built” conditions.<br />
4.8.5 ENGINEERING INFORMATION SUBMISSION SCHEDULE<br />
Prior to the award of Contract, a Detailed Engineering Information Submi Submission Schedule shall<br />
be tied up with the Employer. For this, the Contractor shall furnish a detailed list of<br />
engineering information along with the proposed submission schedule. This list would be a<br />
comprehensive one including all engineering data / drawin drawings gs / information for all bought out<br />
items and manufactured items. The information shall be categorised into the following<br />
parts.<br />
Information that shall be submitted for the approval of the Employer before proceeding<br />
further, and Information that would be submitted for Employer’s information only. The<br />
Engineering Information Schedule shall be updated month wise. The schedule should allow<br />
adequate time for proper review and incorporation of changes/ modifications, if any, to<br />
meet the contract without affect affecting ing the equipment delivery schedule and overall project<br />
schedule. The early submission of drawings and data is as important as the manufacture and<br />
delivery of equipment and hardware and this shall be duly considered while determining the<br />
overall performance e and progress.<br />
4.9 ENGINEERING COORDINATION PROCEDURE<br />
Identification of Principal Engineering Coordinators<br />
4.9.1 The following principal coordinators will be identified by respective organisations at time of<br />
award of contract<br />
RITES’ COORDINATORS<br />
RITES- Engineering Coordinators<br />
Name :<br />
Designation :<br />
Address :<br />
a) Postal :<br />
b) Telegraphic :<br />
TELEX :<br />
FAX : TELEPHONE :<br />
EMPLOYER’S COORDINATORS<br />
NALCO- Engineering Coordinators (NALCO EC)<br />
Name :<br />
Designation :<br />
Address :<br />
a) Postal :<br />
b) Telegraphic :<br />
TELEX :<br />
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Page 8 of 27
FAX : TELEPHONE :<br />
NALCO- SITE CO-ORDINATOR ORDINATOR (NALCO SC)<br />
Name :<br />
Designation :<br />
Address :<br />
a) Postal :<br />
b) Telegraphic :<br />
TELEX :<br />
FAX : TELEPHONE :<br />
VENDOR ENGINEERING CO CO-ORDINATOR (VENDOR EC)<br />
Name :<br />
Designation :<br />
Address :<br />
a) Postal :<br />
b) Telegraphic :<br />
TELEX :<br />
FAX : TELEPHONE :<br />
4.9.2 All engineering correspondence shall be in the name of above coordinators on behalf of the<br />
respective organisations.<br />
4.9.3 Vendors Drawings<br />
(a) The contractor shall furnish, discuss and finalise with the Employer, the engineering<br />
information ion flow schedule at the time of award of the contract. The dates for submission of<br />
drawings as finalised in the above engineering schedule, shall be strictly adhered to. This is<br />
essential for the timely completion of the project.<br />
(b) A detailed drive list sha shall ll be furnished along with the tender. Further drive list shall be<br />
submitted to the RITES’s Engineering coordinator within 60 days from the date of award of<br />
the contract.<br />
(c) In any case, in order to achieve the project completion dates, the contractor must s sstrictly<br />
comply with engineering schedules.<br />
(d) Final distribution copies of all approved drgs. (in Cat. I & IV) shall be submitted by the<br />
contractor to the Engineer within two (2) weeks of the approval.<br />
(e) Copies of all approved drgs. (in cat. I & IV) shall be submitted incorporating all site<br />
modifications, if any, during construction, erection, commission stages and performance and<br />
guarantee testing (till its continuous operation) as ‘As Built Drgs’.<br />
(f) The contractor shall use a single transmittal for drgs. Submission. This shall include<br />
transmittal numbers and date, number of copies being sent, names of the agencies to whom<br />
are all the copies being sent drg. numbers and titles, remarks or special notes if any etc.<br />
(g) All manufacturing and fabrication work in connection with the equipments prior to the<br />
approval of the drg. shall be at contractors risks. (h) Approval of contractor’s drgs. or work<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 9 of 27
y the Engineer shall not relieve the contractor of any of his responsibilities or liabilities<br />
under the contract.<br />
4.9.4 Erection Drawings<br />
(a) Contractor shall furnish erection drawings for the guidance of his/ RITES’s site staff at<br />
least 4 weeks before scheduled commencement of erection or the first shipment,<br />
whichever r is earlier. These shall generally comprise of fabrication/assembly drawings,<br />
various component/part details drawings, assembly, clearance, data requirements etc.<br />
The drawings shall contain details of components/ equipment with identification<br />
numbers, match ch marks, bills of materials, assembly procedures etc.<br />
(b) For all major equipment apart from above details, assembly sequence and instructions<br />
with check lists shall be furnished in the form of erection manuals CLAUSE NO.<br />
4.9.5 ENGINEERING PROGRESS AND EXCEPTION RREPORT<br />
A report giving the status of each engineering information including the list of<br />
drawings/engineering information which remains unapproved for more than one (1)<br />
weeks after the date of first submission Drawings which were not submitted as per<br />
agreed schedule.<br />
4.9.6 TECHNICAL CO-ORDINATION ORDINATION MEETING<br />
(a) The Contractor shall be called upon to organise and attend monthly Design/ Technical<br />
Co-ordination ordination Meetings (TCMs) with the owner/owner’s representatives and other<br />
Contractors of the Employer during the period of contract. The Contractor shall attend<br />
such meetings at his own cost as and when required and fully co co-operate with such<br />
persons and agencies involved during the discussions.<br />
(b) The Contractor should note that Time is the essence of the contract. In order to expedite<br />
the early completion of engineering activities, the Contractor shall submit all drawings as<br />
per the agreed Engineering Information Submission Schedule. The drawings submitted<br />
by the Contractor will be reviewed by the Employer as far as practica practicable within three (3)<br />
weeks from the date of receipt of the drawing .The comments of the Employer shall<br />
then be discussed across the table during the above Technical Co Co-ordination ordination Meeting (s)<br />
wherein best efforts shall be made by both sides to ensure the ap approval proval of the drawing.<br />
(c) The Contractor shall ensure availability of the concerned experts / consultants/<br />
personnel who are empowered to take necessary decisions during these meetings.<br />
(d) Should any drawing remain unapproved for more than one (1) ) weeks after it’s first<br />
submission, this shall be brought out in the monthly Engineering Progress and Exception<br />
Report with reasons thereof.<br />
(e) Any delays arising out of failure by the Contractor to incorporate Employer’s comments<br />
and resubmit the same during the TCM sh shall all be considered as a default and in no case<br />
shall entitle the Contractor to alter the Contract completion date.<br />
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4.9.7 DESIGN IMPROVEMENTS<br />
The Employer/RITES or the Contractor may propose changes in the specification of the<br />
equipment or quality thereof and if the parties agree upon any such changes the<br />
specification shall be modified accordingly. If any such agreed upon change is such that it<br />
affects the price and schedule of completion, the parties shall agree in writing as to the<br />
extent of any changing g the price and/or schedule of completion before the Contractor<br />
proceeds with the change. Following such agreement, the provision thereof, shall be<br />
deemed to have been amended accordingly.<br />
4.9.8 EQUIPMENT BASES<br />
A cast iron or welded steel base plate shall be provided for all rotating equipment which is to<br />
be installed on a concrete base, unless otherwise specifically agreed to by the Employer.<br />
Each base plate which support the unit and its drive assembly, shall bbe<br />
e of a neat design with<br />
pads for anchoring the units.<br />
4.9.9 PROTECTIVE GUARDS<br />
Suitable guards shall be provided for protection of personnel on all exposed rotating and/or<br />
moving machine parts. All such guards shall be designed for easy installation and removal for<br />
maintenance purpose.<br />
4.9.10 LUBRICANTS, SERVO FLUIDS AND CHEMICALS<br />
(a) The Contractor’s scope includes all the first fill of consumables such as oils, lubricants<br />
including grease, servo fluids, gases and essential chemicals etc. Consumption of all thes these<br />
consumables during the initial operation and final filling after the initial operation shall also<br />
be included in the scope of the Contractor.<br />
(b) The variety of lubricants shall be kept to a minimum possible. Detailed specifications for the<br />
lubricating oil, grease, gases, servo fluids, control fluids, chemicals etc. required for the<br />
complete plant covered herein shall be furnished. On completion of erection, a complete list<br />
of bearings/ equipment giving their location and identification marks shall be furnis furnished to<br />
the Employer along with lubrication requirements.<br />
4.9.11 Lubrication<br />
Equipment shall be lubricated by systems designed for continuous operation. Lubricant level<br />
indicators shall be furnished and marked to indicate proper levels under both standsti standstill and<br />
operating conditions.<br />
4.9.12 Material of Construction<br />
All materials used for the construction of the equipment shall be new and shall be in<br />
accordance with the requirements of this specification. Materials utilised for various<br />
components shall be those which have established themselves for use in such applications.<br />
4.9.13 RATING PLATES, NAME PLATES & LABELS<br />
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Each main and auxiliary item of plant including instruments shall have permanently attached<br />
to it in a conspicuous position, a rating plate oof<br />
non-corrosive corrosive material upon which shall be<br />
engraved manufacturer’s name, equipment, type or serial number together with details of<br />
the ratings, service conditions under which the item of plant in question has been designed<br />
to operate.<br />
Each item of plant t shall be provided with nameplate or label designating the service of the<br />
particular equipment.<br />
Such nameplates or labels shall be of white non hygroscopic material with engraved black<br />
lettering or alternately, in the case of indoor circuit breakers, st starters, arters, etc. of transparent<br />
plastic material with suitably coloured lettering engraved on the back. The name plates shall<br />
be suitably fixed on both front and rear sides.<br />
Items of plant such as valves, which are subject to handling, shall be provided with an<br />
engraved chromium plated nameplate or label with engraving filled with enamel..<br />
All segregated phases of conductors or bus ducts, indoor or outdoor, shall be provided with<br />
coloured phase plates to clearly identify the phase of the system<br />
4.9.14 TOOLS AND TACKLES<br />
The Contractor shall supply with the equipment one complete set of all special tools and<br />
tackles and other instruments required for the erection, assembly, ddisassembly<br />
isassembly and proper<br />
maintenance of the plant and equipment and systems (including software). These special<br />
tools will also include special material handling equipment, jigs and fixtures for maintenance<br />
and calibration / readjustment, checking and measure measurement ment aids etc. A list of such tools and<br />
tackles shall be submitted by the Contractor alongwith the offer. The price of each tool /<br />
tackle shall be deemed to have been included in the total bid price. These tools and tackles<br />
shall be separately packed and ssent<br />
ent to site. The Contractor shall also ensure that these tools<br />
and tackles are not used by him during erection, commissioning and initial operation. For<br />
this period the Contractor should bring his own tools and tackles. All the tools and tackles<br />
shall be of f reputed make acceptable to the Employer.<br />
4.9.15 Welding<br />
If the manufacturer has special requirements relating to the welding procedures for welds at<br />
the terminals of the equipments to be per formed by others the requirements shall be<br />
submitted to the Employer in advance of commencement of erection work.<br />
4.9.16 COLOUR CODE FOR ALL EQUIPMENTS/ SERVICES<br />
All equipment/ services are to be painted by the Contractor in accordance with Employer’s<br />
standard colour coding scheme, which will be furnished to the Contractor during detailed<br />
engineering stage.<br />
4.10 PROTECTION AND PRESERVATIVE SHOP COATING<br />
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4.10.1 PROTECTION<br />
All coated surfaces shall be protected against abrasion, impact, discoloration and any other<br />
damages. All exposed threaded portions shall be suitably protected with either metallic or a<br />
nonmetallic protection device. All ends of all valves and pipings and conduit equipment<br />
connections shall be properly sealed with suitable devices to protect them from damage.<br />
The parts which are likely to get rusted, due to exposure to weather, should also be properly<br />
treated and protected in a suitable manner. All primers/paints/coatings shall take into<br />
account the hot humid, corrosive & alkaline, subsoil or over ground environment as the case<br />
may be.<br />
4.10.2 Preservative Shop Coating<br />
All exposed metallic surfaces subject to corrosion shall be protected by shop application of<br />
suitable coatings. All surfaces which will not be easily accessible after the shop assembly,<br />
shall be treated beforehand and protected ffor<br />
or the life of the equipment. All surfaces shall be<br />
thoroughly cleaned of all mill scales, oxides and other coatings and prepared in the shop.<br />
The surfaces that are to be finish finish-painted painted after installation or require corrosion protection<br />
until installation, shall be shop painted with atleast two coats of primer. Transformers and<br />
other electrical equipments if included shall be shop finished with one or more coats of<br />
primer and two coats of high grade resistance enamel. The finished colors shall be as per<br />
manufacturer’s ufacturer’s standards, to be selected and specified by the Employer at a later date.<br />
Shop primer for all steel surfaces which will be exposed to operating temperature below 95<br />
degrees Celsius shall be selected by the Contractor after obtaining specific ap approval of the<br />
Employer regarding the quality of primer proposed to be applied. Special high temperature<br />
primer shall be used on surfaces exposed to temperature higher than 95 degrees Celsius and<br />
such primer shall also be subject to the approval of the Empl Employer.<br />
All other steel surfaces which are not to be painted shall be coated with suitable rust<br />
preventive compound subject to the approval of the Employer.<br />
All piping shall be cleaned after shop assembly.<br />
Painting for Civil structures shall be done as per relevant part of technical specification<br />
4.11 QUALITY ASSURANCE PROGRAMME<br />
The Contractor shall adopt suitable quality assurance programme to ensure that the<br />
equipment and services under the scope of co contract ntract whether manufactured or performed<br />
within the Contractor’s works or at his sub sub-contractor’s contractor’s premises or at the Employer’s site or<br />
at any other place of work are in accordance with the specifications. Such programmes shall<br />
be outlined by the Contracto Contractor r and shall be finally accepted by the Employer/authorised<br />
representative after discussions before the award of the contract. The QA programme shall<br />
be generally in line with IS/ISO IS/ISO- 9001.A quality assurance programme of the contractor shall<br />
generally cover r the following:<br />
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Page 13 of 27
(a) His organisation structure for the management and implementation of the proposed<br />
quality assurance programme<br />
(b) Quality System Manual<br />
(c) Design Control System<br />
(d) Documentation and Data Control System<br />
(e) Qualification data for Contractor’s key personnel.<br />
(f) The procedure for purchase of materials, parts, components and selection of subcontractor’s<br />
services including vendor analysis, source inspection, incoming raw raw-material<br />
inspection, verification of materials purchased etc.<br />
(g) System for shop manufa manufacturing cturing and site erection controls including process, fabrication<br />
and assembly.<br />
(h) Control of non-conforming conforming items and system for corrective actions and resolution of<br />
deviations.<br />
(i) Inspection and test procedure both for manufacture and field activities.<br />
(j) Control of calibration and testing of measuring testing equipment.<br />
(k) System for Quality Audits.<br />
(l) System for identification and appraisal of inspection status.<br />
(m) System for authorising release of manufactured product to the Employer.<br />
(n) System for handling, storage and delivery.<br />
(o) System for maintenance of records, and<br />
(p) Quality plans for manufacturing and field activities detailing out the specific quality<br />
control procedure adopted for controlling the quality characteristics relevant to each<br />
item of equipment/component.<br />
4.12 GENERAL REQUIREMENTS - QUALITY ASSURANCE<br />
4.12.1 All materials, components and equipment covered under this specification shall be<br />
procured, manufactured, erected, commissioned and tested at all the stages, as per a<br />
comprehensive Quality Assurance Progr Programme. amme. An indicative programme of inspection/tests<br />
to be carried out by the contractor for some of the major items is given in the respective<br />
technical specification. This is, however, not intended to form a comprehensive programme<br />
as it is the contractor’s responsibility to draw up and implement such programme duly<br />
approved by the Employer. The detailed Quality Plans for manufacturing and field activities<br />
shall be drawn up by the Contractor and will be submitted to Employer for approval.<br />
Schedule of finalisation ation of such quality plans will be finalised before award. Monthly<br />
progress reports on MQP/FQP submission/approval shall be furnished on enclosed format<br />
No. QS-01-QAI-P-02/F1.<br />
4.12.2 Manufacturing Quality Plan will detail out for all the components and e eequipment,<br />
various<br />
tests/inspection, to be carried out as per the requirements of this specification and<br />
standards mentioned therein and quality practices and procedures followed by Contractor’s/<br />
Sub-contractor’s/ sub-supplier's supplier's Quality Control Organisation<br />
Organisation, , the relevant reference<br />
documents and standards, acceptance norms, inspection documents raised etc., during all<br />
stages of materials procurement, manufacture, assembly and final testing/performance<br />
testing. The Quality Plan shall be submitted on electronic media e.g. floppy or EE-mail<br />
in<br />
addition to hard copy, for review and approval. After approval the same shall be submitted<br />
in compiled form on CD-ROM.<br />
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4.12.3 Field Quality Plans will detail out for all the equipment, the quality practices and procedures<br />
etc. tc. to be followed by the Contractor’s "Site Quality Control Organisation", during various<br />
stages of site activities starting from receipt of materials/equipment at site.<br />
4.12.4 The Contractor shall also furnish copies of the reference documents/plant<br />
standards/acceptance ndards/acceptance norms/tests and inspection procedure etc., as referred in Quality<br />
Plans along with Quality Plans. These Quality Plans and reference documents/standards etc.<br />
will be subject to Employer’s approval without which manufacturer shall not proce proceed. These<br />
approved documents shall form a part of the contract. In these approved Quality Plans,<br />
Employer shall identify customer hold points (CHP), i.e. test/checks which shall be carried<br />
out in presence of the Employer’s Project Manager or his authorised representative and<br />
beyond which the work will not proceed without consent of Employer in writing. All<br />
deviations to this specification, approved quality plans and applicable standards must be<br />
documented and referred to Employer along with technical justif justification ication for approval and<br />
dispositioning.<br />
4.12.5 No material shall be despatched from the manufacturer’s works before the same is<br />
accepted, subsequent to predespatch final inspection including verification of records of all<br />
previous tests/inspections by Em Employer’s ployer’s Project Manager/Authorised representative and<br />
duly authorised for despatch by issuance of Material Despatch Clearance Certificate (MDCC).<br />
4.12.6 All material used for equipment manufacture including casting and forging etc. shall be of<br />
tested quality lity as per relevant codes/standards. Details of results of the tests conducted to<br />
determine the mechanical properties; chemical analysis and details of heat treatment<br />
procedure recommended and actually followed shall be recorded on certificates and time<br />
temperature emperature chart. Tests shall be carried out as per applicable material standards and/or<br />
agreed details.<br />
4.12.7 The contractor shall submit to the Employer Field Welding Schedule for field welding<br />
activities in the enclosed format No.: QS QS-01-QAI-P-02/F3. The field welding schedule shall be<br />
submitted to the Employer along with all supporting documents, like welding procedures,<br />
heat treatment procedures, NDT procedures etc. at least ninety days before schedule start<br />
of erection work at site.<br />
4.12.8 All welding and brazing shall be carried out as per procedure drawn and qualified in<br />
accordance with requirements of ASME Section IX/BS IX/BS-4870 4870 or other International equivalent<br />
standard acceptable to the Employer. All welding/brazing procedures shall be submitte submitted to<br />
the Employer or its authorized representative for approval prior to carrying out the<br />
welding/brazing.<br />
4.12.9 All brazers, welders and welding operators employed on any part of the contract either in<br />
Contractor’s/sub-contractor’s contractor’s works or at site or eelsewhere<br />
lsewhere shall be qualified as per ASME<br />
Section-IX or BS-4871 4871 or other equivalent International Standards acceptable to the<br />
Employer.<br />
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4.12.10 Welding procedure qualification & Welder qualification test results shall be furnished to the<br />
Employer for approval. al. However, where required by the Employer, tests shall be conducted<br />
in presence of Employer/authorised representative.<br />
4.12.11 Unless otherwise proven and specifically agreed with the Employer, welding of dissimilar<br />
materials and high alloy materials sh shall be carried out at shop only.<br />
4.12.12No welding shall be carried out on cast iron components for repair.<br />
4.12.13 All the heat treatment results shall be recorded on time temperature charts and verified<br />
with recommended regimes.<br />
4.12.14 All non-destructive tive examination shall be performed in accordance with written procedures<br />
as per International Standards, The NDT operator shall be qualified as per SNT SNT-TC-IA (of the<br />
American Society of non non-destructive destructive examination). NDT shall be recorded in a report, whic which<br />
includes details of methods and equipment used, result/evaluation, job data and<br />
identification of personnel employed and details of correlation of the test report with the<br />
job. All Bar stock / forgings of diameter equal to or greater than 50mm shall be u uultrasonically<br />
tested. In general all plates of thickness equal to or greater than 40mm and for pressure<br />
parts, pates of thickness equal to or greater than 25mm shall be ultrasonically tested unless<br />
as specified otherwise in respective equipment specificati specification.<br />
4.12.15The Contractor shall list out all major items/ equipment/ components to be manufactured in<br />
house as well as procured from sub sub-contractors. All the subcontractor proposed by the<br />
Contractor for procurement of major bought out items including castings, forging, semifinished<br />
and finished components/equipment etc., list of which shall be drawn up by the<br />
Contractor and finalised with the Employer, shall be subject to Employer's approval. The<br />
contractor’s proposal shall include vendor’s facilities established at the respective works, the<br />
process capability, process stabilization, QC systems followed, experience list, etc. along with<br />
his own technical evaluation ation for identified sub sub-contractors contractors enclosed and shall be submitted<br />
to the Employer for approval within the period agreed at the time of pre pre-awards discussion<br />
and identified in "DR" category prior to any procurement. Monthly progress reports on sub-<br />
contractor ctor detail submission / approval shall be furnished. Such vendor approval shall not<br />
relieve the contractor from any obligation, duty or responsibility under the contract.<br />
4.12.16For components/equipment procured by the contractors for the purpose of the contract,<br />
after obtaining the written approval of the Employer, the contractor’s purchase<br />
specifications and inquiries shall call for quality plans to be submitted by the suppliers. The<br />
quality plans called for from the sub sub-contractor shall set out, during the various stages of<br />
manufacture and installation, the quality practices and procedures followed by the vendor’s<br />
quality control organisation, the relevant reference documents/standards used, acceptance<br />
level, inspection of documentation raised, etc. Suc Such h quality plans of the successful vendors<br />
shall be finalised with the Employer and such approved Quality Plans shall form a part of the<br />
purchase order/contract between the Contractor and sub sub-contractor. contractor. Within three weeks of<br />
the release of the purchase ord orders ers /contracts for such bought out items /components, a<br />
copy of the same without price details but together with the detailed purchase<br />
specifications, quality plans and delivery conditions shall be furnished to the Employer on<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 16 of 27
the monthly basis by the Cont Contractor ractor along with a report of the Purchase Order placed so far<br />
for the contract. **<br />
4.12.17Employer reserves the right to carry out quality audit and quality surveillance of the systems<br />
and procedures of the Contractor’s or their sub sub-contractor’s contractor’s quality management and<br />
control activities. The contractor shall provide all necessary assistance to enable the<br />
Employer carry out such audit and surveillance.<br />
4.12.18The contractor shall carry out an inspection and testing programme during manufacture in<br />
his work and that of his sub sub-contractor’s contractor’s and at site to ensure the mechanical accuracy of<br />
components, compliance with drawings, conformance to functional and performance<br />
requirements, identity and acceptability of all materials parts and equipment. Contractor<br />
shall ll carry out all tests/inspection required to establish that the items/equipment conform<br />
to requirements of the specification and the relevant codes/standards specified in the<br />
specification, in addition to carrying out tests as per the approved quality pla plan.<br />
4.12.19Quality audit/surveillance/approval of the results of the tests and inspection will not,<br />
however, prejudice the right of the Employer to reject the equipment if it does not comply<br />
with the specification when erected or does not give complete sat satisfaction isfaction in service and the<br />
above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring<br />
complete conformance of the materials/equipment supplied to relevant specification,<br />
standard, data sheets, drawings, etc.<br />
4.12.20 For or all spares and replacement items, the quality requirements as agreed for the main<br />
equipment supply shall be applicable.<br />
4.12.21 Repair/rectification procedures to be adopted to make the job acceptable shall be subject to<br />
the approval of the Employer/ authorised representative.<br />
4.13 QA DOCUMENTATION PACKAGE<br />
The Contractor shall be required to submit the QA Documentation in two hard copies and<br />
two CD ROMs.<br />
4.13.1 Each QA Documentation shall have a project specific Cover Sheet bearing name &<br />
identification ation number of equipment and including an index of its contents with page control<br />
on each document. The QA Documentation file shall be progressively completed by the<br />
Supplier’s sub-supplier supplier to allow regular reviews by all parties during the manufacturing. The<br />
final quality document will be compiled and issued at the final assembly place of equipment<br />
before despatch. However CD CD-Rom Rom may be issued not later than three weeks.<br />
4.13.2 Typical contents of QA Documentation is as below: below:-<br />
(a) Quality Plan<br />
(b) Material mill test reports on components as specified by the specification and approved<br />
Quality Plans.<br />
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(c) Manufacturer / works test reports/results for testing required as per applicable codes<br />
and standard referred in the specification and approved Quality Plans.<br />
(d) Non-destructive ructive examination results /reports including radiography interpretation<br />
reports. Sketches/drawings used for indicating the method of traceability of the<br />
radiographs to the location on the equipment.<br />
(e) Heat Treatment Certificate/Record (Time (Time- temperature Chart)<br />
(f) All the accepted Non Non-conformance conformance Reports (Major/Minor) / deviation, including<br />
complete technical details / repair procedure).<br />
(g) Inspection reports duly signed by the Inspector of the Employer and Contractor for the<br />
agreed Customer Hold Points.<br />
(h) Certificate te of Conformance (COC) wherever applicable.<br />
(i) MDCC<br />
4.13.3 Similarly, the contractor shall be required to submit two sets (two hard copies and two CD<br />
ROMs), containing QA Documentation pertaining to field activities as per Approved Field<br />
Quality Plans and other agreed manuals/ procedures, prior to commissioning of individual<br />
system.<br />
4.13.4 Before despatch / commissioning of any equipment, the Supplier shall make sure that the<br />
corresponding quality document or in the case of protracted phased deliveries, t tthe<br />
applicable section of the quality document file is completed. The supplier will then notify the<br />
Inspector regarding the readiness of the quality document (or applicable section) for review.<br />
If the result of the review carried out by the Inspector is sat satisfactory, isfactory, the Inspector shall<br />
stamp the quality document (or applicable section) for release. If the quality document is<br />
unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing to<br />
finalize the quality document (or applicab applicable le section) by time compatible with the<br />
requirements as per contract documents. When it is done, the quality document (or<br />
applicable section) is stamped by the Inspector. If a decision is made despatch, whereas all<br />
outstanding actions cannot be readily cle cleared ared for the release of the quality document by<br />
that time. The supplier shall immediately, upon shipment of the equipment, send a copy of<br />
the quality document Review Status signed by the Supplier Representative to the Inspector<br />
and notify of the committed date for the completion of all outstanding actions & submission.<br />
The Inspector shall stamp the quality document for applicable section when it is effectively<br />
completed. The submission of QA documentation package shall not be later than 3 weeks<br />
after the despatch spatch of equipment.<br />
4.13.5 TRANSMISSION OF QA DOCUMENTATION<br />
On release of QA Documentation by Inspector, one set of quality document shall be<br />
forwarded to Corporate Quality Assurance Department and other set to respective Project<br />
Site of Employer. For tthe<br />
he particular case of phased deliveries, the complete quality<br />
document to the Employer shall be issued not later than 3 weeks after the date of the last<br />
delivery of equipment.<br />
4.14 Project Manager’s Supervision<br />
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4.14.1 To eliminate delays and avoid dispu disputes tes and litigation, it is agreed between the parties to the<br />
Contract that all matters and questions shall be referred to the Project Manager and without<br />
prejudice to the provisions of ‘Arbitration’ clause in GCC, the Contractor shall proceed to<br />
comply with the Project Manager's decision.<br />
4.14.2 The work shall be performed under the supervision of the Project Manager. The scope of the<br />
duties of the Project Manager pursuant to the Contract, will include but not be limited to the<br />
following:<br />
(a) Interpretation of all the terms and conditions of these documents and specifications:<br />
(b) Review and interpretation of all the Contractor’s drawing, engineering data, etc:<br />
(c) Witness or his authorised representative to witness tests and trials either at the<br />
manufacturer’s works or at site, or at any place where work is performed under the<br />
contract :<br />
(d) Inspect, accept or reject any equipment, material and work under the contract:<br />
(e) Issue certificate of acceptance and/or progressive payment and final payment<br />
certificates<br />
(f) Review and suggest modifications and improvement in completion schedules from time<br />
to time, and<br />
(g) Supervise Quality Assurance Programme implementation at all stages of the works.<br />
4.15 INSPECTION, TESTING AND INSPECTION CERTIFICATES<br />
(a) The word ‘Inspector’ shall mean the Proj Project ect Manager and/or his authorized representative<br />
and/or an outside inspection agency acting on behalf of the Employer to inspect and<br />
examine the materials and workmanship of the works during its manufacture or erection.<br />
(b) The Project Manager or his duly aut authorised horised representative and/or an outside inspection<br />
agency acting on behalf of the Employer shall have access at all reasonable times to inspect<br />
and examine the materials and workmanship of the works during its manufacture or<br />
erection and if part of the wo works rks is being manufactured or assembled on other premises or<br />
works, the Contractor shall obtain for the Project Manager and for his duly authorised<br />
representative permission to inspect as if the works were manufactured or assembled on<br />
the Contractor’s own premises remises or works.<br />
(c) The Contractor shall give the Project Manager/Inspector fifteen (15) days written notice of<br />
any material being ready for testing. Such tests shall be to the Contractor’s account except<br />
for the expenses of the Inspector’s. The Project Man Manager/Inspector, ager/Inspector, unless the witnessing of<br />
the tests is virtually waived and confirmed in writing, will attend such tests within fifteen<br />
(15) days of the date on which the equipment is noticed as being ready for test/inspection<br />
failing which the contractor mmay<br />
ay proceed with test which shall be deemed to have been<br />
made in the inspector’s presence and he shall forthwith forward to the inspector duly<br />
certified copies of test reports in two (2) copies.<br />
(d) The Project Manager or Inspector shall within fifteen (15) da days ys from the date of inspection<br />
as defined herein give notice in writing to the Contractor, or any objection to any drawings<br />
and all or any equipment and workmanship which is in his opinion not in accordance with<br />
the contract. The Contractor shall give due consideration to such objections and shall either<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 19 of 27
make modifications that may be necessary to meet the said objections or shall inform in<br />
writing to the Project Manager/Inspector giving reasons therein, that no modifications are<br />
necessary to comply with th the contract.<br />
(e) When the factory tests have been completed at the Contractor’s or sub sub-contractor’s works,<br />
the Project Manager /Inspector shall issue a certificate to this effect fifteen (15) days after<br />
completion of tests but if the tests are not witnessed by the Project Manager /Inspectors,<br />
the certificate shall be issued within fifteen (15) days of the receipt of the Contractor’s test<br />
certificate by the Project Manager /Inspector. Project Manager /Inspector to issue such a<br />
certificate shall not prevent the Co Contractor ntractor from proceeding with the works. The completion<br />
of these tests or the issue of the certificates shall not bind the Employer to accept the<br />
equipment should it, on further tests after erection be found not to comply with the<br />
contract.<br />
(f) In all cases where here the contract provides for tests whether at the premises or works of the<br />
Contractor or any sub-contractor, contractor, the Contractor, except where otherwise specified shall<br />
provide free of charge such items as labour, material, electricity, fuel, water, stores,<br />
apparatus pparatus and instruments as may be reasonably demanded by the Project Manager<br />
/Inspector or his authorised representatives to carry out effectively such tests on the<br />
equipment in accordance with the Contractor and shall give facilities to the Project<br />
Manager/Inspector er/Inspector or to his authorised representative to accomplish testing.<br />
(g) The inspection by Project Manager / Inspector and issue of Inspection Certificate thereon<br />
shall in no way limit the liabilities and responsibilities of the Contractor in respect of th the<br />
agreed Quality Assurance Programme forming a part of the contract.<br />
(h) To facilitate advance planning of inspection, the Contractor shall furnish quarterly inspection<br />
programme indicating schedule dates of inspection at Customer Hold Point and final<br />
inspection ion stages. Updated quarterly inspection plans will be made for each three<br />
consecutive months and shall be furnished before beginning of each calendar month.<br />
(i) All inspection, measuring and test equipment used by contractor shall be calibrated<br />
periodically depending on its use and criticality of the test/measurement to be done. The<br />
Contractor shall maintain all the relevant records of periodic calibration and instrument<br />
identification, and shall produce the same for inspection by NALCO. Wherever asked<br />
specifically, ically, the contractor shall re re-calibrate calibrate the measuring/test equipment in the presence<br />
of Project Manager / Inspector.<br />
4.16 PRE-COMMISSIONING COMMISSIONING AND COMMISSIONING FACILITIES<br />
(a) As soon as the facilities or part thereof has been completed operationally and<br />
structurally cturally and before start start-up, up, each item of the equipment and systems forming part<br />
of facilities shall be thoroughly cleaned and then inspected jointly by the Employer and<br />
the Contractor for correctness of and completeness of facility or part thereof and<br />
acceptability ceptability for initial pre pre-commissioning commissioning tests, commissioning and start start-up at Site. The<br />
list of pre-commissioning commissioning tests to be performed shall be as mutually agreed and<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 20 of 27
included in the Contractor’s quality assurance programme as well as those included<br />
elsewhere where in the Technical Specifications.<br />
(b) The Contractor’s pre pre-commissioning/ commissioning/start-up up engineers, specially<br />
identified as far as possible, shall be responsible for carrying out all the pre-<br />
commissioning tests at Site. On completion of inspectio inspection, n, checking and after the precommissioning<br />
tests are satisfactorily over, the commissioning of the complete facilities<br />
shall be commenced during which period the complete facilities, equipments shall be<br />
operated integral with sub sub-systems and supporting equipment uipment as a complete plant.<br />
(c) The time consumed in the inspection and checking of the units shall be considered as a<br />
part of the erection and installation period.<br />
(d) The check outs during the pre - commissioning period should be programmed to follow<br />
the construction truction completion schedule. Each equipment/system, as it is completed in<br />
construction and turned over to RITES/Employer's Employer's commissioning (startup) Engineer(s),<br />
should be checked out and cleaned. The checking and inspection of individual systems<br />
should then follow a prescribed commissioning documentation [SLs (Standard Check<br />
List) / TS (Testing Schedule) / CS (Commissioning Schedule)] approved by the<br />
Employer/RITES.<br />
(e) On completion of all pre pre-commissioning commissioning activities / tests and as a part of commissioning<br />
the complete facilities shall be put on 'Trial Operation' during which period all necessary<br />
adjustments shall be made while operating over the full load range enabling the<br />
facilities to be made ready for the Guarantee Tests<br />
(f) The duration of 'Trial Operat Operation' ion' of the complete facility as an integral unit shall be 30<br />
continuous days with available wagon loads or as to be mutually agreed agreed. The Trial<br />
Operation shall be considered successful, provided that each item/part of the facility<br />
can operate continuously at the specified operating characteristics, for the period of<br />
Trial Operation with all operating parameters within the specified limits and at or near<br />
the predicted performance of facility/equipment.<br />
(g) For the period of 'Trial Operation', the time of operat operation ion with any load shall be counted.<br />
(h) A Trial Operation report comprising of observations and recordings of various<br />
parameters to be measured in respect of the above Trial Operation shall be prepared by<br />
the Contractor. This report, besides recording the de details tails of the various observations<br />
during trial operation shall also include the dates of start and finish of the Trial<br />
Operation and shall be signed by the representatives of both the parties. The report<br />
shall have sheets, recording all the details of inte interruptions rruptions occurred, adjustments made<br />
and any minor repairs done during the Trial Operation. Based on the observations,<br />
necessary modifications/repairs to the plant shall be carried out by the Contractor to<br />
the full satisfaction of the Project Manager to en enable able the latter to accord permission to<br />
carry out the Guarantee tests on the facilities. However, minor defects which do not<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 21 of 27
endanger the safe operation of the equipment, shall not be considered as reasons for<br />
with- holding the aforesaid permission<br />
(i) Contractor ctor shall furnish the commissioning organization chart for review & acceptance<br />
of employer at least eighteen months prior to the schedule date of synchronization of<br />
1st unit. The chart should contain:<br />
a) Experience of the Commissioning Engineers.<br />
b) Role and responsibilities sponsibilities of the Commissioning Organisation members.<br />
c) Expected duration of posting of the above Commissioning Engineers at site.<br />
4.17 GUARANTEE TESTS<br />
(a) The final tests as to the guarantees shall be conducted at Site, by the Contractor. The<br />
Contractor's Commissioning and start start-up up Engineers shall make the unit ready for such<br />
tests. Such test will be commenced, within a period of three (3) months after the<br />
successful completion of Trial Operation. Any extension of time beyond the above three<br />
months shall be subject to Employer's approval.<br />
(b) These tests shall be binding on both the parties of the Contract to determine<br />
compliance of the equipment with the performance guarantee.<br />
(c) Any special equipment, tools and tackles required for the successful completion of the<br />
Guarantee Tests shall be provided by the Contractor, free of cost cost. The bidder should<br />
particularly note that suitable and necessary method and arrangement for the PG test<br />
for 1200TPH of the new conveyor integrating into 800 TPH of existing conveyor system<br />
has to be made by him/them acceptable to owner/RITES at no extra cost.<br />
(d) The guarantee figures and design/performance parameters of the equipment shall be<br />
proved by the Contractor during these Guarantee Tests/ and or during the 'Trial<br />
operation' as detai detailed led out elsewhere. Should the results of these tests show any<br />
deterioration from the guaranteed values, the Contractor shall modify the equipment as<br />
required to enable it to meet the guarantees. In such case, the Guarantee Tests shall be<br />
repeated and all ccost<br />
ost for modifications including labour, materials and the cost of<br />
additional testing to prove that the equipment meets the guarantees, shall be borne by<br />
the Contractor.<br />
(e) The specific tests to be conducted on equipment have been brought out in the technical<br />
specification.<br />
4.18 Test Codes<br />
The provisions outlined in the ASME Performance Test Codes shall be used as a guide for all<br />
the above test procedures unless otherwise specified in the technical specifications.<br />
4.19 TAKING OVER<br />
Upon successful completio completion n of Initial Operations and all the tests conducted to the<br />
Employer's satisfaction, the Employer shall issue to the Contractor a Taking over Certificate<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 22 of 27
as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably<br />
be with held ld nor will the Employer delay the issuance thereof, on account of minor<br />
omissions or defects which do not affect the commercial operation and/or cause any serious<br />
risk to the equipment. Such certificate shall not relieve the Contractor of any of his<br />
obligations ations which otherwise survive, by the terms and conditions of the Contract after<br />
issuance of such certificate.<br />
4.20 TRAINING OF EMPLOYER'S PERSONNEL<br />
The scope of service under training of Employer’s engineers (min. 3 nos.) shall include a<br />
training module in the areas of Operation & Maintenance. Such training should cover the<br />
following areas as a minimum in order to enable these personnel to individually take the<br />
responsibility of operating and maintaining the wagon tippler system in a manner accepta acceptable<br />
to the Employer:<br />
The scope of services under training shall also necessarily include training of Employer's<br />
personnel. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & operation etc. and<br />
shall include all the related areas like Des Design ign familiarization, training on product design<br />
features and product design softwares of major equipment and systems, engineering,<br />
manufacturing, erection, commissioning, training on operating features of equipment,<br />
quality assurance and testing, plant vis visits its and visits to manufacturer's works, exposure to<br />
various kinds of problems which may be encountered in fabrication, manufacturing,<br />
erection, welding etc. The training module prepared by the contractor, shall be submitted<br />
for the Employer’s approval, pri prior to imparting training.<br />
Contractor shall furnish in his offer, details of training module(s) covering above<br />
requirements which shall be subject to Employer's approval. Consolidated training period<br />
included above (for O&M and Engineering) is indicative only. Employer reserves the right to<br />
reappropriate the training period between O&M and engineering depending upon the<br />
details of training module proposed by the Contractor.<br />
Training schedule shall be finalised based on the Contractor's proposal within two (2)<br />
months prior to commissioning.<br />
In all the above cases, wherever the training of Employer's personnel is arranged at the<br />
works of the manufacturer's it shall be noted that the lodging and boarding of the<br />
Employer's personnel shall be at the cost of Co Contractor.<br />
4.21 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION<br />
In addition to the requirements given in Erection Conditions of Contract (ECC) the following<br />
shall also cover:<br />
1. Working platforms should be fenced and shall have means of access.<br />
2. Ladders in accordance ccordance with Employer’s safety rules for construction and erection shall<br />
be used. Rungs shall not be welded on columns. All the stairs shall be provided with<br />
handrails immediately after its erection.<br />
4.22 NOISE LEVEL<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 23 of 27
The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m above floor<br />
level in elevation and at a distance of one (1) metre horizontally from the nearest surface of<br />
any equipment / machine, furnished and installed under these specifications, expressed in<br />
decibels to a reference of 0.0002 microbar, shall not exceed 85 dBA.<br />
4.23 PACKAGING AND TRANSPORTATION<br />
All the equipments shall be suitably protected, coated, covered or boxed and crated to<br />
prevent damage or deterioration during transit, handling and storage at Site t ttill<br />
the time of<br />
erection. While packing all the materials, the limitation from the point of view of the sizes of<br />
railway wagons available in India should be taken account of. The Contractor shall be<br />
responsible for any loss or damage during transportation, handling and storage due to<br />
improper packing. The Contractor shall ascertain the availability of Railway wagon sizes from<br />
the Indian Railways or any other agency concerned in India well before effecting despatch of<br />
equipment. Before despatch it shall be eensured<br />
nsured that complete processing and manufacturing<br />
of the components is carried out at shop, only restricted by transport limitation, in order to<br />
ensure that site works like grinding, welding, cutting & pre pre-assembly assembly to bare minimum. The<br />
Employer's Inspector shall have right to insist for completion of works in shops before<br />
despatch of materials for transportation.<br />
4.24 ELECTRICAL ENCLOSURE<br />
All electrical equipments and devices, including insulation, heating and ventilation devices<br />
shall be designed for am ambient temperature (50 0 All electrical equipments and devices, including insulation, heating and ventilation devices<br />
C) and a maximum relative humidity (75%).<br />
4.25 INSTRUMENTATION AND CONTROL<br />
All instrumentation and control systems/ equipment/ devices/ components, furnished under<br />
this contract shall be in accordance with the requirements stated herein, unless otherwise<br />
specified in the detailed specifications.<br />
All instrument scales and charts shall be calibrated and printed in metric units and shall have<br />
linear graduation. The ranges shall be selected to have the normal reading at 75% of full<br />
scale. ale. All scales and charts shall be calibrated and printed in Metric Units as follows:<br />
a) Temperature - Degree centigrade (deg C)<br />
b) Pressure - Kilograms per square centimetre (Kg/cm2). Pressure instrument shall<br />
have the unit suffixed with 'a' to indicate absolu absolute te pressure. If nothing is there, that<br />
will mean that the indicated pressure is gauge pressure.<br />
c) Draught - Millimetres of water column (mm wc).<br />
d) Vacuum - Millimeters of mercury column (mm Hg) or water column (mm Wcl).<br />
e) Flow - Tonnes/ hour<br />
f) Flow (Liquid) - Tonnes / hour<br />
g) Flow base - 760 mm Hg. 15 deg.C<br />
h) Density Grams per cubic centimetre.<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 24 of 27
All instruments and control devices provided on panels shall be of miniaturized design,<br />
suitable for modular flush mounting on panels with front draw out facility and flexible plugin<br />
connection at rear.<br />
All electronic modules shall have gold plated connector fingers and further all input and<br />
output modules shall be short circuit proof. These shall also be tropicalised & components<br />
shall be of industrial grade or bette better.<br />
4.26 ELECTRICAL NOISE CONTROL<br />
The equipment furnished by the Contractor shall incorporate necessary techniques to<br />
eliminate measurement and control problems caused by electrical noise. Areas in<br />
Contractor's equipment which are vulnerable to electrica electrical l noise shall be hardened to<br />
eliminate possible problems. Any additional equipment, services required for effectively<br />
eliminating the noise problems shall be included in the proposal. The equipment shall be<br />
protected against ESD as per IEC IEC-801- 2. Radio Frequency equency interference (RFI) and Electro<br />
Magnetic Interference (EMI) protection against hardware damage and control system mal-<br />
operations/errors shall be provided for all systems.<br />
4.27 TAPPING POINTS FOR MEASUREMENTS<br />
Tapping points shall include probes, wwherever<br />
herever applicable, for analytical measurements and<br />
sampling. For direct temperature measurement of all working media, one stub with internal<br />
threading of approved pattern shall be provided along with suitable plug and washer. The<br />
Contractor will be intima intimated ted about thread standard to be adopted. The following shall be<br />
provided on equipment by the Contractor. The standard which is to be adopted will be<br />
intimated to the Contractor. Temperature test pockets with stub and thermo well Pressure<br />
test pockets<br />
4.28 ELECTRONIC MODULE/COMPONENT DETAILS<br />
The Contractor shall have to furnish all technical details including circuit diagrams,<br />
specifications of components, etc., in respect of each and every electronic card/module as<br />
employed on the various solid state as well as microprocessor based systems and equipment<br />
including conventional instruments, peripherals etc. It is mandatory for the Contractor to<br />
identify clearly the custom built ICs used in the package. The Contractor shall also furnish the<br />
details of any equivalents uivalents of the same.<br />
4.29 JUNCTION BOXES<br />
The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates shall be<br />
removable type and made of 3 mm thick sheet steel. The boxes shall be provided with<br />
detachable cover or hinged door with captive screws. Top of the box shall be arran arranged to<br />
slope towards the rear of the box. The box shall be hot dip galvanized and shall be provided<br />
with suitable neoprene gaskets to achieve degree of protection of IP IP--55<br />
as per IS: 2147.<br />
Adequate spacing shall be provided to terminate the external cables cables. . The boxes shall be<br />
suitable for mounting on various types of steel structures. The terminal blocks provided shall<br />
be of 650 V grade, rated for 10 A for control cables. Suitable numbering for terminal blocks<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
Page 25 of 27
shall be done. In case of junction box for powe power r cable, the box shall be rated for maximum<br />
current carrying capacity. Terminal blocks shall be of one piece, klippon RSF RSF-1 or ELMEX<br />
CSLT-1 1 type with insulating barriers.<br />
The bidder shall supply the following.<br />
S. NO. DESCRIPTION NO OF PRINTS (SETS) NO. OF CDROMs<br />
OF MANUALS<br />
(SETS)<br />
1. Drawings "FOR APPROVAL" 4 1 CD<br />
2. Drawings "FOR INFORMATION" 4 1 CD<br />
3. Drawings "FINAL DRAWING" 10 2 CD-ROMs ROMs<br />
4. Drawings "AS BUILT "<br />
10 2 CD-ROMs ROMs<br />
5. DATASHEETS,DESIGN<br />
CALCULATIONS, etc. and Other type of documents<br />
i) For Approval<br />
4<br />
1 CD<br />
ii) FINAL<br />
10<br />
2 CD-ROMs -<br />
iii) Analysis reports of equipments/<br />
piping/ / structures components/<br />
systems employing software<br />
packages as detailed in the specifications<br />
a) Input<br />
4 2CD ROMS<br />
b) Output<br />
4 2CD ROMS<br />
c) Drawings/ Sketches 4 2CD ROMS<br />
6. Erection manual "DRAFT"<br />
7. Erection manual nual "FINAL" 2CD ROMS<br />
8 Operation & Maintenance manual "DRAFT"<br />
9 Operation & Maintenance manual "FINAL" 2CD ROMS<br />
10 Plant Hand Book "DRAFT"<br />
11 Plant Hand Book "FINAL" 2CD ROMS<br />
12 Commissioning and Performance Procedure manual "DRAFT"<br />
13 Commissioning and Performance Procedure manual "FINAL" 2CD ROMS<br />
14 Performance and Functional<br />
GURANTEES TEST REPORT<br />
4 2 CD<br />
15 Progress Reports<br />
4 2 CD<br />
16 Project completion report 10 2CD ROMS<br />
17 QA programme including Organisation for<br />
implementation and QA system manual<br />
(with revision-servicing)<br />
18 Vendor details in respect of proposed<br />
vendors including contractor’s evaluation<br />
report.<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
1<br />
1<br />
Page 26 of 27
19 Manufacturing QPs, Field QPs, Field<br />
welding g schedules and their reference<br />
documents like test procedures, WPS,<br />
(i) For review/comment<br />
3<br />
(ii) For final approval<br />
floppies<br />
4<br />
20 Welding Manual, Heat Treatment Manuals,<br />
Storage & preservation manuals<br />
Draft<br />
-<br />
Final<br />
4 sets<br />
21 Monthly Vendor Approval<br />
and QP approval status<br />
2<br />
22 QA Documentation Package for items /<br />
equipment manufactured and dispatched to site 2<br />
23 QA Documentation Package for field activities<br />
on equipment / systems at site 2<br />
Technical Specifications: Sec-5,General Techn chnical Requirements<br />
1 set<br />
4 sets<br />
2 CD ROMS<br />
1 CD<br />
1 CD<br />
2 CD ROMS<br />
2 CD ROMS<br />
Page 27 of 27
ELECTRICS FOR WAGON TIPPLER SYSTEM<br />
1.0 SPECIAL INSTRUCTIONS TO BIDDERS<br />
1.1 Inspection of site by Bidder<br />
Bidder shall inspect the site and examine and obtain all information required and satisfy<br />
himself regarding all matters such as access to site, communication, transport, right of way,<br />
the availability of local labour, availability and rates of materials, local working conditions,<br />
extreme weather conditions, uncertainty of weather, obstructions and hindrances that m mmay<br />
arise, etc, which may affect the work or cost thereof, before the submission of his tender.<br />
Ignorance of site conditions shall not be accepted as basis for any claim for compensation.<br />
The submission of tender by Bidder will be construed as evidence tha that t such an examination<br />
was made and any later claims / disputes in regard to price quoted shall not be entertained<br />
or considered.<br />
Bidder shall also indicate in his bid all the major assumptions including major design<br />
assumptions / criteria made by him on which the bid is based.<br />
1.2 Compliance with Specification<br />
All equipment and accessories covered under this specification shall conform to the<br />
“Technical Specifications” given in this document.<br />
In case alternative type of equipment is offered, all technical particulars of equipment<br />
offered, number of such equipment supplied in India, reference list of installations where<br />
such equipment is in operation as per qualifying requirements, type test cer certificates of their<br />
collaborators, type test certificates of indigenously made equipment, extent of import<br />
content and availability of spares indigenously, along with any other data for considering the<br />
alternative equipment shall be furnished with the offer offer. . The Purchaser, however, reserves<br />
the right to accept or reject the proposal without assigning any reason.<br />
All equipment shall be suitable for voltage/frequency variations and other data given in<br />
Electrical System Design.<br />
The contractor shall be responsible for satisfactory working of system with guaranteed<br />
parameters. All the major equipment shall be installed, tested and commissioned under<br />
supervision of representative of manufacturer of respective equipment.<br />
1.3 Standards and Regulations<br />
Technical Specification:Sec-6, Electrical<br />
SECTION 6<br />
Page 1 of 97
The design, manufacture, performance, testing and installation (including earthing and other<br />
essential provisions) of equipment and accessories covered under this specification shall, in<br />
general, comply with the latest issue of the follow following:<br />
• Applicable Standards and Codes of Practices published by Bureau of Indian<br />
Standards.<br />
• Central Board of Irrigation and Power<br />
• Indian Electricity Act, 2003<br />
• Central Electricity Authority<br />
• Indian Electricity Rules<br />
• Equipment specific statutory regulations<br />
• Indian Factory Act<br />
Equipment complying with other recognized Standards such as IEC, BS, VDE, DIN etc. will also<br />
be considered if it ensures performance equivalent to or superior to Indian Standards.<br />
Equipment and nd accessories for which Indian Standards are not available, shall be designed,<br />
manufactured and tested in accordance with the latest issues of recognized Standards such as<br />
IEC, BS, VDE, DIN etc.<br />
In case of conflict between applicable Standards referred to in this part and technical<br />
specifications, the Technical Specifications shall govern to the extent of such difference.<br />
1.4 Make & Interchangeability<br />
This specification is issued for procurement of specified equipment and system preferably<br />
from indigenous suppliers who may make use of imported systems / sub sub-systems systems / equipment<br />
/ parts and who have valid collaboration agreement with reputed foreign suppl suppliers with<br />
experience in design and supply of similar systems as specified. The Bidder shall furnish<br />
division list of supplies from foreign and Indian sources indicating the name of the agency or<br />
make against the respective items. It shall be the responsibi responsibility lity of the successful Bidder to<br />
arrange the import license for the imported items offered and to co co-ordinate ordinate the supply of<br />
equipment from foreign and Indian sources and execute the contract within the agreed time<br />
schedule.<br />
The make of major equipment sh shall all be limited to preferred makes indicated under ‘List of<br />
preferred makes'. Makes of all other equipment and accessories are subject to prior approval<br />
by the Purchaser/RITES.<br />
Similar equipment and components shall be of same make; equipment of same type and<br />
rating shall be interchangeable.<br />
The Purchaser has the option of selecting the manufacturer of electrical equipment,<br />
instruments and controls and any other specialized items in the interest of standardization and<br />
the successful Bidder shall have to supply equipment of particular make, if so required.<br />
Technical Specification:Sec-6, Electrical<br />
Page 2 of 97
1.5 Safety<br />
All equipment shall be complete with approved safety devices wherever a potential hazard<br />
exists and with provision for safe access of personnel to and around equipment for<br />
operational and maintenance enance functions.<br />
The design shall include not only those usually furnished with elements of machinery but also<br />
the additional covers, staircases, ladders, etc which are necessary for safe operation of the<br />
plant. All danger and caution notice boards shal shall l be in Hindi, English and Oriya.<br />
The Contractor must take sufficient care in moving his construction plants and equipment<br />
from one place to another so that those may not cause any damage to the property of the<br />
Purchaser particularly to the overhead and underground cables and other service lines.<br />
When the work is carried out at night or in the obscure day light, adequate arrangements for<br />
flood lighting in the working area shall be made by the Bidde Bidder.<br />
The safely postures/regulations for the prevention of accidents shall be displayed by the<br />
Bidder at appropriate places. Notices and warning signs shall be displayed for all sources of<br />
dangers.<br />
All electrical drives and equipment must be equipped with safety devices. The safety<br />
provisions shall conform to the recognized standards, safety codes and statutory regulations.<br />
All safety measures as required to be adopted as per the statutory regulati regulations and the safety<br />
rules of the plant shall be strictly followed by the Contractor during the execution of the<br />
Contract.<br />
Adequate number of first aid boxes as defined in the State Factory Rules shall be provided and<br />
maintained at all the work sites.<br />
1.6 Coding/Numbering ding/Numbering Scheme<br />
A coding scheme for identifying the drawings, plant and equipment, structures, spares and<br />
shipping documents shall be adopted by the contractor in a sequential manner.<br />
1.7 Contractor's License<br />
The contractor shall possess a valid an and d competent contractor's license of specified voltage<br />
issued by the electrical licensing authorities of the Govt. of Orissa for carrying out electrical<br />
installation work of the type and magnitude covered in this document, in the state of Orissa.<br />
The contractor ctor shall also be required to obtain labour license from Statutory Authority.<br />
Technical Specification:Sec-6, Electrical<br />
Page 3 of 97
Copy of the license shall be made available to the Purchaser/consultant for verifications during<br />
the execution of contract.<br />
All linemen, wiremen, electricians, supervisors aand<br />
nd engineers engaged by the Bidder or his<br />
sub-Bidder Bidder shall possess necessary valid license issued by the statutory authority and the same<br />
shall be submitted for verification, if called for.<br />
1.8 Compliance with rules, regulations, and obtaining statutory appr approval<br />
All equipment/materials shall be installed in accordance with the requirements of relevant<br />
standards, Indian electricity Rules, Indian Electricity Act, 2003 and also the Factory Act. It is the<br />
responsibility of the Bidder to see that the electrical install installation ation supplied and erected by him<br />
shall be to the entire satisfaction of Chief Electrical Inspector, Central Electricity Authority or<br />
any other statutory body having jurisdiction in the area and also to the Purchaser/ consultant.<br />
The responsibility for obtaining btaining all statutory approvals for the installation to be carried out<br />
rests entirely with the contractor. It shall be the responsibility of the contractor to prepare and<br />
submit all necessary drawings, calculations, test certificates and relevant details (other than<br />
those given by the Purchaser/consultant) to the Electrical Inspector and obtain prior approval<br />
for commencing the work and for the complete installation work done. The inspection fee for<br />
statutory approvals shall be borne by the bidder.<br />
2.0 SCOPE AND BRIEF DESCRIPTION OF WORK AND ELECTRICAL SYSTEM DESIGN CRITERIA<br />
2.1 General<br />
The scope of work includes the basic engineering, detailed design engineering, manufacture or<br />
procurement of electrical equipment, shop testing, packing, transportation, loading, delivery<br />
at site, unloading, storage at site, handling, erection, pre pre-commissioning commissioning tests and<br />
commissioning of all equipment/system including preliminary acceptance test, performance<br />
guarantee and post commissioning services, inclu including ding insurance cover during transit, storage,<br />
erection and commissioning. The job shall be done on turnkey basis. Scope of Bidder shall also<br />
include the following:<br />
• Supply of commissioning spares<br />
• Supply of mandatory spares required for one year normal O&M<br />
• Supply of special tools and tackles for the equipment/systems supplied<br />
2.2 Bidder shall provide complete design inputs in form of assignment indicating complete<br />
requirements of civil building to accommodate comfortably an electrical substation consistin consisting<br />
of electrical equipment under his scope as well as the equipment under scope of the<br />
Purchaser, if any meeting all the required statutory clearances. The building shall be finalized<br />
and constructed by the bidder<br />
Bidder shall also provide the following ddesign<br />
esign inputs for detailed design and engineering of<br />
civil and structural works i.e. foundations, room, etc. The same shall be taken into<br />
consideration while designing the civil buildings by the bidder:<br />
Technical Specification:Sec-6, Electrical<br />
Page 4 of 97
• Static and dynamic loading of the equipment<br />
• Clearances, , approach, safety exits required<br />
Clearances from all the four sides of the walls shall be maintained, wherever applicable in the<br />
electrical premises while considering the design inputs.<br />
The civil buildings for the complete WTP substation (including sw switchgear itchgear room, battery room,<br />
transformer rooms, etc), dust suppression MCC room, electric room for WTP, Apron feeder feeder,<br />
etc shall be under the scope of work. Electrical sub-station station will be installed in the out door<br />
near the wagon tippler station.<br />
2.3 Bidder er shall also take into consideration of various aspects like clearances, approach, roads,<br />
safety exits, cable trenches, transmission lines, foundations, floor opening, inserts,<br />
underground GI pipes, office premises, etc while finalizing the designing of c ccivil<br />
installations<br />
and building within battery limit of the package.<br />
2.4 Scope cope of the Bidder starts from tapping 33KV source including supply of 33KV/415KV<br />
transformers and corresponding switchboards, bus ducts and down below all the electrical<br />
equipments etc.<br />
For WT System Bidder shall include complete electrics including all the equipment/services on<br />
turnkey basis as per requirement irrespective of the same as s specified in the specification or<br />
not. Separate set of suitable rated 33/0.44 kV transformers, ormers, dedicated MCC for WT System<br />
machine, PLC, UPS with sealed maintenance free batteries, VVVF drive control system,<br />
junction boxes, other equipment, etc shall be included for smooth operation of wagon tippler<br />
system.<br />
Air conditioning of control room to be done with suitable capacity by air cooled packaged AC AC.<br />
For other LT drives and mechanism, Bidder shall include dedicated MCCs consisting of required<br />
number and capacity of outgoing feeders.<br />
For dry fog type dust sup suppression pression systems of transfer points in junction houses, Bidder shall<br />
include a dedicated MCC in pump cum compressor house.<br />
For miscellaneous and non non-critical critical loads like power socket cabinets, ventilation, AC power<br />
requirement of 33KV switchboard / 415V PPCC<br />
CC / transformer marshalling boxes, etc, Bidder<br />
shall include a dedicated PDB.<br />
For illumination of WT System (Wagon Tippler, Apron feeder) including conveyors and<br />
substation, dust suppression room and adjoining areas / sub areas, Bidder shall consider a<br />
dedicated LDB and sufficient number of SLDBs. SLDB shall be timer control. Two numbers<br />
flood light high mast towers 30m high eachshall shall be included for illumination of WT Area with<br />
metal Halide lide Lamps. Illumination of street light and conveyor gallery shall be with LED lamps<br />
within a radius of 500m of wagon tippler tippler.<br />
Technical Specification:Sec-6, Electrical<br />
Page 5 of 97
A separate room shall be provided adjacent to WT control room to house the Dust suppression<br />
MCC, Pumps, compressors etc for the DS System by the Bidder. Bidder shall furnish the<br />
complete requirements quirements including size, cable trenches/opening, etc. The pressurized ventilation<br />
shall be provided by the Bidder in this Dust Suppression Room.<br />
The number of MCCs / DBs shall be provided as per requirement by the bidder.<br />
Following shall also be inclu included in the Bidder’s scope:<br />
• Pressurized ventilation system for the switchgearroom<br />
switchgearroom.<br />
• Pressurized ventilation system for the Dust Suppression cum MCC room.<br />
• Air conditioning of battery and battery charger rooms.<br />
• Exhaust fan in the transformer rooms.<br />
The bidder r shall supply the PLC for safe operation of WT System. Necessary integration with<br />
existing PLC of new coal yard will be scope of tender tenderer. . Design and installation of electrics shall<br />
ensure operation of complete integrated electrics of the various drives/m drives/mechanism without<br />
any constraint during maintenance.<br />
Bidder shall also consider sufficient numbers of local auxiliary PDBs to cater miscellaneous<br />
loads of WT System. These PDBs shall be located at various places and exact locations shall be<br />
finalized during g detailed engineering.<br />
HT Power cables and LT power/control cables shall be laid in different cable trays. LT power<br />
cables and LT control cables shall also be laid in different trays. 24V DC cables shall be laid<br />
entirely in different dedicated trays.<br />
Cable trays in single tier or in multitier shall be installed in vertical arrangement everywhere to<br />
avert coal accumulation and space reduction. Cable trays shall be supplied by the bidder.<br />
Power supply of all voltage levels including 415V AC or 220V DC, 24V DC etc, shall be arranged<br />
by Bidder himself by providing suitable systems. 24V DC supply shall be through screened<br />
cable to be supplied by the Bidder.<br />
Only at receiving point of 33KV, control supply of 415V AC and 220V DC shall be made<br />
available by the he purchaser purchaser.<br />
Following HT cabling shall also be included by the Bidder apart from the above:<br />
1. ACSR conductor for O/H transmission of 33kv line.<br />
2. Cabling required for underground track/road crossings of33 kV System including intake<br />
pump well feeder and ashpond feeder feeder.<br />
Standard power and control cables (Trailing Cables) of required sizes in adequate quantum<br />
shall be supplied and terminated by the Bidder. Hence, complete HT & LT trailing cables for<br />
Wagon Tippler, etc tc shall be supplied and laid by the bidder.<br />
Cables used for 24 VDC supply for PLC system shall be laid separately from 230 V AC control<br />
cables.<br />
Technical Specification:Sec-6, Electrical<br />
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All cables Power cable, Control Cable, Trailing Cable, instrumentation cables, signal cables,<br />
screened cables, es, special cables, fibre optic cables shall be supplied, laid and terminated by the<br />
Bidder as per actual site requirement.<br />
Cabling shall include laying and termination at both ends, cable trays and cable accessories for<br />
the cables to be laid by the Bidd Bidder.<br />
Bidder shall consider all required cables for cable engineering, preparation of cable schedule,<br />
terminal plans, cable support structure layout, cable layout drawings, etc. All cable trays,<br />
accessories, termination kits, glands, lugs, clamps including clamps, etc shall be included in the<br />
scope for all the cables (to be supplied by the Successful Bidder) interconnecting both side<br />
equipment or one side equipment of the Bidder’s scope.<br />
All drives shall be controlled and monitored at existing WT SYSTEM control room from the PLC.<br />
Bidder shall include PLC and all the interfacing/ interconnecting cabling and cable trays. All<br />
Cables required for this interfacing, shall be supplied and laid by the Bidder. Copper power<br />
cables, if required by the bidder, shall also be under scope of supply and laying of the bidder.<br />
Ampere meters for all conveyor belts are to be installed at the control room for monitoring<br />
the current of each drive.<br />
Bidder shall consider numeric PLC and type of Inputs / Outputs (I/Os) required for WT system<br />
for smooth and trouble free operation of various drives / mechanism from the WT SYSTEM<br />
control room. Sufficient number of I/Os in PLC extension shall be considered as per act actual<br />
requirement. Exact number and type of I/Os shall be decided during detailed engineering<br />
based on approved schemes.<br />
Bidder shall also consider sufficient number of I/Os in PLC control and monitoring for electrical<br />
power distribution system for the electrical power distribution system starting from 33KV till<br />
the down most voltage level.<br />
New PLC of WT shall be interfaced with existing PLC of Coal Handling Plant for operation of BC<br />
– 115 and BC – 103.<br />
The earthing system shall be provided for compl complete ete WT SYSTEM plant. The new earthing<br />
system shall be connected to the existing earthing system.<br />
Bidder shall also consider earthing of following equipment:<br />
Technical Specification:Sec-6, Electrical<br />
• 33kv substation equipments.<br />
• WT LT distribution transformers – Neutral as well as body earthing<br />
• 415 5 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room<br />
• Control panel for power distribution equipment at existing WT control room<br />
• LT busducts<br />
• Charger panels, DCDB, etc at WT substation in switchgear cum MCC room<br />
• Underground eart mat.<br />
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Bidder shall consider earthing ring mains at each electrical premise and connect the electrical<br />
equipment with the rings. The earthing ring mains shall be connected with underground<br />
earthing mats to be provided by the bidder made of 2x40mm dia solid MS rod. Adequate<br />
number of risers shall be made available for connection with his earthing ring main. For<br />
transformer neutral earthing, bidder shall consider dedicated plate earthing.<br />
Lightning protection shall be provided by the bidder for complete WT SYSTEM including tall<br />
installations covered under the battery limit.<br />
Bidder shall also include complete illumination of the premises under the battery limit and all<br />
the above electrical premises coming at WT SYSTEM substation and adjoining areas.<br />
Air-conditioning, conditioning, ventilation and exhaust fans for various rooms / premises of WT SYSTEM<br />
along with their complete electrics shall be under scope of the Bidder. The battery and battery<br />
charger room shall be air- conditioned. Switchgear cum MCC room of WT substation shall have<br />
pressurized ventilation. Transformer rooms of the WT substation shall have exhaust fans fans.<br />
All interconnection for power, control and instrumentation/signal amongst equipmen equipment<br />
supplied by the Bidder shall be under Bidder's scope of work. Similar interconnections<br />
including power, control and signal between Purchaser's equipment and Bidder's equipment<br />
shall be done by the Bidder. All the cable terminations at both ends, cable tr trays and cable<br />
accessories shall be under Bidder's scope.<br />
2.5 Electrical system design criteria<br />
a) General<br />
The design, manufacture, assembly and testing as well as performance of the equipment shall<br />
conform to the relevant IS : specifications (latest revision) and other relevant standards. In<br />
case IS specifications is not available in respect of certain items, the Bidder may base his<br />
proposals on IEC/BS/VDE/DIN recommendations or other reputed national or international<br />
standards subject to the approval of the Purchaser Purchaser/RITES. . All equipment supplied and all work<br />
done including system design and detailed engineering shall also comply with the statutory<br />
requirements of the Government of India and the Government of Orissa.<br />
b) Climatic Conditions<br />
Electrical Equipment selection and derating shall generally be based on ambient temperature<br />
of 50 o Electrical Equipment selection and derating shall generally be based on ambient temperature<br />
C. The equipment offered shall be suitable for smooth, efficient and trouble free service<br />
in the climate prevailing at Angul.<br />
c) Standard Voltage levels<br />
Technical Specification:Sec-6, Electrical<br />
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Following power utilization standard voltage levels shall be adopted for various systems:<br />
1. Station supply<br />
3. Power supply to PLC extension 240 V, 1 phase, 2 wire, 50 Hz, A.C. (from UPS)<br />
4. DC control supply<br />
220 V, 2 wire, unearthed<br />
5. Plant illumination<br />
6.<br />
7.<br />
Welding socket / power 415 V, 3 phase, 50 Hz, A.C. outlets<br />
receptacles<br />
240 V, 1 phase, 2 wire, 50 Hz, A.C. outlets<br />
Special socket outlets for 24 V, 1 phase, 2 wire, 50 Hz, A.C. through suitable<br />
portable lamps<br />
transformers<br />
8. Sockets for electrical tools, etc 240 V, 1 phase, 2 wire, 50 Hz, with one point earthed<br />
9 Emergency illumination 220 V DC<br />
d) Permissible variations<br />
The system / unit / plant / equipment shall be designed suitably for following variation in<br />
voltage and frequency;<br />
Permissible variation with rated performance and control<br />
effectiveness maintained<br />
Permissible variation for control and regulation equipment with<br />
rated performance and control quality maintained<br />
Permissible voltage dip at HT switchgear bus during starting of<br />
motor<br />
- 15 % -<br />
Permissible voltage dip at MCC bus during starting of LT motors - 15 % -<br />
e) Symmetrical short circuit ratings<br />
The short circuit ratings of all the equipment like MCCs, motors, PDBs / LDBs, cables, power<br />
socket & lighting cabinets, etc shall be selected keeping in view the fault level capacities of the<br />
Purchaser’s electrical equipment.<br />
The three phase symmetrical short circuit rating at 33 kV level shall be 25 25kA. The three phase<br />
symmetrical short circuit rating at 415 V level shall be 50kA.<br />
The rated short circuit withstand duration for 33 KV shall be 3 sec, whereas for 415 V system,<br />
it shall be 1.0 sec.<br />
f) Criteria for selection of voltage levels ffor<br />
drive motors<br />
Technical Specification:Sec-6, Electrical<br />
33 kV, 3 phase, 3 wire, unearthed system<br />
415 V, 3 phase, 4 wire, solidly earthed<br />
240 V, 1 phase, 2 wire, 50 Hz, A.C.<br />
Voltage Frequency<br />
+/-10% 10% +/-5%<br />
+/- 10 % +/-5%<br />
Page 9 of 97
All AC squirrel cage induction motors shall be fed at 415V V from switchboard through air circuit<br />
breakers with numeric type compreh comprehensive motor protection relays via power contactor and<br />
overload relay.<br />
g) System Earthing<br />
33kV system is unearthed, , 415V system is solidly earthed.<br />
2.6 ELECTRICAL SYSTEM REQUIREMENTS<br />
Minimum number of spare feeders in each of the MCC / PDB / LDB / SLDB shall be 10% subject<br />
to minimum one no. of each type and rating in each section. The rating a aand<br />
type of spare<br />
feeder shall be decided during detailed engineering stage.<br />
Sizes and requirement of various power and control cables shall be decided and intimated to<br />
the Purchaser well in advance to suit the approved scheme/to achieve scheme requiremen requirement.<br />
Space heater power supply to the motors shall be fed from the MCC through same cubicle by<br />
415/240 V transformers. Space heaters shall be interlocked with motor main power supply.<br />
Bidder to submit a system wise drive list indicating required process in interlocks, permissive<br />
conditions etc. with places and mode of control, control system philosophy with provision of<br />
various control, indication, measuring devices at various places. The Purchaser Purchaser/RITES shall<br />
approve this based on above approved philosophy an and d Bidder shall have to provide all<br />
equipment / materials and prepare a control scheme/logic diagram which shall be utilized for<br />
designing the motor feeders at 33 kV switchboard and 415 V MCC at Bidder’s end.<br />
Above-mentioned mentioned control philosophy and interlocking logic shall be prepared as per the<br />
technological requirement.<br />
Suitable electrics for all the material handling equipment like hoist, etc shall be provided for<br />
handling the various drives and mechanism.<br />
Warning hooter shall be of brushless type Siren and AC single phase.<br />
All actuators shall be of geared motors.<br />
Complete 24 V system, wherever required, shall be provided by the bidder.<br />
24 V and 230 V AC shall be taken through separate cables. Screene Screened d cables shall be supplied<br />
and used for 24 V power supply.<br />
All the indication lamps shall be LED based with LVGP (Low Voltage Glow Protection) up to 100<br />
V.<br />
All the hoist control panel shall be located at workable height and platform shall be provided<br />
for r each hoist at one point for maintenance purpose.<br />
Technical Specification:Sec-6, Electrical<br />
Page 10 of 97
Ammeter for Wagon Tippler, Apron feede feeder and Conveyors etc. shall also be provided in<br />
Control Pane for monitoring of currents.<br />
3.0 PERFORMANCE REQUIREMENT AND GUARANTEE<br />
The PG test shall be conducted for overall system of wagon tippler including electrical system<br />
and equipments as mentioned elsewhere.<br />
4.0 TECHNICAL SPECIFICATION<br />
4.1 CONTROL & PROTECTION SYSTEM AND LAYOUT CONTROL PHILOSOPHY<br />
The control, monitoring, interlocking, annunciation and metering functions of various<br />
drives/mechanism shall be performed through PLC at WT SYSTEM control room. All the drives<br />
shall also be operated from local control stations for emergency stop as well as for decoupled<br />
trial run of motors.<br />
Following interlocks ks / alarm, etc shall be provided for various drives/mechanism of cooling<br />
water system:<br />
• When conveyor will trip, Apron feeder will trip.<br />
• When apron feeder trips, Wagon tippler will trip.<br />
• When any of the running drive trips, the standby drive shall start automatically.<br />
• When any of the running conveyor trips, the preceding/succeeding conveyor shall trip<br />
automatically.<br />
• A conveyor shall take start only when it’s preceding conveyor starts<br />
• Auto-Tripping Tripping of conveyor drives through various mechanism like pull chord, belt sway<br />
switch, etc<br />
The above interlocks/alarms and control philosophy are minimum and indicative. The detailed<br />
requirements for the above shall be finalized during detailed en engineering.<br />
Bidder shall furnish details of control, monitoring, interlocking, protection, annunciation and<br />
metering system for all drive. Bidder shall use state of art technology while fulfilling the<br />
functional requirement of all the equipment for smooth and trouble free operation through<br />
PLC.<br />
Various transducers (4-20 20 mA range) as per requirement shall be provided to facilitate control<br />
and monitoring from PLC. Required transducers and wirings to hook up all analog and digital<br />
inputs / outputs to / from PLC shall be included in the scope.<br />
Interlocking arrangement shall also be furnished to take care of all the approved logic<br />
schemes. Bidder shall provide necessary wiring, control and required items to achieve the<br />
approved logic / scheme. Selecting loca local l / remote switch of local control station in local<br />
position shall carry out local mode operation of the drives for test/trial etc. Permissive<br />
Technical Specification:Sec-6, Electrical<br />
Page 11 of 97
conditions for start and tripping of various drives shall be provided as per approved logic<br />
diagrams.<br />
A dedicated ed hardwired control panel / desk shall also be provided by the bidder at WT control<br />
room to control and monitor electrical power distribution system.<br />
Controls of all equipments of wagon tippler including conveyor’s all interlocks shall be PLC<br />
based. The PLC system shall be latest version having dual redundant processor with HMI based<br />
control station. There shall be two HMI control system with one operating station and other<br />
an engineering station. The system shall be designed with 10% extra input/output pprovision.<br />
Input/output of PLC(analog & digital) shall have at least 10% extra channel wired up to TB TBs in<br />
the panels. A portable programming station (Laptop) with all the ladder logic/<br />
programming/software shall be provided for engineering and troubleshooti<br />
troubleshooting functions. The<br />
system shall be capable of communicating with the existing PLC system of the CHP(The<br />
existing PLC is of GE Fanuc make make- Model 90-30,CPU-370). 370). The vendor shall be responsible for<br />
communicating and displaying the important parameters of wago wagon n tippler PLC system to the<br />
existing CHP PLC through optical fibre cable. All electrical power distribution system shall be<br />
controled and monitored through PLC.<br />
PROTECTION SYSTEM<br />
Protections for the different electrical equipment are enlisted below:<br />
For Protection of LT T motor motor, comprehensive omprehensive numeric motor protection shall be provided in the<br />
switchboard.<br />
Laying of control and power cables including supply and laying of signal cables from motors to<br />
switchboard shall be in the scope of Bidder.<br />
Comprehensive ensive numeric motor protection including but not limited to the following:<br />
• Instantaneous over current protection<br />
• Differential protection (for rating above 1000 kW)<br />
• Instantaneous time over current protection in two phases and definite time delayed over<br />
current urrent alarm on the third phase<br />
• Negative phase sequence protection<br />
• Thermal overload taking -ve and +ve phase sequence into account<br />
• Earth fault<br />
• Locked rotor protection<br />
• Winding temp monitoring and alarm for rating beyond 1000 kW<br />
• Under voltage protectio protection<br />
Microprocessor based numeric motor protection relay shall also have following facilities:<br />
• Communication facility with open protocol like IEC/Modbus.<br />
• Relay should store last five fault records (minimum) with date and time stamping.<br />
• Relay should have no. o. of start menu for start inhibition.<br />
• Relay should have facility for displaying three phase and neutral current<br />
Technical Specification:Sec-6, Electrical<br />
Page 12 of 97
• Relay should have heavy duty tripping contact which will be used for breaker tripping<br />
• Battery backup facilities<br />
The Motor Protection Relays shall also have the following additional features:<br />
• Fault recording facility<br />
• Password protection<br />
• Local/remote communication facility with open protocol<br />
• Minimum 4 nos. BI and 4 nos. BO<br />
Protection of LT motor (less than 75 kW)<br />
Motors below 75 kW shall be fed from MCC through MCCB with power contactor and overload<br />
relay.<br />
Motors of 5 kW and above but below 75 kW, shall have fed through MCCBs (for short circuit<br />
protection), numeric motor protection relay like MPR MPR-300 300 or equivalen equivalent (for overload and<br />
other motor protection) and power contactors.<br />
For motor below 5 kW, MPCBs may be considered in place of MCCBs.<br />
Single phasing protection shall also be provided in the MCC modules.<br />
METERING<br />
Following metering shall be provided in various MCC/DBs;<br />
415 V MCC<br />
1. 415 V INCOMER (EACH) • AMMETER (DIGITAL TYPE)<br />
• VOLTMETER<br />
• kWH METER<br />
2. BUS COUPLER<br />
• AMMETER<br />
3. OUTGOING<br />
• AMMETER (DIGITAL TYPE)<br />
MOTOR FEEDER (EACH)<br />
PDB<br />
1. 415 V INCOMER COMER (EACH) • AMMETER (DIGITAL TYPE)<br />
• VOLTMETER 2. OUTGOING (EACH)<br />
• AMMETER (DIGITAL TYPE)<br />
4.2 LT MOTOR CONTROL CENTRE (LT MCC)<br />
Constructional Features<br />
Fully drawout type with modules having service, test and isolated positions. Floor mounting,<br />
free standing with base channel 50 mm high for fixing on the inserts on the floor. MCC shall be<br />
single front, totally enclosed, dust and vermin proof.<br />
All the module of the MCCs shall be spacious to facilitate maintenance of equipment inside the<br />
module. Pollution degree applicable shall be pollution degree 4 as per IS IS-13947 13947 (Pt (Pt-I), 1993.<br />
Technical Specification:Sec-6, Electrical<br />
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Incomer and bus coupler panels<br />
MCC incomers and bus couplers shall have Air circuit breakers. Incomers and bus couplers<br />
shall be rated for at least 125% of maximum de demand mand taking into account the spare feeders<br />
and shall be suitable for the specified fault level.<br />
Incomers and bus coupler shall be electrically interlocked to prevent parallel operation.<br />
However, a definite delay defeat Interlock switch shall be provided to facilitate parallel<br />
operation. Auto changeover facility shall also be provided between the two incomers and bus<br />
coupler.<br />
Feeder Modules<br />
Feeders for motors of 75 kW and above shall be fully drawout type air circuit breakers (ACBs)<br />
with numeric type comprehensive mprehensive motor protection relays. Other motor feeders shall be<br />
consisting of MCCB, contactor, overload relay as main power components to ensure type 2<br />
protection. The short circuit release of MCCBs shall be suitably selected to the applications<br />
concerned.<br />
At least 10% spare feeders (minimum one spare feeder of each type and rating bus sectionwise)<br />
shall be provided. Ammeters with selector switches shall be provided for all continuous /<br />
intermittent running motors beyond 15 kW rated drives.<br />
Busbars and d terminations<br />
Busbars and connection shall be of high conductivity aluminium/aluminium alloy of suitable<br />
hardness and purity complying with as per IS IS-5082-1981. 1981. Busbars shall be insulated by colour<br />
coded heat shrinkable sleeves.<br />
Busbars shall be rated for the nominal current rating of incoming breaker and for the full<br />
short-circuit circuit rating. Earth bus shall run throughout the length of MCC at bottom .<br />
Control bus shall be provided in the bus bar chamber isolated with main bus in all the MCCs.<br />
Similarly power and control terminations shall be in separate chambers in the MCCs. Cable<br />
alley y shall have sufficient space for maintenance and minimum width of cable all alley shall be<br />
300 mm. Shrouding/isolation shall be provided for outgoing power terminations in th the cable<br />
alleys. ys. Modules of MCCs shall be spacious for easy maintenance of the various equipment<br />
inside.<br />
Short circuit strength<br />
Rated short time withstand current shall not be less than 50 kA for 1 second. Rated peak<br />
withstand current not less than 2.1 times the specified short circuit level.<br />
Air circuit breaker (ACB)<br />
Technical Specification:Sec-6, Electrical<br />
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Air break, drawout type conforming to IS 13947 (1993) and sy symmetrical mmetrical breaking capacity not<br />
less than 50 kA for 1 second shall be provided. Service short circuit breaking capacity (Ics) shall<br />
be 100% of rated ultimate short circuit breaking capacity (Icu). Performance category of the<br />
MCC shall be B. ACB used for in incomer comer & bus coupler should have numerical feeder protection<br />
relay.<br />
Motor operated mechanism shall be applicable with air circuit breakers. Spring charged stored<br />
energy mechanism shall be there to ensure high speed closing and tripping independent of the<br />
operating perating forces. Electrical anti pumping and trip free feature shall also be provided. Spring<br />
charging universal motor suitable for rated control voltage (220 DC). The closing coil and trip<br />
coil shall be suitable to DC operation.<br />
Closing and tripping of ACB shall be by closing coil (operating range 85% to 110% of rated<br />
voltage) and tripping by trip coil (operating range 70% to 110% of rated voltage) respectively.<br />
Built-in in direct acting type microprocessor based numerical releases for short circuit, over<br />
current and earth fault shall be provided.<br />
Auto changeover shall be done through under voltage relays and check synchronization relay<br />
with time delay. All the relays shall be microprocessor based numerical relays.<br />
Motor protection moulded case circuit breaker (MCCB)<br />
The characteristic shall match the motor duty application. Rated ultimate short circuit<br />
breaking capacity (Icu) shall be 50 kA. Ratings selected shall be at least 125% of the full load<br />
current of the motor. otor. For small rating drives such as valves, Siemens 3UV13 type (or<br />
equivalent) or motor protection circuit breaker (MPCB) shall be used. Utilisation category shall<br />
be A.<br />
Magnetic contactors<br />
Pick up shall be positively at voltage between 85% to 110% of rated value. For frequently<br />
reversing drives, AC 3 rating selected shall be 50% higher than full load current of the motor at<br />
the specified duty cycle shall be provided. For reversible drives, mechanically as well as<br />
electrically interlocked contactors sh shall be used.<br />
Thermal overload relay<br />
Thermal overload relay shall be triple pole, ambient temperature compensated, inverse time<br />
lag, hand reset type, bimetallic with adjustable setting and built in single phase protection. The<br />
relay shall be able to withstand prospective short circuit circuit-current without damage or injurious<br />
heating till the motor protection MCCB clears the fault. Tripping indication and reset push<br />
button operable from outside shall be provided.<br />
Push Buttons / Indicating Lamps / Indicating instruments<br />
Technical Specification:Sec-6, Electrical<br />
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Push buttons shall be spring ng return, push to actuate type and their contacts shall be suitable to<br />
carry and break 240 V AC, 10 A and 220 V DC, 1 A. Indicating lamps shall be LED LVGP (Low<br />
Voltage Glow Protection up to 100V) type. Standard colours shall be applicable for push<br />
buttons s and for indicating lamps. Indicating instruments shall be flush mounting, square dial<br />
with 900 scale with zero adjusting device for external operation. Accuracy class shall be 1.0 or<br />
better. KWh meter shall also be provided with incomers.<br />
MCC shall have e run / start, stop, tripped, and ready to start push button cum indication lamp<br />
for motor feeders.<br />
Current transformers<br />
The thermal and dynamic stability current for CTs and CT ratio shall be as per requirement.<br />
Protection and measuring current transf transformer ormer shall be bar primary/ window type with 1A<br />
secondary. Burden of CTs shall be as required by the associated measuring equipment.<br />
Potential transformers<br />
Potential transformers shall be provided on incomers as well as on buses and shall be in same<br />
circuit rcuit breaker cubicle. 415 V side of PTs shall have fuses. Accuracy class 1.0 shall be used. VA<br />
burden shall be selected based on meters and relays connected with the PT.<br />
Control transformer<br />
Control transformers shall be dry type 415V/240V, primary taps at +2.5 %, +5 % and shall be<br />
mounted in drawout trolley if outgoing feeders are in drawout execution. Control supply shall<br />
have supervision facility, alarm shall be provided for non availabilit availability y of any one of the control<br />
supply. Automatic/manual changeover facility shall also be provided. Auto Auto-changeover shall be<br />
blocked if power supply to respective section is not available.<br />
For capacity consideration of control transformers, each shall be ca capable pable to meet 100 % load<br />
including spare feeders and 10 % cushion for future and 15 VA for each module for remote<br />
aux. relays and indication lamps. Separate DC and AC control (3 ph & neutral) copper busbars<br />
shall be considered for each MCC. From AC contro control l bus, motor space heater supply shall be<br />
tapped with suitable control and interlocking arrangement.<br />
220V DC Control supply<br />
220V DC supply is required for electrically controlled ACBs. For two sections, two DC buses<br />
shall be there. In bus coupler panel, manual switch shall be there for changeover of one supply<br />
to other section. Non-availability availability of DC supply shall be annunciated in MCC or nearby control<br />
room.<br />
Internal Control Wiring and external Terminations<br />
Technical Specification:Sec-6, Electrical<br />
Page 16 of 97
Internal control wiring shall be by 1100V V grade PVC insulated, single core stranded copper<br />
conductor of minimum cross section 2.5 sq.mm. for CTs and space heater circuits and 1.5<br />
sq.mm for other circuits. For CT secondary wiring, disconnecting type terminal blocks (CAD<br />
type) shall be considered. .<br />
For external terminations, , DIN rail mounting type bakelite type terminal blocks shall be used<br />
complete with insulated barriers, stud type terminals, washers, nuts and lock nuts and<br />
identification strips. Power and control terminals segregated.<br />
Other accessories<br />
Following items shall be provided for the MCCs under the scope of the Bidder:<br />
Breaker lifting/handling trolley (for ACBs) : 1 No. per MCC Room<br />
Breaker racking handle (for ACBs) : 4 Nos. per MCC Room<br />
Panel key (if applicable)<br />
: 5 Nos. per MCC Room<br />
Selection of power components & wiring for continuous duty cage motor drives is given below:<br />
Motor<br />
Rating<br />
at S1<br />
Duty<br />
(KW )<br />
Up to<br />
3.7<br />
5.5<br />
7.5<br />
Minimu<br />
m<br />
rating<br />
of<br />
MCCB<br />
*<br />
*<br />
*<br />
11 *<br />
15 *<br />
18.5 *<br />
22 *<br />
30 *<br />
37 *<br />
45 *<br />
55 *<br />
75 *<br />
90 *<br />
110 *<br />
125 *<br />
135 *<br />
160 *<br />
Technical Specification:Sec-6, Electrical<br />
Minimum<br />
rating of<br />
contactor<br />
(AMPS) AC3<br />
duty<br />
25<br />
40<br />
40<br />
Minimum size for internal<br />
power connections<br />
Copper<br />
wire<br />
(sq.mm)<br />
Aluminium flat<br />
(mm x mm )**<br />
*Minimum rating of MCCB shall be selected to achieve type ‘2' protection.<br />
4<br />
4<br />
6<br />
40 6 -<br />
63 10 -<br />
-<br />
-<br />
-<br />
Minimum size of<br />
power cable<br />
Aluminium<br />
(sq.mm)<br />
4x 2.5(copper)<br />
4x 2.5(copper)<br />
4 x 6<br />
4 x 16<br />
4 x 16<br />
63 16 12 x 2 3.5 x 35<br />
63 16 12 x 2 3.5 x 35<br />
100 25 12 x 2 3.5 x 70<br />
100 35 15 x 3 3.5 x 70<br />
160 50 15 x 3 3.5 x 95<br />
160 70 20 x 3 3.5 x 120<br />
200 95 20 x 5 3.5 x 185<br />
400 20 x 5 3.5 x 185<br />
400 30 x 5 2(3.5 x 120)<br />
400 40 x 5 2(3.5 x 120)<br />
400 40 x 5 2(3.5 x 120)<br />
400 40 x 5 2(3.5 x 185)<br />
Page 17 of 97
** Copper flat of equivalent size can be used instead of aluminium flat.<br />
NOTES : Overload relay shall be selected based on actual full load current and starting time.<br />
GENERAL TECHNICAL PARTICULARS OF MCC<br />
GENERAL<br />
1. System<br />
: 415V, 3 phase, 4 wire, 50 Hz. Solidly earthed neutral<br />
2. Type<br />
: Indoor type, cubicle construction, free standing<br />
3. Pollution degree : 4<br />
4. Creepage distance : As per IS-13947 (1993), Part-I<br />
5. Enclosure<br />
: IP54<br />
6. Mounting<br />
: I/C & B/C in single tier and O/G in multi-tier tier arrangement<br />
execution<br />
7. Neutral earthing : Effectively earthed<br />
8. Control supply : 240V AC / 220 DC for ACB<br />
9. Short time rating : 50 kA for 1 sec<br />
10. Autochangeover required? :Yes<br />
11. Delay drop off required? uired? :Yes<br />
12. Control supply<br />
AIR CIRCUIT BREAKER<br />
: 220 V DC for ACB, 240V AC/220 DC for spring charge motor and<br />
240 V AC for MCCB, etc.<br />
1. Service<br />
2. Type<br />
3. Insulation level : 6 kV (1.2x50 micro Sec) Impulse withsta<br />
4. Utilization Category<br />
5. Operating mechanism<br />
I. Closing<br />
II. Opening<br />
III. Latching<br />
6. Auxiliary Voltage<br />
I. Closing<br />
II. Tripping<br />
CURRENT TRANSFORMERS<br />
1. Type<br />
: Resin cast, window type<br />
2. Rated voltage : 415 V +10%<br />
3. C.T. secondary<br />
4. Accuracy<br />
: 1 Amp rating<br />
i. Protection : 5P10 or better for protection<br />
ii. Metering : Class - 1<br />
Technical Specification:Sec-6, Electrical<br />
: Indoor<br />
: Air – break<br />
: 6 kV (1.2x50 micro Sec) Impulse withstand<br />
: B<br />
: Stored energy type<br />
: Motor wound spring operated<br />
: Shunt trip coil<br />
: Mechanically and electrically trip free arrangement<br />
: DC (85% - 110%)<br />
: DC (70% - 110%)<br />
III. Spring charging : 240V + 10% AC or DC motor<br />
IV. Space heater & Lamp : 240V + 10% AC 50 Hz<br />
7. No. of poles of C.B : 3<br />
Page 18 of 97
POTENTIAL TRANSFORMERS<br />
1. Type<br />
2. Primary/secondary<br />
: Cast Resin<br />
voltage ratio<br />
415V :<br />
3<br />
110V<br />
3<br />
3. Method of connection :Star/Star connection<br />
4. Rated voltage : 1.2 continuous, 1.9 for 30 Sec factor<br />
5. Class of insulation : Class E or better<br />
CONTROL TRANSFORMER<br />
1. Type<br />
2. Voltage ratio<br />
3. Rated burden<br />
4. Quantity<br />
MOULDED CASE CIRCUIT BREAKER<br />
1. Type : Air break (Motor duty)<br />
2. Rated service : 415 V +/ +/- 10% voltage<br />
3. Utilization Category : A<br />
4. Protection<br />
: Type `2 to the contactor<br />
CONTACTORS<br />
1. No. poles : 3<br />
2. Rated service : 415 V + 10% voltage<br />
3. Control circuit : 240V +10% 1ph, 50Hz +5%<br />
4. Utilisation category<br />
5. Limits of operation<br />
: AC23A for uni uni-directional motors<br />
i. Closing (pick-up) : 85% to 110%<br />
ii. Dropout : Shall not be higher than 75%<br />
RELAYS/RELEASE<br />
1. Relay type<br />
2. Release type<br />
THERMAL OVERLOAD RELAYS<br />
1. Type : Ambient temperature compensated bimetal operated hand reset type (direct or<br />
C.T. operated)<br />
2. Hand resetting<br />
: To be provided at the front of the panel feature<br />
3. Single phasing protection : Built in<br />
4.3 CABLE AND CABLE ACCESSORIES<br />
TYPES OF CABLES<br />
Technical Specification:Sec-6, Electrical<br />
: Dry cast resin, class B or better<br />
: 415V/240V<br />
: As per requirement (Minimum 1.5 kVA)<br />
: 2 nos. per board and minimum capacity shall be 1 kVA<br />
: Numeric<br />
: Microprocessor based.<br />
Page 19 of 97
All cables viz.power power and control cables, trailing cables, signal, instrumentation, screened, fire<br />
optics, copper power cables and special purpose cables required for applications concerned<br />
and for satisfactory operation of the all the drives at Wagon Tippler plant shall be in the scope<br />
of the Bidder. All power cables cables(XLPE) should be FRLS (Fire Retardant low sulphur) type (inner<br />
& outer sheath) and shall have round armouring armouring.<br />
Bidder shall include all the cable accessories in his scope of supply aas<br />
s well as installation as per<br />
actual requirement at site.<br />
Trailing Cables<br />
All the trailing cables shall be 4 core XLPE. The cable for application in 33 KV supply system<br />
shall conform to IS:7098(Part (Part-2) 2) 1985 and for low and medium voltage including 1100v shall<br />
conform to IS: 7098(part I) ),1988.<br />
HT trailing cables shall be 33 KV (UE) heavy duty power cable 4 core, flexible. The detailed<br />
specification for the HT trailing cables required shall be fu furnished rnished by the Bidder along with the<br />
tender.<br />
1.1 kV grade flexible trailing cable shall be of heavy duty type having tinned annealed high<br />
conductivity flexible copper conductors, butyl rubber or ethylene propylene (EPR) insulation<br />
and CSP or PCP sheathing. The conductor shall conform to IS:8130 - 1984 and insulation and<br />
sheathing shall be as per IS:6380 - 1984. For high temperature zone and side side-arm-charger the<br />
insulation shall be of silicone rubber.<br />
For all the cabling, Bidder shall include layi laying ng including all the GI prefabricated cable trays/hot<br />
dip galvanized perforated trays and other cable accessories like cable termination/jointing kits,<br />
glands, cable identification tags, connectors, ferrules, clamps, etc<br />
HT Cable End Termination & Straight through jointing kits<br />
All high voltage cable terminations shall meet the test procedures and requirements stipulated<br />
in IEEE 48-1990 as class-I I termination.<br />
Heat shrinkable type of cable termination and joints shall be used for HT cables in i iindoor<br />
and<br />
outdoor applications as specified.<br />
The stress control and grading wherever necessary shall be by means of semi conducting heat<br />
shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces<br />
shall be achieved by using ng hot melted sealants or adhesives.<br />
Technical Specification:Sec-6, Electrical<br />
Page 20 of 97
Where such sealants or adhesives shall be exposed to high electrical stress, same shall be track<br />
resistant type.<br />
Straight through joints and end sealing termination kits of 33 KV (UE) grade cross cross-linked<br />
polyethylene cables shall be of well tried out design compatible for XLPE insulation. The<br />
joints/ends sealing kits shall be of heat shrinkable type and shall be complete with stress<br />
grading material, protective and lug sealing sleeves, self tightening earthing clamp, slide angle<br />
sleeve etc. Outdoor termination shall have necessary skirting over protective sleeving to<br />
increase the creepage distance and the sleeves shall ensure total protection against ingress of<br />
moisture. Straight through joints shall feature moisture pproof<br />
roof environmental seal, mechanical<br />
protection and impact resistance envelope around the joined cables.<br />
The end termination and straight through joints shall conform to the relevant standards. The<br />
complete termination / joint kits shall be of reliable and field proven design having been fully<br />
type tested and relevant type test reports shall be furnished.<br />
In addition the termination and joint shall be tested for various accelerated aging tests such as<br />
thermal aging, weathering etc. to have long and troubl trouble e free service. Necessary type test<br />
certificates for aging tests shall also be furnished.<br />
Following type of cable termination and joints shall be used for HT cables in indoor and<br />
outdoor applications:<br />
1. Tapex type<br />
2. Heat shrinkable type<br />
3. Pre moulded push on type<br />
Tapex type system<br />
The stress grading material shall be wrapped around the cable core, over lapping the edge of<br />
the outer conducting layer. The tape layer shall fuse together to form a compact rubber body<br />
around the stress grading ng material and cable core and thereby exert an active pressure on<br />
cable. This system shall be used for straight through joint only.<br />
Heat Shrinkable type system<br />
The stress control and grading wherever necessary shall be by means of semi semi-conducting heat<br />
shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces<br />
shall be achieved by using hot melted sealants or adhesives.<br />
Where such sealents or adhesives shall be exposed to high electrical stress, same shall be track<br />
resistant type.<br />
Pre-moulded moulded Push On type system<br />
Technical Specification:Sec-6, Electrical<br />
Page 21 of 97
Premoulded refers to moulded Ethylene Propylene Diene monomer rubber components.<br />
Sealing between the pre-moulded<br />
moulded push on material and cable surface shall be achieved by<br />
semi conducting pad which has cold fflow<br />
properties.<br />
Cable trays<br />
All the cable trays shall be prefabricated hot dip galvanised sheet steel trays.<br />
Prefabricated GI ladder type / perforated type cable racks/trays shall be used for laying of<br />
cables in cable trenches, cable spreader floors, cable cellers, through piping and while routing<br />
cables along technological structures etc. The factory made system of cable trays shall be<br />
complete in all respects with all standard accessories like reducers, bends, tees, risers etc. and<br />
shall be suitable for bolted type assembly at site so as to avoid any welding.<br />
The GI ladder type factory fabricated cable trays mmade<br />
ade from 2.5 mm thick hot welded steel<br />
sheets grade ‘o’ shall be provided as per IS : 2062. Hot dip galvanizing of 86 micron thick as per<br />
IS-2629, IS-4759 and IS- 209. Trays shall be of standard length of 3 M / 2.5 M with max<br />
deflection not exceeding 1/400 of span with sufficient load bearing capacity.<br />
Sheet steel thickness shall be minimum 2.5 mm. Rung hall be provided at every 250 mm. At<br />
one meter interval two rungs shall be provided side by side to facilitate clamping. Beside,<br />
Bidder shall also provide suitable pre pre-fabricated fabricated bends of cable trays at all the bending points<br />
as per actual site requirement.<br />
Horizontal tees and 900 bends shall be provided for each size of cable trays as per actual<br />
requirement at site.<br />
Lugs/connectors<br />
Cable termination shall hall be made with aluminium / tinned copper crimped type solderless lugs<br />
of approved make for all aluminium conductor and stud type terminals. The lugs shall be<br />
tinned copper compression type.<br />
Glands<br />
Cable glands to be supplied shall be nickel plated br brass ass double compression type. Glands for<br />
classified hazardous areas shall be certified by CMRS and approved by CCE, Nagpur.<br />
Cable glands for terminating PVC insulated armoured/unarmoured cables (as applicable) shall<br />
be made of brass and shall be of double compression type with necessary provision for armour<br />
earthing.<br />
Cable clamps<br />
All cables shall be clamped with GI (minimum size of 25x3mm) / Al (minimum size of 25x4)<br />
clamps and single core cables shall be clamped with trefoil clamps made of non non-magnetic<br />
materials.<br />
Technical Specification:Sec-6, Electrical<br />
Page 22 of 97
Specifications for miscellaneous materials<br />
Cable identification<br />
Cable tags shall be of 2 mm thick, 20 mm wide aluminium strap of suitable length to contain<br />
cable number as per cable schedule.<br />
Ferrules<br />
Ferrules shall be approved interlocked type & size to suit core size mentioned and shall be<br />
employed to designate the various cores of control cable by the terminal numbers to which<br />
the cores are connected, for ease in identification and maintenance.<br />
LT BUS DUCTS<br />
Electrical design<br />
Bus duct shall be suitable for 33KV/415 415 V, 3 phase, 50 Hz. neutral solidly grounded system and<br />
shall be covered with canopy if required to be installed outdoors outdoors. . Rated short time withstand<br />
current not less than the system short circuit level specified for 1 sec for 415V. Rated peak<br />
withstand current not less than 2.1 times the system short circuit level.<br />
Rated continuous current shall be as per requirement while in enclosure and at specified<br />
ambient temperature with maximum tempe temperature rature of bus bars limited to 85 85˚C. Neutral bus in<br />
LT with rating not less than half the rating of phase bus.<br />
The bus duct shall be rectangular, non non-segregated segregated phase, totally enclosed type.<br />
Insulation level<br />
Rate insulation voltage, one minute PF withstan withstand d voltage & impulse withstand voltage shall be<br />
as specified in technical particulars.<br />
Clearance in air (minimum)<br />
Clearance shall meet the minimum requirement specified in the technical particulars.<br />
Short circuit strength<br />
Rated short time withstand current not less than the system short circuit level specified for 1<br />
sec for 415V.<br />
Rated peak withstand current not less than 2.1 times the system short circuit level.<br />
Rate current<br />
Rated continuous current as specified while in enclosure and at specified ambient<br />
temperature with maximum temperature of bus bars limited to 85 85˚C.<br />
Neutral bus in LT with rating not less than half the rating of phase bus.<br />
Type test certificates<br />
Tenderer shall have type test certificates for similar bus ducts (same voltage level and same or<br />
higher current rating/fault level)<br />
Technical Specification:Sec-6, Electrical<br />
Page 23 of 97
Construction details<br />
Degree of protection for enclosure IP 52 or better for indoor installation.<br />
Enclosure material: : The minimum thickness shall be 2.5 mm. Tender shall include enclosure<br />
with the thickness required red for the shape and mechanical/ electrical strength point of view.<br />
Aluminium enclosure shall be provided for rating equal or more than 3000A. MS enclosure<br />
may be provided for LT bus ducts of rating less than 3000A. Provision shall also be provided<br />
for draining moisture.<br />
Maximum temperature of enclosure under rated operating conditions limited to 70 70˚C. Rubber<br />
bellows shall be provided at transformer end to take care of vibration.<br />
GI supporting structures, wherever required, shall be provided with necessary hardwares. In<br />
horizontal run of more than 10 mtr of bus ducts expansion joint with copper flexibles shall be<br />
provided at every 10 mtr interval.<br />
Maximum temperature of enclosure under rated operating conditions limited to 70 70˚C.<br />
Bolted covers with gaskets sshall<br />
hall be provided for easy inspection and access to insulators and<br />
bus bar joints.<br />
Gasketted (Neoprene) connections shall be provided between adjacent sections of metallic<br />
enclosure.<br />
Tinned copper flexible shall be considered for connection of bus ducts at transformer end as<br />
well as PCC end.<br />
Rubber bellows at transformer end shall be provided to take care of vibration.<br />
Seal off bushing and frames complete with bolts.<br />
Provision shall be provided for draining the moisture.<br />
Provision shall be provided for mounting the bus ducts on brackets.<br />
The bus duct shall include straight run, 90 degree bend, Phase crossover chamber,<br />
transformer end chamber, tinned copper flexible, wall frame assembly, rubber bellows and<br />
other accessories as per the requirements.]<br />
Busbars rs and connections.<br />
Bus bar material shall be EC grade aluminium alloy equivalent to E91E WP conforming to IS<br />
5082-1981.<br />
Final operating temperature of both bus bars and joints under continuous operation in<br />
enclosure limited to 85˚C ˚C by thermometer method. While designing the bus duct, site<br />
condition and solar radiation shall be taken care of.<br />
Bus bar arrangement shall be as per IS 5578 5578-1991. 1991. Phase identification shall be by colour at<br />
ends and at regular intervals. Busbar joints shall be of bolted type, cad cadmium mium plated with zinc<br />
bichromated high tensile steel bolts, nuts and spring washers and coated with oxide inhibiting<br />
grease prior to jointing.<br />
Copper flexible busbars shall be tinned. Copper flexible connections shall be provided for<br />
termination on equipment as well as on expansion joints.<br />
Bimetallic joints /strips shall be provided for jointing between dissimilar metals (if required).<br />
Bus bar support insulators of non non-hygroscopic hygroscopic material having impact and di di-electrical<br />
strength with an anti-trackin tracking contour.<br />
Bus duct of 3000 A and above rating shall be interleaved type.<br />
Bus conductor shall be given a coat of black mat point.<br />
Protective earthing<br />
Double earthing shall be provided for enclosure of bus ducts.<br />
Technical Specification:Sec-6, Electrical<br />
Page 24 of 97
Two numbers 50 x 6 mm GI flat earth buses sshall<br />
hall be provided running separately throughout<br />
the length of the bus duct, positively connected to the enclosure body of the bus ducts.<br />
Provision shall be there at each end of bus duct for terminating external earth conductor.<br />
Surface treatment<br />
Two Coats of synthetic enamel paint for indoor application shall be provided. Various standard<br />
procedures shall be followed in this regard for a quality work.<br />
Shade of paint<br />
Interior<br />
Exterior<br />
Technical particulars of LT busducts<br />
Applicable standard : IS - 8623<br />
Rated system voltage & frequency : 415V, 50 Hz<br />
Maximum ambient temperature : 50˚C<br />
System earthing<br />
System short circuit level(kA rms) : 50 KA<br />
Maximum voltage at which bus duct can operate<br />
continuously<br />
: 500 V<br />
Location of bus duct : Indoor<br />
Type of bus duct<br />
Material of main busbar : Aluminium Alloy<br />
Rated continuous current : As specified<br />
Earth bus material<br />
Bus duct support structure required :` To be provided<br />
Rated continuous current : As specified<br />
Rated short time withstand capacity : 50 kA<br />
Rated short time withstand duration : 1 sec<br />
Technical Specification:Sec-6, Electrical<br />
: Black/white/light yellow<br />
: As per technical particulars<br />
: Solidly grounded<br />
: Non Phase segregated<br />
: Aluminium<br />
Page 25 of 97
Insulation level<br />
Insulation class<br />
1 minute dry power frequency withstand : 2.5 kV<br />
1 minute wet power frequency withstand : 2.5 kV<br />
Support insulator<br />
Type<br />
: Non: hygroscopic SMC<br />
Maximum distance between supports<br />
Clearance<br />
:<br />
moulded/FRP<br />
To be worked out based on<br />
short circuit calculation.<br />
Phase to Phase<br />
Phase to earth<br />
Enclosure<br />
Material<br />
: AI (for >/= 3000 A) / MS<br />
(For < 3000A)<br />
Degree of protection (Minimum ) : IP52 – Indoor<br />
IP55-Outdoor Outdoor<br />
Thickness of material : 2.5 mm (minimum)<br />
Accessories<br />
Sea- Off bushing with wall frame (for wall crossing) : Only wall frame required<br />
Silica gel breather<br />
Space heaters<br />
Maximum temp allowed at max. ambient temp :<br />
Bus conductor<br />
Bus enclosure and support structure : 70˚C<br />
Technical Specification:Sec-6, Electrical<br />
: 1.1 kV<br />
:<br />
: 25.4m<br />
: 19.0m<br />
: Required<br />
: Required<br />
: 85˚C<br />
Page 26 of 97
Paint shade<br />
Phase crossover chamber/section :<br />
Exterior: Approved<br />
One set in one of the bus<br />
duct portion of each<br />
PCC/board.<br />
ERECTION, INSTALLATION ACCESSORIES<br />
All erection & installation accessories required for erection/installation of equipment are<br />
included in the scope of the tenderer.<br />
All the accessories and other erection materials required to complete the erection job in all<br />
respect shall be considered as part of the tenderer’s scope.<br />
Safety insulating mats of minimum thickness of 2 to 3 mm and of suitable voltage grade in<br />
front of all the PCCs/board and control panels shall be provided by the tenderer.<br />
4.4 ELECTRIC MOTORS<br />
General<br />
All motors shall generally conform to IS 325 and CBIP publication No. 140. Motors shall run<br />
continuously at rated output with + 5 % variation in frequency and + 10 % variation in voltage<br />
and + 10 % combined ned variation of frequency and voltage (absolute sum). Motor shall not stall<br />
due to momentary drop in voltage up to 70 % of rated value and shall run satisfactorily for five<br />
minutes at a supply voltage of 75 % of rated value.<br />
The limiting value of voltage at rated frequency under which motor will successfully start and<br />
accelerate to rated speed with load shall be assumed to be a constant value of 80 % rated<br />
voltage throughout the starting period.<br />
All motors shall be supplied with foundation bolts (if app applicable), licable), drain holes with plugs.<br />
Motors shall be designed for 50oC ambient temperature.<br />
Motors supplied shall be complete with required double compression cable glands, crimp type<br />
cable lugs and first filling of lubrication, name plate, etc. Lifting fac facility ility to be provided for all HT<br />
motors and big size LT motors. Guards shall be provided to prevent accidental touch for<br />
couplings and for free shaft ends shall be provided.<br />
Degree of protection for motor and bearings shall be IP IP-55 55 for indoor and IP55 wit with rain<br />
canopy and weather proof construction for outdoor. Motor shall be suitable to withstand at<br />
least three successive starts from system cold condition and two starts from hot condition at<br />
normal system voltage and frequency.<br />
The drive motor shall have e at least 15 % margin over the maximum power requirement of the<br />
driven equipment after considering all losses, de de-rating rating due to temperature and specific site<br />
and operating conditions.<br />
Technical Specification:Sec-6, Electrical<br />
: Interior:<br />
yellow<br />
Black/white/light<br />
Page 27 of 97
The motor may be subjected to sudden application of 150% rated voltag voltage e during bus transfer,<br />
due to phase difference between the incoming voltage and motor residual voltage.<br />
Motor handling facility and canopy<br />
Handling facility and space shall be provided for all the LT motors. Mono rail shall be provided<br />
and shall be extended up to open maintenance space for each of the LLT<br />
motors. Canopies<br />
made of GI sheet of minimum thickness of 2 mm shall be provided to each of the LT motors<br />
located outdoor.<br />
All motors, in general, including conveyor motors shall be 4 pole construction, hence speed of<br />
maximum 1500 rpm. However, motors for travel drives of yard machines shall be of 6 pole<br />
construction, hence speed of 1000 rpm rpm.<br />
LOW VOLTAGE INDUCTION MOTORS<br />
Frame sizes shall be as per IEC. Casing feet shall be integral with the motor body. For motor of<br />
rating up to 5 kW, ball bearings shall be used for both DE & NDE end. For ratings above 5 kW<br />
the DE end shall be provided with ball/roller bearing and NDE end shall be provided with ball<br />
bearing. Bearings shall be suitable for running of motor in either direction. Motors 110 kW and<br />
above shall be provided with bear bearing ing temperature indicators. Explosion proof/increased safety<br />
design for explosion hazardous areas as per requirement.<br />
Terminal box shall be of suitable dimension to receive aluminium cables and shall be rotatable<br />
by 4x90 o<br />
Terminal box shall be of suitable dimension to receive aluminium cables and shall be rotatable<br />
Cooling of motors shall be of TTEFC<br />
EFC (IC0141) design. Ventilation shall be effective irrespective of<br />
direction of rotation.<br />
Motors shall be dynamically balanced. Vibration intensity shall be limited as per IS 12075<br />
(1987). Continuous noise level should not exceed 75 dBA at a distance of 1.0 m from motor<br />
body.<br />
Starting current shall be less than or equal to six times the rated current with IS tolerance.<br />
Motors shall have class ' F' insulation with temperature limited to class ‘B’. Permissible<br />
temperature shall be limited to 120oC in case of class 'B' insulation and 130<br />
insulation as measured by resistance method. Class H insulation shall be considered in specific<br />
cases. Limiting temperature shall also be limited to 130 deg C in case of Class H insulation as<br />
measured by y resistance method.<br />
o C in case of class F<br />
insulation as measured by resistance method. Class H insulation shall be considered in specific<br />
cases. Limiting temperature shall also be limited to 130 deg C in case of Class H insulation as<br />
Space heaters shall be provided for all motors rated above 30kW. Adequate handling space<br />
shall be provided for all the big LT motors.<br />
HIGH VOLTAGE MOTORS<br />
Technical Specification:Sec-6, Electrical<br />
Page 28 of 97
Degree of protection for motor and bearings shall be IP IP-55 55 for indoor use aand<br />
IP-55 with<br />
removable rain canopy for outdoor use.<br />
Vibration monitor with contacts shall be provided at the DE end of motor bearing for motors<br />
of ratings 1000 kW and above. On line vibration measurements shall be provided for larger<br />
and critical motors.<br />
All motors shall be provided with Bearing (DE & NDE) temperature detectors and 6 nos. stator<br />
winding temperature detectors, RTDs for monitoring alarm and trip conditions. Temperature<br />
shall be displayed on VDU's. RTD's shall be of PT100 type and suitable for digital scanner or<br />
PLC input requirement.<br />
Digital igital type bearing temperature indicator for all motors shall be provided for local<br />
measurement with adjustable alarm contacts.<br />
Each terminal box shall have fault withstand capacity equal to at least rated short circuit level<br />
of the system voltage for 00.25<br />
.25 sec and shall have pressure relief device. Terminal boxes shall<br />
be suitable for termination of FRLS, XLPE cables with cable end seals. Separate terminal boxes<br />
shall be provided for space heaters, RTDs for winding/ bearings temperatures, vibration<br />
monitors etc.<br />
All terminal boxes shall be provided with two earthing studs for termination of protective<br />
earth conductor. Box covers shall be provided with handle to facilitate easy removal.<br />
Low kW range machines may be of TEFC (IC0141) design. For higher rrating,<br />
ating, type of cooling<br />
shall be CACA (IC0151). General accessories like flow switches, space heater, terminal boxes,<br />
drain plug, dowel pipe cable lugs, glands clamp etc. shall be provided.<br />
Vibration intensity shall be limited to values as stipulated in tthe<br />
he IS. Motor shall be designed to<br />
withstand the vibration produced by the driven equipment. Continuous noise level should not<br />
exceed 75 dBA at a distance of 1.0 m from the motor body.<br />
Electrical design shall be same as in case of low voltage induction mot motors ors except the following:<br />
All motors shall have class F insulation but with total permissible temperature limited to 1300C<br />
(as measured by resistance method). Starting current of the drives shall be limited to six times<br />
of full load current.<br />
Motors of rating 1000 kW and above shall be provided with differential protection. Matching<br />
CT and cabling up to switchgear shall be provided by the Bidder.<br />
Motors shall be capable of withstanding locked rotor current at 110 % rated voltage for at<br />
least 2.5 sec (for or motors having staring time up to 20 sec) or 5 sec (for motors having staring<br />
time more than 20 sec) longer up to than starting time under rated load condition at 80 %<br />
voltage. If above condition is not possible then, centrifugal type speed switch to be provided<br />
Technical Specification:Sec-6, Electrical<br />
Page 29 of 97
which has to be connected to the motor protection relay. Speed switch shall be capable to<br />
withstand 120 % of the overspeed in either direction.<br />
Insulation of motors shall be designed conforming to IEC 34 34-15/ 15/ 1990. Gland plate for single<br />
core cable shall be non-magnetic magnetic type.<br />
All motors shall have individual dedicated handling and lifting facilities preferably by dedicated<br />
electric hoist.<br />
4.5 POWER DISTRIBUTION BOARD /AUXILIARY POWER DISTRIBUTION BOARD<br />
POWER DISTRIBUTION BOARD<br />
PDB shall be suitable for 415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec) indoor<br />
type.<br />
Board shall be single front, metal clad, front matched, dust and vermin proof, draw draw-out<br />
(incomer & bus coupler) / fixed (outgoing), fully compartmental<br />
compartmentalized ized and extensible on both<br />
sides, IP54 type enclosure.<br />
Shall have isolated busbar chamber for main busbar at the top, running throughout the length<br />
of the board. Chamber shall have removable cover.<br />
Busbars shall have same cross section throughout the length . Rating of the neutral busbar<br />
shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the<br />
length of the panel.<br />
Shall have Moulded case circuit breaker (MCCB) triple pole, air break type with independent<br />
manual quick make and quick break type. MCCB shall be capable of breaking rated current at<br />
0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system.<br />
Generally PDB will have following feeder arrangement. However, details of feeders e.g no.<br />
type and capacity, etc shall be finalized during detailed engineering:<br />
Incomer : ACB of 630A (or as per requirement)<br />
Outgoings : MCCBs of 400/250/125A/63A/16A (or as per requirement)<br />
Number and capacity of PDB given in the enclosed Single Line Diagram is minimum and<br />
indicative. Bidder shall provide as per actual load requirement and same shall be finalized<br />
during detailed engineering.<br />
AUXILIARY POWER DISTRIBUTION BOARD<br />
Aux. PDBs shall be suitable for 415V, 3 phase, 4 wire wire, , 250A, 50 kA (short time rating for 1 sec.)<br />
indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof,<br />
non-drawout, drawout, fully compartmentalized and extensible on both sides, IP54 type enclosure.<br />
Technical Specification:Sec-6, Electrical<br />
Page 30 of 97
The other technical particula particulars rs of aux. PDBs shall be similar to PDB. The tentative feeder<br />
arrangement shall be as follows. However, details of feeders e.g no. type and capacity, etc<br />
shall be finalized during detailed engineering:<br />
Incomer : MCCB of 250A (or as per requirement)<br />
Outgoings : MCCBs of 125A/63A/16A (or as per requirement)<br />
4.6 33 KV ON-LOAD LOAD ISOLATOR WITH EARTH SWITCH<br />
Technical features<br />
• Triple pole air break, fault make load break type.<br />
• Independent manual, quick make, quick break type<br />
• Mechanical trip device<br />
• Mechanical “ON”- “OFF” indicator<br />
• Suitable to connect cables on incoming and outgoing side.<br />
• Shall have 3 NO and 3 NC aux. contacts.<br />
• Earthing switch shall be provided on transformer side having rating same as that of main<br />
switch.<br />
• Totally enclosed, floor mounted, outdo outdoor kiosk type with IP-55 55 protection along with a<br />
canopy<br />
• Shall have padlocking facility<br />
• Panel door shall be mechanically interlocked so that isolator cannot be closed on open<br />
position of door and door cannot be opened on close position of isolator.<br />
• Earthing switch shall be interlocked with isolator blades to prevent simultaneous closing of<br />
both.<br />
• Isolator shall be interlocked with Purchasers upstream breaker.<br />
Technical particulars<br />
1. System voltage<br />
2. System earthing<br />
3. Type<br />
4. Nos. of poles<br />
5. Continuous current<br />
6. carrying capacity<br />
7. S/c withstand capacity : 25KA for 3 sec/43.7 kA for 3 sec.<br />
8. Pf withstand voltage : 75/20 kV<br />
9. Impulse withstand voltage<br />
10. Termination<br />
11. Incomer<br />
12. Outgoing<br />
4.7 HT/LT TRANSFORMERS (OIL OIL IMMERSED TYPE)<br />
4.7.1 Design<br />
Design shall be generally as per IS 1886. Transformer shall be suitable for rated frequency 50<br />
Hz, -5%, 5%, +5%. Insulation level shall be designed according to the voltages specified below:<br />
Description<br />
Technical Specification:Sec-6, Electrical<br />
:33kV<br />
: Resistance earthed<br />
: Air break, fault make & load break type<br />
: Three<br />
: As per requirement<br />
withstand voltage : 170/60 kV<br />
: To accept cables of required size<br />
: To accept cables of required size<br />
33/.415 kV<br />
Page 31 of 97
Capacity<br />
Nominal voltage (kV) 33<br />
Max system voltage (kV) 35<br />
Power frequency withstand voltage (kV) 75<br />
System earthing<br />
No. of phases<br />
Frequency<br />
Impulse test withstand voltage (kV) 170<br />
Short time current rating (for all current 25 kA for 3 sec<br />
carrying parts)<br />
Fault level (3 phase symmetrical) 25kA<br />
Type of Cooling<br />
Connection HV winding DELTA<br />
Connection LV winding STAR<br />
Connection Symbol<br />
HT/LT transformers shall be of the latest design, oil immersed type as per IS : 1886 and testing<br />
as per IS 2026 part I. . All dry type air natural transformers shall be suitable for indoor use line<br />
up with power control centre as unit type.<br />
Bidder shall ensure that manufacturer shall have his own in in-house house core cutting facilities on<br />
CNC machines.<br />
Special care shall be taken ken to make enclosed equipment proof against entry of rats, lizards and<br />
other creeping reptiles which may create electrical short short- circuits inside live equipment. The<br />
design of each transformer shall be such that the risk of accidental short short-circuits due to<br />
reptiles or vermin shall be obviated.<br />
The transformer shall be of cast resin type. The tap changing arrangement shall be of<br />
removable link type.<br />
Each transformer shall be suitable for operation at full rated power on all tappings without<br />
exceeding the temperature rise of 800C over the ambient of 50<br />
shall be F.<br />
o Each transformer shall be suitable for operation at full rated power on all tappings without<br />
C. Minimum class of Insulation<br />
The transformers shall be designed to be capable of withstanding, without injury, the thermal<br />
and mechanical effects of short short-circuits between phases or between n phase and earth at the<br />
terminals of any winding with full voltage applied across the other winding. All transformers<br />
shall be capable of withstanding specified through fault current for minimum of 2 seconds as<br />
per IS: 2026 (Part-1).<br />
The transformers shall all be designed to suppress harmonic currents, especially the third and<br />
fifth, so as to eliminate distortion in the wave form and consequent additional insulation<br />
Technical Specification:Sec-6, Electrical<br />
Low resistance earthed<br />
3<br />
50 Hz<br />
ONAN<br />
Dyn 11<br />
Page 32 of 97
stress, noise on communication system and undesirable circulating currents between the<br />
neutrals ls at different transformer stations.<br />
The Transformers shall operate with minimum noise and vibration. The cores, protective<br />
housings and other structural parts shall be properly constructed and windings properly<br />
braced so that the mechanical vibrations are kept to the minimum, thus reducing the noise. To<br />
this effect, the laminations shall also be bonded together with appropriate resin. The core core-coil<br />
assembly shall also be fixed in such a manner that no shifting or deformations occur during<br />
shipment or installation.<br />
Each transformer shall be designed for minimum no no-load load and load losses within the economic<br />
limit.<br />
All electrical connections and contacts shall be of ample section for carrying the rated current<br />
without excessive heating.<br />
All mechanism shall all be of stainless steel, brass, gunmetal or other suitable material to prevent<br />
sticking due to rust or correction. If any temporary fitting is fixed to the protective housing of<br />
the transformer for transporting / handling purpose, these shall be identica identical as well as<br />
instructions and illustrated drawings shall be furnished to facilitate their removal at site after<br />
erection.<br />
4.7.2 Core<br />
The framework, clamping arrangement and general structure of the cores of each transformer<br />
shall be of robust construction and shall be capable of withstanding any shock to which they<br />
may be subjected during transport, installation and operation. The assembled core shall be<br />
securely clamped on the limbs and the yoke to build up a rigid structure. The clamping<br />
pressure sure shall be uniform over the whole of the core and so adjusted as to minimize noise and<br />
vibration in the core when the transformer is in operation. The framework and the core bolts<br />
shall be effectively insulated from the core so as to reduce the eddy eddy-currents rents to the minimum.<br />
The magnetic circuit shall be built of high quality, low loss, non non-ageing. ageing. Cold rolled, grain<br />
oriented, silicon steel laminations (CRGO Prime Grade) having excellent magnetic properties<br />
and specially suitable as core material. Lamina Laminations tions shall be insulated from each other with<br />
material having high inter inter-lamination lamination insulation resistance and rust inhibiting property and<br />
also capable of withstanding stress and mechanical vibration.<br />
Necessary cooling ducts shall be provided for heat dis dissipation sipation from the core so that the<br />
anticipated maximum hot spot temperature in the core shall not be injurious to any material<br />
used in the core assembly.<br />
The core-clamping clamping frame shall be provided with lifting eyes having ample strength to lift the<br />
complete te core and winding assembly.<br />
Suitable provision shall be made in the dry type transformers for effective core earthing.<br />
Technical Specification:Sec-6, Electrical<br />
Page 33 of 97
4.7.3 Winding<br />
The coils used for transformer winding shall be made of insulated, continuous and smooth<br />
electrolytic copper conductors of high conductivity and of 99.9% purity. Similar coils shall be<br />
connected by accessible joints brazed or welded and finished smooth. No corona discharge<br />
shall result on the winding during induced voltage test as specified in applicable standard.<br />
The insulating materials for dry type transformers shall be of type not inferior to Class “F”. All<br />
insulating materials shall be of proven natu nature re and shall be suitable for the suitable for the<br />
limits indicated in the applicable standards as well as the maximum possible winding<br />
temperature and shall not deteriorate when the transformer is operated continuously at its<br />
specified rating at the specif specified ambient temperature.<br />
The inter-turn and inter-coil<br />
coil insulation shall be so designed that the dielectric stress is<br />
uniformly distributed throughout the winding under all operating conditions.<br />
The windings shall be dry cast resin type.<br />
The transformer er windings shall be designed for basic Impulse insulation level not lower than<br />
those specified above.<br />
4.7.4 Protective Housing for Dry type Transformer<br />
Dry type transformer shall be provided with suitable protective sheet steel housing, with<br />
minimum IP P 23 degree of protection for the enclosure. The housing shall have ventilation<br />
louvers provided with wire mesh screens and shall be supplied with suitable lifting lugs. Safety<br />
limit switches shall be provided and wired in such a way that the incoming supp supply may be<br />
disconnected whenever any one of the sides of the enclosures are opened with the<br />
transformer in energized condition.<br />
Sufficient precautions shall be taken so that doors are closed fully. Door locks shall be<br />
provided and keys shall be universal type.<br />
4.7.5 Off-Circuit Circuit Links<br />
The off-circuit circuit tapping links shall be provided on the HV side with appropriate register plate to<br />
show the link location. The links shall be provided with a separate door for access. The door<br />
shall be provided with appropriate safely limit switches which will trip the transformer HV / LV<br />
sides in open condition.<br />
4.7.6 Cooling<br />
The cooling system for or dry type transformers shall have Air Air-Natural Natural (AN) cooling.<br />
4.7.7 Neutral Bushing Current Transformers<br />
Technical Specification:Sec-6, Electrical<br />
Page 34 of 97
CTs for back up earth fault (51N) as well as for restricted earth fault (64) shall be provided on<br />
the neutral end.<br />
Neutral bushing CT shall be re removable movable at site without opening transformer tank cover/active<br />
part. Secondary leads of 4 sq.mm shall be brought to a weatherproof terminal box and from<br />
there to the marshalling box.<br />
Neutral bushing CTs of suitable ratio, class and adequate burden shall be provided by the<br />
Bidder to cater to the requirement of all standard protection associated with the transformer<br />
of this capacity. CTs for REF shall be PS class.<br />
4.7.8 Marshalling Box<br />
Enclosure mounted marshalling box to be supplied with all controls instruments, protection,<br />
accessories & fitting as required for the transformer and its associated ancillaries. The box<br />
shall be made of 2 mm sheet steel with IP 54 degree of protection.<br />
Sheet heet steel marshalling box of dust dust-proof proof design shall be provided to accommodate<br />
temperature measurement as well as control system, as may be necessary. The box shall be<br />
mounted on the transformer enclosure and shall be provided with internal lighting, spa space<br />
heater and thermostat with their controls accessible from outside.<br />
The box shall be provided with suitable hinged steel doors at the front and all equipment shall<br />
be so placed as to accessible from the front. Provision shall be made for padlocking the doors.<br />
Suitable glazed windows shall be provided at appropriate positions to give an unrestricted<br />
view of the temperature indicators etc, without opening the door.<br />
All initiating tiating “contacts” of shall be wired up to the terminal block in the box. All control wiring<br />
shall be with 1.1kV grade stranded PVC insulated armoured copper cable of 2.5 sq.mm.<br />
Terminal blocks shall have 20% spare capacity.<br />
The external connections betw between een the apparatus on the transformer and the marshalling box<br />
shall be done with suitable heat resisting copper conductor cables of core size not less than<br />
2.5 sq. mm. The cables required to connect the marshalling box and transformer accessories<br />
shall be adequately dequately protected against mechanical damage. There shall be no joints or tappings<br />
between two terminations of any cable. Not more than two terminations shall be made at any<br />
one terminal. All terminations at various devices and terminal blocks shall be pr provided with<br />
plastic ferrules having engraved numbers. All terminals and links shall be so arranged as to<br />
facilitate easy checking and testing of relays, instruments etc. Provision shall be made for<br />
termination of power cables as well as multi multi-core control cables in the marshalling box.<br />
The control circuit terminal blocks provided for external cable connections shall be provided<br />
with screw type terminals and shall be complete with terminal screws, links, cable carries etc,<br />
Each terminal block shall have 20 20% % spare terminals and all wiring shall be such that it is easily<br />
identifiable and accessible for maintenance.<br />
Technical Specification:Sec-6, Electrical<br />
Page 35 of 97
All devices, wires and terminal blocks within the marshalling box shall be clearly identified by<br />
symbols corresponding to those used on relevant schematic or wiring diagrams.<br />
Enclosure class of marshalling box shall be IP IP-55.<br />
Terminal Arrangement HV/LV terminals shall be suitable for cables considered.<br />
4.7.9 Transformer Fittings & accessories<br />
Each transformer shall be fitted with all standa standard rd and special fittings and accessories and shall<br />
include but not be limited to the following:<br />
• Inspection covers.<br />
• Off circuit links in the primary for voltage variations.<br />
• Rating, diagram and tap connection plates.<br />
• Terminal marking plate<br />
• Two nos. earthing g terminals with lugs.<br />
• Winding temperature detectors with microprocessor based Temperature scanners with<br />
digital read out and requisite set of remote signaling contact for alarming/tripping<br />
operation.<br />
• Under carriage with bi bi-directional directional rollers with locking and bolting devices.<br />
• Marshalling box complete with all instruments, accessories and fittings as required for the<br />
transformer.<br />
• Off load tap changers with position indicators and padlocking faciliy<br />
• Neutral eutral bushing CTs with terminal arrangement<br />
• HV cable box with disconnecting chamber and supporting arrangement<br />
• LV side flanges suitable to receive busducts<br />
• Jacking pads<br />
• Haulage lugs<br />
• Flat base, foundation bolts and clamps and other accessories as requ required ired<br />
4.7.10 Details of Fittings<br />
Requisite number of Resistance type temperature detectors shall beprovided with solid state<br />
type temperature signaliser for dry type transformer. The temperature signaliser shall be<br />
provided with two sets of contacts, on one e for alarm and the other for circuit circuit-breaker trip. The<br />
signaliser shall be provided with digital read out for the temperature being measured and for<br />
the zone where the current measurement.<br />
Two nos. earthing terminals of adequate mechanical and electrical capacity shall be provided.<br />
Separate earthing terminals shall also be provided on the enclosure, marshaling box and<br />
terminal boxes.<br />
Rating and diagram plates shall be provided as per adopt adopted ed standards for each transformer.<br />
Lifting lugs and hauling holes as required shall be provided for the transformer as well as for<br />
the enclosure.<br />
Technical Specification:Sec-6, Electrical<br />
Page 36 of 97
Suitable under-carriage carriage fitted with flat rollers shall be provided. The rollers shall have<br />
adequate mechanical ical strength and shall be so designed that the transformer shall roll without<br />
undue effort after it has remained immobile for a long period. The edges of rollers shall be<br />
duly rounded off to permit skidding of transformer on flat surface.<br />
4.7.11 Technical Particulars of HT Transformers (33KV/ (33KV/440V)<br />
1.0 General<br />
1.1 Make<br />
1.2 Type<br />
1.3 Service<br />
1.4 Duty<br />
: Continuous<br />
1.5 Degree of Protection : IP:55<br />
1.6 Reference Standard : IS/IEC Equiv<br />
2.0 Rating<br />
2.1 Rated output<br />
2.2 Quantity<br />
2.3 Type of cooling<br />
2.4 Rated voltage Volt :<br />
H. V.<br />
: 33kv<br />
L. V.<br />
2.5 No. of phases<br />
2.6 Rated Frequency Hz : 50<br />
2.7 Vector group reference : Dyn11<br />
2.8 Connection<br />
H. V.<br />
L. V.<br />
LVn<br />
2.9 Insulation<br />
H. V.<br />
L. V.<br />
2.10 Insulation level kVp/kV<br />
H. V.<br />
L. V.<br />
3.0 Temperature<br />
3.1 Reference ambient temp. : 50 0 C<br />
3.2 Temp. rise over reference ambient<br />
a) Top Oil measured by : 50 0 C Thermometer<br />
b) In winding by<br />
4.0 Tappings<br />
4.1 Type<br />
4.2 Taps<br />
4.3 Taps provided on HV winding : Yes<br />
5.0 Method of earthing : Neutral Grounding Resistor<br />
Technical Specification:Sec-6, Electrical<br />
: Reputed Make<br />
: Two winding<br />
: Outdoor<br />
: As per load calculation<br />
: 2 nos<br />
: ONAN<br />
: 440V<br />
: 3<br />
: Delta<br />
: Star<br />
: Grounded through NGR<br />
: Uniform<br />
: Uniform<br />
: 75/28<br />
: 40/10<br />
:<br />
: 55 0 C Resistance<br />
: Off circuit Tap Changer (OCTC)<br />
: ±10% in steps of 2.5%<br />
Page 37 of 97
6.0 Neutral grounding Resistor<br />
6.1 Rated current<br />
6.2 Application<br />
6.3 Service<br />
6.4 Resistor material & connection : Punched stainless steel grid element type<br />
6.5 Maximum allowable<br />
over ambient 50 0 allowable temperature rise<br />
C<br />
6.6 Enclosure degree of protection : IP - 55<br />
7.0 System Fault Level<br />
7.1 H. V.<br />
7.2 L. V.<br />
8.0 Conductor material : Electrolytic grade copper<br />
9.0 Creepage distance mm/KV : 3lmm/kV<br />
10.0 Terminal connections<br />
10.1 H. V.<br />
10.2 L. V.<br />
11.0 Marshalling box Degree of protection : IP:55<br />
Power frequency to withstand voltage of 33 KV system should be 75KV.Impulse KV.Impulse test voltage<br />
should be 170KV for system voltage of 33 KV.<br />
4.7.12 Technical Particulars of Dry type transformers (LT)<br />
1. Rated capacity<br />
2. Cooling<br />
3. Duty<br />
4. Voltage ratio (HV/LV)<br />
5. Impedance<br />
6. Winding connection<br />
7. Vector group<br />
8. Termination<br />
9. Tap changer<br />
10.Range of tap changer<br />
11. Short circuit level<br />
12. Earthing system (33 kV)<br />
13. Earthing system (415 V)<br />
14. Bushing CTs<br />
15. Ratio of neutral bushing CTs<br />
16. Impulse test withstand voltage (HT/LT)<br />
17. Power frequency rated short duration<br />
18. Temp. rise above 50 0 C<br />
19. Overload capacity<br />
20. Auxiliary supply voltage<br />
Technical Specification:Sec-6, Electrical<br />
: Less than 100A for 10 seconds<br />
: Grounding through Resistor<br />
: Outdoor<br />
: As per Standards<br />
: 25kA<br />
: 50kA<br />
: Segregated phase bus duct/Cable<br />
: Segregated phase bus duct/Cable<br />
: As per requirement<br />
: AN<br />
: Indoor<br />
: 33/0.440kV<br />
: As per IS<br />
: Delta/star<br />
: Dyn11<br />
: HV : 33KV cable<br />
LV : Cable<br />
: OFTC<br />
: +5% in 5 steps @2.5%<br />
: 25 kA (33kV) for 3 sec<br />
: Low Resistance earthed<br />
kV) : Low Resistance earthed<br />
13. Earthing system (415 V) : Solidly earthed<br />
: On neutral<br />
al bushing CTs : As required for Standby E/F Restricted E/F<br />
16. Impulse test withstand voltage (HT/LT) : As per IS/IEC<br />
17. Power frequency rated short duration : As per IS/IEC withstand voltage (HT/LT)<br />
: 80 0 : As required for Standby E/F Restricted E/F<br />
: As per IS/IEC withstand voltage (HT/LT)<br />
C<br />
: As per ANSI standard<br />
20. Auxiliary supply voltage : 240V AC<br />
Page 38 of 97
21. Suitable for parallel operation : Yes<br />
4.8 VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVE<br />
Basic design particulars<br />
All VVVF Converters shall have Digital Control Technology with vector less control. VVVF shall<br />
communicate to basic automation system.<br />
Type of connection<br />
• Three phase frequency converters with rectification and inversion i.e. variable voltage and<br />
variable frequency output with current source / voltage source (PWM) inverters.<br />
• Line reactors for harmonic and noise suppression<br />
• Suitable for 415 V , 3 phase ,50 Hz , 4wire neutral earthed system<br />
Overload capacity<br />
• 150% of the rated current for 1 minutes followi following ng 100% load & to meet the drive overload<br />
capacity.<br />
• Efficiency more than 95% at full load<br />
• Suitable to withstand vibrations more than 0.59.<br />
• Output frequency : 5-50 Hz (Constant torque)<br />
50-100 Hz (Constant power)<br />
• Ramp rate: Linear acceleration and dec deceleration eleration adjustable independently.<br />
Power components<br />
The main power components of the VVVF equipment shall have the following incoming AC<br />
side:<br />
• Matching input power transformer / reactor<br />
• AC line surge suppression network.<br />
• ACB/MCCB<br />
• Line contactors<br />
Converter –Inverter Inverter Equipment<br />
• Thyristor converter bridge for AC/DC<br />
• DC link circuit with reactor/capacitor<br />
• Inverter bridge for DC/AC<br />
• PLC to take care of interlocking and sequencing etc.<br />
• Mimic panel where drive is HT<br />
Load side<br />
• Filter network<br />
• Step-up up transformer, as required<br />
• Isolator and over over-load relay for each motor.<br />
By-pass Arrangement<br />
Technical Specification:Sec-6, Electrical<br />
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• By-pass pass arrangement shall be provided to operate the motor in case of failure in<br />
frequency converter.<br />
Thyristor converter<br />
• Minimum ratings of thyristor cells<br />
• PIV rating : 2.5 times the peak value of line voltage<br />
• dv/dt rating : 200V/microsecond for voltage control and<br />
1000V/microsecond for inverter control.<br />
• di/dt rating : 100A/ microsecond.<br />
Protective features<br />
• AC line surge suppression net network<br />
• Under voltage in supply network<br />
• Phase sequence protection and monitoring<br />
• RC snubber network across each thyristor cell<br />
• Thyristor fuse failure<br />
• Under voltage in Dc line<br />
• Over voltage in Dc line<br />
• Over speed monitor<br />
• Over load<br />
• Earth fault<br />
• Instantaneous over current<br />
• Transformer fault<br />
• Cooling fan failure – Stall monitor for motor Alarms<br />
Above condition shall be annunciated. Following warning signals shall also be provided as<br />
minimum in addition to above.<br />
• Motor fault (winding / bearing te temperature, vibration) as applicable<br />
• Loss of frequency command<br />
• Meters, Switches, Lamps<br />
Following shall be provided as minimum meters:<br />
• Input volt meter and ammeter with selector switches<br />
• Output voltmeter and ammeter with selector switches.<br />
• Output frequency ncy meter<br />
• Selector switches, pushbuttons, and lamps as required.<br />
• kW meter for drive ratings above 200 kW Regulation and controls<br />
Control facilities shall include following but not limited to:<br />
• Reference speed setter<br />
• Ramp generator<br />
• Speed feed back<br />
• Current feed back<br />
• Trigger module<br />
• Pulse transformers<br />
• Logic control module<br />
Technical Specification:Sec-6, Electrical<br />
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• Sequence module<br />
• Zero speed/over speed monitor as applicable<br />
• V/f control<br />
• Current limiter<br />
• Counter current/ regenerative braking unit as applicable<br />
• active electronic components used shall be of industrial grade hermetically sealed<br />
• Regulated power supply for reference setting:<br />
Voltage variation of (+/-) ) 0.1 % with an input variation of +10% - 15%<br />
Steady state regulation of (+/ (+/-)0.25% % guaranteed against 100 to 200 % load disturbance and +<br />
3%, -6% 6% input supply frequency variation.<br />
• Facility to accept speed reference from computer/ programmable controller<br />
Construction features<br />
• Floor mounted, free standing<br />
• Dust and vermin proof<br />
• Sheet steel clad<br />
• Minimum 2.5 mm thick for panels.<br />
• Minimum 2.0 mm thick for doors and side covers.<br />
• Suitable to withstand vibrations to be encountered in steel plant application.<br />
• Cubicles with illumination lamps, door switches, space heaters and adequate sockets<br />
for soldering.<br />
• All control blocks plug –in-type with necessary test sockets.<br />
• Units shall be self contained and serviceable.<br />
Enclosure and Ventilation<br />
• Enclosure conforming to IP IP-52 or more with weather proof enclosures<br />
• Units shall be provided with cooling fans and louvers at the bottom sides. All louvers shall<br />
have fine mesh behind them.<br />
• Ventilation through individual ventilation ducts, from bottom not acceptable.<br />
4.9 RELAY PANELS<br />
Relay panels (RP) housing aux. contactors, timers, relays, etc. shall be provided for equipment<br />
control, sequential control, monitoring, safety alarm signals, annunciation signals, interlocking<br />
of drives ,signal exchange, interface with future system etc. shall be provided. Constructional<br />
features of R.P. shall be similar to MCC. At least 10 % spare auxiliary contactors, timers &relays<br />
shall be provided in the relay panel whose contacts and coils shall be wired up to terminals. terminals.10<br />
% spare terminals shall als also be provided. 10 % of auxiliary contactors, timer and relays shall be<br />
provided as spares which will be wired upto terminals.<br />
4.10 PROGRAMMABLE LOGIC CONTROLLERS (PLC)<br />
Power supply system<br />
Technical Specification:Sec-6, Electrical<br />
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Input power supply shall be fed through UPS system. However, PLC shall be capable of<br />
withstanding power supply from electrical feeder. Alternate source of power supply<br />
arrangement or second UPS shall be provided to take care of the situation when the original<br />
UPS fails.<br />
Built-in in power supply units<br />
• Suitable for the e power supply system as specified above.<br />
• Independent units for the following:<br />
• CPU and associated electronic units<br />
i) sensing the status of input devices<br />
ii) driving outputs if outputs are relays<br />
iii) Insulation level 2.5 kV for 1 minute.<br />
• Protection against t surge protection & short circuit<br />
• Electronic over current protection with feedback feature.<br />
Central processor unit<br />
• Modular and plug-in in type<br />
• 32 bit microprocessor based<br />
• Scan time 2 m sec per one K Words of instructions or better<br />
• Provision to latch desired outputs.<br />
• The processor shall have in in-built built provision for examining input conditions, compare,<br />
compute, logical, conversion from/ to BCD, bit manipulation, block memory manipulation,<br />
diagnostic, shift, sequencing, conditional jumping, subroutine instructions.<br />
• In-built built PID instruction shall be preferred over separate PID hardware Module.<br />
• Timer & counter modules shall be provided wherever required.<br />
Memory units<br />
Modular and plug-in type<br />
• Word length 32 bit as per CPU<br />
• Expandable in blocks of 4K Words<br />
• Minimum size 16K Words<br />
• EPROM/ RAM with battery back back-up<br />
• Back-up up battery shall be as follows:<br />
i) Rechargeable Ni-Cd Cd batteries with necessary charging circuit, Lithium or any other<br />
internationally acceptable type.<br />
ii) Able to retain memory for a minimum of 1 year with no power applied to the controller.<br />
Input units<br />
• High density (32/16 Channels), modular and plug plug-in type<br />
• Insulation level of 1.5 kV<br />
• Input interrogation voltage 24V DC<br />
• Discrete input units shall l have the following:<br />
i) Filter to take care of contact bounce<br />
ii) Opto-isolation isolation to isolate the input device from the controller<br />
Technical Specification:Sec-6, Electrical<br />
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iii) LED status indication iv) BCD input units suitable for four digit input<br />
• Analog input units shall be as follows:<br />
i) Suitable for 4-20 20 mA / 00-10V<br />
/ +/-10V inputs<br />
ii) With necessary A/D converter<br />
• Pulse/ frequency input module shall have range up to 50 kHz. For very high frequency<br />
applications, the range shall be up to 1 MHz.<br />
Output units<br />
• High Density (32/16 Channel), modular and plug plug-in type<br />
• Discrete output units shall be as follows:<br />
i) Opto-isolated isolated outputs with insulation level of 1.5 kV<br />
ii) Rated for 24V DC, 2A<br />
• Power devices like contactor or odd voltage actuating device shall b bbe<br />
actuated through<br />
relays<br />
• LED status indication<br />
• BCD output units shall be as follows:<br />
i) Suitable for four digit output<br />
ii) Rated to drive seven segment LED displays<br />
iii) With insulation level of 1.5 kV<br />
• Analog outputs shall be as follows<br />
i) Suitable for 4-20mA/ 20mA/ 00-10V/<br />
+/-10V 10V outputs capable of driving Digital / Analog Panel<br />
Meters<br />
ii) With necessary D/A converters<br />
iii) With insulation level of 1.5 kV<br />
iv) Any special requirement to control field devices shall be met by using separate<br />
interface modules<br />
PC based programming unit:<br />
• PC used for Programming Terminal shall be commercial grade and latest available in the<br />
Suitable for developing programs in ladder diagram/ block diagram or statement form<br />
• With facility for loading the program from floppy<br />
• The terminal shall be capable of developing multiple programs offline without connecting to<br />
the programmable controller.<br />
Self diagnostic features<br />
• Parity errors, cycle errors and under voltage<br />
• Failure in central processor unit, memory and power sup supply.<br />
• Indication of type of failure<br />
• Automatic turning OFF of all outputs or optionally holding of all outputs in their last state on<br />
failure detection.<br />
Additional features<br />
• Fully pre-programmed<br />
• Connection of field devices with input units throu through ordinary multi-core<br />
copper control<br />
cables of 1.5 sq. mm size, upto a length of 500 m.<br />
Technical Specification:Sec-6, Electrical<br />
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• Connection of remote input/ output units to programmable controller through remote I/O<br />
units, wherever substantial saving in cabling is envisaged.<br />
• Serial interface, ce, RS232C and better shall be provided<br />
• High speed communication among PLC and operator consoles/ display units shall be<br />
provided through ethernet<br />
• Latest appropriate model of HP Inkjet Printer to get hard copy of the program dump/ data<br />
logging / alarm m logging / event logging / data trending etc. [Printer covered also under<br />
“Programming Unit”. Only one printer shall be supplied.]<br />
Special features<br />
• Switch to disable all outputs of the controller during start start-up/ up/ debugging<br />
• Fuse failure indication for outputs Mounted spares<br />
• Min of 30 % of I/O modules used of each input & output type (with at least one module of<br />
each type) shall be offered as unused spare for each I/O rack. Minimum of 30% I/O rack<br />
slots shall be kept reserved rved for future expansion.<br />
• 30 % spare memory capacity shall be provided<br />
Constructional features<br />
• Unitised construction<br />
• Floor mounted, free standing and indoor type<br />
• Bottom cable entry<br />
• Sheet steel clad<br />
• Dust and vermin proof<br />
• Suitable to withstand vibrations as per application<br />
• All modules plug-in in type<br />
Enclosure<br />
• Conforming to IP-42 42 class<br />
• Conforming to IP-54 54 class for remote I/O cubicles located in shops/ bays.<br />
Miscellaneous<br />
• Programmable controllers, even if housed in air air-conditioned enclosure, shall be suitable for<br />
normal industrial environment and ambient temperature upto 50<br />
air filter shall be provided at the top of each PLC panel for proper air circulation.<br />
0 ditioned enclosure, shall be suitable for<br />
C. A suitable fan with inlet<br />
air filter shall be provided at the top of each PLC panel for proper air circulation.<br />
• Dual redundant processor shall be envisaged. Redundancy shall be provided in such a way<br />
that in case of failure of the main processor, the standby shall takeover automatically. The<br />
changeover shall be bump less and the system shall be fail proof. Redundan Redundancy shall be<br />
provided for complete processor system including CPU, Memory, Power supply and<br />
Communication sub system.<br />
• Failure of a single processor shall not affect the system.<br />
• In case of failure of complete processor system, outputs shall take fail safe st state<br />
automatically.<br />
• It shall be possible to generate the first out alarm contact by the PLC in case where a group<br />
of parameters are likely to trip a system.<br />
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• The communication subsystem between PLC processor and I/O subsystem shall be dual<br />
redundant.<br />
• The communication munication subsystem between processor subsystem and PLC console shall be dual<br />
redundant, consisting of two separate communication interfaces and two buses, each one<br />
configured in redundant mode.<br />
• No hardwired alarm system is required. All the alarms are to be displayed in OWS of PLC<br />
with multi tone buzzer and with alarm history provision.<br />
• The software provided at the time of supply should be of latest version.<br />
• Necessary license to be provided along with the software.<br />
• The OS (Operator Station) desk and opera operator tor chair to be supplied by the bidder.<br />
4.11 UNINTERRUPTIBLE POWER SYSTEM (UPS)<br />
General System Description<br />
The required kVA, 50 Hz, single phase UPS system shall provide continuously operating<br />
uninterrupted power supply to critical AC loads such PLC PLC, , instrumentation, etc.<br />
The capacity of UPS shall be suitable to feed power requirement of the PLC which shall control<br />
and monitor all the drives/mechanism of proposed additional coal handling system.<br />
The UPS system shall include but not necessarily limited to the following equipment:<br />
• One 100% rated battery bank<br />
• One set of Float Charger (FC) and one set of Float cum Boost Charger (FCBC) complete<br />
with associated incoming AC switchgear.<br />
• Two nos. 100% capacity inverter banks.<br />
• One no. DC switchgear, cconnecting<br />
onnecting above and also inverter banks stated above<br />
• One no. 3 phase to 1 phase transformer and associated AC switchgear, 230V, 1 phase<br />
voltage stabilizer and backup source static switch.<br />
• One no. 240 V UPS ACDB<br />
• One no. four way manual bypass switch<br />
• Static switches<br />
• All inter connecting cables/wiring with connection accessories and other required items<br />
to make the system complete.<br />
Mode of Operation<br />
Normal Mode<br />
During the normal operation the UPS shall be used to provide power to the critical loa loads. The<br />
primary AC source shall be used to supply power to the rectifier charger. Two (2) no. chargers<br />
shall feed regulated DC power to their individual inverter banks and simultaneously float<br />
charge the backup batteries.<br />
Emergency Mode<br />
Technical Specification:Sec-6, Electrical<br />
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Upon failure of primary AC source supplying three phase power to the battery chargers, the<br />
input power to the inverters shall be supplied from the back up batteries. When the AC power<br />
is restored, input power for the inverter and power for recharging the b bbattery<br />
shall<br />
automatically be supplied from the rectifier charger. The batteries shall supply the inverter<br />
whenever the chargers are unable to supply the sudden load demand or their response to the<br />
load change is slow.<br />
The output of the UPS shall feed al all l the essential loads through the ACDB. The connection<br />
from the UPS to ACDB shall be through a switch and fast acting semiconductor fuses, trip fuses<br />
and micro switch with alarm contacts. The feeders shall be designed by the bidder to suit the<br />
load requirements.<br />
Battery Charger<br />
Two (2) nos. each of 100% capacity, battery chargers shall be provided for each UPS system.<br />
These chargers shall be of static type and shall be provided with suitable transformer and full<br />
wave, SCR type rectifiers. Chargers shall share automatically the load during parallel operation<br />
of the inverter system and shall maintain output voltage within plus or minus one percent of<br />
the nominal value from no load to full load.<br />
Suitable ripple filtering circuits shall be provided to give a smooth DC output. The ripple<br />
content shall be limited to less than +5% on resistive load.<br />
The rectifier charger shall have float, equalising and boost charging facility as well as furnish<br />
the inverter input current. In the `Boost' mode, the ‘boost' ch chargers argers shall recharge the<br />
completely discharged battery to full capacity in eight (8) hours.<br />
In charger system, all the standard protection, metering and static annunciation shall be<br />
provided.<br />
Static Inverters<br />
The two (2) nos. 100% capacity, (IGBT) rrequired<br />
equired kVA inverters shall be static type consisting of<br />
SCR type inverter, static filters, integrated control modules including necessary oscillators,<br />
voltage regulators, current limiting and surge suppression networks. In addition, the inverters<br />
shall have ve features of soft start, wave shaping, transient recovery etc. Any other equipment<br />
required for normal operation of the inverter shall be included irrespective of whether<br />
specified or not.<br />
The output from the inverter shall be 240V AC, sine wave 1 phas phase. e. The output of the UPS shall<br />
be distributed to the essential loads through the AC switchgear. The connection from the UPS<br />
to the AC switchgear shall be through a switch and a quick acting fuse. The feeders shall be<br />
designed by the bidder to suit the load requirements.<br />
Technical Specification:Sec-6, Electrical<br />
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Static Transfer Switches<br />
The static transfer switches shall use SCRs and other static devices, for automatic transfer of<br />
load from the Normal source to the Alternate source. The continuous capacity of each static<br />
switch shall be equal to the full load capacity of one inverter. Maximum transfer time including<br />
sensing shall not be more than 1/4 cycle. The transition shall be "make before break" in both<br />
directions. The static switch shall be provided with fuses in both `normal' and `alternat `alternate'<br />
power source. Provision for annunciation of failure of fuse or failure of alternate source shall<br />
be made. The switch shall be provided with surge suppression networks and shall also be rated<br />
to withstand transient voltages upto 150% of rated voltage. Th The e short time rating of the switch<br />
shall be 150% of the rated full load current for two (2) minutes.<br />
Three phase/single phase Transformer and voltage stabilizer<br />
The transformer connection shall preferably be of Le Blanc type with delta connected winding<br />
on the three phase side or of open delta connection type. Other alternatives shall also be<br />
considered, provided the connection has minimum unbalance on the primary side. The<br />
transformer shall be encapsulated in Class B insulation. The transformer shall be adequately<br />
rated for the duty involved. The actual value may be slightly increased to take care of any<br />
losses in the static voltage stabiliser.<br />
The voltage stabiliser shall employ silicon solid state circuitry and shall maintain the specified<br />
output voltage for 0 to 100% load, with maximum input voltage variation as specified specified.<br />
Manual Bypass<br />
Switch The manual bypass switch shall be a four (4) position swit switch. ch. It shall be used to isolate a<br />
static switch from its load and alternate power supply and to take it out of service without<br />
power interruption to the load. It shall be ‘make before break’ type contacts, so that power<br />
supply to the loads is continuous du during ring switch operations. It shall be capable of carrying rated<br />
continuous full load inverter current.<br />
Fault Diagonistic Unit<br />
Unit Fault diagonistic unit shall be provided to supervise UPS operation. Facility to take print<br />
out and recording of important pparameters<br />
arameters shall be provided. All the alarms shall be interfaced<br />
with DDCMIS.<br />
Battery<br />
DC battery shall be VRLA, sealed maintenance free type. Battery capacity should be 500Amp<br />
Hr with float charger of 110 Amps. Float cum boost charger should be 110Amps also. Battery<br />
shall be located in the battery room. Battery shall be suitable to maintain the power supply for<br />
at least 60 minutes (battery back time) in the event of mains failure.<br />
Technical Specification:Sec-6, Electrical<br />
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Necessary distribution board for distribution of power from UPS output t tto<br />
individual<br />
consumers.<br />
Permissible variations for mains power supply system shall be as follows:<br />
Voltage<br />
: + 10 % , -15 %<br />
Frequency<br />
: As per IS<br />
Harmonic distortion<br />
: < 5%<br />
Output of the uninterruptable power supply system while delivering a load of its rated<br />
capacity (P.F of load shall not effect its output) shall have following variations;<br />
Voltage regulation<br />
:1% (For 0-100% load)<br />
Frequency<br />
: (+/-) 0.5% (For 0-100% load)<br />
Efficiency<br />
:Above 80%<br />
100% to 0% and 0% to 100% load : Volt dip +10%<br />
Enclosure and ventilation<br />
Enclosure conforming to IP IP-41 41 class. Units shall be provided with cooling fans and louvers at<br />
the bottom sides. Individual ventilation ducts for eac each h unit shall be provided.<br />
Distribution Board<br />
The DB shall have two buses, main and standby and shall be protected by semiconductor fuses<br />
with fuse monitoring device, bus healthy lamps, voltmeters and ammeters. Each load shall be<br />
fed by two independent feeders. Isolating and buscoupling switches shall be provided.<br />
The enclosure sheet steel thickness shall be 2.0 mm. with cold rolled sheets and 2.5 mm for<br />
hot rolled sheets and enclosure class protection shall be IP IP-54.<br />
TECHNICAL PARTICULARS<br />
1. Application : Uninterruptible Power supply for PLC aand<br />
nd other essential loads<br />
2. Capacity : 200 % of PLC load<br />
3. Degree of protection : IP 54<br />
4. Cable entry : Bottom<br />
5. Input Supply Voltage : 415V+/ 415V+/- 10%, 3 phase 4 wire, 50 Hz +/- 5%<br />
Batteries<br />
1. Type<br />
2. Application<br />
3. Number of cells in each bank in series<br />
4. Ambient temperature<br />
5. D.C. nominal system voltage<br />
6. Ampere hour capacity<br />
7. Charging method proposed<br />
8. Emergency load duration<br />
Technical Specification:Sec-6, Electrical<br />
: VRLA, SMF<br />
: UPS System<br />
3. Number of cells in each bank in series : As per requirement<br />
: Min.temp. :5.0 deg.C Max.temp. :50 deg. C<br />
5. D.C. nominal system voltage : Suitable to inverter system<br />
: Bidder to furnish along with cal calculations<br />
7. Charging method proposed : . Float and boost<br />
8. Emergency load duration : 60 Minutes (battery back up time)<br />
Page 48 of 97
9. Continuous load/duration : As per requirement<br />
Battery chargers<br />
1. Number required<br />
: 2 nos. (1 FC + 1 FCBC)<br />
2. Type<br />
: Static<br />
3. Method of charging<br />
: Float and boost charge type<br />
4. DC system voltage<br />
: To suit the system<br />
5. Automatic voltage regulator required(AVR) : Yes<br />
6. Regulation with AVR<br />
: +/-1%<br />
7. Permissible harmonics at rated continuous load : +/ +/-2%<br />
8. D.C. load requirement<br />
a) Momentary : As per requirement<br />
c) Continuous : As per requirement<br />
b) Emergency : As per requirement<br />
9. Maximum time for boost charging : 8 Hours<br />
Inverters<br />
1. Type<br />
: Static<br />
2. Suitable for parallel oper : suitable for parallel operation<br />
3. Service<br />
: Indoor<br />
4. Output rating<br />
: As required<br />
5. Output Voltage<br />
: 240 V A.C.<br />
6. Phase<br />
: Single phase<br />
7. Frequency<br />
: 50 Hz<br />
8. Total harmonic content<br />
any single harmonic.<br />
: 5% RMS maximum not more than 3% distort distortion in<br />
9. Duty<br />
: Continuous.<br />
10. Overload capacity<br />
: 125% for 15 minute at 0.8 p.f<br />
11. Efficiency<br />
: Not less than 80% at rated load<br />
12. Cooling<br />
: Natural air cooled<br />
13. Synchronization with source : Yes<br />
Static transfer switch<br />
1. Capacity Continuous<br />
2. Type<br />
3. Voltage<br />
4. Frequency<br />
5. Transfer time<br />
Manual bypass switch<br />
1. Capacity Continuous<br />
2. Type<br />
3. No. of positions<br />
4. Short time rating<br />
5. Transfer<br />
Technical Specification:Sec-6, Electrical<br />
: Make and carry F.L. current of inverter at 0.8 p.f.<br />
: Make before break<br />
: 240V, single phase<br />
: 50 Hz<br />
: 1/4 cycle maximum<br />
: Make and carry F.L. current of inverters at 0.8 p.f.<br />
: Make before break.<br />
: 4<br />
: Short time rating of the inverter for 1Sec & 150% of full load<br />
current for 2 minutes.<br />
: Manual.<br />
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4.12 RESISTORS AND RESISTANCE BOXES<br />
The resistors offered shall be arduous duty, industrial application, shock and vibration proof,<br />
unbreakable, rigid and rust proof punched chromium steel alloy grid and conforming to the<br />
requirements stipulated in IPSS 11-10-002-82<br />
82 "Specification for resistance boxes for power<br />
circuits" with latest amendments. Cast iron resistors shall not be acceptable.<br />
The resistors shall be assembled on high quality asbestos or mica insulated high tensile steel<br />
tie e rods and separated from one another by mica or asbestos washers in required numbers<br />
and rigidly supported to eliminate vibration, breakage, displacement or deformation. Tappings<br />
shall be provided with every resistance element indicating resistance value to enable<br />
adjustments, if required. Individual grids shall be TIG welded at the junctions and terminal taps<br />
shall be welded to grids, ensuring a consistent current path.<br />
The grids shall be assembled on heavy steel frames which shall be suitably stacked, housed<br />
and mounted in minimum 2.5 mm CRCA sheet steel enclosed cubicles with louvers along with<br />
wire mesh to ensure good ventilation and mounted on a base frame of ISMC 125 . The panel<br />
of resistor units shall be free standing, floor mounting type and provi provided ded with two numbers of<br />
grounding pads, tapped holes and bolts suitable for connection of grounding conductor of<br />
50x6 mm G.I flat. Enclosure shall be in single front execution.<br />
Individual banks shall be mounted on bracket welded to the frame, as such individual bank can<br />
be withdrawn out from enclosure without disturbing other banks. All resistor banks shall be<br />
provided with adequate lifting facility for handling during installation and over hauling.<br />
The terminals shall be brought out in the separate terminal box (IP-55) 55) on one side and<br />
marked with metallic tags for external connection with AYFY cables.<br />
The current carrying capacity of the resistor shall be so selected that the temperature shall not<br />
exceed 370 deg. C.<br />
4.13 PLANT ILLUMINATION SYSTEM<br />
The scope includes complete plant illumination system to achieve required illumination levels<br />
as per IS or as per CBIP guidelines. The scope shall cover the following illumination systems:<br />
• Normal AC lighting<br />
• DC Emergency light lighting. Maintenance lighting<br />
• Peripheral, road/street and area lighting within battery limit<br />
Illumination shall be provided in all the following premises:<br />
1. Switchgear room at WT substation<br />
2. Battery room at WT substation<br />
3. Transformer rooms<br />
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4. A/C & ventilation RRoom<br />
5. Peripheries of buildings<br />
6. Coal conveyor galleries<br />
7. Dust suppression MCC room<br />
8. Junction houses and transfer towers<br />
9. Wagon Tippler System<br />
10. Control room of WT<br />
11. MCC room for WT<br />
12. Roads/streets within battery limit<br />
13. Area/sub areas within battery limit<br />
14. Any other premise coming under the battery limit<br />
The illumination system shall include the following in required quantities:<br />
• Lighting DBs/ Sublighting DBs • Steel tubular poles<br />
• Light fittings with lamps • Switches<br />
• Lighting fixtures and accessories • Conduits & brackets<br />
• Cables and wiring • Hangers & clamps<br />
• Ceiling fans<br />
• JBs<br />
• Receptacles • Timers/photocell<br />
• For street light LED lamps preferable<br />
• High mast system should have Metal Halide Lamps<br />
All lighting in outdoor area such as ccWT<br />
areas, road/street and area lighting as well as<br />
peripheral lighting shall have auto ON/OFF facility with suitable 24 hrs timer. All the light<br />
fittings shall be dust and weather proof.<br />
Illumination levels envisaged for different areas will be as indicate indicated d below:<br />
S.N. Area<br />
1 Switchgear room 250 FTL AC normal lighting DC<br />
emergency lighting<br />
2. Battery room 100 FTL AC normal lighting DC<br />
emergency lighting<br />
3. Transformer room 200 FTL AC normal lighting<br />
4. MCC room 250<br />
lighting<br />
5. WT Control Room 250 FTL AC normal lighting DC<br />
emergency lighting<br />
6. Junction house 200 MH AC normal lighting<br />
7. Conveyor gallery 100 MH AC normal lighting<br />
8. Peripheral lighting 20 MH AC normal lighting<br />
9. Street / road / area lighting 20 SV AC normal lighting<br />
Technical Specification:Sec-6, Electrical<br />
Lux Fitting type Remarks<br />
FTL AC normal lighting DC<br />
emergency<br />
Page 51 of 97
Lighting DBs of all the areas shall preferably be located inside the rooms like switchgear cum,<br />
control room, etc.<br />
Sufficient numbers of LDBs, SLDBs, lighting poles, 415/240 V switch socket outlets, ceiling fans<br />
with regulators, earthing pits, MCB controlled socket outlet, junction boxes, etc shall be<br />
considered under scope of the Bidder as per actual requirement.<br />
DC emergency lights shall be fed from separate DCELDB. Similarly, power receptacles shall be<br />
fed from dedicated Receptacles DB. DCELDB at WT SYSTEM substation shall be fed from<br />
Purchaser’s DCDB. Receptacle DB shall be fed from Bidder’s PDBs/aux. PDBs.<br />
Sufficient icient numbers of DCELDBs and Receptacles DBs shall be considered by the Bidder as per<br />
requirement.<br />
LIGHTING DISTRIBUTION BOARD (LDB)<br />
415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec.) indoor type.<br />
Board shall be single front, metal cl clad, ad, front matched, free standing, floor mounted, dust and<br />
vermin proof, non-draw-out, out, fully compartmentalized and extensible on both sides, IP54 type<br />
enclosure. Incomers shall be draw out type. LDBs shall have a series of panels of uniform<br />
height placed side de by side having front access for operation as well as cabling and access for<br />
maintenance of busbars. LDBs shall have two incomers and one bus coupler.<br />
Separate busbar compartments provided on the top shall have bolted covers in the front and<br />
rear. The main busbars shall have continuous current rating as required. The rating of the<br />
neutral busbar shall be 50 % of the phase busbars. The busbars shall be of aluminum alloy<br />
conforming to IS 5082. The busbar sizes shall be so selected that with the passage of rated<br />
current, the temperature rise over 500C ambient does not exceed 400C as measured by<br />
thermometer.<br />
Each cubicle shall have segregated feeder compartments arranged in tier formation with each<br />
compartment housing one feeder circuit with lockable hinge hinged d door having neoprene gasket all<br />
around. Modular construction shall be adopted to cater for different sizes of feeders. The<br />
cubicles shall have common horizontal busbar chamber at the top and vertical risers at the<br />
back. The cable compartment shall be pro provided vided on the side with cable entry arrangement from<br />
bottom. The busbar and cable compartments shall be provided with bolted cover plates. The<br />
rear cover shall be easily removable type construction.<br />
The LDBs shall conform to IS 8623 for factory built asse assemblies, mblies, IS 13947 for general<br />
requirement of switchgear and IS 5578 & IS 11353 – Guide for making and identification of<br />
conductors and apparatus terminals.<br />
Technical Specification:Sec-6, Electrical<br />
Page 52 of 97
The LDBs shall be fabricated from CRCA sheets with 2 mm thickness for all members except<br />
the doors of the modules, the rear covers, the covers of cable chambers and busbar chambers<br />
which may be of 1.6 mm with adequate stiffeners to prevent buckling. Non Non-load bearing<br />
partition walls may be of 1.6 mm thick sheet steel.<br />
The cubicles shall be made up of bolted sheet steel members and side panels of pressed sheet<br />
steel with neoprene gasket at all joints and openings including doors.<br />
Bus bars shall have same cross cross-section section throughout the length. Rating of the neutral bus ba bar<br />
shall be 50% of the main bus bar. Earth bus bar shall run in bottom chamber throughout the<br />
length of the panel.<br />
The LDBs shall have necessary provision at either end for future extension by bolting<br />
additional section.<br />
The busbar shall be supported wi with high quality non-hygroscopic, hygroscopic, insulating, self extinguishing<br />
and fire retardant insulating material, of adequate mechanical strength so as to withstand,<br />
without damage, effects of available short short-circuit circuit current. The busbars shall also be properly<br />
spaced d of facilitate taking vertical connections to individual units. The connections to<br />
individual units shall be taken by taped busbars. The busbars shall be of uniform cross cross-section<br />
and the main busbars shall run throughout the length of the board. Similarly vertical droppers<br />
shall extend for the full height of the panel except the bottom chamber. The connection<br />
between busbars of different metals as well as their connection with the terminals of the<br />
equipment shall be made in such a way to prevent corrosion and local heating.<br />
Liberal space shall be provided for cabling and to accommodate any conventional type of cable<br />
glands for PVC insulated and PVC sheathed armoured aluminum conductor cables.<br />
The cables compartment shall have provision for clamping of ccables<br />
ables inside compartment on<br />
perforated sheet steel sections.<br />
The LDB shall have following meters in each of the two incoming feeders:<br />
• One no. digital type voltmeter with accuracy class of 1.0<br />
• One no. digital type ammeter with accuracy class of 1.0<br />
• One no. digital energy meters with accuracy class of 1.0<br />
Suitable CTs with accuracy class of 1.0 shall be provided in the incomer modules for the above<br />
metering.<br />
Moulded Case Circuit Breakers<br />
LDBs shall have moulded case circuit breaker triple pole, air break type with independent<br />
manual quick make and quick break type. MCCB shall be capable of breaking rated current at<br />
0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system and<br />
shall be current limiting type. All outgoin outgoing g feeders shall have earth fault protection.<br />
Technical Specification:Sec-6, Electrical<br />
Page 53 of 97
The MCCBs shall be suitable for panel mounting and shall be fixed type. All live parts shall be<br />
enclosed in moulded case and all contacts shall be silver plated. The breakers shall be trip trip-free<br />
and with quick make & break operating mechanism. The MCCBs sha shall be provided with<br />
ambient temperature compensated bi bi-metal metal overload releases and a magnetic short short-circuit<br />
release with inverse time characteristic. Releases shall be either static or microprocessor<br />
based.<br />
The operating handle shall be included with mod module ule door such that the door can be opened<br />
only with the breaker in the “OFF” position. The MCCB handle after the breaker tripped due to<br />
a fault shall occupy an intermediate position. The breaker shall be capable of interrupting a full<br />
fault current corresponding onding to the fault level specified.<br />
MCCBs shall have a breaking capacity of 50kA at 415V. Current limiting MCCBs are not<br />
permitted.<br />
The LDB shall be consisting of following feeders:<br />
Incomer : 2 Nos. each of 600 A MCCB with over current and earth pprotection.<br />
Bus coupler : 1 No. of 600 A MCCB<br />
Outgoing : 125 A MCCB<br />
63 A MCCB – 10 Nos.<br />
SUB LIGHTING DISTRIBUTION BOARD (SLDB)<br />
415V, 3 phase, 4 wire, 125/63A (as applicable), indoor/outdoor type (as applicable) generally<br />
conforming to IS 13947 and IS 8623 as applicable.<br />
The SLDB shall comprise of one number of incoming TPN MCCB, three nos. of DP MCBs, and<br />
requisite number of outgoing SPN MCBs (as specified) and adequately rated bus bars. The<br />
SLDBs shall also have timer, contactors, A/M switch, etc as per requirement. The enclosure<br />
class of SLDB shall be IP 54. The terminals of MCCB shall be fully shrouded. The boards shall be<br />
of industrial, totally enclosed dust dust-proof, proof, wall mounted, sheet steel cubicle design. The<br />
thickness of the sheet steel shall be 2 mm. The boards shall have welded back and sides and<br />
gasketted hinged door at the front with door handle and suitable locking devices. For boards<br />
with incoming isolating switch the access to the operating handle shall be from the front of the<br />
cubicle without opening the front door. Operating knobs of outgoing MCBs shall be accessible<br />
only after opening the front door of the cubicle. Protective insulated cover plate shall be<br />
provided inside the cubicle to shroud all the live parts with only the operatin operating knobs of the<br />
MCBs protruding outside the cover plate. The boards shall also be dust dust-proof in door-open<br />
position. Adequate space shall be provided within the boards to facilitate termination of<br />
incoming and outgoing cables. The boards shall be factory wir wired ed and assembled. Where<br />
specifically called for, the boards shall be of special weather weather-proof proof design suitable for outdoor<br />
installation.<br />
Technical Specification:Sec-6, Electrical<br />
Page 54 of 97
The miniature circuit-breakers breakers (MCBs) shall be heat resistant plastic moulded type generally<br />
designed, manufactured an and d tested as per IS 8828. Unless specified otherwise all MCBs shall<br />
be provided with quick break trip free mechanism and direct acting thermal overload and<br />
short-circuit circuit trip elements. The short short-circuit circuit breaking capacity of the MCBs shall not less than 9<br />
kA at 0.8 power factor. Single Single-phase phase MCBs which are not provided with built built-in phase barriers,<br />
and mounted adjacent to each other and connected to different phases, shall be provided<br />
with adequate insulated phase barriers, shall be selected from standard cur current rating.<br />
The TPN busbars shall have continuous current rating as required. The busbars shall be of<br />
copper and sizes shall be so selected that with the passage of rated current, the temperature<br />
rise over 500C ambient does not exceed 400C as measured by thermometer. The minimum<br />
size of busbars shall be 25 x 3 mm. The busbars shall be properly supported with high quality<br />
non-hygroscopic, hygroscopic, self extinguishing and fire retardant insulating material of adequate<br />
mechanical strength so as to withstand, without ddamage,<br />
amage, effects of available short circuit<br />
current. The busbars shall also be properly spaced to facilities mounting of MCBs and taking<br />
connections to individual units.<br />
Detachable cover plate shall be provided at top and bottom for cable glands suitable f ffor<br />
PVC<br />
insulated, PVC sheathed armoured aluminum conductor cables or for direct entry of conduit.<br />
Cable terminals shall be suitable for aluminum conductor cables and so arranged to enable<br />
connecting of each circuit without disturbing any other circuits.<br />
Identification labels, inscription plates, danger boards, etc shall also be provided as per<br />
requirement. Earthing arrangement and danger plates shall be as specified.<br />
SLDBs shall have automatic group switching arrangement for which timer of robust<br />
construction uction and suitable contactors shall be provided in each board. Bypass arrangement of<br />
timer in form of auto/manual switch shall also be provided in the SLDBs. The controller shall<br />
sense the outdoor light and shall switch “ON” through auxiliaries contacts w wwhen<br />
the sunlight<br />
falls bellow a present value. It shall remain in this position till dawn when it shall switch “OFF”<br />
when the sunlight remains a preset level.<br />
Suitably engraved identification labels and inscription plates shall be provided for each circu circuit.<br />
The same shall also be provided for the boards.<br />
One continuous G.I earth bus shall be provided in the bottom part of SLDB along the full length<br />
of the board with two bolted type earthing terminals to comply with the requirements of<br />
Indian Electricity Rules. Proper danger plates shall also be provided on each board.<br />
Each SLDB shall be provided with padlocking facility with sufficient number of keys. The<br />
following types of SLDBs shall be provided:<br />
SLDB, Type A (To be used for 2x40 W FTL light fittin fittings)<br />
Incomer : MCCB, 4 POLE, 63 A : 1 No.<br />
Technical Specification:Sec-6, Electrical<br />
Page 55 of 97
Outgoing : MCB, DP (63 A) : 3 Nos.<br />
Outgoing : MCB, SPN (10 A) : 10 Nos./Phase (Total 30 Nos.)<br />
SLDB, Type B (To be used for 250 W HPSV/MH light fittings inside the building)<br />
Incomer : MCCB, 4 POLE, 63 A : 1 No.<br />
Outgoing : MCB, DP (63 A) : 3 Nos.<br />
Outgoing : MCB, SPN (16 A) : 6 Nos. per phase (Total 18 Nos.)<br />
SLDB, Type C (To be used for 250W/150W/70 W HPSV/MH light fittings outside building)<br />
Incomer : MCCB, 4 POLE, 63 A : 1 No No.<br />
Outgoing : MCB, DP (63 A) : 3 Nos.<br />
Outgoing : MCB, SPN (20 A) : 5 Nos. per phase (Total 15 Nos.)<br />
SLDB, Type D (To be used for 250 W HPSV/MH street light fittings)<br />
Incomer : MCCB, 4 POLE, 125 A : 1 No.<br />
Outgoing : MCB, TPN (63 A) : 8 Nos.<br />
Sufficient number of SLDBs of different types (A, B, C and D) shall be used as per requirement<br />
of different areas and sub sub-areas areas of the coal handling plant. Exact quantity of SLDBs of various<br />
types shall be finalized during detailed engineering. Bidder sha shall ll consider as per requirement<br />
subject to minimum one number of each type of SLDB.<br />
RECEPTACLE DISTRIBUTION BOARD<br />
Receptacles DB shall be suitable for 415V, 3 phase, 4 wire, 125 A, indoor type.<br />
Board shall be single front, metal clad, front matched, ddust<br />
ust and vermin proof, draw draw-out, fully<br />
compartmentalised and extensible on both sides, IP54 type enclosure.<br />
Shall have isolated busbar chamber for main busbar at the top, running through out the length<br />
of the board. Chamber shall have removable cover.<br />
Busbars usbars shall have same cross section through out the length . Rating of the neutral busbar<br />
shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the<br />
length of the panel.<br />
Shall have Moulded case circuit breaker (MCCB) tripl triple e pole, air break type with independent<br />
manual quick make and quick break type. MCCB shall be capable of breaking rated current at<br />
0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system.<br />
Generally all boards will have ffollowing<br />
feeder arrangement.<br />
Incomer : MCCB TPN of 125A : 1 Nos.<br />
Technical Specification:Sec-6, Electrical<br />
Page 56 of 97
Outgoings : MCCB TPN of 32 A : 10 Nos.<br />
220V DC Emergency LDB (DCELDB)<br />
The DCELDB used for emergency lighting distribution shall be industrial heavy duty type<br />
suitable for 2-wire 220V DC operation, and shall have a DC double pole power contractor and<br />
requisite number of auxiliary contractors and timers and outgoing feeders protected with DP<br />
MCBs of suitable ratings.<br />
The incomer shall be of double pole load break design suitable ffor<br />
or operating on 220V DC. The<br />
enclosure shall be made of 2 mm thick sheet steel and shall have requisite number of cable<br />
glands and terminal strips for incoming and outgoing cables. The control circuit voltage shall<br />
be of 220V DC.<br />
The DCELDBs which feed aall<br />
ll the emergency lighting points shall be automatically switched on<br />
the event of power failure through a separate circuit which sense under voltage of normal AC<br />
supply at the specified location. These emergency lighting fittings shall glow for a preset tim time<br />
and shall be switched OFF automatically through a time relay in case the normal AC power<br />
supply is not restored within that time.<br />
Feeder configuration of DCELDB shall be as follows:<br />
Incomer : MCCB, DP (63 A) – 1 No.<br />
Outgoing : MCB, DP (10 A) – 16 Nos.<br />
Supply of battery, battery charger(FC & FCBC, DCDB for 220V DC system shall be in bidder’s<br />
scope.<br />
415 V switch outlets<br />
Switch socket outlets and plugs for 415 V, 33-phase<br />
phase circuits shall be of four four-pin (three pole and<br />
one earth), non-reversible reversible typ type enclosed in dust-proof proof 2 mm thick sheet steel enclosures. The<br />
socket outlets shall be provided with fuses and shall have isolating switch interlocking as per<br />
IS:4160 such that it can be switched ‘ON’ only when the plug has been inserted and plug can<br />
be provided rovided for the socket outlets. The isolating switches shall be of category AC 23<br />
conforming to IS 13947 (Part 3). The socket outlet shall be suitable for terminating aluminum<br />
conductor cables either directly or through GI pipe and shall be provided with c ccompression<br />
type lugs. The socket outlet shall be supplied with metal clad plug. The socket outlets and<br />
plugs shall have porcelain base and shall be of 32A rating.<br />
Weather-proof proof enclosure shall be used for outdoor installation. Inscription plate shall be<br />
provided indicating the voltage rating for the switch outlet.<br />
240 V switch socket outlets<br />
Socket outlet for 240 V supply shall be of 33-pin<br />
(two-pole pole and one earth) nonreversible, metal-<br />
clad, dust-proof, proof, industrial type suitable for horizontal insertion generally as per IS 1293. 240 V<br />
Technical Specification:Sec-6, Electrical<br />
Page 57 of 97
socket outlets shall be controlled by rotary type switch mounted flush in the socket outlet box.<br />
Operating handle of the rotary switch shall be fixed in such a manner that it will not be<br />
possible either to insert or to with withdraw draw the plug without switching off the supply. All socket<br />
outlets shall be supplied with heavy duty type plug and cap with chain. The isolating switches<br />
shall be of industrial type of category AC 23. The isolator shall be housed in dust and vermin-<br />
proof sheet heet steel enclosure suitable for terminating aluminum conductor cables either directly<br />
by means of cable gland or through conduits. The current rating for the socket outlets shall be<br />
20 A. Wherever called for HRC fuses shall be incorporated in the socket outlet box.<br />
Inscription plate shall be provided indicating the voltage rating and feeder identifications for<br />
the switch socket outlet.<br />
MCB Controlled Socket Outlet<br />
The MCB controlled socket outlet shall be similar to the above switch socket outlet and<br />
provided with industrial type socket outlet with cover suitable for 240V, 20A single phase AC<br />
and controlled through single pole 20A MCB.<br />
Ceiling Fans and Regulators<br />
Ceiling fans regulators shall be designed, manufactured and tested as per IS:374. The fans shall<br />
have totally enclosed, capacitor start and run motors, suitable for operation on 240V, single<br />
phase, 50 Hz AC system. The electronic type regulator shall have ‘ON’ – ‘OFF’ position next to<br />
the lowest speed contact, shall be provided with necessary harmonic filters and shall be<br />
suitable for operation at 500C ambient temperature.<br />
Down rods required for installation of ceiling fans shall be included by the Bidde Bidder.<br />
Lighting Poles<br />
Steel tubular road lighting poles with single outreach shall be of swaged and welded<br />
construction conforming to IS:2713 IS:2713-1969 with latest amendments.<br />
The outer surface of pole above foundation shall be painted with two coats of red o ooxide<br />
zinc<br />
chromate primer paint as per IS:2713 and finished with two coats of synthetic enamel paint of<br />
approved shall not be less than 100 microns.<br />
The outer surface of the pole embedded in concrete foundation as well as the entire inner<br />
surface shall be e painted with two coats tar based general type black paint.<br />
The poles shall be provided complete with fixing arrangement for loop loop-in in and loop out box and<br />
lighting fittings. The Bidder shall submit a drawing indicating the general arrangement and the<br />
final l design and arrangement shall be subject to purchaser’s approval.<br />
The 415 loop-in loop-out out box shall be weather weather-proof, proof, dust tight, sheet steel enclosure suitable<br />
for outdoor installation. The box shall have hinged front with front locking device. 3 Nos. open<br />
Technical Specification:Sec-6, Electrical<br />
Page 58 of 97
type terminals for taking looping connection of 4C x 16 sq.mm Al conductors. Conductor<br />
power cables and 2C x 2.5 sq.mm PVC copper wiring cable through rewirable fuse cutout to<br />
the control gear. The box shall be supplied complete with 63A terminal blo block, 5A rewirable<br />
fuses cutouts, brass / aluminum alloy cable gland, clamps, lugs, earthing terminals, danger<br />
plates and other required hardwares.<br />
Street lighting pole shall have a single outreach suitable to hold the street lighting fitting.<br />
Flood lighting ng pole shall have a cross bar on top of the pole and shall be suitable for fixing the<br />
flood light fitting.<br />
Earthing provision of lighting poles<br />
2 Nos. 8 SWG GI wire shall run throughout along with street light poles in loop in loop out<br />
arrangement. One number of earth pit shall be provided for every 5 nos. of lighting poles. Each<br />
earth pit shall be consisting of 40 NB GI pipe of 3 mtr length, funn funnel, el, salt, charcoal, cast iron<br />
cover, clamps, etc.<br />
Junction Box<br />
The 415/240V, TPN junction boxes shall be of fabricated from 2mm thick sheet steel suitable<br />
for mounting on wall / column. The box shall have suitable provision for entry and termination<br />
of aluminum conductor, PVC insulated cable supplied complete with terminal blocks, earthing<br />
terminal, wire support etc. The box shall be painted with anti anti-corrosive corrosive primer both inside and<br />
outside and furnish with two coats of approved colour paint. The junct junction boxes used<br />
outdoors shall be with suitable canopy arrangement. The junction boxes shall be suitable for<br />
terminating one (1) incoming cable and two outgoing cables.<br />
Lighting Fittings<br />
High Mast light fittings shall be with Metal Halide (MH) lamps).Al lamps).All other<br />
LED lamps.<br />
All lighting fittings and accessories shall be manufactured from best quality materials and shall<br />
be completed in all respect ready for installation at site.<br />
Unless otherwise stated lighting fittings shall have provision for 25 mm / 19 mm dia conduit<br />
(as applicable) entry for low low-bay bay fittings. Medium bay fittings shall have eyebolt suspension<br />
arrangement.<br />
Terminals off all fittings shall be suitable for connecting 2.5 sq mm flexible, copper conductor,<br />
PVC insulated ted and PVC sheathed cable for low low-bay bay fittings and 2.5 sq mm flexible copper<br />
conductor cable for high bay fittings.<br />
All the LED fittings and MH fittings shall be non non-integral integral type. Control gear boxes shall be<br />
mounted at man height for ease of maintenanc maintenance.<br />
Technical Specification:Sec-6, Electrical<br />
fittings shall be with<br />
Page 59 of 97
High mast fittings (Non-integral integral type) : 2 nos<br />
Non-integral integral type asymmetrical beam flood light fittings with 2x400W MH lamps complete<br />
with control gear, accessories, etc suitable for installation on 30 M high lighting mast as per<br />
technical specification ion (Bajaj BGENF 22 or equivalent with MH lamps) shall be mounted on the<br />
lantern carriage of each of the high lighting mast.<br />
Lamps<br />
All lamps shall be of high lumen output and with long life.<br />
Incandescent Lamp<br />
All general service incandescent lamps shall be gas filled, clear finished and coiled coil type<br />
where possible. Incandescent lamp cap shall be of screwed type having GES/ES thread<br />
depending on the sizes of the lamp.<br />
Fluorescent Lamp<br />
All fluorescent lamps mps shall be of day day-light light type unless otherwise specified and shall be suitable<br />
for suitable for switch-start start with bi bi-pin type cap.<br />
Sodium vapour lamps shall be suitable for universal burning position. The elliptical outer bulb<br />
shall be coated inside the diffusing powder and shall have good colour appearance. The<br />
sodium vapour lamp shall be of screwed type E40/E27 base depending upon the wattage of<br />
the lamp.<br />
Ballast<br />
The ballast shall be of electronic type and well tried out design to give trouble trouble-free operations<br />
with long service life having provisions for suitable tappings in steps.<br />
Capacitor<br />
Capacitor shall consist of element wound from layers of higher purity aluminum foil and<br />
capacitor paper contained in aluminum cylindrical can. The capacitor sh shall be vacuum dried<br />
and impregnated. The can shall be hermetically sealed and terminals provided over porcelain<br />
insulations. The capacitor shall conform to IS 1569.<br />
Lamp Holder<br />
The lamp holders shall have spring loaded contacts for positive contact wit with pins so as to<br />
prevent the lamp from being extinguished due to vibration. The holder shall be such that the<br />
lamps can be removed easily whenever required for cleaning or replacement purposes.<br />
For fluorescent lamp, bi-pin pin lamp holder shall be provided. TThe<br />
he holder of incandescent lamps<br />
upto 200 W shall be of ES type.<br />
Technical Specification:Sec-6, Electrical<br />
Page 60 of 97
The starter holders shall be of well tried tried-out out design and of robust construction with provisions<br />
for easy insertion and removal of the starter ensuring correct contacts by means of strong<br />
spring action.<br />
Push button for group switching of lights<br />
The push h buttons (one no. ON and one no. OFF) shall be mounted on cast iron box with<br />
2NO+2NC contacts and terminal block.<br />
Conduits and Conduit Fittings<br />
Surface conduit installation shall be carried out using hot dip / electro galvanised rigid steel<br />
seamed by welding, screwed type, designed, manufactured and tested in accordance with IS<br />
9537. The various conduit accessories like couplers, bends, elbows, reducers, saddles, clamps,<br />
lock nuts, junction boxes etc. shall conform to IS 3837 shall be supplied and erec erected as per<br />
requirement along with the conduits.<br />
Point wiring materials and Accessories<br />
The point wiring materials and accessories for lighting for installation, fan points, sockets etc.<br />
where specified shall include wiring cables, conduits and conduit fittings, wiring accessories<br />
inclusive of switches, sockets, fan regulators, switch boxes, junction boxes etc.<br />
Point wiring<br />
The wiring cables used in point wiring installation shall be 1100 volts grade PVC insulated<br />
single core flexible stranded copper conductor type confirming to IS:694. The size of<br />
conductors to be adopted shall be 2.5 sq.mm for lighting, fan and 5/15A socket outlet circuit<br />
and 2.5 sq.mm for 15A socket power circuits.<br />
Wiring Accessories<br />
The various electrical wiring accessories vi viz. z. Switch boxes, switches and sockets shall confrom<br />
to IS 5133, IS 3854 and IS respectively. The switch boxes shall preferably be of passed sheet<br />
steel cadmium coated and passivated or galvanised with knockouts at the top and the bottom<br />
for conduit entry. The surface mounted type boxes shall have necessary provisions for<br />
mounting on the wall. Earthing terminals shall be provided in the box. Junction boxes provided<br />
at intermediate points shall also be identical in construction to the switch boxes. The switch<br />
and junction boxes shall be of standard dimensions with adequate wiring space. The switches<br />
and sockets shall be made of superior quality engineering plastic with excellent dielectric<br />
properties. The switches shall be of piano key design and shall have ad adequately equately rated switch<br />
contacts. The switch contacts shall be silver tipped electrolytic grade copper. The switch plate<br />
forming part of the switch box cover shall be made of plastic material and shall be made with<br />
Technical Specification:Sec-6, Electrical<br />
Page 61 of 97
number of slots in which the switches and ssockets<br />
ockets shall be assembled. The sockets shall be of<br />
three pin design with phase neutral and earth conducts.<br />
Earthing<br />
All electrical equipment shall be effectively earthed as to meet the requirements to Indian<br />
Electricity Rules and IS:3043 IS:3043. . Earthing conductors for individual equipment shall be of either<br />
galvanised mild steel flat or stranded/solid G.I. wire as specified.<br />
Earth pits for street/area lighting poles<br />
The earth pits shall be consisting of 40 NB GI pipe of 3 mtr length, funnel funnel, salt, charcoal, cast<br />
iron cover, clamps, etc. The Bidder shall include all civil work as per requirement. All<br />
accessories shall be included as per requirement.<br />
4.14 LIGHTING HIGH MAST WITH FLOOD LIGHT FITTINGS<br />
General<br />
a. High mast tower for floor ligh lighting ting shall be factory fabricated mild steel plates welded,<br />
polygon section, hot dip galvanized and provided in standard lengths.<br />
b. The structure shall be 30 meter high, well tried, proven design to withstand high wind<br />
speed of 180KM/ hr.<br />
c. The mast shall have ave a movable lantern carriage tower from the top of tower to bottom and<br />
vice-verse verse with the help of a motorised winch arrangement (with motor of minimum 2.2<br />
kW capacity) and shall be provided with suitable gears, pulleys and ropes. The reeling of<br />
ropes shall all be such that to prevent twisting & tangling. Means shall be provided for normal<br />
operation of the winch in case of failure/ non availability of power to the motors. Safety of<br />
lantern carriage in case of breakage of the rope shall be ensured by arresting free fall of the<br />
lantern carriage to the ground by providing Safety locking arrangements.<br />
d. All the carriage components shall be galvanised and mounted inside the tower. The tower<br />
shall be provided with a suitable man entry door at the bottom section to facilitate<br />
inspection and maintenance. The door shall be weather proof and provided with safet safety lock<br />
to prevent unauthorised access.<br />
e. The lantern carriage shall be symmetrical, robust construction housing the luminaire and<br />
control gear boxes. The cables to the luminaries shall be run inside the tubes of the lantern<br />
with junction boxes provided for branch off cables.<br />
f. Proper luminaries carriage ring support arms shall be provided for supporting the<br />
luminaries’ carriage ring when the latter is lowered for maintenance of luminaries. Lantern<br />
carriage ring should be in channel tube and with concealed wwiring<br />
iring the carriage should be<br />
Technical Specification:Sec-6, Electrical<br />
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essentially have a 3 points suspensions system. The mobile luminaries carriage shall be<br />
evenly balanced Rubber Paddle Guide Ring shall be incorporated as a buffer arrangement<br />
between mobile luminaries carriage and mast shaft. TThis<br />
his is to prevent damage to mast<br />
surface during raising and lowering operation of mobile luminaries carriage.<br />
g. The winch shall be provided with a separate control panel housing the control for the winch<br />
drive motor and controls for switching the luminarie luminaries. s. It shall be complete with switch fuse<br />
units/MCCBs, starters, contactors, etc that may be necessary to the operation of the light<br />
tower. It shall be suitable for outdoor installation with IP IP-65 65 degree of protection. It shall<br />
be suitable for mounting on a suitable plinth adjacent to the high mast tower.<br />
h. The winch must be of robust design and completely self self-sustaining sustaining type without the need<br />
for brake -shoe, shoe, springs or clutches. It can be removed from the mast for maintenance if<br />
the need arises in the futu future re with the lower carriage on the top. The reduction gear of the<br />
winch shall be of endless worm gear, operating in oil bath. The minimum safe working limit<br />
of the winch shall not be less than 750 Kg.<br />
i. A minimum 6 turns of wire rope shall be on the drum whe when n the mobile luminaries ring is<br />
fully lowered to rest on the luminaries supporting arms.<br />
j. The winch is entirely self self- sustaining under all normal circumstances and it is not<br />
dependent on the brake or restraining device that uncontrolled or dangerous runaw runaway<br />
speed shall occur in the event of the total failure of this device. Slip test on winch is carried<br />
out by the manufacturer. Test certificate and report shall be submitted up, on request.<br />
k. The speed of the raising and lowering of lantern carriage ring sh shall all be at least 1.5 meter Per<br />
minute.<br />
l. The high mast shall be fitted with flexible standard G.I / S.S. hoisting wire ropes of 7 x 19<br />
construction with a minimum breaking strength of 1900 kgs. The combine lifting capacity of<br />
the hoisting wire ropes shall hhave<br />
ave a factor of safety not less than 5 times the safe working<br />
load (SWL) of the winch and shall be entirely suitable for the design application.<br />
m. A transition plate shall be incorporated to balance the carriage from below of the mast.<br />
n. Cable for lighting and winch control shall be as per approved scheme. The cables shall be<br />
clamped or rolled so that no twisting of cables happens while the winch is hoisted or<br />
lowered. Electrical cable shall be PVC coated round flexible cable suitable for small bending<br />
radius. One standard multi core flexible electrical cable with 4 sq mm conducting areas<br />
shall be provided for connecting of power supply to the light source and shall terminate at<br />
the stationary connecting board in the base compartments.<br />
o. The high mast shall be suitable for asymmetrical loading of with 16 nos. of 2 x 400 W MH<br />
luminaries mounted on the lantern carriage. The luminaries shall be grouped in individual<br />
240V RYB circuits fed through time switches. It shall be possible to switch t tthe<br />
lamp<br />
bypassing the timer. The timer shall be programmable digital/analogue quartz controlled,<br />
Technical Specification:Sec-6, Electrical<br />
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high accuracy real time clock. It shall be set from 6 PM to 6 AM or any other intermediate<br />
time. The tendered shall indicate the controls offered by him clearl clearly y in the offer.<br />
p. The successful Bidder shall submit design and preliminary data for the design of foundation<br />
of the high mast tower indicating the requirements of embedded inserts etc. The<br />
foundation shall be designed and provided by the purchaser. Bidder to include foundation<br />
bolts etc which shall be embedded in the foundation. Grouting of the bolts shall be done by<br />
the Bidder.<br />
q. The high mast shall be provided with lightning protection with air air- termination and down-<br />
comers as per requirements of BIS and aviation warning lamps as per statutory and civil<br />
aviation requirements. All metallic portions of the high mast shall be effectively earthed<br />
and provided with two earth pits near the base. Effective earthing for luminaries shall be<br />
provided during normal ooperation<br />
and in lowered position.<br />
r. Mast structure is designed to withstand wind velocity conforming to IS 875 (Part (Part-III)-1987.<br />
Mast Design Criteria<br />
The high mast and the lowering system with the required number of floodlights and lamp<br />
controls gears etc. tc. In place shall be capable of withstanding a sustained basic wind speed of<br />
180 Km/ hrs.<br />
The design shall be in such a manner that it is capable of withstanding external forces exerted<br />
by wind pressure and should have a minimum wind load factor of 1.25 and material factor of<br />
1.15. Design life of mast shall be 25 years.<br />
CONSTRUCTIONAL FEATURES OF MAST<br />
The mast shaft shall be made with the best steel grade, in compliance with MS IS IS- 2062/BSEN<br />
10025 having adequate characteristics w.r.t. minimum yield strength, tensile strength and<br />
minimum elongation for thickness.<br />
The steel grade for accessories shall also be MS IS 2062 or equivalent, having adequate<br />
characteristics w.r.t. minimum yield strength, tensile strength and minimum elongation for<br />
thickness.<br />
Each mast section to be delivered to site shall have a minimum length of 10.7 Mtrs. The Mast<br />
sections shall have Single longitudinal weld from Bottom to Top.<br />
The base shall have a flange plate for high mast onto the concrete foundation by anchor bolts.<br />
The mast shall be fabricated and welded longitudinally to form a tapered section with<br />
telescopic friction on slip joints. All welding shall be to IS 816 / 82 having the following basic<br />
requirements.<br />
Technical Specification:Sec-6, Electrical<br />
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The wall thickness of each section shall be designed to withstand the loads to which the high<br />
mast shall be subjected to, but shall not be less than 8 mm for base section and 6 mm for<br />
other sections and minimum base dia shall not be less than 530 mm.<br />
Connection between the various sections, shall be achieved by telescopic slip joints, the<br />
overlapping length being at least 1600mm slip joint assembly shall be perform at site. Shaft<br />
section shall not be joined by circumferential weld or bolting at site.<br />
The base plate shall be free from lamin lamination ation and shall be single flange constructed with holes<br />
jig drilled for anchor bolts passage. The bottom of the base mast section shall be securely<br />
welded to the base plate by complete penetration fillet welding. The welded connection of the<br />
base plate to the mast section shall fully develop the strength of the section.<br />
The base section shall be equipped with a hinged service door. The service door opening shall<br />
be complete with a close fitting weatherproof and equipped with a vandal resistant lock. The<br />
service ervice door shall not be smaller than 1400 mm x 300 mm the opening shall be reinforced by a<br />
thick steel door frame.<br />
Base plate of suitable dimensions and thickness, diameter, size and the placement of anchor<br />
bolts shall be determined by calculations. An Anchor chor bolts shall be of deformed steel<br />
reinforcement bars having the adequate characteristics w.r.t. tensile strength.<br />
Welding of two or more anchor rods of shorter lengths to achieve the design length shall not<br />
be permitted. No welding shall be allowed oon<br />
the anchor rod body.<br />
Adequate earthing and earthing terminal shall be provided within the access door area of each<br />
Mast. All high mast shall be hot dip galvanized, in accordance with IS 2629 / TR 7 Timer control<br />
panel shall be provided with overload and single phase preventor. Timer control panel shall<br />
be outdoor type.<br />
Motor capacity of the winch<br />
Motor shall be of hoist duty and of adequate capacity with 15 % minimum margin over<br />
mechanical power requirement. Minimum capacity of 2.2 kW shall be consi considered.<br />
4.15 EARTHING AND LIGHTNING PROTECTION<br />
EARTHING PROTECTION<br />
Bidder shall include complete earthing of WT substation, MCC rooms, Wagon tippler,<br />
apron feeder & conveyor drives etc. The underground earthing mats also<br />
shall be done by the Bidder. Risers shall be available at all the premises for<br />
interconnection of own earthing network. However, Bidder shall pprovide<br />
rovide complete separate<br />
earthing for transformer neutrals.<br />
Bidder shall include the following in each and every substation:<br />
Technical Specification:Sec-6, Electrical<br />
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1. Earthing ring mains at WT substation and all the electrical rooms/premises<br />
2. Equipment earthing<br />
3. Transformer neutral earthing prov providing dedicated pits<br />
Bidder shall include complete earthing material including earthing strips, earth electrodes<br />
other accessories for treated earth pits, etc. and carry out earthing ring mains, earth pits,<br />
interconnections, equipment earthing, all assoc associated iated civil works, etc at all the ubstations.<br />
All the connections of earthing ring mains with available underground earthing grid of<br />
respective substation/premise shall be under scope of the Bidder.<br />
Separate dedicated treated earth pits shall be provid provided ed for transformer neutrals. Two nos.<br />
such earth pits shall be provided for each of the transformers. The treated earth pits shall be<br />
consisting of 3 mtr 65 NB GI pipes, funnels, clamps, 3 mtr long 40 mm MS rod electrodes, MS<br />
cover with lifting lugs, assoc associated civil works, etc.<br />
All the equipment located in the WT premises / sub sub-premises e.g. 33 KV switchboard, LT PCCs,<br />
busducts, transformer bodies, charger panels, DCDBs, LDBs, SLDBs, receptacles, control panels,<br />
MCCs, etc shall be connected by the Bidder with earthing ring mains at least two different<br />
points.<br />
Electronic earthing shall be considerd for PLC, etc<br />
Bidder shall also consider earthing of following equipment to be installed by the bidder.<br />
• 33kV kV WT switchboard at WT substation in switchgear cum MCC room<br />
• WT distribution transformers (2 nos.) – Neutral as well as body earthing<br />
• 415 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room<br />
• Control panel for power distribution equipment at existing WT control room<br />
• LT busducts (2 sets)<br />
• Charger panels, DCDB, etc at WT substation in switchgear cum MCC room<br />
Bidder shall consider earthing ring mains at each electrical premise and connect the electrical<br />
equipment with the rings. The earthing rring<br />
ing mains shall be connected with underground<br />
earthing mats (consisting of 2x40MM dia to be installed by the bidder. . For transformer neutral<br />
earthing, bidder shall consider dedicated plate earthing.<br />
Bidder shall include complete earthing material includin including g earth electrodes, risers, GI earthing<br />
strips, other accessories, etc. and carry out main earth grid mat, earthing ring mains, earth<br />
pits, risers, interconnections, equipment earthing, all associated civil works, etc within battery<br />
limit of the package. All ll the interconnections with other earthing systems of the plant and<br />
with existing systems shall be under scope of the Bidder.<br />
The Bidder shall obtain the actual soil resistivity of the plant area by carrying out soil resistivity<br />
tests and design the earthing thing system accordingly.<br />
Technical Specification:Sec-6, Electrical<br />
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While designing the earthing system, Bidder shall note the following fault levels at 415 V bus<br />
shall be 50 kA. Plant earthing system shall be designed such that overall earthing resistance is<br />
less than 1(One) Ohm without interco interconnections.<br />
The materials shall be galvanized steel laid over the ground and mild steel buried inside the<br />
ground/concrete.<br />
Fault clearing time for sizing of earth conductors and for calculations of the maximum<br />
allowable step and touch potential shall be taken 1 sec. Maximum allowable temperature rise<br />
for steel bolted joints shall be taken as 3100C taking ambient temperature of 50 o C.<br />
The earthing system shall be generally designed on the basis of the following codes &<br />
standards:<br />
• IS 3043 Code of practices for safety and standards<br />
• IEEE 80 Guide for safety in AC substation grounding<br />
• Indian Electricity Rules<br />
Entire system shall be earthed so that the values of the step and contact potentials in case of<br />
faults are kept within safe permissible limit limits.<br />
Parts of all electrical equipment and machinery not intended to be alive shall have two<br />
separate and distinct earth connections each to conform to the stipulation of the Indian<br />
Electricity Rules.<br />
In case of HT system, E/F current will be made to flow through copper screen tape provided<br />
over inner sheathing. Screen will be connected to earth bus at both ends. In case of LT the TN TN-<br />
S system will be followed, i.e. neutral bus of the switchgear shall be connected to switchgear<br />
earth bus and then to DBs sha shall be through armouring of cable.<br />
Bidder shall submit the layout drawings of earthing network with supported calculations for<br />
approval of purchares/consultant. Taking approval of Electrical inspector/CEA and providing all<br />
inputs to them like data/drawing<br />
data/drawings are under scope of the Bidder.<br />
The materials shall be galvanized steel laid over the ground and mild steel buried inside the<br />
ground/concrete.<br />
Earthing of SLDBs, power receptacles, etc shall be connected with respective source LDBs<br />
through armouring of f cables.<br />
Earthing conductors run on walls/floors/cable and equipment structures etc. shall be<br />
supported at suitable intervals and painted with black oxide paint.<br />
The armour of cables and all conduits for cables shall also be connected to the earthing m mmains.<br />
A continuous earth strip shall run in each side of cable channel and in cable ducts/tray route.<br />
All joints in the branch connections except at earthing electrode shall be welded and painted<br />
black. At road/rail crossings earthing strips/rods shall be laid through conduits/concrete ducts.<br />
Technical Specification:Sec-6, Electrical<br />
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The armour of cables and all conduits for cables shall also be connected to the earthing mains.<br />
A continuous earth strip shall run in each side of cable trenches.<br />
All joints in the run of the main earthing conductors will be welded or brazed type. Connection<br />
to equipment structure shall be bolted type. All welded jjoints<br />
oints shall be protected from<br />
corrosion by applying bitumen paint.<br />
Earthing system shall be distinct and separate from the lightning equipment earthing system.<br />
Earthing Conductors and Installation Accessories for Equipment Earthing System<br />
All electrical equipment installed by the successful Bidder as well as equipment installed by<br />
Purchaser shall be effectively earthed in conformity with relevant clauses of Indian Electricity<br />
Rules (1956) and in accordance with IS: 3043 to the complete sati satisfaction sfaction of the Chief<br />
Electrical Inspector to Government of Orissa State. All non non-current current carrying metallic conduit<br />
parts of various electrical equipment as well as cable armouring, metallic conduits, GI pipe,<br />
cable racks, trays, brackets, supporting struc structures tures etc. shall be effectively earthed.<br />
Main earth mat comprising 40 mm dia MS rods and earth electrodes and riser upto + 1.0 M<br />
level shall be supplied and installed by the ownr. All other equipment to complete the earthing<br />
of equipment installed by the Bidder shall be in the scope of the Bidder. The Bidder shall also<br />
connect his sub earth mat to the main earth mat provided by the Bidder.<br />
Conductor size adopted for earthing ring shall in no case be less than that of the earth<br />
continuity conductors conn connected ected to it. The size of conductors used for overground sub earth<br />
mat in switchgear rooms/ control rooms/ plant buildings/ areas shall be 65 mm x 8 mm<br />
galvanized mild steel strips. 50 mmx 6mm galvanized MS strips will be used for earth buses<br />
inside the buildings/ ldings/ floors/ platforms etc. and also for earth conductors laid along cable trays.<br />
For buildings having a number of floors, separate earthing ring shall be established in each<br />
floor and shall in turn be connected to the Purchaser’s earth mat.<br />
Separate earthing system shall in no case have cross cross-sectional sectional area less than 6 sq mm stranded<br />
GI wire.<br />
Size of earth conductors selected for system earthing and earthing of various equipments shall<br />
be as follows.<br />
Galvanized Iron flat conductor strips shall be used for neutral earthing. The minimum size of<br />
conductors for neutral earthing of various transformers shall be as given below unless a higher<br />
size is required from the viewpoint of higher available fault current.<br />
LV neutral of 33/0.440 kV, 1600 KVA tran transformers : 75mm x 10mm<br />
The minimum size of galvanized Iron flats for earthing of various equipment shall be as<br />
follows:<br />
Technical Specification:Sec-6, Electrical<br />
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Ring mains<br />
LT PCCs/board<br />
Control Panels<br />
LT Busducts<br />
DC Distribution Board<br />
LDB<br />
SLDB<br />
Push button station<br />
Transformer bodies<br />
Cable tray (running earthing)<br />
LIGHTNING PROTECTION<br />
All buildings and d plant structures including switchgear building and junction houses shall be<br />
protected against atmospheric flash over and lightning strokes in such a manner as to<br />
eliminate any danger to the personnel employed therein. Stipulations of IS : 2309 - 1969 shall<br />
be followed.<br />
A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and steel<br />
structures crossing this cage ring shall be laid around plant as earthing device. This shall be<br />
separate from the electrical equipment earthing ri ring main.<br />
Design shall be as per the standard like IS 2309 (latest revision) and Indian Electricity Rules.<br />
All lightning arrestor earth leads of the plant shall be connected to this cage ring.<br />
Air termination network should cover all salient points of the structure. All metallic structures,<br />
ducts and the like above the roof of the structure shall be bonded to and form part of the air<br />
termination network. Vertical air termination points shall project at least 30 cm above the<br />
object on which it is fixed.<br />
Down conductors shall follow the most direct path possible between air termination and earth<br />
termination avoiding sharp bends. Down conductor shall have a testing point adjacent to the<br />
earth electrode. Each conductor shall have an independent earth termination. All earth<br />
terminations shall be interconnected.<br />
Earthing electrodes and grid for lightning protection will be distinct separate from the earthing<br />
system for earthing of electrical equipment and at no place will be connected to other<br />
earthing system.<br />
4.16 MISCELLANEOUS ELECTRICS<br />
SAFETY<br />
Technical Specification:Sec-6, Electrical<br />
: 75mm x 10mm<br />
: 65mm x 8mm<br />
: 50mm x 6mm<br />
: 50mm x 6mm<br />
DC Distribution Board : 50mm x 6mm<br />
: 50mm x 6mm<br />
: 25mm x 3mm<br />
: 6 sq mm stranded<br />
: 50mm x 6mm<br />
Cable tray (running earthing) : 50mm x 6mm<br />
Page 69 of 97
All equipment shall be complete with approved safety devices wherever potential hazard to<br />
personnel exists and with provision for safe access of personnel to and around equipment for<br />
operational and maintenance functions. The design shall include all reaso reasonable precautions<br />
and provisions for the safety of operating and maintenance personnel.<br />
Special care shall be taken to make enclosed equipment proof against entry of rats, lizards and<br />
other creeping reptiles which may create electrical short short- circuits inside side live equipment.<br />
MINOR CIVIL WORKS<br />
Minor civil works associated with cabling, earthing, conduit installation, illumination systems,<br />
lighting poles, for buried cables, for erection of equipment supplied by the Bidder, foundation<br />
of lighting masts/poles, es, etc shall be included under scope of bidder. Similarly minor civil works<br />
like widening of floor openings / cable trenches, wall opening for cables, minor chipping, etc<br />
shall be included under scope of bidder.<br />
LOCAL CONTROL STATION<br />
Near all drives local cal control stations shall be provided. Local stations shall have Cast<br />
Aluminium body, dust and vermin proof, and structure mounting. Stat and stop push buttons<br />
shall be mounted on front hinged gasketted and lockable door. Local/remote selector switches<br />
shall all be provided on local control stations. Stop push button shall be lockable type. In addition,<br />
ammeters shall be provided on local control stations for HT drives. Suitable knockouts with<br />
glands shall be provided on the bottom or top cover for cable entry entry. . Terminals shall be suitable<br />
for 2 cores of 2.5 sq.mm conductors with 10% spare terminals. Enclosure shall be conforming<br />
to IP55 with proper rain canopy.<br />
ELECTRICS OF DUST SUPPRESSION SYSTEM<br />
Bidder shall include complete electrics of dust suppression systems coming in the scope within<br />
the battery limit. Bidder shall provide complete electrics including MCC, drives/mechanism,<br />
associated cabling & their termination, local DBs, all power and control ccessories, all related<br />
annunciations, etc.<br />
ELECTRICS OF AIR-CONDITIONING CONDITIONING AND VENTILATION SYSTEM<br />
Bidder shall include complete electrics of air air-conditioning conditioning system and ventilation system.<br />
Complete electrics for the following shall be included:<br />
• Ventilation system for the switchgear cum MCC room at WT SYSTEM substation<br />
• Exhaust fans for the two numbers transformer rooms at WT SYSTEM substation<br />
• Air-conditioning conditioning system for the battery and battery charger room at WT SYSTEM<br />
substation<br />
• Ventilation system stem for dust suppression MCC room<br />
WT SYSTEM ELECTRICS OF HOISTING AND HANDLING EQUIPMENT<br />
Technical Specification:Sec-6, Electrical<br />
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Bidder shall include complete electrics of hoists coming in the scope within the battery limit.<br />
Bidder shall provide complete electrics including source feeders, associated cabling & their<br />
termination, local DBs, all power and control accessories, all rela related ted annunciations, etc.<br />
All the hoist control panel shall be located at workable height and platform shall be provided<br />
for each hoist at one point for maintenance purpose.<br />
33 KV OVERHEAD LINES<br />
In coming power supply to Wagon tippler, apron feeder, & conveyor system will be taken<br />
from 33KV Lean Slurry substation located near the 220KV switch yard with provision of<br />
lighting arrester, load brake switch, 33KV VCB, CT,PT relay and control panel housed in a<br />
suitable building comes under bidder’s scope. Layi Laying ng Power cable/Transmission line from<br />
the substation to wagon tippler area along with provision of transformer, switch gear system<br />
& panels will be the scope of the bidder. Approximate distance from the substation to the<br />
wagon tippler area will be 2.00 KKm.<br />
m. However, actual distance & Suitable route for laying of<br />
cable will be assessed by the party in consultation with NALCO. The transmission line(33 KV)<br />
where ever crossing roads shall be through double run underground cabling arrangement as<br />
per relevant regulations. gulations.<br />
The bidder shall also execute underground cabling and other necessary work for crossing<br />
railway track of the existing Intake Pump House and Ash pond 33KV overhead transmission<br />
lines with provision of DP,lighting arrester and associated switchge switchgear.<br />
Cost of power cable/transmission line shall be in scope of bidder.<br />
RS joist poles of size to 200 X 100 mm shall be erected by excavation of pit size 700 mm X<br />
700 mm to a depth of 1/5th of the pole. The pole shall be erected upright to the plumb. MS<br />
channel shall, be used for ‘V’ type cross arm of size 100 X 50 X 6.4 mm. The spacing between<br />
two extreme conductors shall be 1100 mm and the 3rd conductor shall be provided on the<br />
top of the mast. Suitable porcelain pin type insulators shall be used. A con continuous earth wire<br />
shall be provided for RS joist pole earthing and securely fastened to each pole and<br />
connected to earth, at 4 points in every 1.6 km, the spacing between the points, being as<br />
nearly equidistant as possible. Galvanized steel guard wire mes mesh h having breaking strength of<br />
635 kg shall be connected to earth at different points and shall be used in over head while<br />
crossing street/passage. Suitable lightening arrester shall be provided in the four pole<br />
structure.<br />
Suitable route for 33KV V overhead transmission line will be decided by the bidder in<br />
consultation/coordinating with NALCO to avoid any local/field interference.<br />
HT transformer of suitable capacity (33KV/0.44KV) KV) will be supplied by the bidder confirming to<br />
latest features. Supply y of associated switch gear and measuring equipments will be supplied<br />
by the bidder for the HT system.<br />
Technical Specification:Sec-6, Electrical<br />
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Technical details of HT transformer and other switch gear will be submitted to NALCO / RITES<br />
for its approval. The conductor for 33KV line shall be of AACSR<br />
CSR (dog/Rabbit) type.<br />
The HT transformer (33KV/ (33KV/0.44KV) shall ll be located in the near the wagon tippler area. The<br />
switch gear will be designed in conformity to CEA norms having provision of LA, PT, CT, ISO etc.<br />
Fencing and development of switch gear will be the scope of the bidder. The switch gear will<br />
be located near wagon tippler area.<br />
Room size to be decided by the bidder to house all required equipments (HT & LT switch<br />
gears) at the ground floor.<br />
WT Control room and operating panel will be located aat<br />
t first floor of the building.<br />
Bidders are also advised to visit the site and assess the actual quantum of work to be done for<br />
this diversion and include accordingly.<br />
The operation of the WT SYSTEM plant shall be monitored and controlled from the proposed<br />
WT control rooms by means of VDU operator interface on a microprocessor based<br />
programmable logic controller (PLC). The system shall be envisaged for the purpose of initial<br />
operation, protection and interlock, data acquisition, close loop control, data a aarchiving,<br />
etc for<br />
fully automatic operation. The system shall be capable of monitoring and displaying the status<br />
of equipment, including the analog and digital signal displaying of status in the form of<br />
diagram, trend bar chart, overview, logs, etc with th the e help of CRT, keyboard, mouse and<br />
printers.<br />
Necessary hardware and software license of the proposed PLC shall be provided provided. PLC<br />
programme, ladder logic and control philosophy shall be submitted by the bidder for approval<br />
of NALCO/RITES.<br />
The preferred make of PLC shall be GE GE-FANUC make.<br />
33 kV Unit Vacuum Circuit Breaker<br />
33 kV indoor Vacuum Circuit Breaker shall conform to the following technical particulars:<br />
i) Type<br />
Indoor, Vacuum type, electrically operated,<br />
trip free type, panel mounted<br />
ii) Quantity<br />
iii) System Voltage 33 kV<br />
iv) Maximum system voltage 36 kV<br />
v) Continuous current As per requirement<br />
vi) Rated short time current rating 31.5 kA for 3 sec<br />
vii) Interrupting capacity at 36 kV 31.5kA<br />
Technical Specification:Sec-6, Electrical<br />
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The VCB shall be indoor drawout type with numerical type over current (50+51), earth fault<br />
(51N) relay with timer for instantaneous overcurrent protection as we as master<br />
trip and trip circuit supervision relay. The VCB shall be capable of withstanding through fault<br />
current of 31.5kA for 3 sec. and shall be provided with remote closing and<br />
tripping facilities. Under voltage relay with timer shall be provided in line PT.<br />
transformer nsformer differential protection shall also be provided. PT shall be provided with protection<br />
core of 3P class and metering core of CL 0.5. CT shall be provided with protection core of<br />
5P20 class and metering core of CL 0.5. For transf transformer ormer differential protection PS class CT shall<br />
be considered.<br />
The closing coil of the breaker shall be suitable for operation between 85 to 110 percent<br />
of 220 V DC control power supply voltage available from batteries.<br />
The circuit breaker shall have redundant shunt trip device. The trip coil shall be designed<br />
to operate satisfactorily when the voltage at the terminals of the shunt trip coils is<br />
between 70 to 110 per cent of 220 V DC control power supply voltage available from<br />
batteries. VCB B shall be provided with dual trip coil. For actuation of trip coils, similar set of<br />
contacts shall be provided separately for each trip coil. Hence, necessary arrangement for<br />
duplication of contacts shall be done inside the pane panel l if multiple No. of similar contacts are not<br />
available.<br />
The circuit breaker shall be power operated with motor wound spring closing mechanism with<br />
electrical spring release coil. The motor shall be suitable for operation on 240 V AC single phase<br />
supply. Means shall however be provided for manual operation of the breaker under<br />
emergency or for testing and adjustments.<br />
The operating mechanism shall be anti pumping and trip free type.<br />
The spring operated perated mechanism shall be so designed that the spring gets automatically<br />
recharged immediately after closing.<br />
Imploding type surge suppressor and earthing truck with full capacity circuit breaker, three<br />
(3) Nos. single phase e PT, selector switch and test plugs shall be considered at the outgoing side of<br />
VCB.<br />
Both incoming and outgoing terminals of VCB shall be suitable for terminating 33 kV (E)<br />
grade XLPE insulated PVC sheathed, 3core, aluminium condu conductor cables.<br />
The circuit breaker shall be provided with necessary auxiliary switches for indication,<br />
control, interlocking, protection and alarm. Six spare auxiliary contacts, three (3) NC and<br />
three (3) NO shall be left eft free in the breaker. All the contacts shall be wired to the terminal<br />
block.<br />
Space heaters to prevent moisture condensation within the enclosure shall be provided in<br />
relay and control cubicle. Heaters shall be suitable for opera operation tion from 230 V, AC 50 Hz, single<br />
phase supply.<br />
Technical Specification:Sec-6, Electrical<br />
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33kV Control and Relay Panel<br />
One (1) set of relay and control panels consisting of two (2) feeders and PT complete<br />
with mimic buses, instruments, controls, indication, alarm annunciation relays and<br />
alarm facia and protection relays as required for th the e 33 kV feeder for the proposed plant and<br />
as described below shall be provided.<br />
The mimic diagram shall provide single line representation of the 33 kV<br />
system. The control and relay panel shall be located inside the room for new 33 kV VCB<br />
panel.<br />
The relay and control panel shall be floor mounted type, having sheet steel of 2.5 mm<br />
thickness. A equipment shall be mounted such that removal and rreplacement<br />
eplacement may be<br />
accomplished individually without interruption of service to adjacent equipment. The relay and<br />
control panel shall have rear access.<br />
Test devices shall be provided for C.T. circuits. CTs shall not be open ci circuited rcuited during testing<br />
operation.<br />
Adequate illumination shall be provided inside each cubicle. CFL lamps suitable for 230 V,<br />
50 Hz, single phase supply shall be provided.<br />
Potential circuits for instrumentation aand<br />
nd for metering each shall be protected by<br />
suitable MPCB/MCB.<br />
Annunciator shall be suitable for 220 V DC operation. It shall have a single DC alarm common to<br />
all points.<br />
Space heaters to prevent moisture condensation wi within thin the enclosure shall be provided in<br />
relay and control cubicle. Heaters shall be suitable for operation from 230 V, AC 50 Hz, single<br />
phase supply.<br />
A relay shall be numerical type having communication port conforming commun communication<br />
protocol as per IEC61850 for direct interfacing with plant<br />
PLC/DCS/SCADA system. Numerical relay shall be capable to receive minimum adequate<br />
nos. inputs and output contacts.<br />
415-240 V AC Distribution Board (ACDB (ACDB)<br />
415 V, 3phase, 4wire ACDB shall be provided which will be fed from the secondary side of<br />
33/0.433kV auxiliary control transformer. The auxiliary transformers shall be<br />
tapped from before the incoming HT circuit breakers over HT load break isolator, HRC fuse<br />
and voltmeter. The distribution board shall be provided with two incoming feeders, each<br />
comprising one MCCB and one magnetic contactor connected to one comm common set of busbars.<br />
ACDB shall be floor mounted, totally enclosed, fully compartmentalised, multitier single<br />
Technical Specification:Sec-6, Electrical<br />
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front design. The distribution board shall be suitable for cable entry from the bottom.<br />
Devices requiring operation sh shall all be located in between 450 mm and 1900 mm from the floor<br />
level .<br />
The ACDB shall have indicating voltmeter with selector switch, PT, MPCB & MCB at the line<br />
side of the distribution board. Ammeter with selector switch, CT, MPCB & MCB shall<br />
also be provided. These instruments shall be flush type located on the front door of the<br />
compartments. The sizes of ammeter and voltmeter shall be 96 mm x 96 mm. Phase<br />
indicating lamps shall be provided vided at the bus side of incomer.<br />
The ACDB shall be fabricated from minimum 2.0 mm thick CRCA sheet steel with load<br />
bearing members comprising 2.5 mm thick CRCA sheet steel. The degree of protection<br />
shall be IP:54.<br />
A the outgoing feeders shall be of MCCB/MCB unit.<br />
Power circuit isolation shall be possible without opening the front door and shall have<br />
provision for padlocking in OFF position with the door closed. ON/OFF indications<br />
shall be provided for a feeders by means of cluster LED lamps.<br />
The main phase busbars and tappings shall be made of aluminium having cross sectional<br />
areas to be substantiated during en engineering gineering but in no case the current density shall<br />
be more than 80 A/sq cm. The busbars shall be suitably supported on non hygroscopic<br />
moulded glass reinforced plastic insulators so as to be capable of withstand withstanding dynamic<br />
forces due to 50 kA through fault short circuit. All joints shall be coloured PVC taped.<br />
Temperature rise of busbars/joints while carrying the rated current shall not be more<br />
than 45°C over maximum ambie ambient nt temperature of 45°C when measured by thermometer.<br />
Tappings from the main busbars to individual feeder compartments shall be by means of<br />
insulated single core copper cables with stranded conductor for feeders upto 100 A ratings<br />
above which aluminium busbars shall be used. All copper to aluminium joints shall be<br />
provided with bimetallic nuts/bolts/washers.<br />
A continuous 50 mm x 10 mm aluminium earth bus shall be provided throughout the<br />
length gth of the panels and shall be located in a separate chamber at the bottom with<br />
removable front cover. Provision shall be kept for taking earth connections to external earth<br />
mat. PVC insulated (Green coloured) copper wires shal shall l be used to connect all noncurrent<br />
carrying metallic parts, doors, etc to the earth bus.<br />
All relays, instruments, meters, pushbuttons, switches and other devices of any feeder<br />
shall be located on the respective compartment only.<br />
All operating handles, control switches, pushbuttons, indicating lamps, instruments, meters<br />
etc shall be mounted on the front of the cubicles.<br />
220 V DC Control Battery Bank<br />
Battery bank shall consist st of plante type lead acid cells in transparent plastic containers<br />
with sufficient quantity of electrolyte, acid level indicating floats, intercell connectors,<br />
cell support insulators, cell number plates, properly ttreated<br />
reated and acid resistant painted<br />
wooden stand supported on porcelain insulators, terminal connectors for external<br />
connections etc. as required to make the installation complete in all respects. The wooden<br />
Technical Specification:Sec-6, Electrical<br />
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stands shall be made of good quality teak wood suitably treated with two coats of<br />
linseed oil and three coats of antisulphuric acid paint.<br />
Inter row and intertier connectors for the batteries shall be made of copper coated<br />
with lead. The terminals of each cell shall be indelibly identified for polarity. The<br />
terminals of battery outgoing leads shall have provision for connecting lead coated<br />
copper bars which shall be suitably extended upto the room wall for termination of external<br />
aluminium conductor, XLPE insulated cables. Suitably terminals shall also be provided for takin taking<br />
external connections from cell by aluminium conductor XLPE insulated cables.<br />
The cells shall be delivered in dry and discharged condition. Sufficient quantity of electrolyte<br />
ready to fill condition shall be supplied for tthe<br />
he first filling of the batteries in nonreturnable<br />
airtight plastic/polypropylene containers. Ten (10) percent extra electrolyte shall also be<br />
provided.<br />
Complete battery maintenance equipment required for conven convenient and safe handling and<br />
preparation of electrolyte shall be supplied with the battery bank. These shall include<br />
but not be limited to items like syringe type hydrometer,<br />
mercury in glass thermometer calibrated 0 to 100<br />
and one thermometer, syringe, level testing tube, 150 mm dia glass funnel, spanners, centre<br />
zero cell testing voltmeters, PVC gl<br />
o ient and safe handling and<br />
preparation of electrolyte shall be supplied with the battery bank. These shall include<br />
but not be limited to items like syringe type hydrometer,<br />
C, wall mounted holder for one hydrometer<br />
and one thermometer, syringe, level testing tube, 150 mm dia glass funnel, spanners, centre<br />
zero cell testing voltmeters, PVC gloves, PVC jug, etc.<br />
Load Break Switch (LBS)<br />
Load break switch panel shall consist of the following:<br />
33 KV, 31.5 KA rated HT air break/load break switch suitably interlocked with earth switch shall be<br />
provided. It shall be with front operated spring as assisted sisted manual mechanism with 2 N/O and 2 N/C<br />
auxiliary contacts. It shall contain:<br />
ON/OFF indication lamp – 2 Nos.<br />
Suitably rated copper busbar – 1 set<br />
Space heater with thermo start and switch control<br />
Mechanical interlocks<br />
Provision of receiving incoming coming 33 KV XLPE cable at bottom.<br />
Ring Main Gear (RNG):<br />
The ring main gear shall be indoor type and shall consist of one No. 33 KV suitably rated, short<br />
rating 31.5 KA, load breaks switch with interlocked earth switch front operated spring assisted<br />
manual closing mechanism horizontal draw out, horizontal isolation VCB fitted with motor<br />
operated charging mechanism for controlling the outgoing supply.<br />
Rated voltage – 33 KV<br />
Rated Current- as per requirement<br />
Frequency – 50 Hz<br />
Cubicle – Floor mounted fr free standing dust and vermin proof.<br />
Technical Specification:Sec-6, Electrical<br />
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Encl: IP-45<br />
Control voltage – 220 V DC<br />
BELT SWAY SWITCH<br />
The belt sway switch shall be shall be auto reset type and provided at both ends and at an<br />
interval of 50 mtrs (for conveyor length greater that 200 mtrs) on both sides of conveyors and<br />
also before and after belt weighing system on both sides. It shall be of auto reset type.<br />
The belt sway switch shall be industrial heavy duty type housed in dust and vermin proof box<br />
with degree of protection IP IP-54. 54. The switch shall be designed that conveyor does not come in<br />
direct contact with the switches and mechanism shall have strong rest spring to absorb high<br />
impact of loaded belt edge.<br />
The switch element shall be self rest type and shall have 2NO+2NC contacts each rated for<br />
10A, 240V AC. It shall be suitable for ambient temp. of 600C. Resetting spring mechanism,<br />
built in terminal box, actuating ctuating rollers, roller shafts, supporting frame, etc shall be provided as<br />
per requirement. Belt sway switch shall be J&N make.<br />
PULL CHORD SWITCH<br />
Pull chord switches shall be auto reset type industrial heavy duty enclosed in dust and vermin<br />
proof enclosure with degree of protection IP IP-65. 65. They shall be provided with following<br />
facilities;<br />
• Switch elements shall be 2NO+2NC each rated for 10A, 240V AC.<br />
• Automatic locking arrangement in the operated position with manually reset<br />
• Snap action type for posi positive operation of contacts<br />
• Number of position shall be 11-0-1<br />
• Separate compartment for built in terminal box<br />
• Suitable base plate Pull rope shall be stranded galvanized steel wire with at least 1<br />
mm thick PVC cover and having overall diameter of 6mm to 7m 7mm. m.<br />
Pull rope switch shall be placed at an interval of 25 mtr on both sides of conveyor with<br />
minimum of one pair for conveyor length less than 25 mtr.<br />
ZERO SPEED SWITCH<br />
The unit shall be provided with MS flags, sensing probes, monitoring unit and inte interconnecting<br />
special cables. The unit shall be of multi speed range with setting facility and shall be provided<br />
with output contacts (2NO+2NC) with facility for initial bypass adjustable time delay, nuisance<br />
tripping delay and analog/digital speed display. 4-20mA 20mA isolated DC signal shall be applicable<br />
for external metering. Sensing probe shall be provided with metallic enclosure of degree of<br />
protection IP-67 67 and LED lamp for visual indication of correct functioning of sensing probe.<br />
Technical Specification:Sec-6, Electrical<br />
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PASSIVE FIRE PROTECTION<br />
Fire protection for cables at entry/exit points of the wall shall be provided with proper sealing<br />
by fire sealing material. The fire sealing compound shall be rated for minimum 2 Hours. Fire<br />
retardant painting shall also be provided on cables for 2 Mtrs on both sides of the wall/floor<br />
crossing.<br />
ERECTION & INSTALLATION ACCESSORIES<br />
All cable accessories like conduits, inserts, cable tag markers, clamps, sealing compound, pull<br />
boxes, marshalling boxes etc. shall be considered as part of the Bidders scop scope to complete the<br />
erection job in all respect.<br />
OTHER ITEMS<br />
Bidder shall provide all required switches, cabling and other devices needed for proper<br />
control, operation, interlocking and sequencing of the any other offered systems and<br />
technological mechanism, if specified in technological, e.g. hanging magnets and wi wipers (if<br />
applicable), roof exhaust fans & wall exhaust fans (if applicable), etc.<br />
All required safety items like rubber mats in front of MCC/DB/Panel, shock treatment chart,<br />
first aid boxes, danger boards, boards indicating 'Man on Work, Do not switch ON ON', 'Do not<br />
switch OFF', 'EARTHED' etc. shall be provided in each electrical premises.<br />
Wall mounted aux. AC and DC distribution boards shall be provided in sufficient number to<br />
facilitate proper distribution of the power supply to various users.<br />
Bidder to include closing of all cable and panel openings through a Fire sealing material. This<br />
shall include closing of all bottom opening of control room panels/desks, MCC switch boards,<br />
wall openings in all the areas, etc. Bidder shall also include earthing of all equipments/system,<br />
wherever required, under his scope of supply.<br />
Bidder shall include painting of all the plant and equipment with approved shades and include<br />
primers as well as finishing paints.<br />
Sufficient quantity of GI ladder type factory fabri fabricated cated cable trays made from 2.5 mm thick hot<br />
welded steel sheets grade ‘o’ as per IS: 2062 shall be provided. Hot dip galvanizing of 85<br />
micron thick as per IS-2629, 2629, IS IS-4759 and IS- 209. Trays shall be of standard length of 3 m with<br />
max deflection not exceeding ding 1/400 of span with sufficient load bearing capacity.<br />
4.16 ERECTION OF ELECTRICAL EQUIPMENT<br />
Bidder shall include erection of all the equipment under his scope of supply. Erection of<br />
equipment shall have to be carried out as follows:<br />
Technical Specification:Sec-6, Electrical<br />
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1. Procedure mentioned in manufacturer’s manual<br />
2. Under the expert supervision<br />
3. Sequence and plan of erection as per the guidance of Purchaser’s Site In charge or their<br />
consultant<br />
4. During erection of supplier’s equipment, existing equipment /system shall not be<br />
disturbed.<br />
5. Erection shall be in accordance with approved layout drawing and installation details.<br />
6. Cable laying shall be as per approved cable layout drawings and work shall be carried<br />
out in a neat manner.<br />
All erection-installation installation accessories required for erectio erection/installation n/installation of equipment and<br />
handling equipment required for handling of equipment from store to installation site are<br />
included in the scope of work of Bidder as a whole.<br />
Bidder shall ensure that the work erection and erected equipment shall comply wit with all<br />
statutory norms, regulations and standards applicable to the works/equipment and any<br />
additional work/equipment required, if any, shall be under scope of the Bidder.<br />
Necessary clearance from the wall shall be maintained as per IS/IE Rules from front/ front/rear/ side<br />
of all the panels inside a room.<br />
HT Power cables and LT power/control cables shall be laid in different cable trays. LT power<br />
cables and LT control cables shall also be laid in different trays, however, if necessity arises<br />
due to space constraints ints or lesser number of cables, LT power cables and LT control cables can<br />
be put on the same trays keeping sufficient gap between them. 24V DC cables, if required,<br />
shall be laid entirely in different dedicated trays.<br />
Cable trays in single tier or in mul multitier titier shall be installed in vertical arrangement everywhere to<br />
avert coal accumulation and space reduction.<br />
Fire Prevention:-<br />
Proper design and use of quality material, equipment so as to avoid overloading in<br />
Distribution board, wiring system including sub main, switch & sockets shall be ensured by the<br />
bidder.<br />
Insulating mats in front of PCC, MCC or control panel, protective rubber gloves, earth rods,<br />
artificial respiration apparatus, line man’s belt etc shall be provided in substations by the<br />
bidder.<br />
Fire re extinguishers for various switch gear location, substations, PCC, MCC suitable for<br />
electrical fire (class –C) C) like dry chemical powder, carbon carbon-dioxide, dioxide, carbon carbon-tetra chloride type<br />
shall be provided along with fire buckets filled with sands.<br />
Comprehensive fire protection system in conformity with the requirements of national<br />
building code, ECBC 2007 shall be ensured by the bidder.<br />
5.0 INSPECTION AND TESTING<br />
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5.1 Inspection<br />
Extent of inspection<br />
The extent of inspection & testing by the Purchaser shall vary from equipment to equipment<br />
as per design requirements.<br />
However, indicative extent of inspection for electrical equipment is furnished below:<br />
Extent of inspection to be carried out shall be finalised with the Contractor after award of the<br />
contract on the basis of scope of supply, technical specification and approved GA drawings.<br />
However, in case of similar bulk manufactured items, methods of sampling for inspection of<br />
different lots shall be governed by relevant Indian or inter international national standards.<br />
In case of critical components, the Purchaser reserves the right to undertake 100% inspection.<br />
Final inspection & testing shall be done as per the following:<br />
• Verification of test certificates<br />
• Visual, Workmanship & painting<br />
• Dimensional<br />
• Witnessing of routine/acceptance/type/special tests as per relevant standards.<br />
• Witnessing of proto-type type tests, as applicable<br />
• Verification of type test certificates for identical equipment<br />
• Approved QAP<br />
The inspection shall be carried out on the basis of QAP dully approved by Purchaser /<br />
consultant.<br />
INSPECTION CATEGORIES<br />
All the electrical equipment have been classified in three categories for inspection and issuing<br />
dispatch clearance by the Purchaser/consultant. The three categories are:<br />
Category-A<br />
All the tests shall be inspected by the Purchaser/Consultant. Dispatch clearance shall be given<br />
by Purchaser/Consultant haser/Consultant after the equipment is inspected and found as per requirement and<br />
as per TS. All types tests certificates shall e submitted by the Bidder in this case.<br />
Category-B<br />
Inspection shall be carried out by prime bidder and inspection waiver cert certificate ificate shall be issued<br />
by Purchaser/Consultant based on type test certificates and routine tests certificates furnished<br />
by the Bidder. Purchaser/Consultant shall issue dispatch clearance accordingly.<br />
Category-C<br />
Technical Specification:Sec-6, Electrical<br />
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Dispatch clearance shall be given by Prime bidder without any certificates based on technical<br />
data sheet furnished by the Bidder.<br />
5.2 Testing<br />
General<br />
S. N. DESCRIPTION<br />
1 HT CABLE<br />
2 LT MOTORS<br />
3 LT POWER AND CONTROL CABLES<br />
4 MCC<br />
5 TRANSFORMER<br />
6 PLC & CONTROL DESK<br />
7 UPS<br />
8 ON LOAD 33 kV ISOLATOR<br />
9 TRAILING CABLE / FLEXIBLE (EPR) CABLE<br />
10 PDB/LDB/SLDB/AUX. PDB<br />
11 SIGNAL, INSTRUMENTATION AND OTHER SPECIAL CABLES<br />
12 CABLE ACCESSORIE<br />
13 LIGHT FITTINGS<br />
14 EARTHING AND LIGHTNING PROTECTION MATERIALS<br />
15 FIRE SEALING MATERIALS<br />
16 LOCAL PUSH BUTTON STATIONS<br />
17 POWER SOCKET CABINET AND LIGHTING CABINET<br />
18 CONTROL AND RELAY PANEL<br />
19 415V FEEDER PILLAR<br />
20 33KV VCB<br />
21 LT DISTRIBUTION BOARD<br />
22 33KV LIGHTENING ARRESTER<br />
23 33KV ISOLATOR AND EARTH SWITCH<br />
24 33KV CT,PT<br />
25 BATTERY,BATTTERY CHARGER,DCDB<br />
26 FIRE EXTINGUISHER<br />
27 JB,RUBBER MAT,DANGER BOARD,FIRE BUCKET,FIRST AID<br />
BOX,HAND GLOVES,SHOCK TREATMENT CHART,DISCHARGE<br />
ROD.MEGGAR<br />
Test of all equipment shall be conducted as per latest BIS. Wherever no such standard exists,<br />
tests shall be as per International Standards like IEC/DIN/BS/IEEL/JIS, etc.<br />
All routine tests shall be carried out at manufacturer's works in presence of Purchaser or his<br />
representative.<br />
Technical Specification:Sec-6, Electrical<br />
INSPECTION<br />
CATEGORY<br />
A<br />
A<br />
A<br />
A<br />
A<br />
A<br />
A<br />
A<br />
A<br />
A<br />
A<br />
A<br />
B<br />
B<br />
B<br />
B<br />
B<br />
B<br />
B<br />
B<br />
B<br />
Page 81 of 97<br />
C<br />
C<br />
C<br />
C<br />
C<br />
C
The Bidder shall submit type test certificates (not more than 5 years old) for similar equipment<br />
supplied by him elsewhere. In case type test ccertificates<br />
ertificates for similar equipment is not available,<br />
the same shall be conducted in presence of Purchaser or his representative, without any<br />
financial implications to Purchaser.<br />
The Bidder shall be responsible for satisfactorily working of complete integr integrated system and<br />
guaranteed performance.<br />
Site Tests and Checks<br />
General<br />
All the equipments shall be tested at site to know their condition and to prove suitability for<br />
required performance.<br />
The test indicated in following pages shall be conducted after installation. All tools, accessories<br />
and required instruments shall have to be arranged by contractor. Any other test which is<br />
considered necessary by the manufacturer of the equipment, contractor or mentioned in<br />
commissioning manual has to be conducted aat<br />
site.<br />
In addition to tests on individual equipment, some tests/checks are to be conducted /<br />
observed from overall system point of view. Such checks are highlighted under miscellaneous<br />
tests but these shall not be limited to as indicated and shall be fi finalized nalized with consultation of<br />
client before charging of the system.<br />
The contractor shall be responsible for satisfactory working of complete integrated system and<br />
guaranteed performance.<br />
All checks and tests shall be conducted in the presence of client’ client’s s representative and test<br />
results shall be submitted in six copies to client and one copy to Electrical Inspector. Test<br />
results shall be filled in proper Performa.<br />
After clearance from Electrical Inspector system/ equipment shall be charged in step by step<br />
method.<br />
Based on the test results clear cut observation shall be indicated by testing engineer with<br />
regard to suitability for charging of the equipment or reason reasons s for not charging are to be<br />
brought by the contractor.<br />
Trial Run Test<br />
After the successful test of each equipment as per standard test procedure the entire control<br />
system shall be put on trial run test on actual site conditions and operation of the sy system.<br />
Acceptance Test<br />
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The acceptance test on the system shall be carried out by the supplier as per mutually agreed<br />
test procedures to establish satisfactorily functioning of the system as a whole and each<br />
equipment as part of the system.<br />
Site Tests<br />
The tests to be carried out on the equipment at pre pre-commissioning commissioning stage shall include<br />
following but not limited to the following:<br />
MCC<br />
1. IR test before and after HV test.<br />
2. HV test with 2.5 kV megger<br />
3. Functional test for all feeders<br />
4. Testing and calibration of all meters<br />
5. Checking and calibration of protective relays as per supplier's commissioning manuals<br />
6. Check operation of contactors from local and remote points<br />
7. Checking of interlockings between incomers/bus coupler and other feeders.<br />
8. Test to prove interchangeability of similar parts<br />
9. Tests to prove correct operation of breakers at minimum and maximum specified<br />
control voltages<br />
10. Checking of earthing connection fo for neutral-earth earth bus, cable armour, location of E/F CT<br />
etc. as per the scheme.<br />
11. Check test, service and drawout position of all the breakers and operations of<br />
mechanical flag indicator and electrical indication lamps.<br />
12. Check functioning of various elect. sc schemes hemes like autochangeover signalling etc.<br />
13. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and<br />
between phases in off position<br />
MOTORS<br />
1. IR test of stator and rotor windings.<br />
2. Ensure that checking/testing of associated switchboard<br />
switchboard, , cables, relays /meter<br />
interlocks as mentioned in relevant are completed.<br />
3. Check tightness of cable connection<br />
4. Winding resistance measurement of stator and rotor.<br />
5. Checking continuity of winding.<br />
6. Check tightness of earth connections.<br />
7. Check space heaters and carryout heating of winding (if required)<br />
8. Check direction of rotation in de de-coupled coupled condition during kick start<br />
9. Measure no load current for all phases.<br />
10. Measurement of temperature of body during no load and load conditions.<br />
11. Check for tripping of motor from local/remote switches and from<br />
electrical/technological protection.<br />
12. Checking of vibration<br />
13. Checking of noise level<br />
14. Shaft voltage measurement (if required)<br />
15. Tan delta test, if required<br />
Technical Specification:Sec-6, Electrical<br />
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16. During load running, measurement of stator and bearing temperatures (if applicable)<br />
for every half an hour interval till saturation comes.<br />
17. Checking tightness of foundation bolts<br />
18. Check operation of speed switch (if there)<br />
19. Check continuity of temp. detectors.<br />
20. Check alignment, paralleling oof<br />
f shafts, level of lubricating oil etc. as per manufacturer's<br />
manual<br />
21. Check for polarisation index of stator winding, R10/R1 by motorised megger (The value<br />
should not be less than 2.0). R60/R10 absorption co co-efficient efficient shall not be less than 1.5.<br />
TRANSFORMER<br />
1. IR test on each winding to ground and between windings.<br />
2. Turns ratio test on each tap<br />
3. Polarity and vector group test<br />
4. Measurement of winding resistance by Kelvin bridge<br />
5. IR, wiring and operational tests on all control devices in control cabi cabinet, oil level<br />
indicator, winding and oil temp. indicators etc.<br />
6. Checking of earthing wrt transformer tank (flexible from top cover to tank) other<br />
parts, neutrals.<br />
7. Testing of buchholz relay for alarm and trip conditions.<br />
8. For bushing CTs, tests applicable shall be as for current transformers.<br />
9. Setting of oil/winding temperature indicators, level gauge and checking of alarm/trip<br />
circuits.<br />
10. Check insulators for cracks.<br />
11. Checking for oil leakage and arresting of leakages (if tthere)<br />
12. Checking of operation of all valves.<br />
13. Checking for open position of all the valves (except drain and filter valves)<br />
14. Filtration of oil by using line filter, vacuum pump, and heater set.<br />
15. BDV test on oil samples from top and bottom.<br />
16. Checking of oil for acidity, water content tan delta etc. as per IS 335.<br />
17. Measurement of magnetising current and no load loss.<br />
18. Measurement of PI value.<br />
19. Checking of silica gel breather.<br />
20. Checking of noise level at no load and at full load.<br />
21. Checking of air circulation cconditions<br />
for indoor transformers.<br />
22. Conducting magnetic balance test<br />
23. Checking of other points given in manufacturer's commissioning manual.<br />
24. Frequency response analysis for HT transformers (at manufacturer’s works)<br />
UNINTERRUPTED POWER SUPPLY (UPS)<br />
1. Visual check<br />
2. IR value by megger<br />
3. Current limit test<br />
4. Ripple test<br />
5. Supply variation<br />
Technical Specification:Sec-6, Electrical<br />
Page 84 of 97
6. Functional test<br />
7. Capacity test wrt time<br />
PDB/LDB/SLDB/AUX.PDB<br />
1. IR test before and after HV test.<br />
2. HV test with 2.5 kV megger<br />
3. Functional test for all feeders<br />
4. Testing and calibration of all meters<br />
5. Checking and calibration of overload relays and protective relays as per supplier's<br />
commissioning manuals.<br />
6. Check operation of contactors from local and remote points<br />
7. Checking of interlockings between incomers/bus co coupler upler and other feeders.<br />
8. Test to prove interchangeability of similar parts<br />
9. Tests to prove correct operation of breakers at minimum and maximum specified<br />
control voltages<br />
10. Checking of earthing connection for neutral neutral-earth earth bus, cable armour, location of E/ E/F CT<br />
etc. as per the scheme.<br />
11. Check test, service and drawout position of all the breakers and operations of<br />
mechanical flag indicator and electrical indication lamps.<br />
12. Check functioning of various elect. schemes like autochangeover signalling etc.<br />
13. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and<br />
between phases in off position<br />
CABLES & CABLE SUPPORTING STRUCTURES<br />
1. Checking of continuity/phasing and IR values for all the cables before and after HV test.<br />
2. Checking of earth arth continuity for armour.<br />
3. Check for mechanical protection of cables.<br />
4. Check for identification (tag number system) distance placement of cable marker, cable<br />
joint etc. as per the cable layout drawing.<br />
5. Check earthing of cable structures.<br />
6. Check clearances ces from light fittings for cable structures<br />
7. Check proper fixing of cable structures.<br />
8. Check for proper drainage and removal of water from cable trenches<br />
EARTHING & LIGHTNING PROTECTION<br />
1. Check tightness of all earth connections<br />
2. Check earthing of all metallic equipment, cable trays, busbar supporting structures, all<br />
elect. equipments, etc. as per the requirement of IE rules and IS 3043<br />
3. Measurement of earth resistance for each electrode.<br />
4. Measurement of total earth resistance.<br />
5. Measurement easurement of earth loop resistance for E/F path of biggest LT drive.<br />
ILLUMINATION<br />
1. Lux level measurement in each area/premise<br />
2. Test for black spot, if any<br />
Technical Specification:Sec-6, Electrical<br />
Page 85 of 97
3. Check operation of complete lighting system<br />
MISCELLANEOUS<br />
1. Checking of continuity of the system<br />
2. Checking hecking safe accessibility of all operating points<br />
3. Ensure availability of first aid box, rubber glove, etc.<br />
4. Check for safe movement of operators to pump house w.r.t. proper illumination, light,<br />
uncovered openings, etc<br />
5. Placement of shock treatment chart, danger boards, provision of boards indicating Man<br />
on Work, Do not switch ON', 'Do not switch OFF', 'EARTHED' etc.<br />
6. Check proper dressing of cables, mechanical protection of cables, placement of cable<br />
markers<br />
7. Check sealing of all cable openings including conduit opening with fire resistance<br />
material<br />
8. Check sealing of all openings at bottom of panels<br />
9. Check proper road crossing of cables/earthing materials.<br />
LIST OF IMPORTANT INDIAN STANDARDS<br />
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
1 IS : 732 – 1989<br />
Code of practice for electric al wiring installations.<br />
2 IS: 4648 – 1968<br />
3 IS : 8081 – 1976<br />
4 IS : 8884 – 1978<br />
5 IS: 5578 – 1985<br />
6 IS : 11353 – 1985<br />
7 IS: 5728 – 1970<br />
Guide for short-circuit calculations.<br />
8 IS:7752(Part 1) – 1975 Guide for improvement of power factor in consumer<br />
installation : Low and medium supply voltages.<br />
9 IS:3646(Part 1) – 1966 Code of practice for interior illumination : Principles<br />
for good lighting and aspects of design.<br />
10 IS:3646(Part-3) – 968 Code of practice for interior illumination: Schedule of<br />
illumination and glare index.<br />
11 IS:3646(Part-3)-1968<br />
12 IS:4347 – 1967<br />
Technical Specification:Sec-6, Electrical<br />
Guide for electrical layout in residential buildings.<br />
Code of practice for design, installation and<br />
maintenance of service lines upto and including 650<br />
V.<br />
Code of practice for installation of electrical bells and<br />
call system.<br />
Guide for marking of insulated conductor.<br />
Guide for uniform system of marking and<br />
identification of conductors and apparatus terminals.<br />
Code of practice for interior illumination: Calculation<br />
of coefficients of utilization by the BZ method.<br />
Code of practice for hospital lighting.<br />
Page 86 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
13 IS:6665 – 1972<br />
Code of practice e for industrial lighting.<br />
14 IS:2672 – 1966<br />
Code of practice e for library lighting.<br />
15 IS:10118(Part 1) – 1982 Code of practice for selection, installation and<br />
maintenance of switchgear and control gear; General<br />
16 IS:10118(Part-2)-1982 1982 Code of practice for select ion, installation and<br />
maintenance of switchgear and control gear<br />
selection.<br />
17 IS:101118(Part-3)-1982 1982 Code of practice for select ion, installation and<br />
maintenance of switchgear and control gear<br />
Installation.<br />
18 IS:10118(Part 4) - 1982 Code of practice for select ion, installation and<br />
maintenance of switchgear and control gear<br />
selection.<br />
19 IS:4146 – 1983<br />
20 IS: 4201 – 1983<br />
21 IS:5547 – 1983<br />
22 IS:2309 – 1989<br />
23 IS:3043 – 1987<br />
Code of practice for earthing.<br />
24 IS:5216(Part01) – 1982 Guide for safety procedures and practices in electrical<br />
work : General.<br />
25 IS: 5216(Part 1) – 1982 Guide for safety procedures and practices in electrical<br />
work : Life saving techniques.<br />
26 IS:3696(Part-2) – 1966 Safety code for scaffolds and ladders: Ladders Electric<br />
fans.<br />
27 IS: 555 – 1979<br />
28 IS:1169 – 1967<br />
29 IS:374 – 1979<br />
30 IS:2997 – 1964<br />
31 IS: 2312 – 1967<br />
32 IS:3588 – 1987<br />
33 IS:3963 1987<br />
34 IS:4283 – 1981<br />
35 IS:6272 – 1987<br />
36 IS:4894 – 1987<br />
37 IS:11037 0 1984<br />
38 IS:12155 – 1987<br />
Technical Specification:Sec-6, Electrical<br />
Application guide for voltage transformers.<br />
Application guide for current transformers.<br />
Application guide for capacitor voltage transformers.<br />
Code of practice for the protection and allied<br />
structures against lightening<br />
Electric table type fans and regulators.<br />
Electric pedestal type fans and regulators.<br />
Electric ceiling type fans and regulators.<br />
Air circulator type electric fans and regulators.<br />
Propeller type AC ventilating fans.<br />
Electrical axial flow fans.<br />
Roof extractor units.<br />
Hot Air fans.<br />
Industrial cooling fans (man coolers)<br />
Centrifugal fans.<br />
Electronic type fan regulators.<br />
General and safety requirements for fans and<br />
regulators for house hold and similar purposes, Low<br />
voltage switch gear and control gear.<br />
Page 87 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
SWITCH GEAR<br />
39 IS:4237 – 1983<br />
40 IS:675(Part-1) – 1973 Control Switches (switching devices for control and<br />
auxiliary circuits including contractor (relays) for<br />
voltages upto and including 1000 v AC and 1200 v DC:<br />
41 IS:6875(Part2) – 1973 Control Switches (switching devices for control and<br />
auxiliary circuits including contractor (relays) for<br />
voltages upto and including 1000 v AC and 1200 v DC:<br />
42 IS:6875(Part-3)-1980<br />
43 IS:10027-1981<br />
44 IS:4064(Part 1) -1978 1978 Air break switches, air break disconnectors, air break<br />
switch disconnectors and fuse combination units for<br />
voltages not exceeding 1000 v AC or 1200 v AC :<br />
General requirements.<br />
45 IS:2675 – 1983<br />
46 IS:8828 – 1978<br />
47 IS: 13032 – 1991<br />
48 IS:12640 – 1988<br />
49 IS:2959 – 1985<br />
50 IS:2516(Part01/Sec 1 – Circuit breakers: Requirements and tests: Voltages<br />
1985<br />
not exceeding 1000 v AC or 1200 v DC.<br />
51 IS:12021 – 1987<br />
52 IS:5039 – 1983<br />
Technical Specification:Sec-6, Electrical<br />
General requirements for switch gear and control<br />
gear for voltages not exceeding 1000 V ac or 1200v dc<br />
Control Switches (switching devices for control and<br />
auxiliary circuits including ncluding contractor (relays) for<br />
voltages upto and including 1000 v AC and 1200 v DC:<br />
Composite unit o air break switches and rewireble<br />
type fuses for voltages not exceeding 50 V AC.<br />
Enclosed distribution fuse boards and cutouts for<br />
voltages not exceeding 1000 V.<br />
Miniature air break circuit breakers for voltages not<br />
exceeding 1000 volt.<br />
Miniature circuit breaker boards for voltages upto<br />
and including 1000 volts AC.<br />
Residual current operated circuit breakers.<br />
Voltages not exceeding 1000 v AC or 1200 v DC.<br />
Specifications for control transformers for switch gear<br />
and control gear for voltages not exceeding 1000<br />
volts AC.<br />
Distribution pillars for voltages not exceeding 1000 V.<br />
Page 88 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
53 IS:8623 (Part 1) – 1977 Factory built assemblies of switch gear and control<br />
gear for voltages up to and including 1000 v AC and<br />
1200 v DC : General requirements.<br />
54 IS:8623 (Part 2) – 1980. Factory built assemblies of switch gear and control<br />
gear for voltages up to and including 1000 v AC and<br />
1200 v DC : Particular requirements for bus bar<br />
trunking system (busways)<br />
55 IS:8544(Part 1) – 1977 Motor starters for voltages not exceeding 1000 v :<br />
Direct on line AC starters.<br />
56 IS:8544(Part 2) – 1977 Motor starters for voltages not exceeding 1000 v :<br />
Star-delta starters.<br />
57 IS:8544(Part 4 ) – 1979 Motor starters for voltages not exceeding 1000 v:<br />
Reduced voltage ac starters, two step auto<br />
transformer starters.<br />
POWER CABLE<br />
58 IS:694 – 1990<br />
59 IS:1554(Part 1) -1988 1988 PVC insulated (heavy duty) electric cables: For<br />
working voltages upto and including 1100 v.<br />
59 IS:3961 (Part 5) – 1968 Recommended current ratings for cables: PVC<br />
insulated light duty cables.<br />
60 IS:4288 - 1983<br />
60 IS:4289(Part 1) – 1984 Flexible cables for lifts and other flexible connections:<br />
Elastomer insulated cables.<br />
Electrical Wiring Accessories<br />
61 IS:9537(Part 1) – 1980 Conduits for electrical installations: General<br />
requirement.<br />
62 IS:9537(Part 2) – 1981 Conduits for electrical installations: Rigid steel<br />
conduits.,<br />
62 IS: 3480 – 1966<br />
63 IS:2667 – 1988<br />
63 IS: 3837 – 1976<br />
64 IS:9537 (Part 4) – 1983 Conduits for electrical installations: Pliable self<br />
recovering conduits of insulating materials.<br />
Technical Specification:Sec-6, Electrical<br />
PVC insulated cables for working voltages upto and<br />
including 1100 V.<br />
PVC insulated (heavy duty) electronic cables with<br />
solid aluminum conductors for voltages up to and<br />
including 1100 v<br />
Flexible steel conduits for electrical wiring.<br />
Fittings for rigid steel conduits for electrical wiring.<br />
Accessories for rigid steel conduits for electrical<br />
wiring.<br />
Page 89 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
64 IS:6946 – 1973<br />
Flexible (pliable) non-metallic metallic conduits for electrical<br />
installations.<br />
65 IS:3419 – 1989<br />
Fittings for rigid non-metallic conduits.<br />
65 IS:5133 (Part-1) – 1969 Boxes for enclosure of electrical accessories: Steel<br />
and cast iron boxes.<br />
66 IS:5133 (Part 2) – 1969 Boxes for enclosure of electrical accessories<br />
66 IS:2412 – 1975<br />
67 IS: 371 – 1979<br />
67 IS: 3854 – 1988<br />
68 IS: 4615 – 1968<br />
68 IS:4160 – 1967<br />
69 IS:1293 – 1988<br />
Electric Lamps and their Auxiliaries<br />
70 IS: 418 – 1978<br />
71 IS:2418 (Part 1 ) – 1977 Tubular fluorescent lamps for general lighting service<br />
: Requirements and tests.<br />
71 IS: 990(Part 1) – 1981 High pressure mercury vapor lamps: Requirements<br />
and tests.<br />
72 IS:9974(Part 1) -1981 1981 High pressure sodium vapor lamps :<br />
72<br />
General requirements and tests.<br />
73 IS: 1258 – 1987<br />
Bayonet lamp holders.<br />
73 IS: 3323 – 1980<br />
Bi-pin pin lamp holders for tubular fluorescent lamps.<br />
74 IS: 3324 – 1982<br />
74 IS: 2215 – 1984<br />
Starters for fluorescent lamps.<br />
75 IS: 1534 (Part 1) – 1977 Ballast for fluorescent lamps: For switch start circuits.<br />
75 IS: 1569 – 1976<br />
76 IS:6616 – 1982<br />
76 IS: 1913 (Part 1) – 1978 General and safety requirements for luminaries<br />
Tubular fluorescent lamps.<br />
77 IS: 10322 (Part 1 ) 1982 Luminaries : General requirements.<br />
77 IS: 10322(Part 2) - -1982 1982 Luminaries : Constructional requirements.<br />
78 IS: 10322 (Part5 / Sec 1 ) Luminaries : Particular requirements: Recessed<br />
1987<br />
luminaries<br />
Technical Specification:Sec-6, Electrical<br />
Link clips for electrical wiring.<br />
Ceiling roses.<br />
Switches for domestic and similar purposes.<br />
Switch socket outlets (non-interlocking interlocking type).<br />
Interlocking switch socket outlet.<br />
Plugs and socket outlets of rated voltage upto and<br />
including 16 amperes.<br />
Tungsten filament general service electric lamps.<br />
Holders for starters for tubular fluorescent lamps.<br />
Capacitors for use in tubular fluorescent high<br />
pressure mercury and low pressure sodium vapor<br />
discharge lamp circuits.<br />
Ballasts for high pressure mercury vapor lamps. Light<br />
fittings and luminaries.<br />
Page 90 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
78 IS:10322 (Part 5 / Sec. 3) Luminaries : Particular requirements: luminaries for<br />
1987<br />
road and street lighting.<br />
79 IS:10322 (Part 5 / Sec.4) – Luminaries : Particular requirements: luminaries for<br />
1987<br />
road and street lighting.<br />
79 IS: 10322(Part 5 / Sec 5)<br />
1987<br />
Luminaries : Particular requirements: Flood lights.<br />
80 IS: 3287 – 1965<br />
81 IS: 2206 (Part 1) – 1984 Flame proof electric lighting fittings : Wall glass and<br />
bulk head types.<br />
82 Is:3528 – 1966<br />
83 IS: 3553 – 1966<br />
84 IS: 9030 – 1976<br />
85 IS: 7537 – 1974<br />
86 IS: 9583 – 1981<br />
87 IS: 9583 – 1981<br />
Electric Appliances<br />
88 IS: 6236– 1971<br />
Direct recording<br />
89 IS: 1248 (Part 1) – 1983 Direct acting indicating analogue electrical measuring<br />
instruments<br />
requirements.<br />
and their accessories: General<br />
90 IS:1248 (Part 2) – 1983 Direct acting indicating analogue electrical measuring<br />
instruments and their accessories: Ammeters and<br />
voltmeters.<br />
91 IS:1248 (Part 3) – 1983 Direct acting indicating analogue electrical measuring<br />
instruments and their accessories: Wattmeters and<br />
Varmeters.<br />
92 IS: 1248 (Part 3) – 1983 Direct acting indicating analogue electrical measuring<br />
instruments and their accessories: ssories: Frequency meters.<br />
93 IS: 1248 (Part 5) – 1983 Direct acting indicating analogue electrical measuring<br />
instruments and their accessories: Phase meters,<br />
power factor meters and synchronoscope.<br />
94 IS: 722 (Part 1) – 1988 AC electricity meters: General requirements and<br />
tests.<br />
95 IS: 722 (Part 2) - 1977 AC electricity meters: Single-phase phase whole current<br />
watt hour meters, class 2.<br />
96 IS:722 (Part 3) – 1977 AC electricity meters: Three phase whole current and<br />
transformer operated and single phase transformer<br />
operated watt hour meters, class 2.<br />
Technical Specification:Sec-6, Electrical<br />
Industrial lighting fittings with plastic reflectors.<br />
Water proof electric lighting fittings.<br />
Water tight electric lighting fittings<br />
Luminarires for hospitals.<br />
Road traffic signals.<br />
Emergency lighting units.<br />
Emergency lighting units.<br />
Page 91 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
97 IS: 722(Part 5) – 1980 AC electricity meters: Volt-ampere ampere hour meter for<br />
restricted power factor range : General requirements.<br />
98 IS:722 (Part 7)/Sec.1 - AC electricity meters : Volt-ampere ampere hour meter for<br />
1987<br />
full power factor range: General requirement<br />
99 IS: 722 (Part 8) 1972<br />
100 iS: 722 (Part 9) 1972<br />
101 IS: 8530 – 1977<br />
102 IS: 2992 - 1987<br />
Instrument Transformers<br />
103 IS: 2705 (Part 1) -1981 1981 Current transformers: General Requirement<br />
104 IS: 2705 (Part 2) -1981 1981 Current transformers: Measuring current<br />
transformers.<br />
105 IS: 2705 (Part 3) -1981 1981 Current transformers: Protective current<br />
transformers.<br />
106 IS: 2705 (Part 4) -1981 1981 Current transformers: Protective current<br />
transformers for specific purpose applications.<br />
107 IS:6949 – 1973<br />
Fuses<br />
108 IS: 9224 (Part 1 ) – 1979 Low voltage fuses : General requirements.<br />
109 IS: 9224 (Part 2 ) – 1979 Low voltage fuses : Supplementary requirements for<br />
fuses for Industrial applications.<br />
110 IS: 2086 – 1982<br />
111 IS: 9926 – 1981<br />
112 IS: 8187 – 1976<br />
Miscellaneous<br />
113 10000/1980/Pt.1to12 Methods of tests for IC Engines<br />
114 10028/Pt.1/1985 Code of Practice for Selection ,installation &<br />
maintenance of Transformers - Selection<br />
Technical Specification:Sec-6, Electrical<br />
AC electricity meters: Single phase 2 wire whole<br />
current watt-hour meter (Class 1.0).<br />
AC electricity meters: Three phase whole current and<br />
transformer operated Watt-hour hour meters, and single<br />
phase two wire transformer operated watt watt-hour<br />
meters (Class 1.0).<br />
Maximum demand indicators.<br />
Insulation testing testers<br />
Summation current transformers.<br />
Carriers and bases used in rewireable type electrical<br />
fuses upto 650 volts.<br />
Fuse wire used in rewireable type electric fuses upto<br />
650 volts.<br />
D – Type fuses<br />
Page 92 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
115 10028/Pt.2/1981 Code of Practice for Selection ,installation &<br />
maintenance of Transformers - Installation<br />
116 10322/Pt.3/1984<br />
117 10322/Pt.4/1984<br />
118 10322/Pt.5/ Sec.2/1985 Luminaries :Particular Requirements : Portable<br />
general purpose Luminarie<br />
119 1239/Pt.1/1990<br />
120 1239/Pt.2/1992<br />
121 1255/1983<br />
122 12640/Pt2/2001<br />
123 13118/1991<br />
124 1367/Pt.3/1991<br />
125 1367/Pt.XIII/1983<br />
126 13925/Pt1/1998<br />
127 13925/Pt2/2002<br />
Technical Specification:Sec-6, Electrical<br />
Specification for Luminaries :Screw & Screw less<br />
Terminals<br />
Specification of Luminaries :Methods of Tests<br />
Mild Steel Tubes ,Tubulars & other wrought Steel<br />
Fittings : Mild Steel Tubes<br />
Mild Steel Tubes ,Tubulars & other wrought Steel<br />
Fittings : Mild Steel Tubulars and other wrought steel<br />
pipe fittings<br />
Code of Practice for installation maintenance of<br />
power cables upto and including 33KV rating<br />
Residual Current Operated Circuit Breaker for<br />
household and Similar uses : Circuit Breakers with<br />
Integral Over Current Protection (RCVOs)<br />
Specifications for High Voltage Alternating Circuit<br />
Breakers<br />
Fasteners -Threaded steel -Technical Technical Supply<br />
Conditions - Mechanical Properties and test methods<br />
for bolts ,screws and studs with full load ability<br />
Technical Supply Conditions for Threaded steel<br />
Fasteners --- Hot dip Galvanized coating on threaded<br />
fasteners<br />
Shunt Capacitors for ac power system having a rated<br />
voltage above 1000v : General performance ,testing<br />
rating safety requirements - guide for installation and<br />
operation<br />
Shunt Capacitors for ac power system having a rated<br />
voltage above 1000v : Endurance testing<br />
Page 93 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
128 13947/Pt.1/1993 Specification for Low voltage switchgear and control<br />
gear - General Rules<br />
129 13947/Pt.2/1993<br />
130 13947/Pt.3/1993<br />
131 1445/1977<br />
132 1460/2000<br />
133 14772/2000<br />
134 2016/1967<br />
135 2026/Pt.1/1977<br />
136 2026/Pt.2/1977<br />
137 2026/Pt.3/1981<br />
138 2026/Pt.4 / 1977<br />
139 2086/1982<br />
140 2121/Pt.1/1981<br />
141 2121/Pt.2/1981<br />
142 2268/1994<br />
143 2551/1982<br />
144 2713/Pt.1 to 3<br />
145 3043/1987<br />
146 3419/1988<br />
Technical Specification:Sec-6, Electrical<br />
Specification for Low voltage switchgear and control<br />
gear - Circuit Breakers<br />
Specification for Low voltage switchgear and<br />
controlgear -Switches Switches ,Disconnectors ,Switch<br />
Disconnectors and Fuse combination Units<br />
Porcelain insulators for overhead power lines with a<br />
nominal voltage voltage up to and including 1000<br />
volts<br />
Diesel Fuels : Specification<br />
General requirements for enclosures for accessories<br />
for house hold and similar fixed Electrical installations<br />
- Specification<br />
Specification for plain washers<br />
Power Transformers :General<br />
Power Transformers :Temperature rise<br />
Power Transformers :Insulation Level and dielectric<br />
tests<br />
Power Transformers :Terminal marking ,tappings and<br />
connections<br />
Carrier and based used in rewireable type electric<br />
fuses for voltage up to 650 volts<br />
Conductors and earthwire accessories for overhead<br />
power lines : Armour rods ,winding wires and tapes<br />
for conductors<br />
Conductors and earthwire accessories for overhead<br />
power lines : Mid span jionts and repair sleeves for<br />
conductors<br />
Electric call bells and buzzers for indoor use<br />
Danger Notice Plate<br />
Specifications for Tubular Steel Poles for overhead<br />
Power Lines<br />
Code of Practice for Earthing<br />
Fittings for non metallic conduits<br />
Page 94 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
147 3427/1969<br />
AC Metal Enclosed Switchgear and controlgear for<br />
rated voltage Above 1kV and upto and including 52kV<br />
148 3764/1992<br />
149 3837/1976<br />
150 3842/Pt1 to Pt.12/1967 Pt.12/1967-<br />
1977<br />
Application guide for electrical Relays for ac system<br />
151 3854/1997<br />
152 398/Pt.1/1976<br />
153 398/Pt.2/1976<br />
154 398/Pt.3/1976<br />
155 398/Pt.4/1994<br />
156 398/Pt.5/1992<br />
157 4540/1968<br />
158 4722/2001<br />
159 4794 (Pt.1)/1968<br />
160 4794 (Pt.2)/1986<br />
161 5300/1969<br />
162 5613/Pt.1/Sec.1/1985 Code of Practice for Design , Installation and<br />
Maintenance of over head power lines - Lines upto<br />
and including 11kV: Design<br />
Technical Specification:Sec-6, Electrical<br />
Code of Safety for excavation work<br />
Accessories for rigid steel conduits for electric wiring<br />
Switches for domestic and similar purpose<br />
Aluminium Conductor for Overhead transmission<br />
purpose : Aluminium stranded conductors<br />
Aluminium Conductor for Overhead transmission<br />
purpose : Aluminium conductors, galvanised steel<br />
reinforced<br />
Aluminium Conductor for Overhead transmission<br />
purpose :Aluminium conductors, aluminised steel<br />
reinforced<br />
Aluminium Conductor for Overhead transmission<br />
purpose : Aluminium alloy stranded conductors<br />
Aluminium Conductor for Overhead transmission<br />
purpose : Aluminium Conductor galvanised steel<br />
reinforced for extra high voltage<br />
Monocrystalline semiconductor rectifier assemblies<br />
and equipment<br />
Rotating Electrical Machines - Specifications<br />
Push Button Switches -General General Requirement and test<br />
Push Button Switches -Push Push Button Switches - type 1<br />
Specification for Porcelain Guy Strain Insulators<br />
Page 95 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
163 5613/Pt.1/Sec.2/1985 Code of Practice for Design , Installation and<br />
Maintenance of over head power lines - Lines upto<br />
and including 11kV: Installation and Maintenance<br />
164 5613/Pt.2/Sec.1/1985 Code of Practice for Design , Installation and<br />
Maintenance of over head power lines - Lines above<br />
11kV and upto and including 220kV: Design<br />
165 5613/Pt.2/Sec.2/1985 Code of Practice for Design , Installation and<br />
Maintenance of over head power lines - Lines above<br />
11kV and upto and including 220kV: Installation and<br />
Maintenance<br />
166 5613/Pt.3/Sec.1/1989 Code of Practice for Design , Installation and<br />
Maintenance of over head power lines --400<br />
kV Lines<br />
: Design<br />
167 5613/Pt.3/Sec.2/1989 Code of Practice for Design , Installation and<br />
Maintenance of over head power lines - 400 kV<br />
Lines : Installation and Maintenance<br />
168 6639/1972<br />
169 7098/Pt.1/1988<br />
170 7098/Pt.2/1985<br />
171 7098/Pt.3/1992<br />
172 7935/1975<br />
173 808/1989<br />
Technical Specification:Sec-6, Electrical<br />
Specification for Hexagonal bolts for steel structure<br />
Crosslinked polyethylene insulated PVC sheathed<br />
cables : For Working voltage upto and including 1100<br />
volts<br />
Crosslinked polyethylene insulated PVC sheathed<br />
cables : For Working voltage from 3.3 kV upto and<br />
including 33kV<br />
Crosslinked polyethylene insulated PVC sheathed<br />
cables : For Working voltage from 66 kV upto and<br />
including 220 kV<br />
Insulator fittings for overhead power lines with a<br />
nominal voltage up to and including 1100 V<br />
Dimentions for Hot Rolled Steel Beam , column ,<br />
Channel Angle Sections<br />
Page 96 of 97
SN IS Standard with Latest<br />
Amendment<br />
Title<br />
174 8623/Pt.3/1993<br />
Specifications for Low Voltage Switchgear and<br />
Controlgear Assemblies : Particular requirements for<br />
Equipments Where unskilled Persons have access for<br />
their use<br />
175 9537/Pt.3/1983<br />
176 9537/Pt.4/1983<br />
177 9537/Pt.4/1984<br />
178 9974/Pt.1/1982<br />
179 IS: 1885 (Part 1) - 1961 Electrotechnical<br />
definitions.<br />
vocabulary : Fundamental<br />
180 IS: 1885 (Part 9) 1966 Electro technical vocabulary: Electrical Relays.<br />
181 IS: 1885 (Part 11) 1966 Electro technical vocabulary: Electrical<br />
Measurements.<br />
182 IS: 1885 (Part 16) Sec 1) Electro technical vocabulary: Lighting General<br />
1968<br />
aspects.<br />
183 IS: 1885 (Part 16) Sec Sec-2) Electro technical vocabulary lighting: General<br />
1968<br />
illumination, lighting fittings and lighting for traffic<br />
and signaling.<br />
184 IS: 1885 (Part 16/Sec.3) Electro Technical vocabulary Lighting: Lamps and<br />
1967<br />
Auxiliary apparatus.<br />
185 IS: 1885 (Part 17 1979 Electro Technical vocabulary Lighting : Switch gear<br />
and control gear<br />
186 IS: 1885 (Part 32 1971 Electro Technical vocabulary Lighting: Cables,<br />
conductors and accessories for electricity supply.<br />
187 IS: 4770 – 1991<br />
188 IS: 56424 – 1969<br />
Technical Specification:Sec-6, Electrical<br />
Conduit for Electrical Installation :Regid plain<br />
Conduits of insulating Materials<br />
Specification for Conduit for Electrical Installations<br />
:Pliable self - recovering Conduits of insulating<br />
Materials<br />
Specification for Conduit for Electrical Installations<br />
:Pliable Conduits of insulating Materials<br />
High Pressure Sodium Vapour Lamps :Standard lamp<br />
data sheet<br />
Rubber gloves for electrical purposes.<br />
Rubber mats for electrical purposes.<br />
Page 97 of 97
SECTION 7<br />
(CIVIL)<br />
1.0 GENERAL<br />
1.1 This section of the bidding document deals mainly with the technical specification needed<br />
for the design and preparation of detailed drawings, getting the design and drawings<br />
approved by the Engineer, fabrication, erection and construction of the necessary civil,<br />
structural tural and architectural works associated with the wagon Tippler plant.. The work shall<br />
have to be carried out both below and above ground level and shall be involving, basements,<br />
equipment foundations, slabs, beams, columns, footings, rafts, walls, steel frames, brick<br />
walls, stairs, trenches, pits, finishes, complete architectural aspects, drainage, sanitation,<br />
water supply (from terminal points to various buildings, conveyor galleries) and all other civil<br />
and structural works associated with the wagon Tip Tippler Plant.<br />
1.2 The specifications are intended for the general description of the work, quality and<br />
workmanship. The specifications are not, however, intended to cover minutest details and<br />
the work shall be executed according to the relevant latest Indian Standard Codes / I. R. S. /<br />
I. R. C. specifications. In absence of the above, the work shall be executed according to the<br />
best prevailing local Public Works Department practices or to the recommendations of<br />
relevant American and British Standards or to th the e instructions of the Engineer. List of I. S.<br />
Codes to be followed is mentioned in the Technical Specifications. The Contractor is<br />
expected to get clarified on any doubts about the specifications, etc. before bidding, in<br />
writing with the Employer in respec respect t of interpretation of any portions of this document.<br />
2.0 LAYOUT AND LEVELS<br />
2.1 The layout and levels of all structures, etc. shall be made by the Contractor at his own cost<br />
from the general grid of the plot and bench mark given by the Engineer. He shall provide all<br />
instrument, materials and men to the Engineer for checking the layout and levels. However,<br />
the Contractor shall be fully responsible for correctness of layout and levels.<br />
2.2 The contractor has to mobilize well qualified survey team along with the survey equipment<br />
for day today survey work. They should use “Total Station” survey instrument for this<br />
purpose.<br />
2.3 The contractor has to setup his own laboratory to facilitate the checking of quality of civil<br />
works with equipments for checking of aggr aggregate, egate, sand, concrete cube, etc.<br />
2.4 Area cleaning including jungle,rubbish,grass,trees etc are to be included in the scope of<br />
bidder.<br />
3.0 DRAWINGS / DOCUMENTS<br />
3.1 The drawings included in the Bidding Document provide a general idea about the work to be<br />
performed under the scope of this contract. These are preliminary drawings for bidding<br />
purposes only and are by no means the final drawings or show the full range of the work<br />
under the scope. Work has to be executed according to drawings prepared by the co contractor<br />
and approved by the Engineer.<br />
3.2 Conceptual arrangement of civil works supported by calculations shall be submitted along<br />
with tender bids. Later on, detailed construction drawings and design calculations for all civil<br />
works for static as well as dynamic analysis (wherever essential) shall be submitted for<br />
approval prior to undertaking construction work.<br />
3.3 Design calculations shall be done in STRAPP / M.S. Office (latest version) and Drawings shall<br />
Technical Specification:Sec-7, Civil<br />
Page 1 of 21
e prepared in Auto Cad (latest version). The aanalysis<br />
nalysis shall be done by using STADD PRO /<br />
ANSYS / STRAPP (latest version). However design may be carried out by manually, using<br />
computer worksheets or by using suitable software programmes, as mutually agreed by<br />
Employer/RITES. Final calculations and dr drawings awings shall be submitted in Compact Disc (CD) (2<br />
Sets<br />
3.4 Civil Task drawings indicating various equipment loading and supporting arrangement and<br />
floor loads shall be submitted along with design calculations. Soft copies of all STAAD input<br />
files shall be submitted along with the design calculations for all revisions<br />
3.5 Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works shall be<br />
submitted structure wise and area wise for Employer’s record. However each drawing shall<br />
indicate te approximate quantity of structure (Sectionwise) Concrete (Grade wise) and<br />
reinforcement Diameterwise.)<br />
3.6 Structural steel fabrication drawings to be prepared by the contractor will not be approved<br />
by the Employer/RITES. However, the Contractor for Emp Employer’s loyer’s reference shall submit all<br />
fabrication drawings. Copy of detailed bar bending schedule as prepared by contractor shall<br />
also be submitted to the Engineering and also to Engineer in charge for the reference<br />
3.7 Approval of construction drawings prep prepared ared by the contractor shall not relieve the<br />
Contractor of his responsibility regarding the adequacy of design and correctness of the<br />
drawing.<br />
4.0 WORK DESCRIPTION.<br />
It includes the Civil, Structural and Architectural works related mainly to the following areas<br />
(but not limited to):<br />
4.1 Wagon Tippler Hopper, Machinery Hatches and Underground Tunnel<br />
Wagon Tippler hopper and machinery hatches shall consist of underground portion, which<br />
shall be of R. C. C., and above ground portion, which shall be of structural steel shed covered<br />
with Aluminium Industrial troughed sheets. It essentially consists of R. C. C. frames with R. C.<br />
C. wall panels on the sides and R. C. C. raft at the bottom, fixed to the frames. The top beam<br />
of the R. C. C. frame supports the rail supporting beams and the hopper. Minimum thickness<br />
of R. C. C. raft at bottom shall be 600 mm. Minimum thickness of RCC side walls shall be 600<br />
mm at bottom and 300 mm at top.<br />
No columns shall be provided inside the Machinery Hatches.<br />
The vertical and inclined portion of coal hopper shall be provided with 50 mm thick guniting<br />
(shotcreting). Details of shotcreting have been given elsewhere in this specification<br />
Expansion joints shall be provided at a maximum distance of 40m unless otherw otherwise<br />
instructed. 600 mm wide water stop fabricated with 22G copper plate with bitumen board<br />
fillers and polysulphide sealing compound as specified elsewhere shall be used as expansion<br />
joint material. Floor shall be provided with cross slope not flatter than 1 in 50 towards side<br />
drains. Side drains shall be sloped towards sump where sump pumps as specified elsewhere,<br />
shall be provided. The slope of side drains shall not be flatter than 1 in 400. Arrangement<br />
shall be made for disposal of water right up to the discharge point. Side drains and sump<br />
shall have removable type steel grating cover. Gratings shall be galvanized to grade 610<br />
gm/m.2 Water proofing / Damp proofing of under ground portion of hopper and machinery<br />
hatches, tunnels, underground (i. e. baseme basement) nt) portion of transfer houses shall be done by<br />
providing the following treatments: Chemical injection grouting for inner faces (details as<br />
specified elsewhere). Polymer modified cementitious coating on earth side face as per the<br />
following :<br />
1). On the outer ter surface of walls, frames and roof slabs coming in contact with earth,<br />
polymer modified cementitious coating in two layers as specified and as per manufacturer’s<br />
specifications shall be provided directly on the concrete surface.<br />
(2.) 50 mm thick P. C. C. (1 : 2 : 4 with 10 mm nominal size stone aggregates) shall be<br />
provided under the raft i.e. over the lean concrete, followed by polymer modified<br />
Technical Specification:Sec-7, Civil<br />
Page 2 of 21
cementitious coating in two layers ( slurry mix application ) as per manufacturer’s<br />
specification. 50 mm thick ck P. C. C. ( 1 2 : 4 ) with 10 mm nominal size stone aggregates shall<br />
then be laid over the polymer modified cementitious coating before laying the raft.<br />
Hopper shall have removable type steel grating cover. The opening size for the grating shall<br />
be 300 mm x 300 mm. Machinery hatches shall have removable steel chequered plate cover.<br />
Hopper grating shall be built of min. 200mm x 36mm thick flats. No painting/galvanization<br />
shall be provided in gratings. However, two coats of red oxide primer to be provided<br />
immediately after fabrication.<br />
Catwalk shall be provided along the hopper. Each machinery hatch shall be provided with a<br />
pair of R. C. C. stair for providing access to the base of track hopper / machinery hatch. Both<br />
the stairs shall be interconnected at ssuitable<br />
height.<br />
Plinth protection along with drains shall be provided along the Hopper and around<br />
machinery hatches. However, paving shall also be provided around machinery hatches.<br />
The wagon tippler hopper is a deep underground structure which is subjecte subjected to direct load<br />
from the loaded wagons / loco due to the rake movement over it, in addition to load due to<br />
coal filled hopper and lateral earth pressure. The railway loads, analysis and design of<br />
hopper, machinery hatches, transfer point and the portion oof<br />
f tunnel subjected to rail loads<br />
shall be as specified in design criteria. Coefficient of dynamic augmentation shall be worked<br />
out for a train speed of 30 kms per hour.<br />
Earth pressure to be considered for design shall be due to earth pressure at rest (K<br />
0)condition condition only. Earth pressure due to surcharge intensity of Railway Loads (where<br />
applicable) or Uniformly Distributed Load (U. D. L) of intensity 2 T / Sq. M. whichever is<br />
critical, shall be considered in the design.<br />
A minimum safety factor of 1.2 against uplift of hopper, machinery hatches, wagon tippler,<br />
transfer points (underground or with basement) and tunnels, due to ground water shall be<br />
ensured during execution and after execution, considering dead weight of the structure to<br />
be 0.9 times only, groun ground d water table at adjoining formation level and soil wedge angle of<br />
not more than 15 degrees.<br />
Also, FOS against uplift, to be taken as 1.0, considering the dead wt. of structure and soil<br />
resting on side projections if any in the vertical plane. Inclined wed wedge ge action of soil shall not<br />
be considered in this case.<br />
Walkway width and hand railing shall be provided as specified in the tender drawing.<br />
Wherever, slope of tunnel exceeds 10 o, R. C. C. steps shall be provided for the entire width<br />
of each walkway.<br />
Wagon n Tippler hopper structure shall be analyzed and designed for the worst load<br />
combinations.<br />
4.2 Overhead / Ground Conveyor Galleries and Trestles<br />
Overhead conveyors shall be located in a suitably enclosed gallery of structural steel. The<br />
overhead gallery shall consist of two vertical latticed girders having rigid jointed portal frame<br />
at both ends. Cross beams at floor level supporting conveyor stringer beams shall be made<br />
of single rolled steel beam or single channel section (ISMB or ISMC) or plate girder.<br />
Horizontal bracings are to be provided at top & bottom plan of the gallery (latticed girders<br />
shall be braced together in plan at the top and bottom).Common end portal frame shall not<br />
be used for adjacent conveyor spans. Roof trussshall be provided at upp upper node points of<br />
latticed girders to form an enclosure. Themaximum span of overhead gallery shall be limited<br />
to 25 meters unless higher spanis required due to site conditions, which shall be subject to<br />
approval of the Engineer.The gallery should as far as possible be erected as a box section<br />
keeping all thevertical and horizontal bracing tied in proper position. The gallery should be<br />
checkedfor all erection stresses that are likely to develop during handling and erection and<br />
ifrequired, temporary strengthe strengthening ning of gallery members during erection shall be made.Seal<br />
Technical Specification:Sec-7, Civil<br />
Page 3 of 21
plates under the conveyor galleries shall be provided in such a way thatcomplete gallery<br />
bottom shall form a leak proof floor.<br />
The ground conveyors shall be located in suitably enclosed gallery of structural steel<br />
consisting of rigid portal frames spaced at regular intervals and suitably braced. Plinth<br />
protection along with drains shall be routed along the ground conveyors. Hand r rrailing<br />
should<br />
not be supported on conveyor supporting stringers. The walkways shall be chequered plate<br />
construction with anti - skid arrangement.<br />
Conveyor gallery shall have Aluminum industrial troughed sheets conforming to IS:1254 on<br />
roof & both sides. Adequate provision of windows shall be kept on both sides of conveyor<br />
gallery as appended in Mechanical Section. Windows shall be provided with wire mesh as<br />
specified elsewhere in this specification. Cross - over with chequered plate platform and<br />
ladder for crossing over the conveyors shall be provided at approximately every 100 M<br />
intervals of conveyor. Crossover shall preferably be located over four four-legged rigid trestle<br />
location. For railway tracks passing below overhead conveyor gallery and along conveyors,<br />
the railway clearances both underground as well as over ground shall have to be adhered to<br />
for design, execution and erection of foundations, trestles, galleries etc., so that movement<br />
of locomotives and wagons is not hampered in any way dduring<br />
uring execution and afterwards.<br />
However at the location where the overhead conveyor gallery crosses road, minimum<br />
clearance of 8.0m above the road crest shall be provided.<br />
a) All gallery supporting trestles shall be four legged type only. One end of each gallery span<br />
shall be hinged to the supporting trestle and the other end shall be slide type. Slide type<br />
support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements.<br />
a) In between transfer houses / buildings, four legged trestl trestles es shall be placed at a<br />
maximum interval of 90 metres. The arrangement shall be such so as to ensure that force in<br />
the longitudinal direction (i. e. along the conveyor length) of conveyor gallery of length not<br />
more than 90 m is transferred to any four legg legged ed trestle. In the space between each<br />
successive four legged trestles, two legged trestles shall be provided at regular intervals. The<br />
end supports resting on the four four-legged legged trestle can have either ends hinged or one hinge and<br />
the other on slide type depe depending nding on the arrangements. Slide type support shall be with P. T.<br />
F. E. bearings to allow both rotation & longitudinal movements. End of conveyor gallery<br />
which will be supported over transfer house, shall be so detailed that only vertical reaction is<br />
transferred ferred from conveyor gallery and no horizontal force in longitudinal direction is<br />
transferred from conveyor gallery to transfer house structure and vice - versa. For trestles<br />
and trestle foundations for conveyor galleries located adjacent to existing struc structures, over<br />
ground and under ground facilities, location and details of these trestles and foundations<br />
shall have to be decided such that there is no interference both underground as well as over<br />
ground with existing structures and facilities. Trestle colu columns mns / ground conveyor portal<br />
column base shall be kept 300 mm higher than the existing ground level.<br />
4.3 Transfer Houses<br />
The over ground portion of the transfer house shall be framed structure of structural steel<br />
work with Aluminium Industrial troughed she sheet et side cladding and R. C. C. floors and roof<br />
over structural beams. However the lower portion of side cladding for a minimum height of<br />
0.9 m above the finished floor level shall be one brick thick wall plastered on both side. In<br />
some areas like MCC floors etc., one brick thick wall cladding shall be provided. Brick wall<br />
cladding shall be supported on encased wall beams and suitably anchored to adjoining<br />
columns and beams. Roof shall be provided with water proofing treatment as specified<br />
elsewhere. Adequate steel doors and windows for proper natural lighting and ventilation<br />
Technical Specification:Sec-7, Civil<br />
Page 4 of 21
shall be provided. In addition to steel windows, panels of suitable size to suit the<br />
architectural treatment and made of translucent sheets of polycarbonate material shall also<br />
be provided d on the side cladding for natural lighting.<br />
4.4 Control building, M. C. C. Buildings<br />
These shall be R. C. C. framed structures with columns, beams, slabs and foundations etc.<br />
Cladding shall be of brickwork with plastering on both sides. Roof shall be pro provided with roof<br />
water proofing treatment, as specified elsewhere in the Technical specification. In case of<br />
control building suitable permanent interconnection shall be provided at appropriate level<br />
with the existing respective buildings. All air - conditioned oned areas, shall be provided with the<br />
suspended permanently colour coated aluminium false ceiling system (details specified<br />
elsewhere). Adequate aluminium doors and windows shall be provided for natural lighting,<br />
ventilation and view.<br />
4.5 Pump Houses<br />
These e shall be of R.C.C. or steel framed structure with columns, beams, slab andfoundations<br />
etc. cladding shall be of brick work with plastering on both sides. Roofshall be provided with<br />
roof water proofing treatment as specified elsewhere.Underground sump and water tanks<br />
shall be of R.C.C. Adequate number of doors,Windows and Rolling Shutters shall be<br />
provided.Galvanized steel ladder / rung ladder shall be provided for access to the roof level<br />
ofthe pump house and water tanks.<br />
4.6 Pent House<br />
These shall be of R. C. C. framed structures with columns, beams, slabs andfoundations etc.<br />
Cladding shall be of brickwork with plastering on both sides. Roofshall be provided with roof<br />
water proofing treatment as specified elsewhere. Adequate nos. of steel doors and window windows<br />
shall be provided for natural lighting and ventilation.<br />
4.7 Toilets<br />
Toilet with potable water line facilities shall be provided in each of the following locations:<br />
In all M. C. C. Rooms Control Building Each unit shall have brick enclosure, and the following<br />
fittings.<br />
i ) Squatting type, white, vitreous china Orissa 1 No. pattern, W.C. pan with high level<br />
flushing cistern ( C.I. ) and all requisite fittings<br />
ii ) Bowl type Urinal with automatic flushing 2 Nos. cistern ( C.I. ) and all requisite fittings<br />
iii ) Wash Basin 630 mm x 450 mm with 2 Nos.two taps and all requisite items<br />
iv ) Mirror 600 mm x 450 mm x 5.5 mm thick 2 Nos.with bevelled edges ( Superior sheet<br />
glass )<br />
v ) C.P. Brass Towel Rod 600 x 20 mm 1 No.<br />
vi ) Liquid Soap Container 2 Nos.<br />
vii ) Washing Tap ( CP Brass ) 2 Nos.<br />
viii ) Overhead Polyethylene water tank 1 No.(min. 500 litres capacity)<br />
ix ) Suitable provision for installation of water coolers.<br />
4.8 Staircase<br />
All roofs & floors of transfer houses shall be accessible through staircase. However,for the<br />
pump houses, access to the roof will be provided by cage ladder. All stairs other than those<br />
of M. C. C. rooms and control rooms shall be of steel (min (minimum imum 1000 mm wide)and<br />
maximum rise should not be more than 180 mm and minimum tread width 250 mm.<br />
Stringers shall be of rolled steel channel( minimum ISMC 250 )and tread shall be of steel<br />
gratings. Stairs shall be provided with 32 mm dia nominal bore mediu medium m duty M. S. pipe hand<br />
rail. Handrails (for staircases, around openings, in walkways etc.) shall be of standard weight<br />
steel pipe of flush welded constructions, ground smooth using 32 mm nominal bore medium<br />
class pipe provided with double rail, top rail ab about out 1.0 metre above platform level and pipe<br />
posts spaced not more than 1.5 metres apart. Angle handrail post may be provided when<br />
Technical Specification:Sec-7, Civil<br />
Page 5 of 21
specifically called for in drawings approved by Engineering. Handrails around openings<br />
should have toe plates. Smooth uniform curves and bends shall be provided at stair returns<br />
and also where so ever required. Posts connected to curb plates shall have a neat closure at<br />
the bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All<br />
necessary fittings including ncluding inner dowels at splices, brackets, belts, bends, flanges and<br />
chains, where required shall be plugged and welded. A minimum radius of 3 times the pipe<br />
diameter shall be provided at all points of direction changes in the handrail. Treads and<br />
landing shall be suitable for the prescribed loading. The maximum width of openings in<br />
gratings shall not exceed 40 mm. The minimum thickness of main bars shall be 6 mm. The<br />
usual span of grating will not generally exceed 1.5 meters. Stair case gratings shall be<br />
galvanized to grade 610g/m2 Out side stairs to transfer points shall be open type. However<br />
RCC slab shall be provided at the top. Stairs of control room and M. C. C. room shall be of R.<br />
C. C. construction, and minimum 1200 mm wide, maximum rise should not be more than<br />
180 mm and minimum tread with 250 mm. Numbers and arrangement (including enclosures<br />
etc.) of stair cases shall be such as to meet the fire safety requirement as per guide lines of<br />
statutory regulatory bodies.<br />
4.9 Trenches<br />
All trenches for cables or any other underground facility as detailed out elsewhereshall be of<br />
R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers /chequered plate<br />
cover. Cable trenches as well as pre - cast covers shall be providedwith edge protectio protection<br />
angles and lifting hooks. All embedments / block outs asrequired and specified elsewhere in<br />
these specifications shall be provided. Properdrainage arrangement shall be provided.<br />
Trench pre - cast cover weight shall not bemore than 65 Kgs. Trench covers n nnear<br />
entry or at<br />
road crossings shall be designedfor 10 T wheel load at centre. Pre - cast covers shall be<br />
designed for central pointload of 75 Kgs. R. C. C. cable trenches shall be filled with sand after<br />
erection ofcables, up to top level and covered with pre - cast R. C. C. covers. For<br />
cabletrenches outside buildings, top level shall be 200 mm above G. L.Minimum 50 x 50 x 6<br />
mm size angles with lugs shall be provided as edge protectionall around cut outs / openings<br />
in floor slabs, edges of drains supporting grating/precast RCC covers, edges of R. C. C.<br />
trenches supporting pre - cast covers, supported edges of pre - cast cover, treads of RCC<br />
stairs.<br />
4.10 Approach Road<br />
All approach road required within battery limit is under the scope of the agency with its<br />
connection ion to main road. All approach roads shall be constructed with RCC over suitable<br />
hard sub base.<br />
5.0 Drainage & Water Supply Works<br />
5.1 Drainage System: System:-<br />
The drainage arrangements shall be so planned so as to ensure quick disposal of drainage<br />
water without stagnation tagnation and / or overflow. The water shall overflow into contractor’s R.C.C<br />
drain, which will lead the discharge finally into owner’s drain. Contractor’s scope shall also<br />
include construction of necessary culverts under the rail lines / roads as per rai railway / I. R. C.<br />
standards and approval of Railway culverts from concern Railway authorities<br />
5..2 Internal and external water supply, drainage etc.: etc.:-<br />
The scope for potable water supply includes all distribution systems, tanks, pipes, fittings<br />
etc. as required ed and as described here or elsewhere in these specifications. The scope for<br />
service water supply and dust control water supply shall be as described elsewhere in these<br />
specifications. For water supply, medium class galvanized mild steel pipes conforming to IS:<br />
1239 shall be used. The scope for drainage of surface water shall include design, layout and<br />
construction of drains for and from buildings and drains required for wagon tippler area. All<br />
buildings (including transfer houses and crusher house) shall be provided with open surface<br />
Technical Specification:Sec-7, Civil<br />
Page 6 of 21
drains of minimum size of 300 mm width and 300 mm depth all around the periphery. All<br />
drains shall be of R. C. C. construction. All open drains shall have removable steel grating<br />
designed for loads as specified under loading cclause.<br />
lause. Minimum thickness of grating<br />
(Galvanised to 610 gm/m) 2 shall be 12 mm. However at entry or road crossing point’s<br />
minimum thickness shall be 40 mm. The opening size of grating shall not be more than 90<br />
mm x 35 mm. All drains as well as pre - cast covers vers shall be provided with edge protection<br />
angles and lifting hooks. However, drains in coal stockyard area shall have pre cast R. C. C.<br />
covers. RCC pre - cast cover weight shall not be more than 65 Kgs. RCC pre pre-cast covers near<br />
entry or at road crossings shall be designed for 10 T wheel load at centre. RCC pre – cast<br />
covers shall be designed for central point load of 75 Kgs. The scope for foul water from<br />
toilets shall include layout and laying of sewers up to the Employer’s main sewer line for<br />
sewerage system stem together with all fittings and fixtures and inclusive of ancillary works such<br />
as connections, manholes and inspection chambers within the building and from the<br />
building to the Employer’s sewer line. For rain water down comer and those to be used for<br />
conveying onveying water / coal slurry generated from cleaning of conveyor gallery and buildings<br />
floors, Galvanised MS pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes)<br />
with welded joints shall be used for MCC buildings, pump houses, penthouse, contro control<br />
rooms. Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330 conforming<br />
to IS: 3589 with welded joints shall be used for all TP’s, and Conveyor galleries. Galvanising<br />
shall be as per IS: 4736. The minimum mass of zinc coating shall not be less than 400<br />
gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall be subjected to testing<br />
as per IS: 2633, for uniformity of coating. The zinc coating shall be free from all defects as<br />
per IS: 2629. All rain water down comers shall be prov provided ided with roof drain heads and<br />
complete with shoes bends, junctions, sockets, adapters, brackets and finished with anti<br />
corrosive painting over a coat or primer. For design of building drainage system IS: 1742 shall<br />
be followed. For sanitary / sewerage pip pipes es above ground, sand cast iron pipes conforming to<br />
IS : 1729 with leak proof lead joints. For underground drain pipes, minimum class NP - 2<br />
pipes conforming to IS: 458. At road crossings, concrete pipes of class NP 3 conforming to IS:<br />
458 and at rail crossing sing R.C.C. box culvert to be provided. For sewerage below ground<br />
stoneware pipes conforming to IS: 651 with concrete bedding and haunch.<br />
6.0 COLOUR COATED AND OTHER SHEETING WORK<br />
Permanently colour coated sheet of approved shade and colour using galvanize galvanized mild steel<br />
sheet of minimum 0.6mm BMT(bare metal thickness i.e. metal thickness excluding thickness<br />
for coating and galvanizing) galvanised to grade 275 as per IS 277,of minimum yield strength<br />
of 250 Mpa of drawing grade as per IS 513 or high tensile st steel eel of minimum 0.5mm<br />
BMT(bare metal thickness i.e. metal thickness excluding thickness for zinc aluminium<br />
coating and colour coating ) coated with zinc aluminium alloy @ 150gm/sq.m.of minimum<br />
yield strengthof 350 as per AS1397. Steel shall be colour coate coated d with total coating thickness<br />
of 35 microns (nominal) comprising of silicon modified polyester (SMP with silicon content of<br />
30% to 50%) paint or Super Polyester paint, of minimum 20 microns (nominal) dry film<br />
thickness (DFT) on external face on 5 microns (nominal) primer coat and 5 microns (nominal)<br />
SMP or super polyester paint over 5 microns (nominal) primer coat (or 10 micron SMP/super<br />
polyester paint) on internal face. SMP and Super polyester paint systems shall be of category<br />
3 as per AS2728. Coated su surface rface shall be provided with a protected guard film (polyethylene)<br />
of about 40 microns to avoid any damage to the coating during handling. For metal deck,<br />
minimum 0.8 mm (bare metal thickness i.e. metal thickness excluding thickness for coating<br />
and galvanizing) izing) galvanised to grade 275 as per as per IS 277, of minimum yield strength of<br />
250 Mpa of drawing grade as per IS 513, troughed profile having nominal trough depth 44<br />
mm and pitching of 130 mm shall be used. However alternative profile meeting the stren strength,<br />
defection and other functional requirements such as sections modulers and moment of<br />
inertia shall be provided. To minimize the number of joints, the length of the sheet shall<br />
Technical Specification:Sec-7, Civil<br />
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preferably be not less than 4.5 cut pieces shall not be used, unless specifi specifically approved by<br />
the Engineer. However, the actual length shall be such so as to suit the purling / runner<br />
spacing. No negative tolerance shall be allowed in bare metal thickness. The nominal depth<br />
of trough shall be 30 mm. The polycarbonate sheet to be uused<br />
sed for cladding and glazing<br />
purpose in conveyor galleries shall have toughed profile to match with the metal cladding<br />
profile. Minimum 2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of<br />
GE plastic or equivalent approved make shall be used. The polycarbonate sheet shall be<br />
installed along with the metal cladding so as to have a watertight lapping arrangement.<br />
Suitable detailing shall be made to cater for the thermal expansion. IS: 14434 to be referred<br />
for other details. Polycarbonate ssheet<br />
heet minimum 6mm thick multi (twin) wall fire retardant<br />
(Continuous use under temperature 100 oC), impact resistant and ultraviolet resistant sheet<br />
shall be provided (as glazing) in transfer houses, pump houses, etc.<br />
7.0 Roof Details<br />
Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD<br />
reinforcement bars placed at 200 mm center both ways at top and bottom. For efficient<br />
disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This<br />
gradient can be provided ided either in structure or subsequently by screed concrete M MM-15<br />
(using<br />
12.5 mm coarse aggregate) and / or cement mortar (1:4). However, minimum 25 mm thick<br />
cement mortar (1: 4) shall be provided on top to achieve smooth surface.900 mm high and<br />
minimum 100 mm thick R. C. C. parapet wall shall be provided over roofs of all buildings.<br />
Parapet wall shall have suitable coping. External face of parapet wall of the buildings<br />
provided with metal cladding shall also be finished with metal cladding of design and col colour<br />
as per approved architectural drawings. Junction of roof and parapet shall be provided with<br />
150 x 150 mm size concrete fillet. Drain level shall be provided with 45 x 45 cm size khurras<br />
having minimum thickness of 30 mm of M-15 15 concrete over PVC sheet of 1 m x 1m x 400<br />
micron and finished with 12 mm 1 : 3 cement : sand plaster. Roofs of all transfer houses,<br />
crusher houses, control rooms, M. C. C. rooms, penthouse etc., shall have roof water<br />
proofing treatment. Roof water proofing treatment shall be provided ided using high solid<br />
content liquid applied urethane based elastomeric water proofing membrane to give<br />
uniform joint less dry film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898),<br />
with separate wearing course as per ASTM C - 898. This treatment shall also include<br />
application of polymerized mastic over the roof to achieve smooth surface and primer coat.<br />
Wearing course on the top of membrane shall consist of 25 mm thick P. C. C. (M (M-15) cast in<br />
panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized<br />
chickenwire mesh and sealing of joints using sealing compound / elastomeric water proofing<br />
membrane. Pathways for handling of materials and movement of personnel shall be<br />
provided with 22 mm thick chequered cement concrete tiles as per IS : 13801 for awidth of<br />
1000 mm in place of P. C. C.<br />
8.0 Floors and Grade level details<br />
The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia HYSD<br />
reinforcement bars placed at 200 mm center both ways at top and bottom Floors of transfer<br />
points shall have cross slope of not flatter than 1: 80, towards the floor washing drainage<br />
outlets, for efficient drainage. For ground conveyor & crusher house slope shall be 1:100.<br />
Chequered plates (used for floors, walkways etc.) shall be mi minimum nimum 6 mm thick o/p or as<br />
indicated on drawings. The chequered plate pattern shall be approved by Employer / RITES.<br />
Mild steel flats/angles of suitable size shall be welded to the bottom portion of chequered<br />
plates at a designed spacing to stiffen chequer chequered ed plates suitably. Chequered plates shall be<br />
fixed by staggered welding of suitable size. Floors of trenches shall have integral finish to<br />
concrete base. Toe guard of size 100 x 6 mm shall be provided at various openings provided<br />
in floors e.g. around st stair air case openings, chute openings and other similar cutouts. For<br />
conveyor walkways, angle runner to act as toe guard shall be provided. All along the<br />
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periphery of R. C. C. floors (where no brick masonry walls are provided)shall be provided<br />
with one brick thick hick 300 mm high brick wall and 700 mm high steel hand rails all around over<br />
this brick work. All buildings (including track hopper and machinery hatches, penthouse,<br />
transfer houses ) and ground conveyors shall be provided with 750 mm wide plinth<br />
protection n all around. It consists of 50 mm thick P.C.C. MM-20<br />
20 grade with 12 mm maximum<br />
size aggregate over 200 mm thick stone soling using 40 mm nominal size rammed,<br />
consolidated and grouted with fine sand. An area of 5 m width all round the transfer houses<br />
shall be e paved. This paving will be in addition to plinth protection. Plinth level of all buildings<br />
shall be kept at least 500 mm above the finished grade / formation level.<br />
9.0 Brickwork and allied masonry works<br />
All brick walls shall be non - load bearing in-filled filled panel walls. All brickwork shall be designed<br />
as per Indian Standards and shall be plastered on both faces. All external walls shall be<br />
minimum one brick thick in 1: 6 cement: sand mortar. Brick walls sh shall all be provided with 12<br />
mm and 18 mm thick 1: 6 cement: sand plaster on smooth and rough face of the brick work<br />
respectively. Bricks to be used in brickwork shall be of minimum Class designation 50.<br />
Brickwork cladding for various structures shall be so pro provided vided that there is a clear gap of 40<br />
mm between inside face of external brick wall and outside face of column flange. Structural<br />
steel wall beams supporting brickwork shall be suitably encased with plaster or 1: 2: 4<br />
concrete as the case may be. In case of box type steel beam, encasement shall be done with<br />
cement sand plaster in specified thickness and proportions over G. I. wire netting of 0.9 mm<br />
thickness. Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be<br />
provided with drip course in 1 : 4 cement sand mortar.50 mm thick Damp proof course shall<br />
be provided at plinth level for all brick wall. All R. C. C. ceilings shall be rendered smooth and<br />
finished with whitewash unless otherwise specified. Ceiling of control rooms, M. C. C. rooms<br />
(except areas provided with false ceiling) shall be provided with 6 mm thick plaster.<br />
10.0 Earthing Mat<br />
2X40 mm Dia MS rod as earthing mat, placed at a distance of 1.0M away and at depths<br />
between 0.60M and 1.00M shall be supplied and laid all aaround<br />
round the periphery of buildings,<br />
structures, and outdoor equipment, as per the approved drawings. Risers of 40 mm Dia MS<br />
rod and connecting to the above Earthing mat shall also be supplied and laid in position by<br />
the Contractor, as per the approved drawi drawings. ngs. Risers shall be laid up to a height of 300 mm<br />
above the local Ground level, at each of the columns of the buildings on outside of the<br />
buildings, and minimum 2 (Two) numbers for structures and outdoor equipment. The<br />
contractor also supply and lay nec necessary essary number of 3.0 M deep vertical 40 mm Dia MS rod<br />
Earthing electrodes and connecting them to the Earthing mat, as per the approved drawings<br />
and the supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing<br />
mat with the Employer's r's earthing mat separately at two locations.<br />
11.0 Fencing<br />
Fencing with toe wall and steel gates shall be provided around the transformers. Fencing<br />
shall comprise of PVC coated GI chain link fencing of minimum 8G (including PVC coating) of<br />
mesh size 75 mm and of height 2.4 m above the toe wall. The diameter of the steel wire for<br />
chain link fence (excluding PVC coating) shall not be less than 12G. Fence posts shall be of<br />
pre – cast R. C. C. of minimum M20 grade. All corner posts will have two stay posts and every<br />
tenth post will have transverse stay post. Suitable R. C. C. foundation for the post and stays<br />
shall be provided based on prevailing soil conditions. Gates shall be sturdy with locking<br />
provisions. Toe walls of brick masonry shall be provided between fence posts all along the<br />
run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above the<br />
formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend minimum 300<br />
mm below the formation level. Toe wall shall be plast plastered ered on both sides and painted with<br />
two coats of cement paint of approved colour and shade. Toe wall shall be provided with<br />
weep holes at suitable spacing.<br />
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Page 9 of 21
12.0 LOADING<br />
For consideration of loads on structures IS : 875 - ‘Code of practice for structural sa safety of<br />
buildings’ shall be followed. In addition to the dead load, live load, equipment load<br />
(including impact / vibration). Temperature loads etc. various loading conditions arising due<br />
to operation and maintenance of equipment shall be considered in the design. The structure<br />
and equipment shall also be designed for seismic loads as per the “Criteria for Earthquake<br />
Resistant Design of Structures and equipment" and the “Criteria for Wind Resistant Design of<br />
Structures and equipment" specified in the Annexu Annexure re A and B respectively in Civil Section,<br />
whichever is governing. Wind and seismic forces shall not be considered to act<br />
simultaneously. The following minimum live loads shall be adopted for the design of various<br />
structures. If actual expected load is more than the specified load, then actual load is to be<br />
considered<br />
a )Roofs 150 Kgs. / Sq. M. for accessible roofs and 75 Kgs. / Sq. M. for non<br />
accessible roofs. In addition to this coal dust load of 150 KKgs.<br />
gs. / sq. m. shall also be<br />
considered.<br />
b ) R. C. C. floors 500 Kgs. / Sq. M.<br />
c ) Stair and balconies 500 Kgs. / Sq. M.<br />
d ) Toilet rooms 200 Kgs. / Sq. M.<br />
e )Chequered plate floors 400 Kgs. / Sq. M.<br />
f ) Walkways ( including walkways in 300 Kgs. / SSq.<br />
q. M.conveyor galleries )<br />
g)Conveyor galleries In addition to the live loads, loads due to cable trays, fire fighting /<br />
service water pipes shall also be considered @ 125 Kgs. / m ( minimum ) on each of the<br />
longitudinal girder. Roof Roof-truss members are to o be checked for supporting fire fighting<br />
pipes/Service water pipes.<br />
h ) Road Culverts and its allied For class 'AA' loading and checked for structures including R.<br />
C. C. pipe class A loading as per IRC standard crossing & road crossing of trenches.<br />
i ) Channels / trenches In addition to earth pressure and water pressure, etc. additional<br />
earth pressure due to surcharge of 2T / Sq. M. shall<br />
j ) Covers for trenches/channels Covers for channels & trenches, shall be designed for a live<br />
load of 0.4T Sq.M. M. &loading mentioned under clause in trenches, whichever is critical.<br />
k ) Sumps and tanks and other In addition to earth pressure with a underground basement<br />
type surcharge of 2T / Sq. M. (or surcharge structures due to Railway loading whichever<br />
is critical for Railway load bearing structures etc.) and sub - soil water pressure etc. These<br />
are also to be designed for the following conditions :<br />
i ) Water / liquid inside and no earth outside (applicable only to such structures which are<br />
liable to be filled up with water or any liquid ).<br />
ii ) Earth with surcharge outside and no water / liquid inside<br />
iii ) For underground (basement) structures protection against buoyancy during execution<br />
and after execution shall be ensured without superimposed loadings with minimum factor<br />
of safety of 1.2 against buoyancy.<br />
l ) Unit weight of coal shallbe taken as 1100 Kgs. / cum. Fordesign purposesIf the er erection<br />
load is higher than the specified live loads on any floor or part thereof,then the erection<br />
loads are to be considered for the design.Permissible increase in stresses of materials and<br />
bearing pressure of soil due to windload or seismic load shall be as per relevant I. R. S. and I.<br />
S. code.<br />
13.0 DESIGN CRITERIA<br />
The loads for all railway load bearing structures e. g. track hopper includingmachinery<br />
hatches, wagon tippler, tunnel and under ground transfer houses etc. and the analysis and<br />
the design of these structures shall be made strictly in accordancewith the pr provisions of<br />
Indian Railway Bridge rules (latest edition), and Indian RailwayCodes of practice (latest<br />
Technical Specification:Sec-7, Civil<br />
Page 10 of 21
edition) with all amendments up to the date of opening ofbids. However, the axle load for<br />
analysis and design shall be considered as 35 MT.Coal heap of 1. 1.2m 2m height shall be<br />
considered above hopper top for design of, hopper and supporting elements of hopper. The<br />
analysis, design anddetail drawing for the structure coming below the railway track shall be<br />
got approvedby the contractor from the concerned railw railway ay authorities before taking<br />
upconstruction. All necessary payment for the above work shall be made by the bidder to<br />
the railway authority.The design of all R. C. C. structures shall be carried out as per ‘code of<br />
practice forplain and reinforced concrete for general building construction’, IS : 456 ( latest ).<br />
The steel structures shall be designed and fabricated as per ‘code of practice for use of<br />
structural steel in general building construction’, IS : 800 ( latest ) and other relevant IS<br />
Standards. Minimum mum size of the angle section to be used as structural members shall be<br />
50X50X6. Minimum weld size shall be 6 mm. Connections shall bedesigned for 70% of shear<br />
capacity of the member or the actual shear force, whichever is higher. The building shall<br />
conform to local bye - laws, rules and regulations for industrial buildings and also B. I. S.<br />
publications, SP 32 and 41. Slotted holes shall not be assumed to act as expansion joint for<br />
relieving of stresses and suitable bearings shall be provided at the supp supports. All gallery<br />
supporting trestles shall be so proportioned that the transverse deflection of gallery due to<br />
wind / seismic load should not exceed trestle height / 1000 as stipulated in IS: 11592. This<br />
deflection condition shall be strictly followed. Th The e transfer house structures shall be so<br />
designed that transverse deflection at places where conveyor galleries meet, should be<br />
equal to the respective transverse deflection of conveyor supporting trestles. Horizontal<br />
bracing system shall be provided at flo floor or levels around the openings. Shear force in steel<br />
columns shall be transferred to the pedestals / foundations exclusively either through<br />
foundation bolts or the shear key arrangement. For design of liquid retaining structures, IS :<br />
3370 ( Part - I to IV ) ( latest ) shall be followed. Face of the structure in contact with liquid<br />
shall be designed as un -cracked cracked section. For design of R. C. C. pipes for culverts, latest<br />
editions of IS : 458, IS : 783 should be followed. For design of all underground struct structures /<br />
foundations, ground water table shall be assumed at the formation level ( i. e. the adjoining<br />
ground level ). Design of Hopper walls shall be done for both Static & Dynamic flow condition<br />
using Walker’s theory. Design of masonry walls shall be made as per IS : 1905. Civil task<br />
drawing indicating various equipment loading and supporting arrangement and floor loads<br />
to be submitted along with the design calculation. For metal roofing and side cladding, the<br />
spacing of purlins/runners shall be such that tthe<br />
he deflection of metal sheet used is limited to<br />
span/250 under adverse loading condition. Minimum reinforcement shall be provided at the<br />
top face of the footing, even if, no reinforcements are required as per design<br />
14.0 CONCRETE<br />
All R. C. C. works to the done under this specification, unless specified otherwise shall be<br />
design mix concrete. Minimum grade of concrete for various structures shall be as follows:<br />
a ) M35 - For all railway load bearing structures<br />
b ) M25 - For underground / sub structural R. C. C. work (other than railway load bearing<br />
structures).<br />
C ) M20 - For R. C. C. superstructure works including ground floor slabs, trenches & drains.<br />
Minimum 75 mm thick P.C.C MM-7.5<br />
7.5 shall be provided as mud mat below all foundations. For<br />
concreting of underground structures requiring water tightness, plasticizer cum water<br />
proofing admixture shall be added to the concrete mix. Both coarse and fine aggregates shall<br />
conform to IS: 383 for concrete, shotcreting etc. unless otherwise directed. Batching plant<br />
or reversible drum mixer with weigh batcher and concrete pumps must be used for all<br />
concreting works(RCC).<br />
15.0 Excavation Details<br />
15.1 Excavation in soil<br />
Excavation for foundation shall be to the bottom of lean concrete and as shown on drawing<br />
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Page 11 of 21
or as directed by the Engineer. The bottom of all excavations shall be trimmed to required<br />
levels and when excavation is carried below such levels by error, it shall be brought back to<br />
the specified level by filling with concrete of nominal mix 1 : 3 : 6 ( (cement: cement: coarse sand: 40<br />
mm down aggregates ), as directed by the Engineer. The Contractor shall ascertain for<br />
himself the nature of materials to be excavated and the difficulties, if any, likely to be<br />
encountered in executing this work. Cofferdams, sheet ppiling,<br />
iling, shoring, bracing to maintain<br />
suitable slopes, draining etc. shall be provided and installed by the contractor, to the<br />
satisfaction of the Engineer. Surplus excavated materials shall be disposed off by the<br />
contractor at locations within plant boundary wall as directed by the engineer. The<br />
Contractor shall have to constantly pump out any water collected in excavated pits and<br />
other areas due to rain water, springs etc. and maintain dry working conditions at all times<br />
until the excavation, placement of reinforcement, shuttering, concreting, Backfilling is<br />
completed. The Contractor shall remove all slush/muck from the excavated areas to keep<br />
the work area dry. The Contractor, if required, shall employ sludge pumps, for this purpose.<br />
15.2 Excavation avation in rock<br />
For the work of excavation in rock, Contractor shall engage specialized agency having<br />
experience of excavation in rock involving wedging and blasting. The agency shall be subject<br />
to approval of Engineer and the Contractor shall furnish det details ails of relevant experience in<br />
support while seeking approval for the agency agency. Only Control Blasting shall be resort resorted to<br />
with the written permission of the Engineer. In case blasting method can not be adopted<br />
considering the safety aspect of the existing rrail<br />
ail network, buildings, structures etc, hard rock<br />
shall be excavated by using expansive chemical or any other suitable means means. All the<br />
statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. pertaining to the<br />
acquisition, transport, storage, handling and use of explosives etc. shall be strictly followed.<br />
The contractor shall obtain Licenses from Competent Authorities for undertaking blasting<br />
work as well as for procuring, transporting to site and storing the explosives as per<br />
Explosives es Act. The Contractor shall be responsible for the safe transport, use, custody and<br />
proper accounting of the explosive materials. Surplus excavated materials shall be disposed<br />
off by the contractor at locations within plant boundary wall as directed by th the engineer.<br />
The Contractor shall have to constantly pump out any water collected in excavated pits and<br />
other areas due to rain water, springs etc. and maintain dry working conditions at all times<br />
until the excavation, placement of reinforcement, shuttering shuttering, , concreting, backfilling is<br />
completed.<br />
15.3 De-watering watering of Deep Excavations<br />
For deep underground structures like wagon tippler hopper, machinery hatches, tunnels and<br />
underground transfer houses, requiring open excavation with extensive de - watering,<br />
completely letely dry working conditions during excavation, shuttering, placement of<br />
reinforcement, concreting, water proofing of structures, backfilling and any other operation<br />
shall be maintained by suitable de - watering method of suitable capacity.<br />
15.4 Backfilling, ng, Disposal and Stacking of materials<br />
Backfilled earth shall be compacted to minimum 90 % of the standard proctor density at<br />
OMC. Sand filling shall be compacted to minimum 80 % of the relative density. However, the<br />
backfill under the rail lines and roads shall be compacted to minimum 95 % of the standard<br />
proctor density at OMC unless otherwise stated by rail Authorities. The contractor is<br />
required to excavate upto any depth as shown on the drawings or as directed by the<br />
Engineer. Lifting of excavated mate materials rials shall be done either by manual or mechanical or<br />
both means if called for by the Engineer. The disposal / stacking areas for excavated<br />
materials shall be indicated by the Engineer. If directed by the Engineer this material shall be<br />
used directly for filling illing purposes. For leads exceeding 500 m the Contractor shall transport<br />
the excavated materials by mechanical means only and as directed by the Engineer. The<br />
Contractor may be allowed to carry materials through Kuccha roads. Providing and<br />
Technical Specification:Sec-7, Civil<br />
Page 12 of 21
maintaining of the Kuccha roads shall be the responsibility of the Contractor. The<br />
transported material shall be neatly stacked as directed by the Engineer. Double handling of<br />
materials shall be avoided as far as possible. However, depending on site condition<br />
excavated materials carried beyond a lead of 500 m may also be required to be brought back<br />
for filling purpose. Materials to be used for filling purpose shall be stone, sand or other<br />
inorganic materials and they shall be clean and free from shingle, salts, organic m mmatter,<br />
large<br />
roots and excessive amount of sod, lumps, concrete or any other foreign substances which<br />
could harm or impair the strength of the substances in any manner. All clods shall be<br />
suitably broken to small pieces. When the materials are mostly rock boulders, these shall be<br />
broken into pieces not larger then 150 mm size. Sand used for filling shall be clean, medium<br />
grained and free from impurities. Fines less than 75 microns shall not be more than 20%. In<br />
any case, the materials to be used for filling purposes shall have the prior written approval of<br />
the Engineer. In case the materials have to be brought from pits / quarries, then it shall be<br />
the Contractor’s responsibility for identification ion of such quarry areas, obtaining approval<br />
from their use from concerned authorities, excavation / quarrying loading and carriage of<br />
such material, unloading and filling at specified locations. The Contractor shall pay any fees,<br />
royalties etc. that may have to be pain for utilizationof borrow areas.<br />
16. 0 GALVANISING SING<br />
All burrs and irregular edges of the structural steel members to be galvanized shallbe ground<br />
smooth before galvanizing.Purity of Zinc to be used for galvanizing shall be 99.5 % as per IS :<br />
209 ( latestedition ).The weight of the zinc coating shall be at least 610 Gms. /m2unless<br />
noted otherwise.<br />
17.0 CHEMICAL INJECTION GROUTING<br />
Minimum, 12 mm dia ( NB ) threaded nozzle of suitable length, shall be provided over the<br />
surface and along the construction joint line in a grid pattern at a spacing not excee exceeding 1.5<br />
m c / c before concreting operation. Adequate precaution shall betaken to keep the nozzles<br />
plugged at both ends to prevent them from getting closedby concrete. For fixing of any<br />
nozzle in set concrete suitable size hole shall be drilled, preferabl preferably y by using repercussive<br />
hammer drill electrically operated, in grid pattern and grouting nozzle shall be fixed in these<br />
holes. After the nozzles are fully set, neat cement slurry admixed with water soluble non -<br />
shrink polymer / monomer based chemical shal shall l be injected through the net - work of<br />
nozzles with low pressure grout pumps at a pressure of about 2.0Kgs. /cm2. Cement slurry<br />
shall be prepared by mixing cement with non non-shrink shrink polymer/monomer @ 500 gm/50 kg bag<br />
of cement and water, ensuring that Water: Cement ratio does not exceed 2 (by weight).<br />
Wetter the structure, lesser should be the water cement ratio. The property of the<br />
polymer/monomer should be such that when it is mixed with water @0.5% by weight of<br />
water, the viscosity of the resultant solut solution ion (water and polymer/monomer) should not be<br />
more than 1.2 centipoises. Plasticizing agent shall be added wherever required. The grouting<br />
shall be started at very low pressure and increased gradually to a required pressure. The<br />
grouting shall continue, ti till ll the hole refuses to take any further grout, even at an increased<br />
pressure. Applied pressure shall not be more than the designed strength of the concrete.<br />
After completion of grouting operation, the nozzles shall be sealed properly to the<br />
satisfaction of the Engineer.<br />
18.00 POLYMER MODIFIED CEMENTITIOUS COATING<br />
18.1 Materials<br />
Modified liquid polymer blend shall be a dispersion containing 100 % acrylic based polymer<br />
solids. Polymer shall be mixed in the ratio of 1 cement: 0.5 polymer (for minimum solid<br />
content of polymer 30%). Portland cement based dry powder. Clean, fine specially prepared<br />
quartz sand approximately 0.6 mm size.<br />
18.2 Mixing<br />
The liquid polymer shall be stirred well and cement based powder shall then be added<br />
Technical Specification:Sec-7, Civil<br />
Page 13 of 21
slowly to make a Slurry Mix. For preparation of Brush Topping Mix, quartz sand shall be<br />
added slowly and mixed well till a homogeneous mixture is obtained. The mix shall be used<br />
within half an hour of the preparation. Addition of quartz sand may not be necessary, in case<br />
dry power contains the same.<br />
18.3 Properties of Coating<br />
It must adhere to wet surface. It should develop adequate bond strength, with the concrete<br />
surface, not less than 2N / Sq. mm.Co - efficient of permeability shall be about 5x10Cm /<br />
Sec.-1 0 Water r absorption after continuous soaking shall not be more than 1 %. The<br />
materials shall be permeable under water vapor. The material shall be resistant to acids and<br />
alkalis present in the soil and underground water with normal pH value between 4 and 14.<br />
The co - efficient of thermal expansion of the material shall be close to that of concrete<br />
18.4 Application<br />
The concrete surface shall be cleaned and made free from grease, oils or loosely adhered<br />
particles. The surface shall be damp without any free water. Fo For r exterior underground part,<br />
application (b) pertaining to Brush topping Mix shall be followed.<br />
(a) For Slurry Mix<br />
A minimum of 2 coats shall be applied on the surface. The first coat being applied, when<br />
the surface is still damp and left to harden for 4 to 6 hours. After 4 to 6 hours of the<br />
application of second coat, it shall be finished by rubbing down with a soft dry sponge.<br />
The coverage shall not be less than 1 : 1 Kgs. / m in the 2 coats. A lap of 75 2 mm shall be<br />
provided at the joints. The coating shal shall l be air dried for 4 to 6 hours and, thereafter,<br />
cured for 7 days after the application of last coat.<br />
(b) For Brush Topping Mix<br />
This shall be applied in two coats. A primary coat of slurry mix can also be firstapplied on the<br />
surface as first coat. After the coating has dried up, a coat of BrushTopping Mix shall be<br />
applied over it with a push broom or any other similar brush. Itshall be left in broom finished<br />
condition. The nominal thickness shall be 1.5 mm andminimum thickness shall be 1.0 mm. A<br />
lap of 75 mm shall be provided at the joints. Itshall be ensured that no pinhole exists and<br />
rebrushing shall be done to cover thepinholes, if any.The Coating shall be air dried for 4 to 6<br />
hours and thereafter cured for 7 days afterthe application of last coat.Rate of application of<br />
coating shall be established to achieve the required thickness.<br />
19.0 Architectural Features<br />
All architectural features of buildings like control rooms, M. C. C.rooms, transfer houses and<br />
conveyor galleries etc. shall be detailed by contr contractor’squalified actor’squalified architect. Necessary<br />
projections, fins etc. in addition to the minimumspecified elsewhere in this specification<br />
shall be provided as required. The Contractor for Employer/RITES’s approval shall submit<br />
detailed architectural drawings along with colour schemes. Nothing extra shall be payable<br />
for any changes required while getting the drawings / schemes approved and for executing<br />
the same.In case structural column base plates are proposed below the floor level, the same<br />
shall be encased with aadequate<br />
dequate cover up to the finished floor level with minimum M -20<br />
grade concrete. Dowels shall be left from the pedestals to be lapped to the<br />
skinreinforcement of the encasing.<br />
20.0 Glazing<br />
Window glazing for various locations shall be as below:<br />
(i)In transfer er houses and pump houses etc: Polycarbonate sheet.<br />
(ii)In Switchgear / M. C. C. buildings<br />
(a) In air conditioned (A / C) areas: Double glazing with two 6 mm thick clear toughened<br />
safety glass hermetically sealed and separated by 12 mm thick gap for therma thermal insulation at<br />
partition of A / C and non A / C areas.<br />
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(b) In toilets: Ground glass of minimum thickness 4 mm.<br />
(c) In other areas: Toughened glass of minimum thickness 4 mm The above mentioned glass<br />
thickness are bare minimum only and actual thickness will depend on the panel size of the<br />
glazing to be provided.<br />
21.0 False Ceiling<br />
All air - conditioned areas, shall be provided with the suspended permanently colour coated<br />
aluminium false ceiling system with corrosion resistance aluminium alloy panels of m mminimum<br />
thickness 0.5 mm. 50 mm thick mineral wool insulation (as per IS: 8183) having a density of<br />
32 kg/cum for glass wool or 48 kg/cum for rock wool, bound in polythene bags shall be laid<br />
on top of panels. Additional hangers and height adjustment clips shall be provided for<br />
returns air grills, light fixtures, A. C. ducts etc. Suitable M. S. channel (Minimum ISMC 75)<br />
grid shall be provided above the false ceiling level for movement of personnel to facilitate<br />
maintenance of lighting fixtures, AC ducts etc. Under deck insulation shall be provided on<br />
the ceiling (underside of roof slab) and underside of floor slab of air - conditioned areas<br />
depending upon the functional requirements. This under deck insulation shall consist of 50<br />
mm thick mineral wool insulat insulation ion mat conforming to IS: 8183 having a density of 32 kg/cum<br />
for glass wool or 48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G<br />
x 25 mm mesh wire netting and shall be fixed to the ceiling with 14G wire ties.<br />
22.0 Acid / Alkali Resis Resistant Lining<br />
Battery Room For Floor and dado, bitumen primer followed by 12 mm thick bitumastic 6 mm<br />
thick potassium silicate mortar bedding and 20 mm thick A. R. tiles shall be provided. Dado<br />
height shall be minimum 2.0 m from floor. M. S. Grating / Cheque Chequered red plate cover and any<br />
other steel structure likely to come in contact with chemicals shall be provided with epoxy<br />
coating 150 microns thick over epoxy primer. Acid / Alkali resistant lining material shall<br />
conform to the following: Bitumen primer shall co conform nform to IS: 158. Bitumastic compound<br />
shall conform to IS: 9510. Where the height of bitumastic layer on vertical surface is more<br />
than 2.0 m, the bitumastic layer shall be reinforced with diamond pattern expanded metal<br />
steel sheets conforming to IS: 412. A. R. tiles shall conform to IS: 4457. Mortar: Potassium<br />
silicate and resin type mortars shall conform to IS : 4832 Parts – I and II respectively.<br />
23.0 FINISHING SCHEDULE<br />
The contractor's scope also includes all doors, windows, glazing, rolling shutters, f ffinishes,<br />
damp proofing, inserts, anchor bolts, embedments, stairs, nosing, railings, toe - guards,<br />
ladders, edge protection angles, etc. The Contractor shall adhere to the finishing schedule as<br />
given.<br />
23.1 Flooring<br />
I. P. S. ( cement concrete flooring ) with metallic hardener topping shall be provided for all<br />
floors in transfer houses, including ground floors of transfer houses, ground conveyors,<br />
operating floor of pump houses, M. C. C. rooms, cable vault / cable spreader rooms,<br />
maintenance enance and unloading areas, general storage areas and all other areas in plant<br />
buildings where heavy duty flooring is required. Heavy Duty Ceramic Tiles ( matt finish ) shall<br />
be provided for toilets, office rooms, laboratories, control rooms and control eq equipment<br />
rooms. Well polished Kota stone shall be provided for staircases, passages, lobbies and<br />
general circulation areas. The floor shall be laid on an already laid and matured concrete<br />
base. Sunken R. C. C. slab shall be provided in toilet area so as to keep the finished floor<br />
level of these areas same as that of the surrounding area Wherever specified metallic<br />
hardener topping shall be 12 mm thick using uniformly graded iron particles, properly<br />
treated. Wherever specified Heavy duty ceramic tiles of siz size e 300 x 300 x 7 mm thick<br />
(minimum) of reputed manufacturer (Kajaria, Spartek or equivalent) of approved finish,<br />
shade and colour to be used. The tiles shall have a scratch resistance of minimum 5 on<br />
Mohr’s scale and shall have a bending strength of 350 Kgs Kgs. . / cm.2 Paving details shall be<br />
similar to grade slab excluding metallic hardener. Skirting in general shall be 150 mm high.<br />
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Dado in toilets and pantries shall be up to 2.1 m height from finished floor level. Skirting and<br />
dado shall match with the floor ffinish.<br />
23.2 Interior Wall / Ceiling Finish<br />
For all air - conditioned areas and stair case acrylic emulsion paint of approved make and<br />
shade over 2-3 mm cement based putty of approved make shall be provided provided. For toilets<br />
minimum 5 mm thick decorative coloure coloured d ceramic tiles of approved make and shade with<br />
approved pattern up to 2.10 m. height from finished floor level shall be provided. Oil bound<br />
distemper over 2-3 mm cement based putty of approved make above 2.10 m height shall be<br />
provided. For all other area areas s oil bound distemper ( IS : 428 ) of approved shade over cement<br />
based putty of approved make shall be provided. For battery room and other areas coming<br />
in contact with acid / alkali fumes, chemical resistant chlorinated rubber paint shall be<br />
provided above e 2.1 m height. Up to 2.1 m height from finished floor level acid alkali resistant<br />
tiles shall be provided as specified elsewhere. All R. C. C. ceilings shall be oil bound<br />
distemper over cement based putty putty.<br />
23.3 Exterior Finish<br />
Aluminium Industrial troughed sheet cladding ( non - insulated ) of approved colour<br />
combination shall be provided for transfer points, conveyor galleries, elevator shafts, and<br />
parapet walls of buildings where metal cladding is specified. Exterior weathered coat paint<br />
shall be provided for the under mentioned areas :<br />
(a) All buildings with R. C. C. framework unless specified otherwise in this specification<br />
(b) Brick work in the lower portion of metal cladding.<br />
(c) Fire walls<br />
(d) Projections and facia : R. C. C. parapets ( excepting parapets of buildings<br />
(e) where metal cladding is specified )Exterior brick walls.<br />
24.0DOORS, DOORS, WINDOWS AND ROLLING SHUTTERS.<br />
24.1 Doors and Windows<br />
All doors, windows and venti ventilators of control room building and M. C. C. buildings shall have<br />
Electro colour coated (anodised) aluminium frame work with glazing. All doors of office and<br />
toilet areas shall be of factory made pre pre- laminated particle board (M D F exterior grade). All<br />
other buildings shall have steel doors, windows and ventilators. Single glaz glazed panels with<br />
aluminium framework shall be provided as partition between two air - conditioned areas<br />
wherever clear view is necessary. Coal conveyor galleries shall have steel windows of<br />
openable type. The window shutters shall be provided with M. S. louv louvers. All steel doors<br />
shall consist of double plate flush door shutters. The door shutter shall be 45 mm thick with<br />
two outer sheets of 18 G rigidly connected with continuous vertical 20 G stiffeners at the<br />
rate 150 mm centre to centre. Side, top and bottom edges of shutters shall be reinforced by<br />
continuous pressed steel channel with minimum 18G. The door shall be sound deadened by<br />
filling the inside void with mineral wool. Doors shall be complete with all hardware and<br />
fixtures like door closer, tower bolts bolts, , handles, stoppers aldrops, etc. Windows of coal<br />
galleries shall be provided with welded wire fabric of 1.6 mm thick wire as per IS: 4948 and<br />
12 mm x 30 mm mesh size. Wherever functionally required rolling shutters shall be provided<br />
and these shall be electrically ctrically operated. In transfer points, windows near floors shall be steel<br />
and openable types. The window shutters shall be provided with MS louvers. Windows /<br />
ventilators at higher level can be of steel with fixed glazing. All openable windows shall be<br />
provided ovided with suitable stays. All windows and ventilators onground floor of all switchgear<br />
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and M. C. C. buildings shall be provided with suitable anodized aluminium grill. Fire - Proof<br />
doors with panic devices shall be provided at all fire exit points as pe per r the recommendations<br />
of statutory regulatory bodies These doors shall generally be as per IS : 3614 ( Part I and Part<br />
II ). Fire rating of the doors shall be as per requirements of statutory regulatory bodies.<br />
However minimum rating shall be 2 hours. Thes These e doors shall be double cover cover-plated types<br />
with mineral wool insulation. Hollow extruded section of minimum 3 mm wall thickness as<br />
manufactured by INDAL or equivalent shall be used for all aluminium doors, windows, and<br />
ventilators. Doors and windows on ext external ernal walls of the buildings having brick enclosures i.e.<br />
enclosure other than with Aluminium Industrial troughed sheet cladding, shall be provided<br />
with sunshade over the openings with width 600 mm more than the opening width.<br />
Projections from the wall fo for r the sunshade shall be 450 mm over window openings and 750<br />
mm over door openings. Minimum size of door provided should be 2.1 m high and 1.2 m<br />
wide, except for toiler rooms, where door may be 0.75 m wide. All doors ( other than those<br />
in W/C and urinal area a ) shall be double plate flush door shutters. For W/C and urinals area,<br />
wooden panel doors shall be provided. Area of windows shall be at least 10 % of the floor<br />
area of the respective building. The area of translucent polycarbonate sheet panels shall als also<br />
be at least 10 % of the floor area of the respective building. Monorail doors shall be provided<br />
with steel stays / chains etc for convenient operation of the shutters. The louvre blade shall<br />
be ‘Z’ shaped and made out of 18G sheets in EZ7 steel frames. TThe<br />
he frames shall be of ISMC<br />
100.<br />
24.2 Rolling Shutters<br />
Rolling Shutters/ grills shall be with motor drives, gear arrangement including all accessories<br />
and shall conform to IS: 6248. All electrical work shall be in strict accordance with the<br />
relevant Indian Electricity Rules. After installing the shutters, the Contractor shall test the<br />
performance of the shutter in presence of the Engineer. The shutters shall be smoothly<br />
operable under all ambient conditions. All control and locking devices shall give fault f ffree<br />
performance.<br />
25.0 PAINTING<br />
Painting of all steel structures, including seal plates, hand rails, steel doors & windows,<br />
ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc. shall be as per<br />
specification mentioned elsewhere in this document.<br />
26.0 Miscellaneous<br />
26.1 Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings,<br />
pedestals, cable trenches, pits etc., Plywood form work shall be used for all over ground<br />
exposed work like columns, beams, floors an and d ceilings in control room and M. C. C. buildings.<br />
26.2 Monorail girders and fixtures shall be provided for monorails at the locations as<br />
required and as described elsewhere in these specifications or drawings. Monorail openings<br />
in the walls shall be prov provided ided with steel frame doors preferably sliding type or otherwise<br />
open able inside, access platforms and ladders.<br />
26.3Steel Steel frame around openings in roof and on external walls for mounting of exhaust<br />
fans shall be provided.<br />
26.4 Ready mix non - shrink nk cementitious grout of reputed manufacturer as approved by<br />
the Employer shall be used for grouting of block outs and foundation bolts, underpinning of<br />
base plates and machine bases. Crushing strength of grout shall be one grade higher than<br />
the foundation concrete. Minimum crushing strength shall be 30 N / mm2 unless higher<br />
strength requirement is specified by the equipment supplier or the grout manufacturers.<br />
26.5The The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m<br />
Technical Specification:Sec-7, Civil<br />
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above e the ground except for rail / road crossing where it shall be 8m above the rail top /<br />
road crest/ground. Further in bunker areas it shall be 8 m above the ground.<br />
26.6Polysulphide Polysulphide Sealing Compound shall be two two-part part polysulphide sealant and shall be<br />
from om approved manufacturer, conforming to IS : 12118. Materials shall consist of<br />
polysulphide polymer and a curing agent. Gun grade material shall be used unless otherwise<br />
specified. The application of the sealant shall be strictly followed as per manufactur manufacturer’s<br />
guidelines<br />
27.0 SHOTCRETING<br />
27.1 General Requirements<br />
27.2 Generally, shotcreting shall be done in accordance with IS : 9012.<br />
27.3 Reinforcement for shotcreting shall be as detailed below, unless specified otherwise.<br />
(i) Reinforcement in one directio direction n consisting of 6 mm M. S. bars at 750 mm c / c shall be<br />
connected to the lugs for fastening of the wire fabric. This shall be used in case of 50 mm or<br />
above thick shotcreting.<br />
(ii) Wire fabric conforming to IS : 1566 shall be used as reinforcement and sh shall consist of<br />
wire, 3 mm diameter, spaced 50 mm both ways and shall be electrically cross welded. Wire<br />
fabric shall be securely tied to 6 mm bars for 50 mm thickness. Adjacent sheet of wire fabric<br />
shall be lapped at least 100 mm and tied.<br />
(ii) Clear cover r to reinforcement mesh shall not be less than 15 mm. 22.01.03 Minimum<br />
thickness of shotcreting shall be 50 mm. for abrasion resistant work and 25mm for ordinary<br />
surface protection work.<br />
27.4 Material<br />
Generally, the materials shall be in accordance wwith<br />
ith aggregates specification given<br />
hereunder.<br />
Fine aggregate shall consist of natural sand or crushed stone from a known source and shall<br />
be strong, hard, coarse, sharp, chemically inert, clean and free from any coating. It shall be<br />
free from clay, coal or coal residue, organic or any other impurities that may impair the<br />
strength or durability of the concrete and shall conform to IS :383.Fine aggregate (Sand)<br />
shall be well graded and particles shall range in size within the following limits. The Engineer,<br />
may ay approved the use of any other grading as per requirement or as erIS : 9012.<br />
The fineness modulus shall be preferably between 2.5 and 3.3. Any other value an be used,<br />
with prior approval of the Engineer.<br />
27.5 Application<br />
After the placement of reinforcement and / or welded mesh and not more than six ours<br />
prior to the application of shotcrete, the surface shall be thoroughly cleaned of all loose<br />
aterials and dirt. The Contractor shall properly prepare the surfaces, reinfo reinforcement and / or<br />
welded esh to receive the shotcrete. Cleaned surfaces shall be wetted not more than hour<br />
prior to hotcreting.<br />
The mix as placed on surface shall be one part cement to three parts approved sand by<br />
mass. Cement and sand shall be dry mixed mixed; ; not water shall be added after mixing and before<br />
sing in the gun. The quantity of water when added shall be only that which is sufficient to<br />
hydrate the cement. For average atmospheric conditions, the water cement ratio for<br />
shotcrete in place shall be between 0.35 and 0.5 by mass.Suitable admixture shall be used<br />
wherever required.<br />
A uniform pressure of not less than 25 Kgf / Cm2 at the nozzle shall be maintained.<br />
Necessary adjustments shall be made to ensure this pressure, taking into account the length<br />
of ose and height of the place to be shotcreted, above location of the machine.<br />
The application shall proceed in an upward direction. Beams, stiffeners andintermediate<br />
walls, if any, shall be wrapped with wire fabric and completely covered with hotcreting hotcreting. All<br />
rebound shall be removed from the area of application as the work progresses andsuch<br />
rebound material shall not be reused.<br />
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Page 18 of 21
As soon as the freshly shotcreted surface shows the first dry patches, a fine spray 0f water<br />
shall be applied to keep too moist moist. . After the surface has hardened, it shall be kept<br />
continuously moist for minimum seven days. If there is extreme heat, especially when<br />
ccompanied by hot winds, the shotcreted surface, immediately upon completion, shall be<br />
covered with burlap or similar co covering, vering, which must be kept continuously moist for 14 days<br />
after shotcreting. The temperature of the lining shall not be permitted to exceed 38 oC<br />
during placing and curing.<br />
28.0 PTFE (Poly Tetra Fluoroethylene) Bearing<br />
The bearing shall be of reputed make and manufacturer as approved by theEngineer, for<br />
required vertical load and end displacement/rotation. PTFE bearingshall be sliding against<br />
highly polished stainless steel and the coefficient of frictionbetween them shall be less than<br />
0.06 at 55 kg/sq.cm. In order to prevent cold flow inPTFE surface it shall be rigidly bonded by<br />
a special high temperature resistanceadhesive to the stainless steel substrata. The stainless<br />
steel surface that slidesagainst the PTFE is mirror polished. The stainless steel shall be<br />
bonded to the topplate by special high strength adhesive. The thickness of stainless steel<br />
plate shallbe between 1.0 mm to 1.5 mm.<br />
29.0 TESTS FOR MATERIAL / WORKMANSHIP<br />
All tests required for all materials, quality of workmanship or any other tests asdesired by<br />
the Engineer shall be at contractor’s cost.<br />
30.0 MATERIALS<br />
30.1 For Civil, Structural and Architectural works<br />
Employer will not supply any material. All materials including cement, reinforcementsteel<br />
and structural steel, whatsoever required ffor<br />
or execution and completion of theentire scope<br />
of work covered under this specification shall be arranged by thecontractor at his own cost.<br />
All materials procured by the contractor shall meet thequality requirements specified in this<br />
specification.The contractor ractor shall keep sufficient stock of cement and steel at site at any<br />
point oftime when the work is in progress excluding what has been already incorporated<br />
inthe works, so that any disruption / delay in availability of these materials<br />
duringprocurement will ll not affect the progress of work at site. The minimum quantity<br />
ofsuch materials in stock at site shall not be less then the Requirement of one( 1 )month in<br />
case of Cement and Requirement of two ( 2 ) Consecutive months in caseof Steel.<br />
30.2 Cement<br />
The contractor shall use cements conforming to, IS: 455, IS: 8112. Higher grade of cement<br />
namely GR - 53 of ordinary portland cement conforming to IS: 12269 can also be used.<br />
30.3 Reinforcement steel shall conform to to:<br />
a) Mild steel grade I of IS: 432 Part – I and grade A of IS: 2062.<br />
b) High yield deformed bar of IS: 1786 (Gr. Fe 415 and Fe. 500).<br />
30.4 Structural steel:<br />
Rolled olled sections and plate shall conform to Grade A as per IS: 2062 2062-1992 1992 and/or as per<br />
specification specified at relevant clauses clauses.<br />
31.0 Guarantee for water proofing<br />
The contractor shall furnish guarantee for the water proofing or similsr work wherever it is<br />
included in civil work for three years. The contractor shall furnish a Bank Guarantee<br />
equivalent to 105 of the value of water proofing work to be valid additional two years<br />
beyond the defect liability period of the contract. The BG/SD towards the defect liability<br />
period can be returned only on submission of bank guarantee for water proofing as stated<br />
above.<br />
32.0 CODES AND STANDARDS<br />
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Page 19 of 21
All standards, specifications, acts and code of practice referred to herein shall be the latest<br />
editions including all applicable official amendments and revisions. Other Indian, foreign<br />
Codes and Standards not listed here but referred to elsewhere within thi this specification shall<br />
also be deemed to be part of this list. In case of conflict between this specification and those<br />
(IS standards, codes etc.) referred to herein, the former shall prevail. Some of the relevant<br />
Indian standards, Acts and Codes applicable to this section of the specification are listed<br />
below<br />
IS : 383 Specification for coarse and fine aggregates from natural sources for Concrete.<br />
IS : 432 Specification for mild steel and medium tensile steel bars and hard drawn steel wire<br />
for concrete reinforcement.<br />
nforcement.<br />
IS : 456 Code of practice for plain and reinforced concrete.<br />
IS : 458 Specification for concrete pipes.<br />
IS : 516 Method of test for strength of concrete.<br />
IS : 800 Code of practice for use of structural steel in general building construction<br />
construction.<br />
IS : 814 Specification for covered electrodes for metal arc welding for weld steel.<br />
IS : 816 Code of practice for use of metal arc welding for general construction.<br />
IS : 817 Code of practice for training and testing of metal arc welders.<br />
IS : 875 (Pt. I to V) Code of practice for design loads other than earthquake) for buildings<br />
and structures.<br />
IS : 1038 Steel doors, windows and ventilators.<br />
IS : 1172 Basic requirements for water supply, drainage and sanitation.<br />
IS : 1361 Steel windows ows for industrial buildings.<br />
IS : 1786 Specification for high strength deformed steel bars and wires for concrete<br />
reinforcement.<br />
IS : 1892 Code of practice for subsurface investigation for foundation.<br />
IS : 1893 Criteria for earthquake resistant design of structures.<br />
IS : 1904 Code of practice for design and construction of foundations in soils; general<br />
requirements<br />
IS : 1905 Code of practice for structural safety of buildings -Masonry Masonry walls.<br />
IS : 1948 Specification for aluminium doors, windows and ventilators.<br />
IS : 2062 Steel for general structural purposes. IS : 2131 Method of standard penetration<br />
test for soils.<br />
IS : 2212 Code of practice for brickwork.<br />
IS : 2645 Specification for Integral cement water proofing compounds.<br />
IS:2720 (Part-II, Methods ethods of test for soils - determination for water content<br />
IV TO VIII, XIV, etc code of practice for earth work on canals. XXI, XXIII, XXIV, XXVII TO XXIX,<br />
XL)<br />
IS : 2911 Code of practice for design and construction of pile foundations.<br />
(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<br />
piles. (Part-IV) IV) Load test on piles. IS : 2974 (Part – I Code of practice for design and<br />
construction of machine TO V) foundations.<br />
IS : 3370 (Part I to Code of practice for con concrete crete structures for the storage of IV) liquids.<br />
IS : 3658 Code of practice for liquid penetrant flaw detection.<br />
IS : 3664 Code of practice for ultra sonic testing by pulse echo method.<br />
IS : 4326 Code of practice for earthquake resistant design and cons construction truction of buildings.<br />
IS : 4990 Specification for plywood for concrete shuttering work.<br />
IS : 5624 Specification for foundation bolts.<br />
IS : 7215 Tolerances for fabrication steel structures.<br />
IS : 8112 Specification for 43 grade Ordinary Portland Cement Cement.<br />
IS : 9103 Specification for admixtures for concrete.<br />
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Page 20 of 21
IS : 9595 Code of procedure of manual metal arc welding of mild steel.<br />
IS : 10262 Recommended guidelines for concrete mix design<br />
IS : 13311 Method of non - destructive testing of concrete.<br />
IS : 13755 Dust pressed ceramic tiles with water absorption of 3%,E6% (Group B11a)<br />
ASTM 898 -89 89 Standard guide for use of high solid content, cold liquid liquid-applied<br />
elastomeric<br />
water proofing membrane for use with separate wearing course. AS/NZS 2728 Pre finis finished /<br />
pre painted sheet metal product for interior / exterior building applications – Performance<br />
requirements.<br />
AS : 1365 Standards for steel manufacturing.<br />
AS : 1397 A steel sheet & strip – hot – dipped-zinc-coated or Aluminium--Zinc<br />
coated.<br />
AS : 3566 Self drilling screws for building and construction industry.<br />
IRC : 37 Guidelines for the design of flexible pavements. - Manual on sewerage and sewage<br />
treatment (Published by CPH & EEO) As updated. Indian Explosives Act. 1940 as updated<br />
Technical Specification:Sec-7, Civil<br />
Page 21 of 21
1.0 GENERAL<br />
1.1 The following provisions shall supplement the conditions already contained in the other parts<br />
of these specifications and documents and shall govern that portion of the work of this<br />
contract which is to be performed at site. The erection requirements and procedures not<br />
specified in these documents shall be in accordance with the recommendations of the<br />
equipment manufacturer, or as mutually agreed to between the Employer and the Contractor<br />
prior to commencement of erection work.<br />
1.2 The Contractor upon signing of the Contract shall, in addition to a Project Coordinator,<br />
nominate another responsible officer as his representative at Site suitably designated fo for the<br />
purpose of overall responsibility and co co-ordination ordination of the Works to be performed at Site. Such<br />
a person shall function from the Site office of the Contractor during the pendency of Contract.<br />
2.0 REGULATION OF LOCAL AUTHORITIES AND STATUTES<br />
2.0.1 In n addition to the local laws and regulations, the Contractor shall also comply with the<br />
Minimum Wages Act and the Payment of Wages Act (both of the Government of India) and<br />
the rules made there under in respect of its labour and the labour of its sub sub-contractors<br />
currently employed on or connected with the contract.<br />
2.0.2 All registration and statutory inspection fees, if any, in respect of his work pursuant to this<br />
Contract shall be to the account of the Contractor. However, any registration, statutory<br />
inspection pection fees lawfully payable under the provisions of the Indian Boiler Regulations and any<br />
other statutory laws and its amendments from time to time during erection in respect of the<br />
plant equipment ultimately to be owned by the Employer, shall be to the account of the<br />
Employer. Should any such inspection or registration need to be re re-arranged arranged due to the fault<br />
of the Contractor or his Sub Sub-Contractor, Contractor, the additional fees for such inspection and/or<br />
registration shall be borne by the Contractor.<br />
2.1 Qualification ation of Weld Procedures<br />
Only qualified welding procedures as per ASME Section IX shall be used by contractor at site.<br />
Procedure qualification records along with WPS shall be submitted to NALCO for review.<br />
Welding procedure shall indicate all essential aand<br />
non-essential essential parameters as per ASME<br />
Section IX. Makes of welding consumables shall be subject to employer’s approval.<br />
3.0 SITE RUN MISCELLANEOUS PIPING<br />
Sketches or diagrams of the proposed routings of all piping, not already indicated and routed<br />
on the shop drawings which were reviewed by the Employer, shall be submitted to the<br />
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SECTION 8<br />
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Employer for review, Employer's acceptance of such site routings shall be obta obtained before the<br />
piping is erected. All these site run piping shall be installed in such a manner as to present an<br />
orderly and neat installation. They shall be located as to avoid obstruction of access and<br />
passages. Valves, instruments or any other special items shall be located convenient for<br />
operation by the operating personnel. Pipe runs shall be plumb or level except where pitch for<br />
drainage is required. Pipe runs that are not parallel to the building structure, walls or column<br />
rows shall be avoided. No miscellaneous pipe shall be routed and installed above or adjacent<br />
to electrical equipment.<br />
4.0 PIPING SUPPORTS<br />
4.1 Hangers, supports and anchors shall be installed as required to obtain a safe, reliable and<br />
complete pipe installation. All supports shall be properly levelled and anchored when<br />
installed. The anchors shall be so placed that thermal expansion will be absorbed by bends<br />
without subjecting the valves or equipment to excessive strains.<br />
4.2 The hanger assemblies shall not be used for the attachm attachment ent of rigging to hoist the pipe into<br />
place. Other means shall be used to securely hold the pipe in place till the pipe support is<br />
completely assembled and attached to the pipe and building structures and spring support is<br />
set to accommodate the pipe way. All temporary rigging shall be removed in such a way that<br />
the pipe support is not subjected to any sudden load. All piping, having variable spring type<br />
supports, shall be held securely in place by temporary means during the hydraulic test of pipe<br />
system. Constant onstant support type spring hangers used during hydraulic test shall be pinned or<br />
blocked solid during the test. After complete installation and insulation of the piping and filling<br />
of the piping with its normal operating medium, the pipe support springs s sshall<br />
be adjusted to<br />
the cold positions. If necessary, the spring support shall be re re-adjusted adjusted to the hot positions<br />
after the line has been placed for service at its normal maximum operating temperature<br />
conditions. Electric arc welding only shall be used to weld all pipe supports to structural steel<br />
members that form part of the building supporting structure. The structural beams shall not<br />
be heated more than necessary during welding of supports and such welds shall run parallel to<br />
the axis of the span. All lugs or any other attachments welded to the piping shall be of the<br />
same material as the pipe.<br />
5.0 CODE REQUIREMENTS<br />
The erection requirements and procedures to be followed during the installation of the<br />
equipment shall be in accordance with the relevant Indian Electricity Rules & Codes, Indian<br />
Boiler Regulations, ASME codes and accepted good practices, the Employer's Drawings and<br />
other applicable Indian recognised codes and laws and regulations of the Government of<br />
India.<br />
6.0 ELECTRICAL SAFETY REGULATION<br />
REGULATIONS<br />
6.1 In no circumstances will the Contractor interfere with fuses and electrical equipment<br />
belonging to the other Contractor or Employer.<br />
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6.2 Before the Contractor connects any electrical appliances to any plug or socket belonging to<br />
the other Contractor or Employer, he shall:<br />
a) Satisfy the Employer that the appliance is in good working condition;<br />
b) Inform the Employer of the maximum current rating, voltage and phases of the<br />
appliances;<br />
c) Obtain permission of the Employer detailing the socket to which the appli appliances may<br />
be connected.<br />
6.3 No repair work shall be carried out on any live equipment. The equipment must be declared<br />
safe by the Employer and a permit to work issued before any work is carried out.<br />
6.4 The Contractor shall employ the necessary number of qualified, full time electricians to<br />
maintain his temporary electrical installation.<br />
7.0 REMOVAL OF MATERIAL<br />
No material brought to the Site shall be removed from the Site by the Contractor and/or his<br />
Sub-Contractors Contractors without the prior written approval of the Employer.<br />
8.0 INSPECTION, TESTING AND INSPECTION CERTIFICATES<br />
The provisions of the clause entitled Inspection, Testing and Inspection Certificates given in<br />
General Technical Requirement, shall also be applicable to the erection portion of the Works.<br />
The Employer shall have the right to re re-inspect inspect any equipment though previously inspected<br />
and approved by him at the Contractor’s works, before and after the same are erected at Site.<br />
If by the above inspection, the Employer rejects any equipment, tthe<br />
he Contractor shall make<br />
good for such rejections either by replacement or modification/ repairs as may be necessary<br />
to the satisfaction of the Employer. Such replacements will also include the replacements or<br />
re-execution execution of such of those works of other CContractors<br />
ontractors and/or agencies, which might have<br />
got damaged or affected by the replacements or re re-work work done to the Contractor’s work.<br />
9.0 ACCESS TO SITE AND WORKS ON SITE<br />
9.1 Suitable access to site and permission to work at the Site shall be accorded to th the Contractor<br />
by the Employer in reasonable time.<br />
9.2 In the execution of the Works, no person other than the Contractor or his duly appointed<br />
representative, Sub-Contractor Contractor and workmen, shall be allowed to do work on the Site, except<br />
by the special permission, sion, in writing by the Employer or his representative.<br />
10.0 CONTRACTOR’S SITE OFFICE ESTABLISHMENT<br />
The Contractor shall establish a Office at the Site and keep posted an authorized<br />
representative for the purpose of the Contract. Any written order or instruction of the<br />
Employer or his duly authorised representative, shall be communicated to the said authorised<br />
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esident representative oof<br />
f the Contractor and the same shall be deemed to have been<br />
communicated to the Contractor at his legal address.<br />
11.0 CO-OPERATION OPERATION WITH OTHER CONTRACTORS<br />
11.1 The Contractor shall co-operate operate with all other Contractors or tradesmen of the Employer, who<br />
may be performing other works on behalf of the Employer and the workmen who may be<br />
employed by the Employer and doing work in the vicinity of the works under the Contract. The<br />
Contractor shall also arrange to perform his work as to minimise, to the maximum ex extent<br />
possible, interference with the work of other Contracts and their workmen. Any injury or<br />
damage that may be sustained by the employees of the other Contractors and the Employer,<br />
due to the Contractor’s work shall promptly be made good at his own expen expense. The Employer<br />
shall determine the resolution of any difference or conflict that may arise between the<br />
Contractor and other Contractors or between the Contractor and the workmen of the<br />
Employer in regard to their work. If the work of the Contractor is de delayed layed because of the any<br />
acts of omission of another Contractor, the Contractor shall have no claim against the<br />
Employer on that account other than an extension of time for completing his works. Employer<br />
shall have full access to visit the contractor’s sit site e at any time for inspection and surveillance<br />
checks.<br />
11.2 The Employer shall be notified promptly by the Contractor of any defects in the other<br />
Contractor’s works that could affect the Contractor’s Works. The Employer shall determine<br />
the corrective measures res if any, required to rectify this situation after inspection of the works<br />
and such decisions by the Employer shall be binding on the Contractor.<br />
12.0 DISCIPLINE OF WORKMEN<br />
The Contractor shall adhere to the disciplinary procedure set by the Employer i iin<br />
respect of his<br />
employees and workmen at Site. The Employer shall be at liberty to object to the presence of<br />
any representative or employee of the Contractor at the Site, if in the opinion of the Employer<br />
such employee has mis mis-conducted himself or is incompetent, mpetent, negligent or otherwise<br />
undesirable then the Contractor shall remove such a person objected to and provide in his<br />
place a competent replacement.<br />
13.0 CONTRACTOR’S FIELD OPERATION<br />
13.1 The Contractor shall keep the Employer informed in advance regarding his field activity plans<br />
and schedules for carrying out each part of the works. Any review of such plan or schedule or<br />
method of work by the Employer shall not relieve the Contractor of any of his responsibilities<br />
towards the field activities. Su Such ch reviews shall also not be considered as an assumption of any<br />
risk or liability by the Employer or any of his representatives and no claim of the Contractor<br />
will be entertained because of the failure or inefficiency of any such plan or schedule or<br />
method of work reviewed. The Contractor shall be solely responsible for the safety, adequacy<br />
and efficiency of plant and equipment and his erection methods.<br />
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13.2 The Contractor shall have the complete responsibility for the conditions of the Work Work- Site<br />
including g the safety of all persons employed by him or his Sub Sub-Contractor Contractor and all the<br />
properties under his custody during the performance of the work. This requirement shall<br />
apply continuously till the completion of the Contract and shall not be limited to normal<br />
working hours. The construction review by the Employer is not intended to include review of<br />
Contractor’s safety measures in, on or near the Work Work- Site, and their adequacy or otherwise.<br />
14.0 PHOTOGRAPHS AND PROGRESS REPORT<br />
14.1 The Contractor shall furnis furnish h three (3) prints each to the Employer of progress photographs of<br />
the work done at Site. Photographs shall be taken as and when indicated by the Employer or<br />
his representative. Photographs shall be adequate in size and number to indicate various<br />
stages of erection. Each photograph shall contain the date, the name of the Contractor and<br />
the title of the photograph.<br />
14.2 The above photographs shall accompany the monthly progress report detailing out the<br />
progress achieved on all erection activities as compare compared d to the schedules. The report shall also<br />
indicate the reasons for the variance between the scheduled and actual progress and the<br />
action proposed for corrective measures, wherever necessary.<br />
14.3 The Contractor shall submit the progress of work in video ccassettes<br />
assettes (2 copies) quarterly<br />
highlighting the progress and constraints at site.<br />
15.0 MAN-POWER REPORT<br />
15.1 The Contractor shall submit to the Employer, on the first day of every month, a man hour<br />
schedule for the month, detailing the man hours scheduled for the month, skill skill-wise and areawise.<br />
15.2 The Contractor shall also submit to the Employer on the first day of every month, a man<br />
power report of the previous month detailing the number of persons scheduled to have been<br />
employed and actually employed, skill- wise and the areas of employment of such labour.<br />
16.0 PROTECTION OF WORK<br />
The Contractor shall have total responsibility for protecting his works till it is finally taken over<br />
by the Employer. No claim will be entertained by the Employer or the representative of the<br />
Employer for any damage or loss to the Contractor’s works and tthe<br />
he Contractor shall be<br />
responsible for complete restoration of the damaged works to original conditions to comply<br />
with the specification and drawings. Should any such damage to the Contractor’s Works occur<br />
because of other party not being under his supervi supervision sion or control, the Contractor shall make<br />
his claim directly with the party concerned. If disagreement or conflict or dispute develops<br />
between the Contractor and the other party or parties concerned regarding the responsibility<br />
for damage to the Contracto Contractor’s r’s Works the same shall be resolved as per the provisions of the<br />
as specified at clause no 11 of this chapter entitled “Co “Co-operation operation with other Contractors.”<br />
The Contractor shall not cause any delay in the repair of such damaged Works because of any<br />
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delay in the resolution of such disputes. The Contractor shall proceed to repair the Work<br />
immediately and no cause thereof will be assigned pending resolution of such disputes.<br />
17.0 EMPLOYMENT OF LABOUR<br />
In addition to all local laws and regulations pertaining to the employment of labour to be<br />
complied with by the Contractor pursuant to GCC, the Contractor will be expected to employ<br />
on the work only his regular skilled employees with experience of the particular work. No<br />
female labour shall be employe employed d after darkness. No person below the age of eighteen years<br />
shall be employed.<br />
All travelling expenses including provisions of all necessary transport to and from Site, lodging<br />
allowances and other payments to the Contractor’s employees shall be the sole responsibility<br />
of the Contractor.<br />
The hours of work on the Site shall be decided by the Employer and the Contractor shall<br />
adhere to it. Working hours will normally be eight (8) hours per day – Monday through<br />
Saturday. Contractor’s employees shall wear id identification entification badges while on work at Site.<br />
In case the Employer becomes liable to pay any wages or dues to the labour or any<br />
Government agency under any of the provisions of the Minimum Wages Act, Workmen<br />
Compensation Act, Contact Labour Regulation Aboli Abolition tion Act or any other law due to act of<br />
omission by the Contractor, the Employer may make such payments and shall recover the<br />
same from the Contractor’s payments.<br />
18.0 FACILITIES TO BE PROVIDED BY THE EMPLOYER<br />
18.1 Space<br />
The Contractor shall advise the EEmployer<br />
mployer within thirty (30) days from the date of acceptance<br />
of the Notification of Award about his exact requirement of space for his office, storage area,<br />
pre-assembly assembly and fabrication areas, labour and staff colony area, etc. The above requirement<br />
shall be reviewed by the Employer and space as decided by Employer will be allotted to the<br />
Contractor for construction of his temporary structures/ facilities like office, storage sheds,<br />
pre-assembly assembly and fabrication areas, labour and staff colony, toilets, etc. for Contractor's as<br />
well as his Sub-Contractor’s Contractor’s use.<br />
18.2 Electricity<br />
The Contractor shall submit to the Employer within thirty (30) days from the date of<br />
acceptance of the Notification of Award, his electrical power requirements, if any, to allow the<br />
planning anning of the same by the Employer. The Contractor shall be provided with supply of<br />
electricity on chargeable basis for the purposes of the Contract, only at two locations in the<br />
Employer’s Site and at 415V level. The Contractor shall make his own further distribution<br />
arrangement. All temporary wiring must comply with local regulations and will be subject to<br />
Employer’s inspection and approval before connection to supply. The free supply of power will<br />
not be provided for the use in the labour and staff colon colony. y. Power supply for labour and staff<br />
colony shall be provided at one point and the Contractor shall be charged at rates prevalent at<br />
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the site. Illumination of wagon tippler and the conveyor area shall be the scope of the<br />
tenderer.<br />
18.3 Water<br />
Contractor shall make all arrangements himself for the supply of construction water as well as<br />
potable water for labour and other personnel at the worksite/colony.<br />
18.4 Communication<br />
The Employer will extend the telephone facilities, if available at Site, for purpos purposes of Contract.<br />
The Contractor shall be charged at actuals for such facilities.<br />
19.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR<br />
19.1 Contractor's site office Establishment<br />
The Contractor shall establish a site office at the site and keep posted an autho authorized<br />
representative for the purpose of the contract, pursuant to GCC.<br />
19.2 Tools, tackles and scaffoldings<br />
The Contractor shall provide all the construction equipments, tools, tackles and scaffoldings<br />
required for pre-assembly, assembly, installation, testing, commissioning and conducting Guarantee<br />
tests of the equipments covered under the Contract. He shall submit a list of all such materials<br />
to the Employer before the commencement of preassembly at Site. These tools and tackles<br />
shall not be removed from the Si Site te without the written permission of the Employer. The<br />
Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of fabrication,<br />
erection and commissioning.<br />
19.3 Testing Equipment and Facilities:<br />
The contractor shall provide the necessa necessary ry testing, equipment and facilities.<br />
19.4 Site laboratory for civil works:<br />
Contractor shall provide and maintain a site laboratory for the testing of construction material<br />
under the direction and general supervision of employer.<br />
19.5 First-aid<br />
19.5.1 The Contractor shall provide necessary first first-aid aid facilities for all his employees, representatives<br />
and workmen working at the Site. Enough number of Contractor’s personnel shall be trained<br />
in administering first-aid.<br />
19.5.2 The Employer will provide the CContractor,<br />
ontractor, in case of any emergency, the services of an<br />
ambulance for transportation to the nearest hospital.<br />
19.6 Cleanliness<br />
19.6.1 The Contractor shall be responsible for keeping the entire area allotted to him clean and free<br />
from rubbish, debris etc. during the period of Contract. The Contractor shall employ enough<br />
number of special personnel to thoroughly clean his work work-area area at least once in a day. All such<br />
rubbish and scrap material shall be stacked or disposed in a place to be identified by the<br />
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Employer. oyer. Materials and stores shall be so arranged to permit easy cleaning of the area. In<br />
areas where equipment might drip oil and cause damage to the floor surface, a suitable<br />
protective cover of a flame resistant, oil proof sheet shall be provided to prote protect the floor<br />
from such damage.<br />
19.6.2 Similarly the labour colony, the offices and the residential areas of the Contractor’s<br />
employees and workmen shall be kept clean and neat to the entire satisfaction of the<br />
Employer. Proper sanitary arrangements shall bbe<br />
e provided by the Contractor, in the work work-<br />
areas, office and residential areas of the Contractor.<br />
20.0 LINES AND GRADES<br />
All the Works shall be performed to the lines, grades and elevations indicated on the<br />
drawings. The Contractor shall be responsible to locate and layout the Works. Basic horizontal<br />
and vertical control points will be established and marked by the Employer at Site at suitable<br />
points. These points shall be used as datum for the works under the Contract. The Contractor<br />
shall inform the Employer yer well in advance of the times and places at which he wishes to do<br />
work in the area allotted to him so that suitable datum points may be established and checked<br />
by the Employer to enable the Contractor to proceed with his works. Any work done without<br />
being ng properly located may be removed and/or dismantled by the Employer at Contractor’s<br />
expense.<br />
21.0 FIRE PROTECTION<br />
21.1 The work procedures that are to be used during the erection shall be those which minimise<br />
fire hazards to the extent practicable. Comb Combustible ustible materials, combustible waste and rubbish<br />
shall be collected and removed from the Site at least once each day. Fuels, oils and volatile or<br />
flammable materials shall be stored away from the construction and equipment and materials<br />
storage areas in safe fe containers. Untreated canvas, paper, plastic or other flammable flexible<br />
materials shall not at all be used at Site for any other purpose unless otherwise specified. If<br />
any such materials are received with the equipment at the Site, the same shall be re removed<br />
and replaced with acceptable material before moving into the construction or storage area.<br />
21.2 Similarly corrugated paper fabricated cartons etc. will not be permitted in the construction<br />
area either for storage or for handling of materials. All such materials used shall be of water<br />
proof and flame resistant type. All the other materials such as working drawings, plans etc.<br />
which are combustible but are essential for the works to be executed shall be protected<br />
against combustion resulting from wel welding ding sparks, cutting flames and other similar fire<br />
sources.<br />
21.3 All the Contractor’s supervisory personnel and sufficient number of workers shall be trained<br />
for fire-fighting fighting and shall be assigned specific fire protection duties. Enough of such trained<br />
personnel ersonnel must be available at the Site during the entire period of the Contract.<br />
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21.4 The Contractor shall provide enough fire protection equipment of the types and number for<br />
the warehouses, office, temporary structures, labour colony area etc. Access to such fire<br />
protection equipment, shall be easy and kept open at all time.<br />
22.0 SECURITY<br />
The Contractor shall have total responsibility for all equipment and materials in his custody<br />
stores, loose, semi-assembled assembled and/or erected by him at Site. The Contrac Contractor shall make<br />
suitable security arrangements including employment of security personnel to ensure the<br />
protection of all materials, equipment and works from theft, fire, pilferage and any other<br />
damages and loss. All materials of the Contractor shall enter and leave the Employer Site only<br />
with the written permission of the Employer in the prescribed manner.<br />
23.0 CONTRACTOR’S AREA LIMITS<br />
The Employer will mark-out out the boundary limits of access roads, parking spaces, storage and<br />
construction areas for the Contractor and the Contractor and his personnel shall not trespass<br />
the areas into other areas of the plant. In case of a need for the Contactor’s personnel to work<br />
in the areas beyond that marked out for him, the same shall be done only with the written<br />
permission of the Employer.<br />
24.0 CONTRACTOR’S CO-OPERATION OPERATION WITH THE EMPLOYER<br />
In case where the performance of the erection work by the Contractor affects the operation of<br />
the system facilities of the Employer, such erection work of the Contractor shall be scheduled<br />
to be performed only in the manner stipulated by the Employer and the same shall be<br />
acceptable at all times to the Contractor. The Employer may impose such restrictions on the<br />
facilities provided to the Contractor such as electricity, etc. as he may think fit in the interest<br />
of the Employer and the Contractor shall strictly adhere to such restrictions and co co-operate<br />
with the Employer. It will be the responsibility of the Contractor to provide all necessary<br />
temporary instrumentation and other measuring devices required during start start-up and<br />
operation of the equipment systems which are erected by him. The Contractor shall also be<br />
responsible for flushing and initial filling of all the oil and lubricants required for the<br />
equipment furnished and installed by him, so as to make such equipment ready for operation.<br />
The Contractor shall be responsible for supplying such flushing oil and other lubricants.<br />
25.0 PRE-COMMISSIONING COMMISSIONING AND COMMISSIONING ACTIVITIES<br />
(a) GENERAL<br />
The Contractor upon completion of installation of equipments and systems, shall conduct<br />
pre-commissioning commissioning and commissioning activities, to make the equipment/systems ready for<br />
safe, reliable and efficient operation on sustained basis. All pre precommissioning/commissioning<br />
/commissioning activities considered essential for such readiness of the<br />
equipment/systems including those mutually agreed and included in the Contractor’s quality<br />
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assurance programme as well as those indicated in clauses elsewhere in the technical<br />
specifications cations shall be performed by the contractor.<br />
(b) The pre-commissioning commissioning and commissioning activities including Guarantee tests, checks and<br />
trial operations of the equipment/systems furnished and installed by the contractor shall be<br />
the responsibility of the he Contractor as detailed in relevant clauses in Technical Specification.<br />
The Contractor shall provide, in addition, test instruments, calibrating devices etc. and labour<br />
required for successful performance of these operations. If it is anticipated that th the above test<br />
may prolong for a long time, the Contractor’s workmen required for the above test shall<br />
always be present at site during such operations.<br />
(c) The following activities shall be carried out by the contractor, prior to schedule date of<br />
commissioning ioning of the equipment/systems installed by him.<br />
(i) The contractor shall furnish the organization chart of his operation and commissioning<br />
engineers for the acceptance of employer. Adequate number of operation and<br />
commissioning engineers shall be deplo deployed yed by the contractor to effectively meet the<br />
requirement of round the clock operation in shifts also, till the plant is taken over by the<br />
employer.<br />
(ii) The contractor shall submit the bio bio-data data containing the details of experience of his<br />
operation and commissioning mmissioning engineers for the acceptance of employer.<br />
(iii) The contractor shall furnish the deployment schedule of his operation and commissioning<br />
engineers for the acceptance of the employer.<br />
(iv) Apart from above, contractor shall ensure deployment of sufficientskilled/semi-<br />
skilled/unskilled manpower during pre pre-commissioning commissioning and commissioning activities.<br />
(d) It shall be the responsibility of the Contractor to provide all necessary temporary<br />
instrumentation and other measuring devices required during sstart-up<br />
up and initial operation of<br />
the equipment/systems which are installed by him.<br />
(e) The Contractor shall also be responsible for flushing and initial filling of all oils and lubricants<br />
required for the equipment furnished and installed by him so as to make such equipment<br />
ready for operation. The Contractor shall be responsible for supplying such flushing oil and<br />
other lubricants unless otherwise specified elsewhere in these specifications and documents.<br />
26.0 COMMISSIONING DOCUMENTATION<br />
(a) The contractor shall submit the commissioning documentation, comprising of Standard<br />
checklists, pre-commissioning commissioning procedures, testing schedules, commissioning schedules and<br />
commissioning networks for various equipment/systems covered under the contract, f ffor<br />
the<br />
approval of employer.<br />
(b) Standard checklist, as the name suggests, shall be a fairly general documents, containing<br />
the list of all checks required to be carried out for similar and repetitive type of equipment to<br />
ensure consistent and thorough checking.<br />
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(c) The testing schedule sh shall all be prepared for systematic commissioning of individual<br />
equipment/sub-system system Commissioning. The format of testing/Commissioning schedule shall<br />
be such as to maintain consistency of presentation, content and reporting<br />
(d) The contractor shall submit the li list st of commissioning documentation to be submitted by<br />
him, alongwith their submission schedule for various equipment/systems covered under the<br />
contract, with in 6(six) month from the date of award of contract, for the acceptance of<br />
employer.<br />
(e) The Contractor r shall submit the commissioning documentation, for various<br />
equipment/covered under the contract, for the approval of employer, at least 18 months<br />
before the scheduled date of commissioning of the equipment/systems.<br />
27.0 COMMISSIONING ACTIVITIES<br />
(a) Upon completion ompletion of pre pre-commissioning commissioning activities/tests, the contractor shall initiate<br />
commissioning of facilities. During commissioning the Contractor shall carry out system<br />
checking and reliability trials on various sub sub-systems of the facilities.<br />
(b) Contractor shall carry out the checks/tests at site to demonstrate to the Employer that<br />
each of the equipment of the supplied complies with requirements stipulated and is installed<br />
in accordance with requirements specified.<br />
(c) Before the plant is put into initial opera operation tion the Contractor shall be required to conduct<br />
test to demonstrate to the Employer that each item of the plant is capable of correctly<br />
performing the functions for which it was specified and its performance, parameters etc. are<br />
as per the specified/appro<br />
specified/approved ved values. These tests may be conducted concurrently with those<br />
required under commissioning sequence.<br />
(d) Other tests shall be conducted, if required by the Employer, to establish that the plant<br />
equipment are in accordance with requirements of the specifica specifications.<br />
(e) The Contractor shall conduct all the commissioning tests and undertake commissioning<br />
activities pertaining to all other auxiliaries and equipments including all electrical<br />
equipment/systems not specifically brought out above but are within the sco scope of work and<br />
facilities being supplied and installed by the Contractor and follow the guidelines indicated<br />
above or elsewhere in these technical specifications(Section<br />
specifications(Section- VI)<br />
(f) Initial Operation<br />
Upon completion of system checking/Tests as above and as a pa part rt of commissioning of<br />
facilities, complete plant/facilities shall be put into initial operation as stipulated in General<br />
Technical Requirements.<br />
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28.0 MATERIALS HANDLING AND STORAGE<br />
(a) All the equipments furnished under the Contract and arriving at Site shall be promptly<br />
received, unloaded and transported and stored by the Contractor.<br />
(b) Contractor shall be responsible for examining all the shipment and notify the Employer<br />
immediately of any damage, shortage, discrepancy etc. for the purpose of Employe Employer's<br />
information only. The Contractor shall submit to the Employer every week a report detailing<br />
all the receipts during the week. However, the Contractor shall be solely responsible for any<br />
shortages or damage in transit, handling and / or in storage and eerection<br />
rection of the equipment at<br />
Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways<br />
etc. shall be to the account of the Contractor.<br />
(c) The Contractor shall maintain an accurate and exhaustive record detailing out the list of<br />
all equipment received by him for the purpose of erection and keep such record available for<br />
the inspection of the Employer.<br />
(d) All equipment shall be handled with care to prevent any damage. No bare wire ropes,<br />
slings, etc. shall be used for unl unloading oading and/or handling of the equipment without the specific<br />
written permission of the Employer. The equipment stored shall be properly protected to<br />
prevent damage to the equipment. The equipment from the store shall be moved to the<br />
actual location at the appropriate time so as to avoid damage of such equipment at Site.<br />
(e) All electrical panels, controls gear, motors and such other devices shall be properly dried<br />
by heating before they are installed and energised. Motor bearings, slip rings, commutators<br />
and nd other exposed parts shall be protected against moisture ingress and corrosion during<br />
storage and periodically inspected. Heavy rotating parts in assembled conditions shall be<br />
periodically rotated to prevent corrosion due to prolonged storage.<br />
(f) The Contractor ontractor shall ensure that all the packing materials and protection devices used for<br />
the various equipments during transit and storage are removed before the equipment are<br />
installed.<br />
(g) The consumables and other supplies likely to deteriorate due to sto storage must be<br />
thoroughly protected and stored in a suitable manner to prevent damage or deterioration in<br />
quality by storage.<br />
(h) All the materials stored in the open or dusty location must be covered with suitable<br />
weatherproof and flameproof covering mater material wherever applicable.<br />
(i) If the materials belonging to the Contractor are stored in areas other than those<br />
earmarked for him, the Employer will have the right to get it moved to the area earmarked for<br />
the Contractor at the Contractor’s cost.<br />
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Page 12 of 23
(j) The Contractor shall be responsible for making suitable indoor storage facilities to store<br />
all equipment which require indoor storage. Normally, all the electrical equipments such as<br />
motors, control gear, exciters and consumables like electrodes, lubricant lubricants s etc. shall be stored<br />
in the closed storage space . The Employer, in addition, may direct the Contractor to move<br />
certain other materials, which in his opinion will require indoor storage, to indoor storage<br />
areas which the Contractor shall strictly comply with.<br />
29.0 CONSTRUCTION MANAGEMENT<br />
(a) The field activities of the Contractors working at Site, will be coordinated by the Employer<br />
and the Employer decision shall be final in resolving any disputes or conflicts between the<br />
Contractor and other Contracto Contractors rs and tradesmen of the Employer regarding scheduling and<br />
co- ordination of work. Such decision by the Employer shall not be a cause for extra<br />
compensation or extension of time for the Contractor.<br />
(b) The Employer shall hold weekly meetings of all the Con Contractors tractors working at Site, at a time<br />
and place to be designated by the Employer. The Contractor shall attend such meetings and<br />
take notes of discussions during the meeting and the decisions of the Employer and shall<br />
strictly adhere to those decisions in per performing forming his Works. In addition to the above weekly<br />
meeting, the Employer may call for other meeting either with individual Contractors or with<br />
selected number of Contractors and in such a case the Contractor if called, will also attend<br />
such meetings.<br />
(c) Time is the essence of the Contract and the Contractor shall be responsible for<br />
performance of his works in accordance with the specified construction schedule. If at any<br />
time, the Contractor is falling behind the schedule, he shall take necessary action t tto<br />
make<br />
good for such delays by increasing his work force or by working overtime or otherwise<br />
accelerate the progress of the work to comply with the schedule and shall communicate such<br />
actions in writing to the Employer, satisfying that his action will comp compensate ensate for the delay. The<br />
Contractor shall not be allowed any extra compensation for such action.<br />
(d) The Employer shall however not be responsible for provision of additional labour and/or<br />
materials or supply or any other services to the Contractor excep except t for the coordination work<br />
with other Contractors, if necessary.<br />
30.0 FIELD OFFICE RECORDS<br />
The Contractor shall maintain at his Site Office up up-to- date copies of all drawings,<br />
specifications and other Contract Documents and any other supplementary data complete<br />
with all the latest revisions thereto. The Contractor shall also maintain in addition the<br />
continuous record of all changes to the above Contract Documents, drawings, specifications,<br />
supplementary data, etc. effected at the field and on completion of his total assignment under<br />
the Contract shall incorporate all such changes on the drawings and other Engineering data to<br />
indicate as installed conditions of the equipment furnished and erected under the Contract.<br />
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Page 13 of 23
Such drawings and Engineering data shall be submitted to the Employer in requisite number<br />
of copies.<br />
31.0 CONTRACTOR’S MATERIALS BROUGHT ON TO SITE<br />
(a) The Contractor shall bring to Site all equipment, components, parts, materials, including<br />
construction equipment, tools and tackles for the purpose of the Works under intimation to<br />
the Employer. All such goods shall, from the time of their being brought vest in the Employer,<br />
but may be used for the purpose of the Works only and shall not on any account be removed<br />
or taken away by the Contracto Contractor r without the written permission of the Employer. The<br />
Contractor shall nevertheless be solely liable and responsible for any loss or destruction<br />
thereof and damage thereto.<br />
(b) The Employer shall have a lien on such goods for any sum or sums which may at any time<br />
be due or owing to him by the Contractor, under, in respect of or by reasons of the Contract.<br />
After giving a fifteen (15) days notice in writing of his intention to do so, the Employer shall be<br />
at liberty to sell and dispose off any such goods, in such manner as he shall think fit including<br />
public auction or private treaty and to apply the proceeds in or towards the satisfaction of<br />
such sum or sums due as aforesaid.<br />
(c) After the completion of the Works, the Contractor shall remove from the Site u uunder<br />
the<br />
direction of the Employer the materials such as construction equipment, erection tools and<br />
tackles, scaffolding etc. with the written permission of the Employer. If the Contractor fails to<br />
remove such materials, within fifteen (15) days of issue oof<br />
f a notice by the Employer to do so<br />
then the Employer shall have the liberty to dispose off such materials as detailed under as<br />
specified at clause no 31 (b) above and credit the proceeds thereto to the account of the<br />
Contractor.<br />
32.0 PROTECTION OF PROPERTY TY AND CONTRACTOR’SLIABILITY<br />
(a) The Contractor shall be responsible for any damage resulting from his operations. He<br />
shall also be responsible for protection of all persons including members of public and<br />
employees of the Employer and the employees of ot other her Contractors and Sub Sub- Contractors and<br />
all public and private property including structures, building, other plants and equipments and<br />
utilities either above or below the ground.<br />
(b) The Contractor will ensure provision of necessary safety equipment such as barriers, sign<br />
- boards, warning lights and alarms, etc. to provide adequate protection to persons and<br />
property. The Contractor shall be responsible to give reasonable notice to the Employer and<br />
the Employers of public or private property and utili utilities ties when such property and utilities are<br />
likely to get damaged or injured during the performance of his Works and shall make all<br />
necessary arrangements with such Employers, related to removal and/or replacement or<br />
protection of such property and utilities utilities.<br />
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Page 14 of 23
33.0 PAINTING<br />
All exposed metal parts of the equipment including pipings, structure railings, etc. wherever<br />
applicable, after installation unless otherwise surface protected, shall be first painted with at<br />
least two coats of suitable primer which matc matches hes the shop primer paint used, after throughly<br />
cleaning all such parts of all dirt, rust, scales, greases, oils and other foreign materials by wire<br />
brushing, scraping or sand blasting and the same being inspected and approved by the<br />
Employer/RITES for painting. nting. Afterwards, the above parts shall be finished painted with t ttwo<br />
coats of synthetic enamel paint paint. . The minimum thickness of paint film shall not be less than<br />
100 microns. The quality of the finish paint shall be as per the standards of Bureau of Indian<br />
Standards (BIS) or equivalent and to be of the colour as approved by the Employer.<br />
34.0 INSURANCE<br />
34.1 In addition to the conditions covered under the Clause entitled “Insurance” in Section General<br />
Conditions of Contract (GCC), the following provisions will also apply to the portion of works<br />
to be done beyond the Contractor’s own or his Sub Sub-Contractor’s Contractor’s manufacturing Works.<br />
34.2 Workmen’s Compensation Insurance<br />
This insurance shall protect the Contractor against all claims applicable under the Workmen’ Workmen’s<br />
Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor<br />
against claims for injury, disability disease or death of his or his Sub Sub-Contractor’s Contractor’s employees,<br />
which for any reason are not covered under the Workmen’s Compensati Compensation Act, 1948. The<br />
liabilities shall not be less than the following:<br />
Workmen's Compensation - As per Statutory Provisions<br />
Employee's Liability - As per Statutory Provisions<br />
Property Damage: Rs.100,000 for each occurrence<br />
34.3 Comprehensive General Liability Insurance<br />
34.3.1 The insurance shall protect the Contractor against all claims arising from injuries, disabilities,<br />
disease or death of members of public or damage to property of others, due to any act or<br />
omission on the part of the Contractor, his agents, his employees, his representatives and<br />
Sub-Contractors Contractors or from riots, strikes and civil commotion. This insurance shall also cover all<br />
the liabilities of the Contractor arising out of the Clause entitled “Defence of Suits” in Section<br />
General Conditions nditions of Contract (GCC).<br />
34.3.2 The hazards to be covered will pertain to all the Works and areas where the Contractor, his<br />
Sub-Contractors, Contractors, his agents and his employees have to perform work pursuant to the<br />
Contract.<br />
34.4 The above are only illustrat illustrative ive list of insurance covers normally required and it will be the<br />
responsibility of the Contractor to maintain all necessary insurance coverage to the extent<br />
Technical Specification:Sec-8l<br />
Page 15 of 23
oth in time and amount to take care of all his liabilities either direct or indirect, in pursuanc pursuance<br />
of the Contract.<br />
35.0 UNFAVOURABLE WORKING CONDITIONS<br />
The Contractor shall confine all his field operations to those works which can be performed<br />
without subjecting the equipment and materials to adverse effects during inclement weather<br />
conditions, like e monsoon, storms, etc. and during other unfavourable construction conditions.<br />
No field activities shall be performed by the Contractor under conditions which might<br />
adversely affect the quality and efficiency thereof, unless special precautions or measures are<br />
taken by the Contractor in a proper and satisfactory manner in the performance of such<br />
Works and with the concurrence of the Employer. Such unfavourable construction conditions<br />
will in no way relieve the Contractor of his responsibility to perform the Works as per the<br />
schedule.<br />
36.0 PROTECTION OF MONUMENTS AND REFERENCE POINTS<br />
The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc. which he<br />
may come across during the course of performance of his Works either during excavation or<br />
elsewhere, are properly protected and handed over to the Employer. Similarly the Contractor<br />
shall ensure that the bench marks, reference points, etc., which are marked either with the<br />
help of Employer or by the Employer shall not be disturbed in any way during the<br />
performance of his Works. If, any work is to be preformed which disturb such reference, the<br />
same shall be done only after these are transferred to other suitable locations under the<br />
direction of the Employer. The Contractor shall pro provide vide all necessary materials and assistance<br />
for such relocation of reference points etc.<br />
37.0 WORK & SAFETY REGULATIONS<br />
37.1 The Contractor shall ensure proper safety of all the workmen, materials, plant and<br />
equipments belonging to him or to Employer or to others, working at the Site. The Contractor<br />
shall also be responsible for provision of all safety notices and safety equipment required both<br />
by the relevant legislation and the Employer as he may deem necessary.<br />
37.2 All equipment used in construction and erection by Contractor shall meet Indian/International<br />
Standards and where such standards do not exist, the Contractor shall ensure these to be<br />
absolutely safe. All equipments shall be strictly operated and maintained by the Contractor in<br />
accordance with th manufacturer’s operation Manual and safety instructions and as per<br />
Guidelines/Rules of Employer in this regard.<br />
37.3 Periodical Examinations and all tests for all lifting/ hoisting equipment & tackles shall be<br />
carried-out out in accordance with the relevan relevant t provisions of Factories Act 1948, Indian Electricity<br />
Act 1910 and associated Laws/Rules in force from time to time. A register of such<br />
examinations and tests shall be properly maintained by the Contractor and will be promptly<br />
produced as and when desired by Employer or by the person authorised by him.<br />
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Page 16 of 23
37.4 The Contractor shall provide suitable safety equipment of prescribed standard to all<br />
employees and workmen according to the need, as may be directed by Employer who will also<br />
have right to examine thes these e safety equipments to determine their suitability, reliability,<br />
acceptability and adaptability.<br />
37.5 The Contractor shall provide safe working conditions to all workmen and employees at the<br />
Site including safe means of access, railings, stairs, ladders, scaffoldings etc. The scaffoldings<br />
shall be erected under the control and supervision of an experienced and competent person.<br />
For erection, good and standard quality of material only shall be used by the Contractor.<br />
37.6 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical<br />
equipment belonging to the Employer or other Contractors under any circumstances,<br />
whatsoever, unless expressly permitted in writing by the Employer to handle such fuses,<br />
wiring or electrical equipment equipment.<br />
37.7 No electric cable in use by the Contractor/Employer will be disturbed without prior<br />
permission. No weight of any description will be imposed on any cable and no ladder or<br />
similar equipment will rest against or attached to it.<br />
37.8 The Contractors shall employ necessary number of qualified, full time Electricians/ Electrical<br />
Supervisors to maintain his temporary electrical installations.<br />
37.9 In case any accident occurs during the construction/ erection or other associated activities<br />
undertaken by the Contractor thereby causing any minor or major or fatal injury to his<br />
employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to<br />
promptly inform the same to the Employer in prescribed form and also to all the authoritie authorities<br />
envisaged under the applicable laws.<br />
37.10 The Employer shall have the right at his sole discretion to stop the work, if in his opinion the<br />
work is being carried out in such a way that it may cause accidents and endanger the safety of<br />
the persons and/or property, and/or equipments. In such cases, the Contractor shall be<br />
informed in writing about the nature of hazards and possible injury/accident and he shall<br />
comply to remove shortcomings promptly. The Contractor after stopping the specific work<br />
can, if felt elt necessary appeal against the order of stoppage of work to the Employer within 3<br />
days of such stoppage of work and decision of the Employer in this respect shall be conclusive<br />
and binding on the Contractor.<br />
37.11 The Contractor shall not be entitled fo for r any damages/ compensation for stoppage of work due<br />
to safety reasons as provided above and the period of such stoppage of work will not be taken<br />
as an extension of time for completion of the facilities.<br />
38.0 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES<br />
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38.1 The surfaces of foundations shall be dressed to bring the top surface of the foundations to the<br />
required level, prior to placement of equipment/equipment bases on the foundations.<br />
38.2 All the equipment/ equipment bases, shall be grouted and finished as per these specifications<br />
unless otherwise recommended by the equipment manufacturer.<br />
38.3 The concrete foundation surfaces shall be properly prepared by chipping, grinding as required<br />
to bring the top of such foundation tto<br />
o the required level, to provide the necessary roughness<br />
for bondage and to assure enough bearing strength.<br />
38.4 Grout<br />
The grout shall be high strength grout having a minimum characteristic compressive strength<br />
of 60 N/mm2 at 28 days. The grout shall be chloride - free, cement based, free flowing, non non-<br />
metallic grout. The Grout shall have good flowability even at very low water/ grout powder<br />
ratio. The Grout shall have characteristics of controlled expansion to be able to occupy its<br />
original volume to fill l the voids and to compensate for shrinkage. Grout shall be of pre pre-mix<br />
variety so that only water needs to be added before use. The mixing of the Grout shall<br />
conform to the recommendations of the manufacturer of the Grout.<br />
38.5 Finishing of the Edges of tthe<br />
Grout<br />
The poured grout should be allowed to stand undisturbed until it is well set. Immediately<br />
thereafter, the dam shall be removed and grout which extends beyond the edges of the<br />
structural or equipment base plates shall be cut off, flushed and remov removed. ed. The edges of the<br />
grout shall then be pointed and finished with 1:2 cement mortar pressed firmly to bond with<br />
the body of the grout and smoothened with a tool to present a smooth vertical surface. The<br />
work shall be done in a clean and scientific manner and the adjacent floor spaces, exposed<br />
edges of the foundations, and structural steel and equipment base plates shall be thoroughly<br />
cleaned of any spillage of the grout.<br />
38.6 CHECKING OF EQUIPMENT AFTER GROUTING<br />
After the grout is set and cured, the Cont Contractor ractor shall check and verify the alignment of<br />
equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals,<br />
centering of rotors with respect to their sealing bores, couplings, etc. as applicable and the like<br />
items to ensure that hat no displacement had taken place during grouting. The values recorded<br />
prior to grouting shall be used during such post grouting check check- up and verifications. Such pre<br />
and post grout records of alignment details shall be maintained by the Contractor in a manner<br />
acceptable to the Employer.<br />
39.0 SHAFT ALIGNMENTS<br />
All the shafts of rotating equipment shall be properly aligned to those of the matching<br />
equipments to as perfect an accuracy as practicable. The equipment shall be free from<br />
excessive vibration so as to avoid overheating of bearings or other conditions which may tend<br />
to shorten the life of the equipment. The vibration level of rotating equipments measured at<br />
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Page 18 of 23
earing housing shall not exceed forty (40) microns and shall conform to VDI 2056.All<br />
bearings, gs, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated<br />
before starting.<br />
40.0 DOWELLING<br />
All the motors and other equipment shall be suitably doweled after alignment of shafts with<br />
tapered machined dowels as per the directi direction of the Employer.<br />
41.0 CHECK OUT OF CONTROL SYSTEMS<br />
After completion of wiring, cabling furnished under separate specification and laid and<br />
terminated by the Employer, the Contractor shall check out the operation of all control<br />
systems for the equipmen equipment t furnished and installed under these specifications and documents.<br />
42.0 COMMISSIONING SPARES<br />
42.1 It will be the responsibility of the Contractor to provide all commissioning spares including<br />
consumable spares required for initial operation till the Completion of Facilities. The<br />
Contractor shall furnish a list of all commissioning spares within 60 days from the date of<br />
Notification of Award and such list shall be reviewed by the Employer and mutually agreed to.<br />
However. such review and agreement will not absolve the Contractor of his responsibilities to<br />
supply all commissioning spares so that initial op operation eration do not suffer for want of<br />
commissioning spares. All commissioning spares shall be deemed to be included in the scope<br />
of the Contract at no extra cost to the Employer.<br />
42.2 These spare will be received and stored by the Contractor atleast 3 months prior to the<br />
schedule date of commencement of initial operation of the respective equipment and utilised<br />
as and when required. The unutilised spares and replaced parts, if any, at the end of<br />
successful completion of guarantee tests shall be the property of the Contractor and he will be<br />
allowed to take these parts back at his own cost with the permission of Employer. Employer<br />
will be informed of the list of commissioning spares brought to site by the contractor before<br />
bringing the same to the site.<br />
43.0 CABLING<br />
43.1 All cables shall be supported by conduits or cable tray run in air or in cable channels. These<br />
shall be installed in exposed runs parallel or perpendicular to dominant surfaces with right<br />
angle turn made of symmetrical bends or fittings. When ccables<br />
ables are run on cable trays, they<br />
shall be clamped at a minimum intervals of 2000mm or otherwise as directed by the<br />
Employer.<br />
43.2 Each cable, whether power or control, shall be provided with a metallic or plastic tag of an<br />
approved type, bearing a cable reference number indicated in the cable and conduit list<br />
(prepared by the Contractor), at every 5 meter run or part thereof and at both ends of the<br />
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Page 19 of 23
cable adjacent to the terminations. Cable routing is to be done in such a way that cables are<br />
accessible for r any maintenance and for easy identification.<br />
43.3 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC insulted<br />
cables 1100 V grade shall be 15 D where D is the overall diameter of the cable. Installation of<br />
other cables like high igh voltage, coaxial, screened, compensating, mineral insulated shall be in<br />
accordance with the cable manufacturer’s recommendations.<br />
43.4 In each cable run some extra length shall be kept at a suitable point to enable one or two<br />
straight through joints to be made, should the cable develop fault at a later date.<br />
43.5 Control cable terminations shall be made in accordance with wiring diagrams, using<br />
identifying codes subject to the Employer’s approval. Multicore control cable jackets shall be<br />
removed as required equired to train and terminate the conductors. The cable jacket shall be left on<br />
the cable, as far as possible, to the point of the first conductor branch. The insulated<br />
conductors from which the jacket is removed shall be neatly twined in bundles and<br />
terminated. inated. The bundles shall be firmly but not tightly tied utilizing plastic or nylon ties or<br />
specifically treated fungus protected cord made for this purpose. Control cable conductor<br />
insulation shall be securely and evenly cut.<br />
43.6 The connectors for control rol cables shall be covered with a transparent insulating sleeve so as to<br />
prevent accidental contact with ground or adjacent terminals and shall preferably terminate in<br />
Elmex terminals and washers. The insulating sleeve shall be fire resistant and shall be long<br />
enough to over pass the conductor insulation. All control cables shall be fanned out and<br />
connection made to terminal blocks and test equipment for proper operation before cables<br />
are corded together.<br />
44.0 EQUIPMENT DELIVERY AND ERECTION<br />
44.1 General Requirements<br />
(a.) This part covers Contractor's responsibilities for packing, shipping, warehousing and the<br />
installation of all equipment and materials furnished and installed under this specification.<br />
(b.) The Contractor shall submit for Employer's approval draft manual for Equipment Delivery<br />
and Erection covering detailed instructions, write up, technical data, drawings, check check-lists,<br />
documentation formats for all activities after equipment manufacture upto installation of<br />
equipment. This manual shall cover genera general l instructions for all equipment and specific<br />
instructions for individual equipment wherever required and shall include at least the<br />
following :<br />
Technical Specification:Sec-8l<br />
i. Instructions for packing, shipping, receiving handling, ware ware-housing housing and storage.<br />
ii. Instructions for location an and d installation of equipment furnished by this specification.<br />
iii. Installation drawings for field mounted equipment, panels, cubicles and other<br />
equipment covered under this specification.<br />
iv. Instruction relating installation of piping/ tubing, support and routing drawings of<br />
impulse pipes/signal tubes and tube/cable trays.<br />
Page 20 of 23
Technical Specification:Sec-8l<br />
v. Check lists and quality assurance hold points.<br />
vi. Format for all related documentation.<br />
(c.) The Manual shall conform to the requirements of this specification, all applicable codes and<br />
standards, recommendations mendations of equipment manufacturers and accepted good engineering<br />
practices and shall be subject to Employer approval during detailed engineering.<br />
(d.) The Contractor shall ensure that all work under this part shall be performed as per the<br />
requirements of this is specification, Employer approved Manual and drawing/documents<br />
approved by the Employer during detailed engineering stage of work.<br />
44.2 Crating<br />
(a) All equipment and materials shall be suitably coated, wrapped, or covered and boxed or<br />
crated for moist humid tropical shipment and to prevent damage or deterioration during<br />
handling and storage at the site.<br />
(b) Equipment shall be packed with suitable desiccants, sealed in water proof vapour vapour-proof<br />
wrapping and packed in lumber of plywood enclosures, suitably braced, tied and skidded.<br />
Lumber enclosures shall be solid, not slatted.<br />
(c) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to provide the<br />
required surface area and activated prior to placing in the packaging. Calcium sulphate<br />
desiccants s shall be of a chemical nature to absorb moisture. In any case, the desiccant shall<br />
not be of a type that will absorb enough moisture to go into solution. Desiccants shall be<br />
packed in porous containers, strong enough to withstand handling encountered dur during<br />
normal shipment. Enough desiccant shall be used for the volumes enclosed in wrapping.<br />
(d) Review by the Employer of the Contractor's proposed packaging methods shall not relieve<br />
the Contractor of responsibility for damage or deterioration to the equipment and materials<br />
specified.<br />
(e) All accessory items shall be shipped with the equipment. ; Boxes and crates containing<br />
accessory items shall be marked so that they are identified with the main equipment. The<br />
contents of each box and crates shall be indicated by mmarkings<br />
arkings on the exterior.<br />
(f) All boxes, crates, cases bundles, loose pieces, etc. shall be marked consecutively from No.1<br />
upward throughout all shipments from a given port to completion of the order without<br />
repeating the same number.<br />
(g) An itemized list of contents shall be enclosed inside each case and one other copy securely<br />
fastened to the outside of the case in a tin or light weight sheet metal envelope or pocket.<br />
The lists shall be plainly marked and placed in accessible locations to facilitate receipt and<br />
inspection. The packing list shall indicate whether shipment is partial or complete and shall<br />
incorporate the following information on each container, etc., according to its individual<br />
shipping number :<br />
1. Export case markings<br />
2. Case number<br />
3. Gross weight eight and net weight in Kilograms<br />
4. Dimensions in centimeters<br />
5. Complete description of material<br />
Page 21 of 23
(h) Packaging or shipping units shall be designed within the limitations of unloading facilities<br />
and the equipment which will be used for transport. Complicatio Complications ns involved with ocean<br />
shipment and the limitations of ports, railways and roads shall be considered. It shall be the<br />
Contractor's responsibility to investigate these limitations and to provide suitable packaging<br />
to permit safe handling during transit and at the job site.<br />
(i) Electrical equipment, control and instrumentation shall be protected against moisture and<br />
water damage. All external gasket surfaces and flange faces, couplings, motor pump shafts,<br />
bearing and like items shall be thoroughly cleaned and coa coated ted with rust preventive<br />
compound as specified above and protected with suitable wood, metal or other substantial<br />
type covering to ensure their full protection.<br />
(j) Equipment having antifriction or sleeve bearings shall be protected by weather tight<br />
enclosures.<br />
(k) Coated surfaces shall be protected against impact, abrasion, discolouration and other<br />
damage. Surfaces which are damaged shall be repaired.<br />
(l) All exposed threaded parts shall be greased and protected with metallic or other substantial<br />
type protectors. All female threaded openings shall be closed with forged steel plugs. All<br />
pipings, tubing, and conduit equipment and other equipment openings shall be sealed with<br />
metallic or other rough usage covers and tapped to seal the interior of the equipment<br />
piping, tubing, ing, or conduit.<br />
(m) Provisions shall be made to ensure that water does not enter any equipment during<br />
shipment or in storage at the plant site.<br />
(n) Returnable containers and special shipping devices shall be returned by the manufacturer's<br />
field representative at the Contractor's expense.<br />
(o) While packaging the material, care shall be taken for the limitation from the point of view of<br />
availability of railway wagon sizes in India.<br />
44.3 Equipment Installation<br />
(a.) General Requirements<br />
The Contractor shall furnish all construction materials, tools and equipment and shall perform<br />
all work required for complete installation of all control and instrument equipment furnished<br />
under this specification. Contractor shall prepare detailed install installation ation drawings for each<br />
equipment furnished under this specification for Employer's approval. Installation of all<br />
equipment/systems furnished by this specification shall be as per Employer's approval.<br />
Erection procedures not specified herein shall be in ac accordance cordance with the recommendations of<br />
the equipment manufacturers. The procedures shall be acceptable to the Employer. The<br />
Contractor shall coordinate his work with other suppliers where their instruments and devices<br />
are to be installed under specifications<br />
specifications.<br />
(b.) Installation Materials<br />
All materials required for installation, testing and commissioning of the equipment shall be<br />
furnished by the Contractor.<br />
(c.) Regulatory Requirements<br />
Technical Specification:Sec-8l<br />
Page 22 of 23
All installation procedures shall confirm with the accepted good engineering practi practice and with<br />
all applicable governmental laws, regulations and codes.<br />
(d.) Cleaning<br />
All equipment shall be cleaned of all sand, dirt and other foreign materials immediately after<br />
removal from storage and before the equipment is brought to installation site.<br />
(e.) Equipment Assembly<br />
Equipment installed under these specifications shall be assembled if shipped unassembled.<br />
The equipment shall be dismantled and reassembled as required to perform the installation<br />
and commi ssioning work described in these specifications<br />
specifications.<br />
(f.) Defects<br />
All defects in erection shall be corrected to the satisfaction of the Employer and the Project<br />
Manager. The dismantling and reassembly of Contractor furnished equipment to remove<br />
defective parts, replace parts, or make adjustments shall be inclu included ded as a part of the work<br />
under these specifications. The removal of control and instrument equipment in order to<br />
allow bench calibration, if required, and the re re-installation installation of the said equipment after<br />
calibration shall also be included as a part of the work under these specifications.<br />
45.0 DEVIATIONS DISPOSITIONING:<br />
Any deviation to the contract and employer approved documents shall be properly recorded<br />
in the format prescribed by NALCO. Al the deviations shall be bought to the knowledge of<br />
employer’s representative for suitable dispositioning.<br />
46.0 NON-DESTRUCTIVE DESTRUCTIVE TESTING ( NDT):<br />
The contractor shall record results of NDTs carried out at site in the format acceptable to<br />
employer. All the radiographs & its report duly signed & correlated to the job sh shall be handed<br />
over to the employer. Sensitivity of all the test equipment shall be compatible to the job &<br />
acceptance norms agreed.<br />
47.0 TESTING EQUIPMENT & FACILITIES:<br />
Contractor shall provide the testing equipment and facilities necessary to carry out tests &<br />
inspections.<br />
Technical Specification:Sec-8l<br />
Page 23 of 23
PAINTING<br />
1.0 GENERAL<br />
1.1 This specification covers the materials, tools, facilities and quality requirement for surface<br />
preparation and painting of steel structures, equipment, piping including supports, hangers,<br />
gas and air ducts including hangers, chutes etc.<br />
The term "painting" g" referred herein covers rust preventive, preventive and decorative coating<br />
along with surface protection.<br />
1.2 Surfaces in direct bonded contact with concrete, aluminium, asbestos, brass; bronze,<br />
galvanized steel, stainless steel, cast iron and other ccorrosion<br />
orrosion resistant alloys,<br />
rubber/synthetic polymers are not required to be painted unless specified except for aesthetic<br />
purposes or for identification bands. Except for such surfaces, painting and surface<br />
preparation shall be provided to protect all surf surfaces aces that shall be subjected to atmospheric<br />
action and exposed to corrosive medium.<br />
All machined mating surfaces (eg. flanges) shall be properly cleaned, greased and protected<br />
before dispatch.<br />
1.3 The complete paint system for any item includes the fo following activities:<br />
i) Proper surface preparation<br />
ii) Application of primer coats<br />
iii) Application of intermediate coats<br />
iv) Application of finished coats<br />
All the above coats shall be of quality paint products and of approved make as stipulated in<br />
this specification. The he work shall also include supply of all paint materials as per specification<br />
described herein and of approved quality.<br />
2.0 SURFACE PREPARATION<br />
2.1 Surface preparation being a pre requisite for any paint application, shall be such as to clean<br />
the surface ace thoroughly of any materials which will be conducive to premature failure of the<br />
paint substrates.<br />
2.2 All surfaces shall be cleaned of loose substances and foreign materials, such as dirt, rust, scale,<br />
oil, grease, welding flux, etc. irrespective of whether the same has been spelt out in the<br />
standards in order that the prime coat is rigidly anchored to the virgin metal surface. The<br />
surface preparation shall conform to pictorial representation of surface quality grade of DIN<br />
Technical Specification:Sec-9,Miscellaneous<br />
SECTION 9<br />
(MISCELLANEOUS)<br />
Page 1 of 55
55928 (Part 4) or BS 4232 or IS 1477 - 1971 ( Part I ). Any grease, oil, dust or foreign matter<br />
deposited on the surface after preparat preparation ion shall be removed and care taken that the surface is<br />
not contaminated with acids, alkalis moisture or other corrosive chemicals. The prime coat<br />
shall be applied as soon as possible after the surface preparation is completed.<br />
2.3 The acceptable surface e preparation quality / grades are described under each painting system.<br />
The procedures covered are solvent cleaning, hand tool cleaning, power tool cleaning and<br />
blast cleaning.<br />
2.4 Solvent cleaning<br />
The surface shall be cleaned by wiping, immersion, sspraying<br />
praying or vapor contacting of a suitable<br />
solvent or washing with an emulsion or alkaline solution to remove oil, grease, dirt, old paint,<br />
etc. Solvent cleaning shall not remove rust, scales, mill scales or weld flux. Therefore, before<br />
application of paint, , solvent cleaning shall be followed by other cleaning procedures as stated<br />
elsewhere.<br />
2.5 Hand tool cleaning<br />
The surface shall be cleaned by vigorous wire brushing done manually to St St-2 quality. This<br />
method effectively removes loosely adherent materi materials, als, but would not affect residues of rust<br />
or mill scales that are intact and firmly adherent.<br />
2.6 Power tool cleaning<br />
Electric or pneumatic tools shall clean the surface to St - 3 quality. The tools shall be used<br />
carefully to prevent excessive roughi roughing ng of surface and formation of ridges and burns. This<br />
method will remove loosely adherent materials but would not affect residues of rust or mill<br />
scales that are firmly adherent.<br />
2.7 Blast cleaning<br />
The surface shall be cleaned by impingement of abrasi abrasive ve materials, such as graded sand at<br />
high velocity created by clean and dry compressed air blast. This method will remove loosely<br />
adherent materials as well as adherent scales and mill scales. Prior to application of blast,<br />
heavy deposit of oil and grease are removed by solvent cleaning and excessive surface scales<br />
are removed by hand tools or power tool cleaning. The surface shall be cleaned to Sa - 2 1/2<br />
quality i.e. 95 % of surface area is free from all rust, mill scales and visible residues, foreign<br />
materials, erials, etc. The blast cleaning is not recommended for sheet metal work.<br />
3.0 PRIMER PAINTS (P)<br />
Primer paints shall be applied only on dry and clean surfaces.<br />
3.1 Primer paint P1 - (Phenolic - Alkyd based)<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 2 of 55
A single pack air drying phenolic modified alkyd composition with zinc phosphate as<br />
a primer paint.<br />
Air drying time - About 60 minutes (touch dry)<br />
-Overnight (hard dry)<br />
Dry film thickness - 40 microns (min)<br />
(DFT / Coat)<br />
3.2 Primer paint P2 - (Epoxy based)<br />
A two pack air drying Epoxy polyamide with zinc dust of at least 92 % zinc dust on<br />
the dry film.<br />
Epoxy content (% wt.) - 8 to 10<br />
Air drying time<br />
- 10 minutes (touch dry)<br />
- 2 hours (hard dry)<br />
DFT / coat<br />
- 40 microns (min)<br />
3.3 Primer paint P3 - (Ethyl zinc silicate, EZS, based)<br />
A two pack heavy duty zinc dust rich silicate primer which protects the surface with<br />
just a single coat.<br />
Total solids ( % wt ) - 84 +/- 2<br />
Density ( g / cc ) - 3.07 +/- 0.05<br />
Air drying time<br />
- To top coat 16 hours<br />
DFT / coat<br />
- 60 microns<br />
4.0 INTERMEDIATE PAINTS ( I )<br />
These paints shall be applied over primer coats as an intermediate layer to provide<br />
weatherproof seal of primer coats.<br />
4.1 Intermediate Paint I-1 1 (Phenolic alkyd based)<br />
A single pack high build phenolic based paint of synthetic micaceous iron oxide.<br />
Air drying time<br />
-4 to 6 hours (touch dry)<br />
-2 days (hard dry)<br />
DFT / coat<br />
-75 microns (min)<br />
Temperature resistance --upto<br />
100 deg C dry heat<br />
Compatible with --Primer<br />
P1<br />
4.2 Intermediate Paint II-2<br />
A two-pack pack air drying high build epoxy resin based paint with MIO.<br />
Air drying time<br />
- 6 to 8 hours (touch dry)<br />
- 7 days (full cure)<br />
DFT / coat<br />
- 100 microns<br />
Compatible with - Primer P2<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 3 of 55
5.0 FINISH PAINTS (F)<br />
Finish paint coats shall be applied over primer coats and intermediate coats after proper<br />
cleaning and touch up of primed coats.<br />
5.1 Finish Paint F1<br />
A single pack air drying high gloss phenolic alkyd modified synthetic enamel paint suitably<br />
pigmented.<br />
Air drying time -3 to 4 hours (touch dry) -24 24 hours (hard dry)<br />
DFT / coat<br />
- 25 microns (min)<br />
Compatible with<br />
Intermediate I1 - Primer P1<br />
Colour<br />
- generally all shades<br />
5.2 Finish Paint F2<br />
A two pack air drying epoxy polyamide enamel suitably pigmented.<br />
Air drying time - 2 to 3 hours (touch dry)<br />
- 7 days (full cure)<br />
DFT / coat<br />
- 40 microns (min)<br />
Compatible with<br />
Intermediate I2 - Primer P2<br />
Colour<br />
- generally all shades<br />
5.3 Finish Paint F3<br />
A single pack heat resistant silicon resin based paint with leafing Aluminium powder.<br />
Air drying time<br />
- 3 to 4 hours (touch dry)/24 hrs (hard dry)<br />
DFT / coat<br />
- 20 microns (min)<br />
Compatible with - no primer paint except P3<br />
(shall l be applied on blast cleaned steel surface)<br />
Colour<br />
- smooth aluminium<br />
6.0 PAINT APPLICATION<br />
6.1 Paint shall be applied in accordance with paint manufacturer's recommendations.<br />
Manufacture of paints, mixing of paints, etc. shall be as per the IS codes of practice. The work<br />
shall generally follow IS 1477 -1971 1971 (Part II) for jobs carried out in India and or DIN 55928<br />
(latest) or equivalent for jobs carried out outside India.<br />
6.2 Paint shall not be applied when the ambient temperature is 50<br />
below. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and<br />
above unless the manufacturer's recommendations permit. Application of paint shall be only<br />
by spraying or brushing as per IS 486<br />
0 C and d above or 45<br />
. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and<br />
above unless the manufacturer's recommendations permit. Application of paint shall be only<br />
by spraying or brushing as per IS 486 - 1983 and IS 487 - 1985.<br />
0 C and<br />
. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and<br />
above unless the manufacturer's recommendations permit. Application of paint shall be only<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 4 of 55
6.3 Each coat of paint shall be continuous, free of pores and of even film thickness without thin<br />
spots.<br />
6.4 Each coat of paint shall be dry sufficiently before application of next coat.<br />
6.5 The colour code to be followed during painting shall be intimated to the successful Tenderer<br />
during finalization of order.<br />
6.6 In the event of conflict between this general procedure for painting and the paint<br />
manufacturer's specification, the same shal shall l be immediately brought to the notice of the<br />
Purchaser. Generally in cases of such conflicts, manufacturer's specifications /<br />
recommendations shall prevail.<br />
6.7 General compatibility between primer and finishing paints shall be certified by the paint<br />
manufacturer anufacturer supplying the paints.<br />
6.8 Areas that become inaccessible after assembly shall be painted before assembly (after<br />
painting clearance has been given by the inspecting authority) after requisite surface cleaning<br />
as specified.<br />
6.9 Surfaces which h cannot be painted but require protection shall be given a coat of rust inhibitive<br />
grease according to IS 958 - 1975 or solvent deposited compound according to IS 1153 - 1975<br />
or IS 1674 - 1960.<br />
6.10 Parts of steel structures embedded in concrete shall be given a protective coat of Portland<br />
cement slurry immediately after fabrication and after surfaces of this part is thoroughly<br />
cleaned from grease, rust, mill scales, etc. No paint shall be applied on this part.<br />
6.11 The proposed make, quality and shad shade e of the paint shall have the approval of the Purchaser.<br />
6.12 Zinc rich primer paints which have been exposed several months before finishing coat is<br />
applied shall be washed down thoroughly to remove soluble zinc salt deposits.<br />
6.13 The machine finished hed surfaces shall be coated with white lead and tallow before shipment or<br />
before being put out into the open air.<br />
6.14 Total DFT for heat resistant paints should not exceed 100 -120 120 microns, otherwise flaking<br />
occurs ( as per paint manufacturer's recomme recommendations ).<br />
6.15 Heat resistant paints should be applied by brush.<br />
7.0 PAINTING SCHEME<br />
7.1 For a complete painting scheme of any item being painted, all types of paints are to be<br />
procured from the same manufacturer as approved by the Purchaser.<br />
7.2 Legend<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 5 of 55
SP - Surface preparation quality<br />
2P1 - Two (2) coats of primer paint type P1<br />
1I1 - One ( 1 ) coat of intermediate paint type<br />
I1 2F1 - Two ( 2 ) coats of finish paint type F1<br />
DFT - Dry film thickness<br />
Type of paint products like P1, P2, P3, I1, I2, F1, F2 and F3 have been specified under sl.<br />
nos.03, 04 and 05 of this specification.<br />
7.3 The painting scheme to be followed for various equipment/ structures is briefly given below<br />
for guidance to the Tenderer.<br />
Sl. No. Description<br />
Painting scheme<br />
At shop At site<br />
SP - St 3<br />
DFT Total<br />
1. Steel structure 2P1+1I1 2F1 100<br />
2.<br />
Mechanical<br />
equipment(temp.<br />
not over 80 deg C)<br />
Both static and<br />
rotary equipment<br />
for indoor or<br />
outdoor duty<br />
Equipment with<br />
3. hot surfaces SP- Sa 2 1/2<br />
(temp. 200 deg C<br />
and above)<br />
P3 2F3 100<br />
8.0 Colour code<br />
For painting certain standard colour as listed below, shall be used by the bidder.<br />
8.1 For electrical equipment<br />
DESCRIPTION<br />
11 kV, AC machine<br />
3.3 kV, AC machine<br />
400 V, AC machine<br />
460 V, DC machine<br />
250 V, DC machine<br />
230 V, AC equipment Light orange<br />
110 V, AC equipment Canary yellow<br />
All indoor control and switchgear panels Grey<br />
Technical Specification:Sec-9,Miscellaneous<br />
SP - Sa 2 1/2 (or St 3)<br />
2P1+1I1<br />
or 2P2+1I2<br />
2F1 & 2F2<br />
COLOUR<br />
Light grey<br />
Post office red<br />
Brilliant green<br />
Azure blue<br />
Oriental blue<br />
205<br />
(260)<br />
SHADE AS<br />
IS:5<br />
631<br />
538<br />
221<br />
104<br />
174<br />
557<br />
309<br />
697<br />
Page 6 of 55
All outdoor transformers, switchgear, control Dark admiralty<br />
panel etc.<br />
grey<br />
Instrumentation panels Opaline green<br />
Telecommunication panels Smoke grey<br />
8.2 For mechanical equipment<br />
-Indoor Indoor and outdoor mechanical equipment excepting cranes : Grey.<br />
8.3 For pipes, ducts, conduits and others<br />
Service<br />
River water (untreated)<br />
Cooling Water<br />
Boiler feed water<br />
Condensate<br />
Drinking water<br />
Industrial water<br />
Hydraulic power water<br />
Compressed air<br />
Instrument air<br />
Vacuum<br />
Steam below 3.5 kg/cm2 (g)<br />
3.5-20 kg/cm2 (g)<br />
21-40 kg/cm2 (g)<br />
Above 40 kg/cm2 (g)<br />
Drainage<br />
Lubricating oil<br />
Hydraulic oil<br />
Technical Specification:Sec-9,Miscellaneous<br />
Colour<br />
Base - Sea green<br />
Band - White<br />
Base - Sea green<br />
Band - French blue<br />
Base - Sea green<br />
Base - Sea green<br />
Band - Light brown<br />
Base - Sea green<br />
First band - French blue Second<br />
band - Signal red<br />
Base - Sea green<br />
Band - Light orange<br />
Base - Sea green<br />
Band - Black<br />
Base - Sky blue<br />
Base - Sky blue<br />
Band - Light brown<br />
Base - Sky blue<br />
Band - Black<br />
Base - Silver grey if Bitulac or Al Aljacket<br />
Band - Brilliant green<br />
628<br />
221<br />
Base - Silver grey if Bitulac or Al Aljacket<br />
Band - French blue<br />
628<br />
166<br />
Base - Al-jacket<br />
Band - Dark violet<br />
Base - Al-jacket<br />
Band - Signal red<br />
Base - Black<br />
Base - Light brown<br />
Band - Light grey<br />
Base- Light brown<br />
632<br />
275<br />
692<br />
Page 7 of 55<br />
Shade as IS:5<br />
217<br />
-<br />
217<br />
166<br />
217<br />
217<br />
410<br />
217<br />
166<br />
537<br />
217<br />
557<br />
217<br />
-<br />
101<br />
101<br />
410<br />
101<br />
-<br />
-<br />
796<br />
537<br />
-<br />
-<br />
410<br />
631<br />
410
Transformer oil<br />
Fuel oil<br />
Coke oven/coal gas/other fuel gases<br />
Freon (chlorofluore derivative of<br />
methane and ethane)<br />
Argon<br />
Acetylene<br />
LP gas<br />
Nitrogen<br />
Oxygen<br />
Regenerated acid (dilute) (1)<br />
Hydrochloric acid (conc.) (1)<br />
Spent liquor<br />
Wash liquor<br />
Dilute acidic liquor<br />
Hydrofluoric acid (conc.) (1)<br />
Acidic slurries<br />
Alkalis<br />
Non-acidic slurries<br />
Fire fighting system<br />
Rain water down pipes<br />
Technical Specification:Sec-9,Miscellaneous<br />
Band - Dark violet<br />
Base - Light brown<br />
Band - Light orange<br />
Base - Light brown<br />
Band - Signal red<br />
Base - Canary yellow<br />
Band - Signal red<br />
Base - Canary yellow<br />
Band - Light grey<br />
Base - Canary yellow<br />
Band - French blue<br />
Base - Canary yellow<br />
Band - Dark violet<br />
Base - Canary yellow<br />
First band - Signal red<br />
Second band - Traffic green<br />
Base - Canary yellow<br />
Band - Black<br />
Base - Canary yellow<br />
Band - White<br />
Base - Dark violet<br />
Band - Light brown<br />
Band - Dark violet<br />
First band - Light brown Second<br />
band - Light brown<br />
Base - Dark violet<br />
First band - Light brown<br />
Second band - Light brown<br />
Base - Dark violet<br />
Band - Light grey<br />
Base - Dark violet<br />
First band - Light grey<br />
Second band - Brilliant green<br />
Base - Dark violet<br />
Band - Silver grey<br />
Base - Dark violet<br />
Band - White<br />
Base - Dark violet<br />
Band - Deep buff<br />
Base - Sea green<br />
Band - White<br />
Base - Signal red<br />
Base - Sea green<br />
Band - Sky blue<br />
796<br />
410<br />
557<br />
410<br />
537<br />
309<br />
537<br />
309<br />
631<br />
309<br />
166<br />
309<br />
796<br />
309<br />
537<br />
267<br />
309<br />
-<br />
309<br />
–<br />
796<br />
410<br />
796<br />
410<br />
410<br />
796<br />
631<br />
410<br />
796<br />
631<br />
796<br />
631<br />
221<br />
796<br />
628<br />
796<br />
-<br />
796<br />
360<br />
217<br />
-<br />
537<br />
217<br />
101<br />
Page 8 of 55
Duct work<br />
Lighting conduits<br />
Instrument conduits<br />
Power conduits<br />
Technical Specification:Sec-9,Miscellaneous<br />
Base - Aluminium<br />
Base - Black<br />
Band- Yellow<br />
Base - Black<br />
Band - Red<br />
Base - Black<br />
-<br />
-<br />
309<br />
-<br />
537<br />
–<br />
Page 9 of 55
LIST OF MANDATORY SPARES<br />
A. MECHANICAL<br />
1.0 Belt Conveyor<br />
Sl.No. DESCRIPTION<br />
1.<br />
2. Idlers<br />
Pulleys<br />
-Driving Pulley<br />
-Non-Driving Driving Pulley<br />
3. Input shaft assembly (only pinion & input shaft) 1 no. each type<br />
4. 1st Reduction Gear 1 no. each type<br />
5. Oil seal<br />
6. Coupling<br />
7. Hold back<br />
8.<br />
Safety devices<br />
- Pull chord switches<br />
- Belt sway switches<br />
- Zero speed switches<br />
2.0 Actuator operated flap gate<br />
SL. NO. DESCRIPTION<br />
1. Plummer box<br />
2. Self aligning ball bearing 1 set.<br />
3. Gaskets<br />
1 set.<br />
4. Limit Switch<br />
5. Sealing<br />
6. Oil Seal<br />
3.0 Side Arm Charger<br />
SL. NO. DESCRIPTION<br />
1. Gear box spares (complete gear box assy., oil seal and<br />
bearing)<br />
1 set.<br />
2. Carriage wheels a) Bearings b) Oil Seals c) Plummer<br />
block d) Carriage wheel fitted with shaft (without<br />
Plummer Block)<br />
3. Coupling<br />
4. Travel wheel assembly 1 No.<br />
5. Bearing<br />
6. Motor including slip ring motor, Bearings and Oil seal 1 set.each of<br />
type and size<br />
Technical Specification:Sec-9,Miscellaneous<br />
QTY.<br />
1 no. of each size & type.<br />
1 no. of each size & type<br />
2 nos. each type<br />
1 no. each type<br />
1 no. each type<br />
5% of total quantity<br />
5% of total quantity<br />
5% of total quantity<br />
QTY.<br />
1 set.<br />
1 set.<br />
1 set.<br />
1 set.<br />
QTY.<br />
a)1 set. b) 2 sets<br />
c) 1 set d) 1set<br />
1 set.<br />
1 set.<br />
Page 10 of 55
7. Brakes complete assembly with lining and springs 1 set.<br />
8. Couplings with complete assembly, pins, bushes, and<br />
nuts<br />
1 set.<br />
9. Hydraulic power Pack with all accessories 1 set.<br />
3.0 Wagon Tippler and Accessories<br />
SL.<br />
NO.<br />
DESCRIPTION<br />
1. Speed Reducers (a)complete gear box assy., (b)oil seal and a)1 set. b) 4 sets<br />
(c) bearing)<br />
c) 2 set of each type and<br />
rating<br />
2. Motor a) Motor including slip ring motor, b)Bearings c) Oil a)1 set. b) 1 sets<br />
seal<br />
c) 1 set of each type and<br />
rating<br />
3. Brakes a) Complete assembly b) Linings and springs 1 set. of each type and rating<br />
4. Couplings with complete assembly, pins, bushes, and nuts 1 set. each type and<br />
rating/sise<br />
5. a) Thyristor /VVVF cards/ Modules a) 1 No. of each type. B) 2<br />
b) Relays<br />
No. of each type and rating<br />
6 (a) Hydraulic Pump with electric motor, coupling, valves<br />
(mounted on pump) etc:<br />
1 Set of each type and size<br />
(b) Hydraulic Motor<br />
1 No. of each type and size<br />
(c) Valves<br />
1 No. of each type and size<br />
(d) O.P. Coolers<br />
1 No.<br />
(e) Filter Elements<br />
10 Nos. of each type<br />
(f)Pressure Switch<br />
1 No. of each type<br />
(g)Temperature Switch<br />
1 No. of each type<br />
7 Bearings (not covered separately) 1 Set of each<br />
type and size<br />
8 Limit Switches<br />
2 Nos. of each type.<br />
9 Cylinder Manifold block with all valves mounted on it 1 Set<br />
10 Hydraulic cylinder with piston 1 Set of each type and size<br />
11 Seals of hydraulic cylinder and pumps etc. 2 Sets of each type<br />
12 Hydraulic hoses<br />
13 Gear box total<br />
14 Gear flexible coupling 1set<br />
15 Rod end bearings with housing 1 set for all four clamps<br />
16 Pressure Switches, Common manifold block complete with<br />
all valves mounted on it, Main Pivot bearing,<br />
17 Pinion support & bearing 1 No each type<br />
18 Pinion<br />
19 Latch (Pinion & rack segment locking device) 1 No.<br />
20 Chain & Sprocket 1 set<br />
5.0 Apron Feeder<br />
Technical Specification:Sec-9,Miscellaneous<br />
QTY.<br />
2 sets<br />
1 set<br />
1 no. each<br />
2 nos<br />
Page 11 of 55
6.0 Electric Hoist<br />
7.0 Manual Hoist<br />
SL. NO. DESCRIPTION QTY.<br />
1. Head Pulley complete with shaft 1 No.<br />
2. Tail pulley complete with shaft 1 No.<br />
3. Drive Motor 1 No. of each type and size<br />
4. Gear Box 1 No. of each type and size & direction.<br />
5. Complete internals of gear box<br />
including input and output shafts<br />
6. Reduction gears 1 Set of each type and size<br />
7. Fluid coupling, flexible coupling etc. 1 Set of each type and size<br />
8. Traction rollers 20% of population<br />
9. Carrying idlers 20% of population<br />
10. Return Rollers 20% of population<br />
11. Sprocket segments 2 Sets of each type and size<br />
12. Link Chain 20% of each type and size<br />
Pans (flights) 10%<br />
14 Hydraulic cylinder 1 set of each type and size<br />
15 Seal kit of hydraulic cylinders 1 set<br />
16 Plummer blocks 1 No. of each type and size<br />
17 Bearings 1 Set of each type and size<br />
SL. NO. DESCRIPTION QTY.<br />
1. Ball bearing 1 set.<br />
2. Needle bearing with inner race 1 set.<br />
3. Bush bearing 1 set.<br />
4. Rope tightener 1 set.<br />
5. Rope guide 1 set.<br />
6. Rope sheave 1 set.<br />
7. Thrust bearing 1 set.<br />
8. Roller bearing with inner race 1 set.<br />
9. Brake lining 1 set.<br />
10. Limit switch complete 1 set.<br />
11. Rotor pinion 1 set.<br />
SL. NO. DESCRIPTION QTY.<br />
1. Grooved sheave 2 sets<br />
2. Pinion 1 set<br />
3. Bearing 1 set<br />
Technical Specification:Sec-9,Miscellaneous<br />
1 No. of each type and size<br />
Page 12 of 55
B. ELECTRICAL<br />
33 KV SYSTEMS<br />
MOTORS<br />
4. Shaft pin 1 set<br />
Sl. No. DESCRIPTION QUANTITY<br />
MCC<br />
1. Busbar support insulators 10 Nos. of each type / MCC<br />
2. Current transformers 1No. of each type & rating / MCC<br />
3. Potential transformers 415/110V 1 No. / MCC<br />
4. Male contact of ACB (main and aux.) 1 set /MCC<br />
5. Female contact of ACB (main and aux.) 1 set / MCC<br />
6. Limit switch of ACB 3 Nos. /MCC<br />
7. Spring charging motor of ACB 3 Nos. /MCC<br />
8. Closing coil of ACB 2 Nos. /MCC<br />
9. Tripping coil of ACB 2 Nos. /MCC<br />
10. Breaker control switch 2 Nos. /MCC<br />
11. Relays 1No. of each type/ MCC<br />
12. Auxiliary relay 2 Nos. of each type / MCC<br />
13. Indicating Lamp assembly (LED LVGP<br />
type)<br />
14. Phase sequence meter 2 Nos.<br />
Sl. No. DESCRIPTION QUANTITY<br />
1. Lightning arrester 1 set each at receiving and WT<br />
substation<br />
2. Isolator with earth heel 1 set each at receiving and WT<br />
substation<br />
3. Relays 1No. of each at receiving and WT<br />
substation<br />
1. Bearing (drive end) 1 No. of each type<br />
2. Bearing (Non (Non-drive end) 1 No. of each type<br />
3. End shield (DE and NDE) 1 set of each type<br />
4. Cooling fan of motors 1 No. of each type<br />
5. Fan cover 1 No. of each type<br />
6. Bearing puller 1 Nos. of each type<br />
7. Grease gun 2 Nos.<br />
Technical Specification:Sec-9,Miscellaneous<br />
10 Nos. of each type & colour<br />
/MCC<br />
Page 13 of 55
PDB/LDB/SLDB/AUX. PDB<br />
LT TRANSFORMER<br />
UPS/PLC<br />
1. Bus bar support insulators 3 Nos. of each type / DB<br />
2. MCCB<br />
2 Nos. of each rating/DB<br />
3. MCB<br />
4. Breaker control switch 2 Nos. /DB<br />
5. Control switch 2 Nos. of each type/DB<br />
1. HV bushing (1 set = 3 nos.) 1 set<br />
2. LV bushing (1 set = 3 nos.) 1 set<br />
3. Temp. scanner 1 no.<br />
4. Neutral bushing CT 1 no. of each type/ ratio<br />
1. Thyristor fuse 1 no. of each rating<br />
2. Electronic logic card for UPS 1 no. of each type<br />
3. Electronic logic card for PLC 1 no. of each type<br />
CONTROL DESK/ AMMETER CONTROL PANEL<br />
ILLUMINATION<br />
1. Ammeter 1 No. of each range<br />
2. Indicator Lamp Assembly 5 sets<br />
3. Control switch 1 no. of each type<br />
4. Push button 1 no. of each type<br />
1. Lamps 4 Nos. of each type<br />
2. Fittings 2 Sets of each type<br />
3. Control gear complete 2 Sets of each type<br />
4. Timer<br />
C. VENTILATION, AIRCONDITIONING & DRY FOG DUST SUPPRESSION SYSTEM<br />
SYSTEM / EQUIPMENT DESCRIPTION QUANTITY<br />
Air Washing type Ventilation Systems.<br />
Centrifugal Fans & Filters V -Belt<br />
Bearings<br />
Flexible<br />
Connection Filter element<br />
Water Pump<br />
Technical Specification:Sec-9,Miscellaneous<br />
2 Nos. of each rating/DB<br />
1 No.<br />
1 set of each type<br />
1 set of each type<br />
1 set of each type<br />
20% of requirement<br />
Impeller 1 set of each type<br />
Page 14 of 55
Nozzles<br />
Valves<br />
Exhaust Fans<br />
Dry Fog & Plain Water Sprinkling type Dust Suppression Systems<br />
Water Pump<br />
Nozzles<br />
Sprinklers<br />
Solenoid Valves<br />
Pressure gauges<br />
Sensors and Instruments Sensors & Instruments 1 set of each type<br />
Valves<br />
Valves 1 set of each type<br />
Pressure Regulating Units<br />
(PRU)<br />
PRU 1 set of each type<br />
Flow Activation Station<br />
(FAS)<br />
FAS 1 set of each type<br />
Compressor<br />
Technical Specification:Sec-9,Miscellaneous<br />
Coupling<br />
1 set of each type<br />
Bearings<br />
1 set of each type<br />
Gland Packing<br />
2 sets of each type<br />
Nozzles 10% of requirement<br />
Valves 1 set of each type<br />
Bearings 1 set of each type<br />
Impeller<br />
Coupling<br />
Bearings<br />
Gland Packing<br />
Nozzles<br />
Nozzle tips<br />
1 set of each type<br />
1 set of each type<br />
1 set of each type<br />
2 sets of each type<br />
10% of requirement 20%<br />
of requirement<br />
Nozzles 10% of requirement<br />
Solenoid Valves 10% of requirement<br />
Pressure Gauges 1 set of each type<br />
Bearings<br />
Couplings / V Belts<br />
Pulleys<br />
Filters<br />
Gaskets / O Rings<br />
Valves /Safety valves<br />
Piston rings<br />
1 set of each type<br />
1 set of each type<br />
1 set of each type<br />
1 set of each type<br />
1 set of each type<br />
1 set of each type<br />
1 set of each type<br />
Page 15 of 55
INFORMATIONS TO BE FURNISHED BY THE BIDDER<br />
Check List for Bid submission<br />
1. All drawings and documents duly signed as per TS submitted along<br />
with Bid<br />
- Yes/ No<br />
2. Clause wise list of deviations from TS furnished<br />
- Yes/ No<br />
3. Time bar chart and level of PERT network furnished as per the TS<br />
4. Separate price bid submitted<br />
5. Necessary particulars to establish the possession of technical know know-<br />
how and facilities available furnished as per TS<br />
- Yes/ No<br />
6. Reference list for supply of similar equipment along with users’<br />
certificate furnished as per the TS<br />
- Yes/ No<br />
7. Write up of testing facilities available at works furnished as per the TS - Yes/ No<br />
8. Brief scope of collaboration for collaboration agreement furnished as<br />
per the TS<br />
- Yes/ No<br />
9. Clause wise list of deviations / exclusions furnished as per the TS - Yes/ No<br />
10. Delivery schedule indicated as per TS<br />
11. Bought out items conforms to TS<br />
12. Location and size of MCC & control room indicated<br />
13. List of tools furnished as per TS<br />
14. List of commissioning spares furnished as per TS<br />
15. List of spares for two years operation along with item wise price<br />
furnished as per TS<br />
- Yes/ No<br />
16. List of insurance spares with price furnished as per TS<br />
17 Erection plans furnished as per TS<br />
2.0 Questionnaire<br />
The Bidder shall fill in this questionnaire and submit in hard as well as a soft copy with their<br />
Bid. This data shall form a part of the contract with successful Bidder.<br />
2.1 General<br />
1. Name and address of the Bidder<br />
2. Previous experience of the Bidder<br />
3. List of similar equipment supplied<br />
4. Whether the Bidder has any technical collaboration with any other<br />
company / organization for his equipment<br />
5. If answer to question 4.0 is yes, furnish the following details.<br />
a) Name and address of the collaborator<br />
b) Nature of the collaboration in detail<br />
c) Previous experience of the collaborator<br />
6. List of drawings literatures enclosed with the offer<br />
Technical Specification:Sec-9,Miscellaneous<br />
- Yes/ No<br />
- Yes/ No<br />
- Yes/ No<br />
- Yes/ No<br />
- Yes/ No<br />
- Yes/ No<br />
- Yes/ No<br />
- Yes/ No<br />
- Yes/ No<br />
Page 16 of 55
7 Is it the Bidder's intention, if awarded the contract, to comply fully in<br />
all respects with owner’s specifications covering the work? If not, he<br />
shall state specific exception in details<br />
A. WAGON TIPPLER<br />
GENARAL<br />
Type:<br />
Designed capacity<br />
Guaranteed capacity<br />
Make:<br />
Capacity:<br />
Angle of tipping:<br />
Drive:<br />
Tippler drive:<br />
Side arm charger:<br />
Indexer:<br />
Clamping:<br />
Wt. of the machine<br />
Tippling time cycle:<br />
Rail Gauge:<br />
Drive Rack Assembly<br />
Spherical roller bearing SKF NO.24168<br />
ECACK30/W33/Equivalent.<br />
CLAMP CYLINDER<br />
Bore<br />
Rod<br />
Stroke<br />
Tippler Ballast-25T 25T at each end frame Made<br />
from concrete with steel scrap<br />
DRIVE PINION<br />
P.C.D<br />
Face width<br />
No.of teeth<br />
Pressure angle<br />
Material<br />
CYLINDER FOR INHAUL CLICKING STOP<br />
Bore<br />
Rod<br />
Stroke<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 17 of 55
HYD.POWER PACK DETAILS FOR WT<br />
Type<br />
Oil pump proportional control of capacity<br />
Tank capacity<br />
Electric motor for WT main drive<br />
Electric motor for WT clamp<br />
Cooling<br />
HYDRAULIC MOTOR DATA FOR WAGON<br />
TIPPLER<br />
Type<br />
Model<br />
Displacement<br />
Speed<br />
Details of Motor<br />
Pressure (Max)<br />
Torque theoritical<br />
Power theoritical (Max)<br />
Speed (Max)<br />
HYDRAULIC CYLINDER DATA FOR WAGON<br />
TIPPLER<br />
Bore<br />
Rod<br />
Stroke<br />
SIZE OF WAGON TO BE HANDLED<br />
Length<br />
Width<br />
Height<br />
B. APRON FEEDER:<br />
GENERAL<br />
Make:<br />
Capacity:<br />
Pan width:<br />
Length:<br />
Motor<br />
DRIBBLE CONV.<br />
GENERAL<br />
Conv.Belt<br />
Belt width<br />
Belt length<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 18 of 55
C. WEIGHBRIDGE<br />
GENERAL<br />
Make<br />
Quantity required<br />
Carrying capacity /strength<br />
Weighing capacity<br />
Type<br />
Platform size<br />
Mounting<br />
Resolution<br />
Taring facility<br />
Auto tare<br />
Purpose<br />
Cycle of weighment<br />
Duty<br />
Power supply required<br />
Operating temp.range<br />
Platform size<br />
Material of construction<br />
Load cell<br />
Load cell capacity<br />
D. SPECIFICATION OF LOAD CELL<br />
GENERAL<br />
Characterstic<br />
Make<br />
Type<br />
No.of loadcells<br />
Capacity of each loadcell<br />
Rated output<br />
Combined error<br />
Repeatability<br />
CREEP ON LOAD (30min)<br />
Zero balance voltage<br />
Input resistance<br />
Output resistance<br />
Compensated temp.range<br />
Operating temp.range<br />
Temp.effect on span<br />
Temp.effect on tare<br />
Technical Specification:Sec-9,Miscellaneous<br />
Specification<br />
Page 19 of 55
Excitation voltage<br />
Safe overload<br />
Ultimate overload<br />
Insulation resistance<br />
Protection<br />
Cable<br />
E. CONTROLLER<br />
GENERAL<br />
CHARACTERISTIC<br />
F.<br />
Model no.<br />
Type<br />
Power supply<br />
Operating temperature<br />
Range<br />
Resolution<br />
Non - linearity<br />
Repeatability<br />
Excitaton to transducer<br />
Display<br />
Input<br />
Output<br />
Programmable parameters<br />
Casing dimension<br />
SIDE ARM CHARGER<br />
Type of side arm charger (sac)<br />
Sac pulling capacity<br />
SAC total travel<br />
Max.wagon size that sac can handle<br />
Type of luffing system for sac<br />
Track gauge<br />
Operating speed of sac in m/s<br />
Forward with single wagon<br />
Return<br />
Type of power supply system for sac<br />
Support roller wheel<br />
Guide roller wheel<br />
Feston support post<br />
Electric motor for sac<br />
Cooling<br />
DRIVE PINION<br />
P.C.D<br />
Face width<br />
Technical Specification:Sec-9,Miscellaneous<br />
SPECIFICATION<br />
Page 20 of 55
No.of teeth<br />
Pressure angle<br />
Material<br />
RACK FOR SAC TRAVEL<br />
Total nos<br />
Pitch<br />
Pressure angle<br />
Teeth per rack<br />
Material<br />
HYD.POWER PACK DETAILS FOR SAC<br />
TYPE<br />
Oil pump proportional control of capacity<br />
Tank capacity<br />
Electric motor for SAC<br />
Cooling<br />
HYD.MOTOR DETAILS FOR SAC<br />
Hyd.motor double displacement type<br />
Motor model:<br />
Displacement:<br />
Details of Motor<br />
Pressure (Max)<br />
Torque theoritical<br />
Power<br />
Speed (Max)<br />
SAC RAISE & LOWER CYLINDER<br />
Bore<br />
Rod<br />
Stroke<br />
SAC UNCOUPLING CYLINDER<br />
Bore<br />
Rod<br />
Stroke<br />
SAC DELATCH CYLINDER<br />
Bore<br />
Rod<br />
Stroke<br />
G. INDEXER<br />
Type of side arm charger (sac)<br />
Max.rake (Train) size that Indexer can handle<br />
Type of luffing system for Indexer<br />
Track gauge<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 21 of 55
No.of wagon handled by Indexer<br />
Operating speed of Indexer in m/s<br />
Forward with rake<br />
Return<br />
Type of power supply system for Indexer<br />
Fixed support roller wheel<br />
Guide roller wheel<br />
Sprung support roller assembly<br />
Feston support post<br />
Indexer normal travel<br />
DRIVE PINION<br />
P.C.D<br />
Face width<br />
No.of teeth<br />
Pressure angle<br />
Material<br />
RACK FOR INDEXER TRAVEL<br />
Total nos<br />
Pitch<br />
Pressure angle<br />
Teeth per rack<br />
Material<br />
HYD.POWER PACK DETAILS FOR INDEXER<br />
TYPE<br />
Oil pump proportional control of capacity<br />
Electric motor for Indexer<br />
Cooling<br />
HYD.MOTOR DETAILS FOR INDEXER<br />
Hyd.motor double displacement type<br />
Motor model:<br />
Displacement:<br />
Details of Motor<br />
Wt<br />
Pressure (Max)<br />
Torque theoritical<br />
Power theoritical (Max)<br />
Speed (Max)<br />
INDEXER ARM RISER CYLINDER<br />
Bore<br />
Rod<br />
Stroke<br />
INDEXER UNCOUPLING CYLINDER<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 22 of 55
Bore<br />
Rod<br />
Stroke<br />
2.2 BELT CONVEYORS<br />
Sl. No Description<br />
Belt Conveyor System<br />
1 Conveyor capacity, Mt/h<br />
a) Rated (guaranteed)<br />
b) Design<br />
2 Belt width, mm<br />
3 Belt speed, m/sec<br />
4 Length, centre to centre, m<br />
5 Lift, m<br />
6 Max. angle of inclination, degree<br />
7 Radius of curvature for :<br />
a) Concave<br />
b) Convex<br />
8 Details of take-up<br />
9 Belting<br />
i) Type of take-up<br />
a) For Boom conveyor of stacker / reclaimer<br />
b) For Intermediate Conveyor of stacker<br />
c) For all other conveyors<br />
i) Type of fabric<br />
ii) Cover grade<br />
iii) Cover thickness, mm<br />
- Face cover, mm<br />
- Back cover, mm<br />
iv) No. of plies<br />
v) Troughing angle<br />
vi) Factor of safety<br />
vii) Normal working tension<br />
viii) Type of belt joint<br />
10 i) Idler type:<br />
a) Carrying (except in case of reversible conveyor)<br />
b) Return<br />
c) At loading point<br />
ii) Idler Spacing<br />
a) Carrying<br />
b) Return<br />
c) At loading point<br />
d) Self aligning (carrying side)<br />
e) Self aligning (return side)<br />
11 Pulleys :<br />
i) Minimum shell thickness<br />
ii) End disc thickness<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 23 of 55
iii) Shaft deflection at hub<br />
iv) Lagging thickness<br />
v) Lagging<br />
vi) Pulley Material (For ILMS conveyor)<br />
vii) Shaft material<br />
12 Drive Pulleys<br />
i) Lagging<br />
ii) Diamond pattern groove<br />
iii) Minimum angle of wrap<br />
iv) Maxm. out of roundness<br />
13 Rubber for pulley lagging<br />
i) Type<br />
ii) Shore Hardness<br />
iii) Elongation<br />
iv) Strength<br />
v) Abrasion loss<br />
vi) Specific gravity<br />
vii) Adhesion Strength<br />
14 Emergency Stop Switch & Belt Sway Switch System<br />
i) Spacing (Emergency stop)<br />
ii) Spacing (Belt Sway Switch)<br />
iii) Degree of protection<br />
15 Zero Speed Switch<br />
i) Type<br />
ii) Mounting location<br />
16 Conveyor Gallery<br />
a) Walkways width<br />
b) Side windows in staggered fashion<br />
i) Spacing (c/c)<br />
ii) Size<br />
17 Deck plates<br />
a) Material<br />
b) Thickness, mm<br />
18 Seal plates<br />
a) Material<br />
b) Thickness<br />
19 Stone picking arrangement<br />
20 Chute Jamming Detector<br />
(a) Type<br />
(b) Degree of Protection<br />
21 Reduction gears<br />
a) Type<br />
b) Size<br />
22 Fluid Couplings<br />
a) Type<br />
23 Brakes<br />
b) Rating, kW<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 24 of 55
a) Type<br />
b) Rating<br />
c) Protection<br />
24 Flexible couplings<br />
a) Type<br />
b) Rating<br />
25 Drive motors<br />
a) Type<br />
b) Make<br />
c) Insulation class<br />
d) Motor nameplate rating, kW at 500 C ambient<br />
e) Protection Class<br />
2.3 CHUTES, HOPPERS,SKIRT BOARD<br />
Sl. No Description<br />
1 Chutes & hoppers construction<br />
2 Minimum valley angle (from the horizontal), degree<br />
3 Material & Plate thickness<br />
Technical Specification:Sec-9,Miscellaneous<br />
a) Sliding zones and adjacent sides<br />
b) Non striking/ non sliding zones<br />
c) Chute with valley angle 80° and above<br />
d) In the zone of magnetic field of ILMS<br />
e) In the zone of flap gates<br />
f) Discharge Hoods over head pulleys<br />
g) Location of Inspection door/sealing<br />
4 Skirt board<br />
a) Plate thickness, mm<br />
b) Length of each skirt board, m<br />
c) Height, mm<br />
d) Width, mm<br />
e) Top cover plate thickness , mm<br />
2.4 ACTUACTOR OPERATED FLAP GATE<br />
Sl. No Description<br />
1. Make<br />
2. Dimensions<br />
3. Material of construction of the gate<br />
4. Liner plate specification<br />
5. Method of fixing of liner plates<br />
6. Type and make of drive and rating<br />
7. Capacity and designation of the equipment<br />
8. Total weight and weight of individual parts<br />
9. Type of actuator and thrust in kg of each actuator<br />
10. Stroke in mm of each actuator<br />
11. Velocity mm per of each actuator<br />
12. Motor: Type, rating, power supply, class of duty, insulation, make<br />
number of starts/ hours<br />
Page 25 of 55
13. Make, ratings, type of limit switches<br />
14 Effort required for manual operator, kgf<br />
15. Type of limit switches<br />
2.5 ELECTRIC HOISTS<br />
Sl. No Description<br />
1. Location<br />
2. Capacity<br />
3. Duty classification as per IS:3938 IS:3938-1983<br />
4. Total weight of hoist including electrical equipment<br />
5. Make of hoist block<br />
6. Speeds with safe working load<br />
7. Lifting height<br />
a) Above floor level<br />
b) Below floor level<br />
8. Wire ropes<br />
a) Type of construction<br />
b) Size<br />
c) Number of falls<br />
d) Factor of safety<br />
9. Rope drum<br />
a) Materials<br />
b) Diameter<br />
10. Drives<br />
11. Motors<br />
a) Type & material of gear box<br />
b) Gear & pinion<br />
c) Material & hardness<br />
a) Type & number<br />
b) Kw rating<br />
c) Synchronous speed<br />
d) Class of insulation<br />
e) Pull out torque<br />
f) Frame size<br />
12. Brakes<br />
a) Type<br />
b) size<br />
c) Torque rating<br />
13. Type & details of limit switches<br />
14. Type of couplings<br />
15. Type of bearings<br />
16. Lifting hook<br />
a) Type<br />
b) Material<br />
17. Type & details of control<br />
18. Trolley Speed with safe working load<br />
19. Wheels<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 26 of 55
20. Drive<br />
a) Numbers<br />
b) Diameter<br />
c) Material & hardness<br />
d) Max. wheel load<br />
e) Wheel base<br />
a) Type & material of gear box<br />
b) Gears & pinions<br />
c) Material & hardness<br />
d) Kw rating<br />
e) Synchronous speed<br />
f) Class of insulation<br />
g) Pull out torque<br />
h) Frame size<br />
21 Brakes<br />
a) Type<br />
b) Size<br />
c) Torque rating<br />
22. Type & details of limit switches<br />
23. Type of coupling<br />
24. Type of bearings<br />
25. Type & details of controls<br />
26. Clearance diagram indicating the basic dimensions<br />
27. Type & lubrication provided<br />
28. Type & size of cables<br />
29. Location & control details of hoist block power feeding<br />
30. Any other information<br />
2.6 EOT CRANE<br />
Sl. No. Description<br />
(a) During participation in technical Bid:<br />
1.0 G.A. Drawing. VENDER TO CONFIRM<br />
2.0 Wheel Load Diagram (Wheel Distance & Wheel Load).<br />
3.0 Sketches showing full details of cranes with dimensions/ end clearances<br />
(between centre of LT rails to column face of building), overhead clearance<br />
from LT rails, hook approach limits, llift<br />
ift height, Details of Web thickness baffle<br />
plates, Stiffeners ,of Girder section , End carriage (Boggies) Trolley Section etc.<br />
4.0 Vendor to submit appropriate Q.A. Plan.<br />
(b) After Receipt of Order:<br />
1.0 Calculation for Box Girder, End Carriage structural plates/ Web / Stiffener<br />
plate, Wheel Load calculation & Calculation for selection of Diameter of<br />
Wheel, Motor, Gearbox and Brake etc. 3 - sets of followings documents like<br />
G. A Drawings, Structural drawin drawings like End-carriage, carriage, Box Girder, Assembly<br />
Drawings/ Sub--<br />
assembly Drawings, Gear Box Drawings (specially of Typical<br />
Gears having Helix Angle, Pressure Angles, Modules etc.) ,Bracket/ Current<br />
Collector System, Hook Block, LT & CT wheel, Main Hook assembly LT<br />
machinery, Hoisting machinery, Electrical Drawings comprising Power ,<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 27 of 55
Technical Specification:Sec-9,Miscellaneous<br />
Control Circuits , Electronic Circuitry diagram for RRC etc. No fabrication /<br />
purchase of BO. Items should be taken up before the approval of the<br />
drawings.<br />
(c) With the supply of ccrane:<br />
1.0 Operating manuals of Crane - 3 Sets.<br />
2.0 Detailed Maintenance manual of Crane. Spares Spares- part list / concerned drawing<br />
of the spares -3 3 Sets.<br />
3.0 Maintenance, Interface & commissioning manuals for Controller & drives - 2<br />
Sets along with drive parameterisation software.<br />
4.0 Catalogues, O&M Manuals of all bought out items including drawings,<br />
wherever applicable.<br />
5.0 Detailed specification of all rubber items like Oil Oil- Seals / O- Rings etc.<br />
6.0 One Soft copy for the above requisites shall also be supplied in CD.<br />
2.7 MANUAL HOISTS<br />
Sl. No Description<br />
1. Name of the manufacturer, type & model no<br />
2. Numbers offered & their location<br />
3. Safe working load for each hoist (in tones)<br />
4. Duty class as per IS:3832 IS:3832-1983<br />
5. Head room, mm<br />
6. Lift, mm<br />
7. Minimum radius of curvature of which this hoist can negotiate (mm)<br />
8. Weight of each hoist<br />
9. Specification of each chain<br />
10 Tools & tackles included in offer<br />
11. Commissioning spares & 2 years<br />
12. Operating spares included in offer<br />
13. Any other information<br />
3.0 DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE BIDDER<br />
Drawings /Data along with the Bid<br />
1) Schematic drawings showing flow of materials.<br />
2) Layout drawings of Additional Coal Storage and Handling System showing clearly the Major<br />
Equipment, Junction Houses, Conveyor Galleries, Approach Road, Rail Track for Yard<br />
Equipment, Yard Drainage Scheme etc.<br />
3) General Arrangement Drawing of Additional Coal Storage and Handling System showing<br />
clearly the Major Equipment, Junction Houses, Conveyor Galleries, Belt Conveyor with drive,<br />
tail and take up arrangement, hoisting & handling facilities envisaged for maintenance of<br />
equipment.<br />
4) Cross Section of Additional tional Coal Storage Yard showing the coal stock pile, yard equipment,<br />
track rail for stacker and reclaimer, yard drainage system etc.<br />
Page 28 of 55
5) General Arrangement of Major Equipment showing plan, elevation, cross sections along with<br />
mounting details, with broad ddimensions<br />
and technical parameters.<br />
6) Basic calculation substantiating selection of all major equipment, motors, gear boxes,<br />
couplings, brakes etc.<br />
7) Equipment wise List of commissioning spares and consumables with item wise description and<br />
quantity included d in the main offer.<br />
8) Equipment wise list of 2 years operational spares (un (un-priced). priced). The list shall indicate description<br />
and quantity for each item.<br />
9) List of special tools and tackles<br />
10) Details /drawings for Civil & Structural Engineering works.<br />
11) Single line diagram of power distribution system.<br />
12) Electrical schematic diagrams<br />
13) Cable specifications, cables schedule and cable layout drawings.<br />
14) Any other structural / mechanical / electrical etc. drawings / data mentioned elsewhere in<br />
the technical specification as well as considered necessary by the Purchaser/ Consultants.<br />
15) List of exclusion, if any from Bidder’s Scope of Work.<br />
16) List of deviations from technical specification.<br />
4.0 ELECTRICS<br />
4.1 DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE TENDERER<br />
Drawings / Data / Documents along with the Bid<br />
1. Detailed scope of work with general description of the system & equipment offered<br />
specifying the important features and detailed design criteria and design philosophy<br />
including full details of reference data, assumptions, etc.<br />
2. Description to be accompanied by single line diagrams and equipment layout to enable<br />
owner to have proper appreciation of equipment offered and its operation.<br />
3. Bill of Quantities (un --priced)<br />
priced) in specified format, with division list of supplies from foreign<br />
and indigenous sources.<br />
4. List of specific exclusions, if any, from Bidder’s Scope of Work.<br />
5. List of deviations from technical specifications,<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 29 of 55
6. Equipment wise List of commissioning spares and consumables with item wise<br />
description and quantity included in the main offer.<br />
7. List of 2 years operation spares, equipment wise (un (un-priced). priced). The list shall indicate<br />
description and quantity for each item.<br />
8. List of special tools and tackles<br />
9. Work Schedule with bar chart indicating all activities for electrics.<br />
10. Phase-wise wise construction power requirements for erection / testing activities.<br />
11. Questionnaire as asked, duly filled filled-in.<br />
12. Reference list of similar jobs carried out<br />
13. Dimensional details & weights of each equipment offered (tentative)<br />
Technical Data to be submitted with the Bid.<br />
1. Name and capacity of MCC considered<br />
2. List of LT drives of each MCC along with single line diagrams<br />
3. Connected load and Maximum demand of each section of 33 kV switchboard/ 415 V PCC<br />
4. Connected load and Maximum demand of each section of MCC.<br />
5. List of motors with ratings ( working working+ + standby) 6. List of performance tests proposed by<br />
the tenderer to demonstrate the guaranteed parameters for the electrical equipments. 7.<br />
Specific energy consumption, maximum demand and annual energy consumption. 8.<br />
Type test certificates for major categ categories ories of equipment, issued by independent testing<br />
authority. 9. Technical catalogues of major equipment offered. 10. Services to be<br />
provided by owner at battery limit with specification 11. Single Line Diagram of each<br />
MCC/ DB 12. Capacity of UPS for stacke stacker r & reclaimer 13. Capacity of PLC for stacker &<br />
reclaimer 14. Size of HT/LT trailing cables considered 15. Rating of 33 kV on load isolators<br />
considered<br />
4.2 TECHNICAL PARTICULARS TO BE SUBMITTED BY THE BIDDER ALONG WITH THE BID<br />
GENERAL<br />
The information /data data asked under this section shall be furnished by the tenderer along with<br />
the offer. In the event of the contract being awarded , the data/technical particulars furnished<br />
here under and accepted by the owner shall be deemed to form a part of the contract contract.<br />
Design Considerations<br />
:<br />
1. List of Drives/ Mechanism with kW Rating :<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 30 of 55
2. Aux. Power Consumption :<br />
Spares and tools & tackles<br />
1 .List of commissioning spares : List to be submitted<br />
2. List of mandatory spares : List to be submitted<br />
3. List of special tools and tackles : List to be submitted<br />
Summary Of Technical Parameters Of Major Electrical Equipment<br />
Sl.<br />
No.<br />
Equipment<br />
Description<br />
& Qty<br />
Technical Specification:Sec-9,Miscellaneous<br />
Make & type<br />
/ Country of<br />
manufacture<br />
MOTOR<br />
1. Make, type & applicable standard<br />
2. Furnish following for all drives<br />
Sl. No Application<br />
Rated Parameters<br />
kW Voltage Speed Enclosure Qty<br />
MCC<br />
1. Make, Type & Applicable Standard :<br />
2. Rated Voltage, current & Frequency :<br />
3. Short time rating<br />
:<br />
4. Bus bar material & type of sleeving :<br />
5. Protection class<br />
:<br />
Components of MCC<br />
1 Air Circuit Breaker<br />
2. MCCB<br />
3. AC Contactor<br />
4. DC Contractor<br />
5. Thermal Relay<br />
6. Control Devices<br />
7. Meters<br />
Total<br />
Weight<br />
:<br />
:<br />
:<br />
:<br />
:<br />
:<br />
:<br />
Dimension Rating as<br />
per design<br />
condition of<br />
Tender<br />
Make & Type<br />
Guaranteed<br />
Tech Data<br />
Working<br />
/Standby<br />
Page 31 of 55
MCC WISE DATA<br />
Sl.<br />
No<br />
RELAYS<br />
METERS<br />
MCC<br />
Designation<br />
1. Make<br />
2. Type<br />
Rating of<br />
Volt,<br />
Amps<br />
3. Draw out type with built in test facility<br />
4. Relay details<br />
1. Make<br />
2. Type<br />
3. Reference standard<br />
4. Size<br />
CURRENT TRANSFORMER<br />
POTENTIAL TRANSFORMER<br />
1. Make, type & applicable standard<br />
2. Ratio & accuracy class: metering/protection<br />
3. Rated voltage – short time rating<br />
1. Type<br />
2. Primary/secondary voltage ratio<br />
3. Method of connection<br />
4. Rated voltage factor<br />
5. Class of insulation<br />
PDB/LDB/SLDB/AUX. PDB (SEPARATELY FOR EACH DB)<br />
1. Make, Type & Applicable Standard<br />
2. Rated Voltage, current & Frequency<br />
3. Short time rating<br />
4. Bus bar material & type of sleeving<br />
5. Protection class<br />
Technical Specification:Sec-9,Miscellaneous<br />
Rating of Single<br />
Front/<br />
Double<br />
Front<br />
No. of<br />
bus<br />
sections<br />
Connected<br />
load per<br />
section<br />
Max.<br />
load d per<br />
section<br />
No. of<br />
panels<br />
Page 32 of 55<br />
Overall<br />
dimensi<br />
ons
Components of DB<br />
DB-WISE DATA<br />
Sl.<br />
No<br />
1. Breaker<br />
2. MCCB/MCB<br />
3. AC Contactor<br />
4. Thermal Relay<br />
5. Control Devices<br />
6. Meters<br />
DB<br />
Designation<br />
TRANSDUCER (For each type)<br />
1. Make<br />
Technical Specification:Sec-9,Miscellaneous<br />
Rating<br />
of<br />
Volt,<br />
Amps<br />
2. Output range<br />
3. Accuracy<br />
4. Maximum burden on CT/PT<br />
5. Nominal input/rated I/V<br />
6. Overload capacity without loss in accuracy<br />
LIGHTNING PROTECTION<br />
1. Whether lightning conductors have been<br />
envisaged for the lightning protection : Places to be indicated<br />
2. Angle of protection<br />
:<br />
3. Whether building is also protected : Yes/No<br />
4. Number of electrodes provided :<br />
5. Earthing resistance value :<br />
6. Size of down conductors :<br />
EARTHING<br />
Single<br />
Front /<br />
Double<br />
Front<br />
No.of<br />
bus<br />
sections<br />
1. Material and size of earth strip for the<br />
various places<br />
:<br />
2. Size of main outer strip :<br />
3. Galvanising content on GI strip :<br />
Connected<br />
load per<br />
section<br />
Max.<br />
load<br />
per<br />
section<br />
No. of<br />
panels<br />
Page 33 of 55<br />
Overall<br />
dimensions
4. Value of earthing resistance<br />
(proposed to be achieved) :<br />
5. Type & size of electrodes :<br />
6. Construction of earthing mat, etc as per TS : Included<br />
UPS SYSTEM<br />
1. Make of the system<br />
:<br />
2. Capacity in kVA<br />
:<br />
3. Battery back up time<br />
:<br />
4. Make & type of battery<br />
:<br />
5. Number of cells per battery :<br />
6. Overall dimension(L x B x H) mm of battery :<br />
7. Ventilation requirements :<br />
8. Make, Rating & type of charger :<br />
9. Make, Rating & type of rectifier transformer :<br />
10. Make & current rating of SCR & Diode :<br />
11. Make & rating of inverter :<br />
12. Make & type of static transfer switch :<br />
13. Make & rating of manual bypass switch :<br />
TRANSFORMER<br />
1. Name of manufacturer<br />
:<br />
2. Service-whether whether indoor or outdoor :<br />
3. Type of cooling<br />
4. Rating<br />
:<br />
a. Rated KVA<br />
:<br />
b. Rated current, amp (rms), HV/LV :<br />
c. Rated voltage, kV (HV/LV) :<br />
5. Temperature rise above 500C ambient<br />
a. In oil by thermometer, 0C :<br />
b. In winding by resistance, 0C :<br />
c. Hot spot temperature in winding limited to, 0C :<br />
6. Insulation class<br />
:<br />
7. Vector group<br />
:<br />
8. Type of tap changer with capacity/steps/range :<br />
9. Tapping provided on HV side?<br />
10. Losses<br />
: Yes/No<br />
a. No-load load loss at rated voltage and frequency :<br />
b. Load loss at rated load :<br />
c. Cooler loss<br />
:<br />
11. Impedance at rated current frequency :<br />
12. Reactance at rated current and frequency, % :<br />
13. Efficiency at 0.80 p.f lag % at 100%/75%/50% load :<br />
14. Load/p.f. at which max. efficiency occurs, % full load :<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 34 of 55
15. Maximum efficiency, % :<br />
16. Minimum clearances in mm HV LV<br />
a. Between phases<br />
:<br />
b. Between phase and ground :<br />
17. Withstand time without injury for 3 ph short circuit, sec :<br />
18. Insulation strength<br />
a. one minute power frequency test KV rms :<br />
b. Impulse withstand voltage, KV<br />
19. Tap changer provided with<br />
:<br />
i. Tap position indicators ? : Yes/No<br />
ii. Operation counter ?<br />
: Yes/No<br />
iii. Padlocking provisions ?<br />
20. Details of tank<br />
: Yes/No<br />
i. Material<br />
:<br />
ii. Maximum internal withstand pressure of tank kg/cm2:<br />
21. Enclosure details (for dry type transformer)<br />
i. Material<br />
:<br />
ii. Thickness<br />
:<br />
iii. Degree of protection<br />
:<br />
22. Details of core material :<br />
23. Insulation material<br />
:<br />
24. Details of bushings<br />
HV LV LV- Neutral<br />
a. Make<br />
:<br />
b. Type<br />
:<br />
c. Voltage class, KV<br />
25. Insulating oil<br />
:<br />
a. Approx volume of oil, liter :<br />
b. Whether first filling of oil with 10% excess included ? :<br />
c. Oil conforms to IS:335 :335 ?<br />
26. Marshalling Box<br />
:<br />
a. Weatherproof, suitable for outdoor for oil filled type ?: Yes/No<br />
b. Degree of protection<br />
:<br />
27. Each transformer with fittings andaccessories : Yes/No<br />
28. Approximate overall dimensions, (LxBxH) mm :<br />
29. Approximate weights, Kg :<br />
a. Core and coil<br />
:<br />
b. Tank and fittings<br />
:<br />
c. Oil<br />
:<br />
d. Total weight<br />
:<br />
30. List of special maintenance tools and accessories : Furnished<br />
Neutral CT of transformers (for each type)<br />
1. Make, type & applicable cable standard :<br />
2. Ratio & accuracy class: metering/protection :<br />
3. Rated voltage – short time rating :<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 35 of 55
LIGHTING MAST<br />
General<br />
1. Make<br />
:<br />
2. Material of construction :<br />
3. Cross section of mast in polygon (No. of sides) :<br />
4. Thickness in mm (bottom/middle/top sections) :<br />
5. Length of individual sections (mm) :<br />
6. Base dia & top diameter (OAF) :<br />
7. Type of joints<br />
:<br />
8. Length of overlap (joint at site mast Section in mm):<br />
9. Thickness of galvanization (minimum) :<br />
10. Size of opening door at base (mm) :<br />
11. Type of locking arrangement & door construction:<br />
12. Weights in kgs of 30 mtrs high mast :<br />
13. Dynamic loading as prevailing actual at site :<br />
14. Maximum wind pressure (Basic wind speed) :<br />
15. Maximum gust speed ed time :<br />
16. Factor of safety for wind load :<br />
17. Factor of safety for other loads :<br />
Lantern Carriage<br />
1. Diameter of carriage ring (mm) :<br />
2. Load carrying capacity :<br />
3. Total weights of assembly with fittings :<br />
4. Number of fittings<br />
:<br />
Winch<br />
1. Make of winch, number of drums per winch :<br />
2. Capacity<br />
:<br />
3. Operating speed<br />
:<br />
4. Method of operation<br />
:<br />
5. Tested load per drum (kg)<br />
Wire Rope<br />
:<br />
1. Grade<br />
:<br />
2. Number of ropes/thickness :<br />
3. Construction<br />
:<br />
4. Breaking load capacity :<br />
5. Factor safety<br />
:<br />
Cable<br />
1. Type<br />
2. Make<br />
3. Current carrying capacity<br />
4. Cable size<br />
3. Current carrying capacity :<br />
:<br />
Technical Specification:Sec-9,Miscellaneous<br />
:<br />
:<br />
Page 36 of 55
Power Supply arrangement<br />
1. Input supply :<br />
2. KW rating of motor :<br />
3. Speed of motor :<br />
4. Reversible / Non reversible :<br />
5. Remote control switch type :<br />
6. Lifting capacity of torque Limiter :<br />
5.0 Ventilation, Air Conditioning and Dust Suppression System.<br />
5.1 Bidders shall furnish all information as stipulated in relevant chapter. Bidders shall<br />
also furnish the following information:<br />
a) Process flow, process instrumentation and control diagram and water and<br />
compressed air balance diagrams.<br />
b) Dimensioned general arrangement and relevant cross sectional drawings of the<br />
pump house, compressed ai air r station etc. with specification and bill of material.<br />
c) Dimensioned general arrangement drawings of all equipment.<br />
d) All relevant basic design calculations supporting the selection of equipment, location<br />
of valves, specials and supports along with forces and moments of fixed support.<br />
5.2 Ducting including Supply Air Diffusers with Volume Control Dampers<br />
a) Duct : Material, thickness & quantity<br />
b) Damper: material, thickness, size, quantity<br />
c) Supply Air Diffuser: material, thickness, size, quantity<br />
5.3 Ventilation Systems<br />
a) Type of ventilation system<br />
b) Capacity of each ventilation system<br />
c) Make of equipment<br />
d) Design heat load for each premise<br />
e) Indoor climatic condition to be maintained<br />
f) Power requirement of each system<br />
g) Air change/hr<br />
h) Any specific design consideration<br />
i) Noise level at 1 m distance from the ventilation equipment<br />
j) Noise level at served premises<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 37 of 55
5.4 Centrifugal Fan<br />
a) Make & Model No<br />
b) Quantity, no.<br />
c) Type of blade<br />
d) Capacity, m3/h<br />
e) Total pressure, mm WC<br />
f) Speed, rpm<br />
g) Shaft power, KW<br />
h) Total Efficiency, %<br />
i) Motor rating, KW/ pole<br />
j) Fan Characteristic Curve<br />
k) Impeller Diameter, mm<br />
l) Velocity at inlet & outlet of fan, m/sec m<br />
m) Weight of fan and motor, kg<br />
n) Coupling details<br />
o) Vibration isolator type & quantity<br />
p) Thickness of scroll, blade, Back plate, shaft mm<br />
q) Noise level at 1m distance<br />
r) Overall size<br />
s) Drive Motor rating suggested<br />
5.5 Fan Drive Motor Details<br />
a) Type & make<br />
b) Voltage, phase & frequency<br />
c) Rated power<br />
d) Speed<br />
e) Starting/ pull out torque<br />
f) Line current<br />
g) Starting current<br />
h) Overall efficiency<br />
i) Class of insulation<br />
j) Type of enclosure<br />
k) Any other information<br />
5.6 Exhaust fan<br />
a) Make & Model<br />
b) Capacity in m3/h.<br />
c) Total Pressure, mm WC<br />
d) Material of construction and its thickness<br />
e) Speed in rpm.<br />
f) Drive details.<br />
g) Shaft Power consumption.<br />
h) Wheel diameter<br />
i) Efficiency<br />
j) Static & Dynamic weight of fan & motor assembly<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 38 of 55
k) Critical speed of fan<br />
l) Noise level at 1m distance in dB(A<br />
m) Performance curve. n<br />
n) Air flow direction. o<br />
o) Fixing details. p<br />
p) Vibration level.<br />
5.7 Dry Panel type filter<br />
a) Make & Model<br />
b) Capacity in m3/h<br />
c) Pressure drop in mmWC. – both in clean & in dirty condition<br />
d) Effective cross sectional area in m<br />
e) Velocity through filter in m/sec.<br />
f) Material of filtering panel.<br />
g) Cleaning efficiency Vs particle size<br />
h) Methods of surface regeneration.<br />
i) Filter box construction details.<br />
j) Overall dimensions & no. of filters.<br />
k) Fixing frame details.<br />
l) Total weight.<br />
2<br />
Velocity through filter in m/sec.<br />
Material of filtering panel.<br />
Cleaning efficiency Vs particle size<br />
Methods of surface regeneration.<br />
Filter box construction details.<br />
Overall dimensions & no. of filters.<br />
5.8 Air Washer Unit<br />
a) Make & Model No.<br />
b) Type of unit (Horizontal/vertical)<br />
c) Overall dimensions (mm)<br />
d) Weight (kg) with and without water Capacity in m3/h.<br />
e) Total Pressure drop, kgf/ m<br />
f) Material, dia and nos. of nozzles<br />
g) Make up water requirement<br />
h) Details of makeup, overflow, drain, supply & return<br />
i) Saturation efficiency<br />
j) Amount of water and its pressure at the nozzle<br />
k) Casing and tank thickness<br />
l) Water tank capacity<br />
2 g<br />
Material, dia and nos. of nozzles<br />
Make up water requirement<br />
Details of makeup, overflow, drain, supply & return water pipe lines<br />
Amount of water and its pressure at the nozzle<br />
Casing and tank thickness<br />
5.9 Centrifugal Pump (indicate separately for ventilation and dust suppression)<br />
a) Make and model no.<br />
b) Type of pump<br />
c) Capacity in m3/hr.<br />
d) Total head in m WC.<br />
e) Quantity<br />
f) Material of construction<br />
g) Shaft<br />
h) Impeller Casing<br />
i) Pump speed (rpm)<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 39 of 55
j) Shaft power<br />
k) Drive details<br />
a. Motor make<br />
b. Motor KW<br />
c. Insulation class<br />
d. Frame size<br />
l) Bearing type & make<br />
m) Type of coupling<br />
n) Vibration level<br />
o) Noise level at 1 m distance from pump set<br />
5.10 Dry Fog & Plain Water Sprinkling type Dust Suppression Systems<br />
a) Technical details and quantity of main equipment including Nozzles, PRU, FAS and<br />
Instrumentation for Auto Operation.<br />
b) Technical details and qua quantity ntity of auxiliary equipment including air compressors, pumps,<br />
etc.<br />
c) Technical details of circular swiveling sprinklers<br />
d) Compressed air & water requirement, capacity of compressor, air receiver, capacity of<br />
water pump unit etc.<br />
e) Total power consumption. Capacity of each motor for pump and compressor.<br />
f) Details of air & water pipelines with sizes and quantities.<br />
g) Details of valves and fittings<br />
h) Details of solenoid valves, sensors, pressure gauges and other instruments.<br />
i) Details of tanks<br />
j) Details of hood / skirt boards modification<br />
k) Size of compressor cum pump house.<br />
l) Size of only pump house (In case compressed air is not provided)<br />
5.11 Split Air – Conditioner<br />
a) Make & Model<br />
b) Quantity<br />
c) Capacity in TR (Nominal / Actual<br />
d) Air Flow m3/h<br />
e) Flow direction and volume control grill<br />
f) Material of construction<br />
g) Compressor type<br />
h) Drive details and total power consumption<br />
i) Overall dimensions<br />
j) Refrigerant type<br />
k) Filter efficiency<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 40 of 55
l) Weight of unit<br />
m) Noise level at 1m distance in dB(A)<br />
n) Fixing details.<br />
o) Vibration level.<br />
p) Accessories included<br />
6.0 Drawings/documents for Fire Protection System<br />
Drawings/documents to be furnished with offer<br />
The tenderer shall submit the offer along with the following drawings / documents.<br />
a) Scope of work with general description of the sy system stem and equipment offered specifying the<br />
important features. The tenderer has to give a confirmation with respect to the scope of<br />
work as detailed in this specification excepting for the deviations, if any, to be listed in the<br />
schedule of deviation. The ddescription<br />
escription to be accompanied by single line diagrams, and<br />
equipment layout to enable the Purchaser to have a proper appreciation of the equipment<br />
offered and its operation.<br />
b) Specific exclusions, if any, from scope of work .<br />
c) Block Scheme diagram for all fire protection system along with tentative BOQ for major<br />
equipments.<br />
d) Specification of equipment along with their makes/catalogues and material of construction.<br />
e) Reference list of job executed for each type of system.<br />
f) List of mandatory spares as per requ requirement irement for 2 years operation and maintenance.<br />
g) List of special tools and tackles.<br />
h) Amp. hour capacity of DC battery required for MFAP.<br />
i) Write up with control schematic on working of all fire protection systems.<br />
j) Detector type and Catalogues<br />
k) Linear heat t sensing cable details<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 41 of 55
1.0 FORMAT FOR GENERAL AND COMMERCIAL PARTICULARS<br />
<strong>COMPANY</strong> SEAL<br />
1. Name and Address of Bidder.<br />
2. Telegraphic Address of Bidder<br />
3. Name and designation of the person to whom all<br />
references shall be made to expedite technical<br />
coordination<br />
4. Place of Manufacturer<br />
5. Proposal No. & Date<br />
6. Current Registration No. with D.G.S. & D<br />
7. Whether all service facilities available?<br />
8. Whether necessary spare parts available?<br />
9. Has tenderer paid Earnest Money Deposit?<br />
10. Is offer valid for four (4) months from Price bid<br />
opening?<br />
11. Has bidder quoted F.O.R site prices?<br />
12. Is price break up given in Price Bid?<br />
13. Are prices quoted FIRM? (Price should be firm.)<br />
14 Is the tenderer agreeable to the terms of payment? If<br />
not, has terms of payment acceptable to him been<br />
indicated?<br />
15. Does the tenderer agree to the delivery periods<br />
indicated?<br />
16. Are the delivery periods guaranteed under penalty<br />
clause?<br />
17. Is the tenderer agreeable to pay 10% Security<br />
Deposit?<br />
18. Are all schedules for technical particulars and prices<br />
filled in?<br />
19. Has tenderer brought out all deviations in schedule of<br />
deviations?<br />
20. Warranty period from takeover of plant / equipment.<br />
21. Are equipment guaranteed as per various guaranteed<br />
clauses of tender documents?<br />
Technical Specification:Sec-9,Miscellaneous<br />
SIGNATURE ___________________<br />
DESIGNATION ___________________<br />
<strong>COMPANY</strong> ____________________<br />
DATE ____________________<br />
Format - 1<br />
Page 42 of 55
2.0 FORMAT FOR BIDDERS EXPERIENCE LIST<br />
Sl.<br />
No<br />
Technical Specification:Sec-9,Miscellaneous<br />
Purchaser & Customer’s<br />
Location PO No. and<br />
Date<br />
1 2 3<br />
NOTE: Bidder may also furnish the above details for ongoing assignments.<br />
<strong>COMPANY</strong> SEAL<br />
Period &<br />
Year of<br />
Completion<br />
Details<br />
of work<br />
Capacity<br />
of plant<br />
4 5 6 7 8 9<br />
SIGNATURE ___________________<br />
DESIGNATION ___________________<br />
<strong>COMPANY</strong> ____________________<br />
DATE ____________________<br />
Format - 2<br />
Page 43 of 55<br />
Total cost of<br />
work done by<br />
bidder
8.0 LIST OF DRAWINGS ENCLOSED WITH BID<br />
<strong>COMPANY</strong> SEAL<br />
Sl. No.<br />
1<br />
Technical Specification:Sec-9,Miscellaneous<br />
Drawings Title<br />
2 3<br />
SIGNATURE ___________________<br />
DESIGNATION ___________________<br />
<strong>COMPANY</strong> ____________________<br />
DATE ____________________<br />
Format - 3<br />
Page 44 of 55
SCHEDULE OF COMPONENTS IN USE AT NALCO’S EXISTING COAL HANDLING PLANT, CPP, ANGUL<br />
Components schedule given below are for information to Bidders for standardization and<br />
interchangeability with existing Coal Handling Plant only. Bidders must take a note o oof<br />
these<br />
components details while selecting a new supply to control the inventory level.<br />
A) Conveyor Pulley Schedule<br />
Pulley<br />
Type<br />
Drive/<br />
Discharge<br />
Pulley<br />
Non Drive<br />
Pulleys<br />
Pulley<br />
Diameter<br />
(mm)<br />
630<br />
630<br />
630<br />
800<br />
400<br />
400<br />
500<br />
B) Bearing & Plummer Block Schedule.<br />
Shaft diameter (mm) Bearing size Plummer Block Schedule<br />
Drive Pulleys Non Drive Pulley<br />
65 22215K 1 – 1328 - AL 1 – 1328 - AL<br />
75 22217K 1 – 149 - AL 1 – 149 - AL<br />
90 22220K M – 1034 - BL M – 1034 - BL<br />
100 22222K M – 1033 - CL M – 1033 - CF<br />
115 22226K M – 1035 - AL M – 1036 - AF<br />
125 22228K M – 1036 - BL M – 1036 - BL<br />
140 22232K M – 1035 - CL M – 1036 - CF<br />
150 22234K 1 – 829 - AL 1 – 1330 – AF<br />
160 22236K 1 – 1487 - L 1 – 1488 - F<br />
C) Gear Box Schedule.<br />
Technical Specification:Sec-9,Miscellaneous<br />
Gear box size Reduction Ratio<br />
SZN-200<br />
SZN-225<br />
SZN-250<br />
SZN-280<br />
SZN-320<br />
SZN-250<br />
Face<br />
width<br />
(mm)<br />
Shaft<br />
Diameter<br />
(mm)<br />
KDA-200 200 125:1<br />
Bearing<br />
Diameter<br />
(mm)<br />
Shaft<br />
length<br />
(mm)<br />
1150 125 115 1690 1550<br />
1150 150 140 2095 1650<br />
1150 165 150 2100 1650<br />
1150 175 160 2120 1650<br />
1150 90 75 1760 1650<br />
1150 100 90 1760 1650<br />
1150 115 100 1770 1650<br />
16 : 1<br />
16 : 1<br />
16 : 1<br />
20 : 1<br />
20 : 1<br />
16 : 1<br />
PlummerBlockCenter<br />
(mm)<br />
Page 45 of 55
D) Fluid Coupling Schedule<br />
E) Idler Schedule<br />
Technical Specification:Sec-9,Miscellaneous<br />
Fluid coupling size Baffle Ratio<br />
FCU-16.25 16.25 1.5B<br />
FCU-17.75 17.75 1.5B<br />
FCU-23<br />
1.5B<br />
FCU-41<br />
The idlers are drop in slot type.<br />
1.5B<br />
Page 46 of 55
LIST OF PREFERRED MAKES<br />
1.1. MECHANICAL<br />
SL. NO. EQUIPMENT<br />
1. GEAR BOXES<br />
2. CONVEYOR BELTS DUNLOP, NIRLON, MRF, PHOENIX, NORTHLAND, FORECH, ANIL<br />
RUBBERS, ORIENTAL.<br />
3. IDLER<br />
4. PULLEY<br />
5. BEARINGS<br />
6. SLEW RING BEARINGS ROTHE ERDE, TITANUS, LYC-CHINA<br />
7. FLEXIBLE COUPLING FMG, DAVID BROWN, HICLIFF, CONCORD, ROMA, WELLMAN<br />
INCAD. GREAVES LTD., NAW, GBM, ALLFLEX<br />
8. FLUID COUPLING PEMBRIL, FLUDOMAT, VOITH, ELECON<br />
9. FASTENERS<br />
10. MANUAL HOISTS WH BRADY, KANUBHAI, HERCULES, TRACTEL TIRFOR, REVA<br />
ENGG. MM ENGRS, BRADY&MORRIS<br />
11. OIL SEALS<br />
12. LUBRICATION<br />
13. POWER PACK<br />
14. HYDRAULICS<br />
15. HOSES<br />
16. a) BELT CLEANERS a) HOSCH, KAVERI,TECHNOFAB, PROMAC, BMH CONCARE<br />
b) SKIRTS AND SKIRT<br />
SEALING<br />
ARRANGEMENT<br />
17. ACTUATOR OPERATED<br />
FLAP GATES<br />
UNITED TECHNOMECH, PREPEC, PEBCO<br />
18. IN LINE MAGNETIC ELECTRO-ZAVOD, ZAVOD, MBIL, ELECTROMAG, POWER BUILD, MCI,<br />
SEPARATORS ELECTROMAGNETIC INDUSTRIES<br />
19. BELT WEIGH SCALES SCHENK-JENSON, JENSON, TRANSWEIGH, IPA, SARTORIUS<br />
20. BELT SWITCHES<br />
21 BRAKES<br />
22 ELEC. HOISTS<br />
Technical Specification:Sec-9,Miscellaneous<br />
MAKE<br />
ELECON, FLENDER, SHANTHI, SEW, NAW, GRAEVES<br />
ELECON, TRF, KALI, KRUPP, MACMET, HINDUSTAN UDYOG<br />
ELECON, TRF, KALI, HEC, HINDUSTAN UDYOG, McNALLY<br />
BHARAT, HITECH, MASYC, KRUPP, SIMPLICITY, ARUDRA,<br />
MACMET.<br />
SKF, FAG, NTN, NBC, NORMA, TATA, EAST EUROPIAN EUROPIAN, ZKL<br />
GKW, SUNDERAM, PRECISION FASTENERS<br />
VACCA, RUBBER EQPT. & ENGG. CO. L TD<br />
TECALEMIT, SURMAC, LUBCON, PRAKASH, AFMC, HELIOS<br />
PROTOS, LINCOLN HELIOS<br />
REXROTH, PARKER, ETON, YUKEN, VICKERS, HAGGLUNDS<br />
REXROTH, YUKEN, CARTER, VELJAN CYLINDERS UTL,<br />
MONTECH, WIPRO, OSCAR, HAGGLUNDS, PARKERCALZONI<br />
AEROLEX, GATES INDIA PVT. LTD<br />
b) UNITED TECHNO MECH, TEGA, KAVERI, HOSCH<br />
JAYSHREE, SCHNEIDER, TELEMECHANIC, INDUSTRY SYNDICATE,<br />
PROTO CONTROL<br />
BCH, INDUSTRIES SYNDICATE, STORM KRAFT, ELECTROMAG,<br />
SPEED O CONTROL, STROMAG<br />
ARMSEL, SHIVPRA, WH BRADY, BRADY & MORRIS, GRIP<br />
ENGRS., HI-TECH, TECH, CENTURY CRANE, TUOBRO FURGUSON,<br />
UNITECH<br />
Page 47 of 55
In case the Tenderer/ Contractor intends to substitute any particular make of equipment /<br />
components/ ents/ materials by their/ his own make other than that listed in this document, the<br />
Tenderer shall clearly bring out the same in his tender along with justification and indicate the<br />
makes offered by him. It will be prerogative of the Purchaser to accept or reject the tenderer’s<br />
own makes so offered.<br />
1.2. ELECTRICAL<br />
Sl.No ITEM<br />
APPROVED SUB VENDORS<br />
1. 415 V MCC/ (Drawout type) 1. ABB<br />
2. GE Power Control Ltd<br />
3. L&T<br />
4. Siemen Ltd<br />
5. Schneider Eectric India Pvt.Ltd<br />
2. 415 V PDB/DB (Fixed type) 1. Control & Switchgear Co. Noida<br />
2. GE Power Control Ltd<br />
3. L&T<br />
4. Schneider Eectric India Pvt.Ltd<br />
5.ABB<br />
6.SIEMENS<br />
3. HT Cables<br />
1. CCI<br />
2.Universal<br />
3.Polycab<br />
4.NICCO<br />
5.KEI<br />
4. LV Motors<br />
1. Alstorm<br />
2. Asea Brown Boveri Ltd, Faridabad<br />
3. Bharat Bijlee<br />
4. Kirloskar Electric Co.Ltd, Banbalore & Hubli<br />
5. Siemens<br />
6. CGL<br />
5. Local Control Stations (Weather 1. Bhartiya Industries<br />
Proof)<br />
2. Baliga Lighting Eqpt(p)Ltd<br />
3. Ex-protecta<br />
4. Electrical Equpt.Corporation<br />
5. Flexpro Electricals Pvt.Ltd<br />
6. Prompt Engineering Works<br />
6. Bimetal Relays 1. ABB,Bangalore<br />
2. Bhartiha Industries<br />
3. L&T<br />
4. Siemens<br />
5. Schneider Eectric India Pvt.Ltd<br />
7. Contactors<br />
1. ABB,Bangalore<br />
2. Bhartiha Industries<br />
3. Control & Switchgears Contactors Ltd.<br />
4. GE Power Control India Ltd<br />
5. L&T<br />
6. Siemens Ltd<br />
7. Schneider Electric India Pvt.Ltd<br />
8 Control Switches/Selector 1. Alstom Ltd<br />
Switches<br />
2. Havells India<br />
3. Hotline Switchgear &Controls<br />
4. Kaycee Industries<br />
5. L&T<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 48 of 55
9. Fuse Switch<br />
6. Reliable Electronic Components Pvt. Ltd<br />
7. Siemens Ltd<br />
8. Switron Devices<br />
1. ABB Ltd, Bangalore<br />
2. Control & Switchgears Co Ltd<br />
3. Havells India<br />
4. Indo Asian Fuse Gear<br />
5. L&T<br />
6. Siemens Ltd<br />
7. Standard Electricals<br />
8. Alstom<br />
9. Schneider Electric India Pvt.Ltd<br />
10 Timers<br />
1. Bhartiha Industries<br />
2. Concord Controls<br />
3. Electronic Automation Pvt Ltd<br />
4. L&T<br />
5. Siemens Ltd<br />
6. Schneider Electric India Pvt.Ltd<br />
11 Fuse<br />
1. GE Power Controls<br />
2. Indo Asian Fuse Gear<br />
3. L&T<br />
4. Siemens Ltd<br />
5. Ferraz<br />
6. Bussman<br />
12 ELCBs<br />
1. Datar Switchgear Pvt Ltd<br />
2. Indo Asian Fuse Gear<br />
3. Legrand India<br />
4. ABB<br />
5. Siemens<br />
6. Schneider Electric India Pvt.Ltd<br />
7. GE<br />
13. MCBs<br />
1. Datar Switchgear Pvt Ltd<br />
2. Havells India<br />
3. Indo Asian Fuse Gear<br />
4. Indian Current Control<br />
5. Legrand India<br />
6. Standard Electricals<br />
7. ABB<br />
8. Siemens<br />
9. GE<br />
10.L&T<br />
14 MCCBs<br />
1. GE Power Controls<br />
2. L&T<br />
3. Schneider Electric India Pvt.Ltd<br />
4. Siemens<br />
5. ABB<br />
15 Meters<br />
1. Automatic Electric<br />
2. Meco Instruments Pvt Ltd<br />
3. Nippen Electrical Instruments Co<br />
4. Risabh Instruments Pvt.Ltd<br />
5. Industrial Meters(P) Ltd<br />
16 Push Buttons & Indicating Lamp 1. Bhartiha Industries<br />
2. Concord Controls<br />
3. Control & Switchgears Co Ltd<br />
4. Hotline Switchgears & Controls<br />
5. L&T<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 49 of 55
17 Lighting & Power panels<br />
6. Precifine Products Pvt. Ltd<br />
7. Siemens<br />
8. Shri Tulsi Switchgears<br />
9. Teknick Controls<br />
10. Schneider Electric India Pvt.Ltd<br />
11. Binoy Opto Electrics,Kolkata<br />
1. Control & Switchgears Co Ltd<br />
2. Havells India<br />
3. Masstechm Switch gear<br />
4. Legrand India<br />
5. Standard Electricals<br />
18 Lighting Fixtures 1. Bajaj Electricals<br />
2. Comptron Greaves 3. Philip India<br />
19 Terminal Blocks 1. Essen<br />
2. Connect well<br />
3. Elmex<br />
20 Switch socket outlets 1. ALSTOM<br />
2. CGL<br />
3. B & C<br />
4. ESSEN<br />
21 Transducer<br />
1. ABB<br />
2. MECO<br />
22 LT Transformer 1.CGL<br />
2.KEC<br />
3.BBL<br />
4.BHEL<br />
5.AREVA<br />
6.BMCC<br />
7.T&R<br />
8.VIJAY ELECTRICAL<br />
23 PLC<br />
1.GE-FANUC<br />
2. ALLEN BRADLY<br />
3.SCHNEIDER<br />
24 UPS<br />
1.EMERSION<br />
2.HI-REL<br />
3.NUMERIC<br />
4.TATA LIBERT<br />
25 Control Desk<br />
1. SIEMENS<br />
2. ALSTOM<br />
3. L&T<br />
4. ABB<br />
27 VVVF Drive<br />
1. ALSTOM<br />
2. BHEL<br />
3. DANFOS<br />
4. L&T<br />
5. NELCO<br />
6. ROCKWELL<br />
7. SIEMENS<br />
8. ABB<br />
9. SCHNEIDER<br />
10. YASKAWA<br />
29. 33 K V Isolator 1. PANICKER<br />
2. BOND STRANDS<br />
3. DRISCHER<br />
30 Trailing Cables 1. KEI<br />
2. NICCO<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 50 of 55
31 HT Switch gear 1. BHEL<br />
2 Siemens<br />
3. ABB<br />
32 HT Transformer 1. BHEL<br />
2 Siemens<br />
3 TELK<br />
4 ABB<br />
5 AREVEA<br />
33 33KV VCB<br />
1. ALSTOM<br />
2.ABB<br />
3.SIEMENS<br />
34 Protection relays 1.ABB<br />
2.ALSTOM<br />
3EASUN REY ROLLE LTD<br />
4L&T (FOR NUMERICAL RELAYES ONLY) .<br />
5SIEMENS (FOR NUMERICAL RELAYES ONLY) .<br />
35 Breaker Control switches 1.ALSTOM<br />
2.RELIABLE RELIABLE ELECTRONIC COMPONENT PVT.LTD.<br />
3.SWITORN DEVICES<br />
36 LV CT/PT<br />
1.COTROL AND SWITCH CO.LTD.<br />
2.GEILBERT & MAXWELL ELECTRICAL<br />
3.KAPPA ELECTRICALS<br />
4.L&T<br />
5.NARYAN POWER TRON PVT.LTD.<br />
6.SILKAANS ELECTRICAL<br />
7.PRECISE ELECTRICAL<br />
8.PROGATI ELECTRICAL PVT.LTD.<br />
37 HVCT/PT<br />
1.AE<br />
2.BHEL<br />
3.CGL<br />
4.SILKAANS<br />
5.JYOTI<br />
6.KAPPA<br />
7.ABB<br />
8.PROGATI.<br />
38. Solid State Annuncitaor 1.APLAB<br />
2.MINILEC<br />
3.IL<br />
39. Lightning Arrests 1.WSI<br />
2.ELPRO.<br />
40. 33KV Air Break switch 1.DRIESCHER PANNIKER<br />
41. High Mast Tower 1.BAJAJ<br />
2.PHILIPS<br />
42. Cable accessories 1.DOWELLS<br />
43. ACSR/AAAC Conductor 1.RELIANCE CONDUCTORS<br />
44. 415V PCC<br />
1. L&T<br />
2.SIEMENS<br />
45. Cable termination 7 jointing 1.RAYCHEM RPG<br />
kits<br />
46. LT power and control cables 1.CCI<br />
2.UNIVERSAL<br />
3.POLYCAB<br />
4.NICCO<br />
Technical Specification:Sec-9,Miscellaneous<br />
3. UNIVERSAL<br />
Page 51 of 55
47. Signal and Instrumentation<br />
5.KEI<br />
6.CORDS<br />
7.GEMSCAB<br />
1.CCI<br />
cable<br />
2.UNIVERSAL<br />
3.POLYCAB<br />
4.NICCO<br />
5.KEI<br />
6.CORDS<br />
7.GEMSCAB<br />
48. VRLA battery<br />
1.AMAR RAJA<br />
2.EXIDE<br />
49. Battery charger 1. AMAR RAJA<br />
2.CHABI ELECTRICAL<br />
3.CALDYNE<br />
4.HBL NIFE<br />
1.3. AIR CONDITIONING, VENTILATION & DUST SUPPRESSION SYSTEM<br />
Ventilation system<br />
- EFE, C. Doctor, Voltas<br />
Dust Suppression System - TPS, Kaveri, F. Harley<br />
Air Conditioning system - Blue Star, Voltas, Carrier<br />
1.3 CIVIL<br />
CEMENT- ACC,L&T Ultra Tech, Zuari, RAASI GOLD or equivalent approved manufacturer.<br />
REINFORCEMENT STEEL STEEL-SAIL,Tata SAIL,Tata Steel, RINL, or equivalent approved manufacturer.<br />
Note:<br />
1. Makes indicated above shall also be read with preferred makes as listed elsewhe elsewhere in<br />
this specification.<br />
2. For make of any item, not appearing in the above list, specific approval shall be taken by<br />
the bidders from Purchaser.<br />
Technical Specification:Sec-9,Miscellaneous<br />
Page 52 of 55
1.0 LIST OF TOOLS AND TACKLES<br />
S.NO DESCRIPTION<br />
1. Manually operated Hydraulic Jack<br />
i) 50T X 150 mm stroke<br />
2. Bastard (Rough Cut) Files 250 mm size<br />
i) Flat<br />
ii) Round<br />
iii) Half Round<br />
iv) Triangular<br />
3. Fine Cut Files 250 mm size<br />
i) Flat<br />
ii) Round<br />
iii) Half Round<br />
iv) Triangular<br />
4. Adjustable Outside Micrometer Interchangeable Anvil<br />
Type<br />
i) 0-150 mm<br />
ii) 150 – 600 mm<br />
5. Inside Micrometer<br />
i) 50 – 150 mm<br />
6. Vemier Calipers –<br />
i) 0-150 mm size<br />
ii) 0 – 300 mm size<br />
7. Feeler Gauge<br />
i) 10 mm thk. 6 inch<br />
ii) 10 mm thk. 12 inch<br />
8. Sprit Level<br />
i) 150 mm<br />
9. Torque Wrench with socket<br />
75 – 150 kg.m<br />
10. Standard Ring spanners<br />
(Upto 32 mm )<br />
11 Standard D.E. spanners<br />
(Upto 32 mm )<br />
12. Adjustable spanners<br />
(Upto 50 mm each set of 3 Nos.)<br />
13. Socket Head Spanners<br />
(Box Spanners 10 to 32 mm )<br />
14 Sledge Hammers<br />
i) 5 kg.<br />
ii) 10 kg<br />
15. Nylon Faced Hammers (4 Sizes)<br />
Technical Specification:Sec-9,Miscellaneous<br />
QUANTITY<br />
2 Nos<br />
1 No.<br />
1 No.<br />
1 No.<br />
1 No<br />
1 No.<br />
1 No.<br />
1 No.<br />
1 No<br />
1 No.<br />
1 No<br />
1 No<br />
1 No.<br />
1 No<br />
1 No.<br />
1 No<br />
2 No<br />
1 set<br />
1 set<br />
1 set<br />
1 set<br />
2 set<br />
2 Nos.<br />
2 Nos<br />
1 set<br />
Page 53 of 55
16. 4” dia portable motor operated grinding m/c with flexible<br />
grinder<br />
2 Nos<br />
17 Ball Pein Hammers in different sizes.<br />
18. Dial Gauge 00-10<br />
mm LC-0.01 mm with mag.<br />
Stand<br />
19. Steel Tapes<br />
i) 3 m Size<br />
ii) 6 m Size<br />
20 Steel Scales<br />
i) 0.3 m Size<br />
ii) 0.5 m Size<br />
21. Internal Calipers<br />
i) 150 mm Size<br />
ii) 300 mm Size<br />
22. External Calipers<br />
i) 150 mm Size<br />
ii) 300 mm Size<br />
23 Hand operated Hacksaw Frame with 1 Doz. Blades (12”) 1 Set<br />
24 Tri-square square (6” x 12”)<br />
25. Screw Operated Coupling and Bearing Puller – 300 mm<br />
Size<br />
2 Nos<br />
26. Grease Gun with hose & adopter (Manual)<br />
27 Bucket Grease Gun (Manual)<br />
28. Self supporting, extendable aluminum ladder with<br />
maximum height of 6m<br />
2 Nos<br />
29 Hydraulic flange puller of reputed make<br />
2 Sets<br />
30. Pipe Wrenches – 6” & 12”<br />
31 Digital Tachometer (0 – 3000 rpm)<br />
32 Screw Drivers<br />
i) 150 mm Size<br />
ii) 300 mm Size<br />
33 Sling with Eye Bolt and DD-Shackle<br />
of 2,3,5 &10 tonnes<br />
34. Plum Bobs<br />
35. All types of Pliers of different size of reputed make to suit<br />
the eqpt.<br />
i) Cutting pliers<br />
ii) Internal Circlip<br />
iii) External Circlip<br />
36. Adjustable Pliers<br />
37 Marking Punches<br />
38 Scribers<br />
39 Insulation resistance Tester (Megger)<br />
i) 500 V<br />
ii) 1000 V<br />
Technical Specification:Sec-9,Miscellaneous<br />
6 Nos<br />
2 Nos<br />
1 No.<br />
1 No<br />
1 No.<br />
1 No<br />
1 No.<br />
1 No<br />
1 No.<br />
1 No<br />
2 Nos<br />
2 Nos<br />
1 No<br />
4 Nos<br />
2 Nos<br />
2 Nos.<br />
2 Nos<br />
2 Sets<br />
2 Nos<br />
2 Nos.<br />
2 Nos.<br />
2 Nos<br />
2 Nos<br />
2 Sets<br />
4 Nos<br />
1 No.<br />
1 No<br />
Page 54 of 55
40. Tong Tester<br />
41. Portable Emergency Light (Hand Torch with Dry Cells)<br />
42. 100 W Hand Lamp with 50 M Flexible Wire<br />
43. Hand drills (pistol)<br />
44. Digital Multimeter<br />
45 Digital Clamp meter<br />
46 Hand drill – Electrical ½ “ & 1”<br />
47 Crimping Tool ( Hand Operated) - 5 mm<br />
48. Crimping Tool ( Hand Operated)<br />
2 to 16 mm 2<br />
Crimping Tool ( Hand Operated) -16 mm 2 to 240 mm 2<br />
49 Milli Ohm Meter<br />
50 Combination Plier<br />
51 Nose Plier<br />
52 Earth Megger<br />
53. Phase Sequence meter (0 – 415V)<br />
2.0 LIST OF TENDER PURPOSE DRAWINGS FOR BIDDER’S REFERENCE<br />
SL. NO. DESCRIPTION DRAWING NO<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7<br />
Handling System<br />
Technical Specification:Sec-9,Miscellaneous<br />
Layout of Coal Storage Yard & 1034/Q6Q3/A-02A/LO 02A/LO-001 Rev 05<br />
Coal Flow Diagram FD-CHP<br />
General Layout of CPP, NALCO 6-08-0-07734-01<br />
G.A. & Marking of Conveyor BC BC-115 02728-M-BM-CS-GA--0027<br />
Rev C<br />
G.A. & Marking of Conveyor BC BC-103 CKIH-3901-M0-B057 B057 Rev D<br />
G.A. of Junction House JH JH-1 CKIH-3901-M0-B004 B004 Rev C<br />
G.A. of wagon tippler & receiving RITES/PORTS/NALCO/FS/L<br />
RITES/PORTS/NALCO/FS/L-01<br />
conveyor<br />
(Set of three drawings)<br />
(Set of five drawings)<br />
2 Nos<br />
2 Nos<br />
2 Nos<br />
2 Nos<br />
1 No<br />
1 No<br />
2 Sets<br />
1 Set<br />
1 Set<br />
1 No<br />
2 Nos<br />
2 Nos<br />
1 No<br />
1 No.<br />
Page 55 of 55
1.0 COMPLETION SCHEDULE<br />
Special Instructions to Bidders<br />
Annexure - II<br />
The schedule for completion in all respect as per Tender Documents from Brief Order (BO) date is<br />
specified in Instruction to Bidders.<br />
2.0 DUE DATE<br />
Please ensure your offer, complete in all respects reaches us by the bid due date specified in<br />
Instructions to Bidders. Offers received after the bid due date and time will be considered as Late<br />
Offers and will not be considered.<br />
3.0 PRICE FORMAT<br />
Please furnish the prices strictly as per the format enclosed. Prices shall not appear any where<br />
else in the offer, and if prices are mentioned any where else the same shall not be considered.<br />
Prices should be submitted in duplicate sealed super scribed envelope along with un-priced copies<br />
as per Tender documents (Un-priced copy of price bid should also be enclosed with un-priced<br />
copies with prices blanked out but “Quoted/ Not Quoted” marked against respective clauses).<br />
4.0 VALIDITY OF BIDS<br />
The bid should be kept valid for acceptance for a period of 4 (four) months from the final due date<br />
for bid submission.<br />
5.0 EVALUATION/ LOADING/ REJECTION CRITERIA<br />
5.1 All evaluation shall be made on landed and erected on destination basis including design and<br />
engineering, supply of equipment, spares etc. (excluding One Year O&M Spares) and all other<br />
erection, construction, installation, supervision and commissioning charges along with the taxes<br />
and duties for the same, as per scope of Tender Documents.<br />
5.2 Supply prices shall be evaluated as follows:<br />
1. FOT Despatch Point : As quoted<br />
2. Add ED & E-cess : As Quoted<br />
3. Add CST/ LST/ VAT : As Quoted<br />
4. Total Price : 1+2+3<br />
5. Transit Insurance : 0.25% on (4)<br />
6. Freight Charges : As quoted<br />
7. Total FOT Site : 4+5+6<br />
8. Entry Tax : @ 2% on (7)<br />
9. Total Price : 7+8<br />
10. Technical loadings, if any : On FOT Despatch point price<br />
Annexure II, Special Instructions to Bidders Page 1 of 9
11. Commercial loading, if any : On FOT Despatch point price<br />
12. CENVAT Benefit (-) 2<br />
13. Total Comparable Price : 9+10+11+12<br />
5.3 Price loading on account of payments and other conditions required by various vendors will be<br />
based on following:-<br />
(i) Payment terms:<br />
a) Price loading on account of payment terms at variance with Bidding Document<br />
payment terms will be loaded @ 12% per annum for the relevant period.<br />
(ii) Price Variation:-<br />
Terms offered by vendor price loading<br />
(a) Firm Price : No loading<br />
(b) In case of ceiling on : Loading by ceiling percentage offered<br />
Price Variation Clause<br />
(c) No ceiling on the formula : Offer may be rejected<br />
(d) No formula and no : - do -<br />
ceiling specified by vendor<br />
(iii) Vendors should quote firm inland freight charges from dispatch point to Site at Angul,<br />
Orissa. If a vendor does not quote firm inland freight charges then their offer will be loaded<br />
with maximum of the inland freight charges as quoted by the other bidders from that region<br />
or based on estimation by NALCO in case there is no other offer from that region.<br />
(v) Any differential in taxes and duties will be cost loaded on case-to-case basis. If a vendor<br />
states that taxes/duties are not applicable at present and will be charged as applicable at<br />
the time of delivery then no advantage will be given.<br />
(vi) All materials are required to be transported by Bank-approved carriers, preferably having<br />
an office at the place of concerned unit.<br />
(vii) Cost loading in respect of utilities will be considered where guaranteed consumptions have<br />
been asked in NIT as per methodology defined in the NIT.<br />
5.4 All cost loadings will be calculated on F.O.T. despatch point prices.<br />
5.5 No deviation to terms & conditions of the bid documents is allowed. Further Non acceptance of<br />
following commercial clauses shall lead to rejection of bid:<br />
Annexure II, Special Instructions to Bidders Page 2 of 9
(i) Bids that do not meet the qualification criteria as specified in the NIT/ bid documents shall<br />
be summarily rejected.<br />
(ii) A bid with incomplete scope of work and / or which does not meet the technical<br />
specifications and requirements as specified in the NIT documents shall be considered as<br />
non-responsive and rejected.<br />
(iii) Prices must be furnished in accordance to the price schedule format enclosed and strictly<br />
based on the terms specified related to the bid prices in the instructions / conditions. Non<br />
compliance to this requirement shall make the bid liable for rejection.<br />
(iv) Bidders are requested to note that exceptions / modifications taken by them to the<br />
following clauses of Tender Documents - Commercial may result in rejection of their bid :-<br />
6.0 REFERENCE LIST<br />
(a) Proforma of Bank Guarantee for Advance Payment, if any, and Contract - cum -<br />
Performance Bank Guarantee<br />
(b) Contract Performance Guarantee clause<br />
(c) Completion Schedule<br />
(d) Period of validity of bid<br />
(e) Guarantee / Warranty<br />
(f) Replacement of Defective parts and materials<br />
The bidders are requested to submit a list of buyers to whom the same or similar type of equipment<br />
have been supplied by them and which are under operation. The detailed addresses of such<br />
buyer’s office/works including Telephone, Fax Nos. and Contact Person and Order Reference are<br />
to be mentioned.<br />
Annexure II, Special Instructions to Bidders Page 3 of 9
SL. NO. DESCRIPTION<br />
1.0 COST OF BIDDING<br />
2.0 SITE VISIT<br />
3.0 BIDDING DOCUMENT<br />
APPENDIX - A<br />
TO<br />
SPECIAL INSTRUCTIONS TO BIDDERS<br />
INDEX<br />
4.0 CLARIFICATION OF BIDDING DOCUMENT<br />
5.0 AMENDMENT OF BIDDING DOCUMENT<br />
6.0 CONFIDENTIALITY OF BIDDING DOCUMENT<br />
7.0 LANGUAGE OF BID<br />
8.0 FORMAT AND SIGNING OF BIDS<br />
9.0 MODIFICATION & WITHDRAWAL OF BIDS<br />
10.0 OPENING OF UN-PRICED BIDS<br />
11.0 OPENING OF PRICE BIDS<br />
12.0 COMPARISON OF BIDS<br />
13.0 CONTACTING THE OWNER/CONSULTANT<br />
14.0 AWARD CRITERIA<br />
15.0 OWNER’S/CONSULTANT’S RIGHT TO ACCEPT ANY BID AND TO REJECT ANY<br />
OR ALL BIDS<br />
17.0 ISSUE OF ORDER<br />
Annexure II, Special Instructions to Bidders Page 4 of 9
1.0 COST OF BIDDING<br />
1.1 All direct and indirect costs associated with preparation and submission of bid (including clarification<br />
meetings and site visit, if any) shall be to bidder’s account and NALCO / RITES, will in no case, be<br />
responsible or liable for these costs, regardless of the conduct or outcome of the bidding process.<br />
2.0 SITE VISIT<br />
2.1 Bidder is advised to visit and examine the Site, its surrounding and familiarize himself of the<br />
existing facilities and environment and collect all other information which he may require for<br />
preparing and submitting the bid and entering in to the contract. Claims and objections due to<br />
ignorance of existing conditions or inadequacy of information will no be considered after<br />
submission of the bid and during implementation.<br />
2.2 The bidder or any of his personnel or agents will be granted permission by the Owner to enter upon<br />
his premises and land for the purpose of such inspection but only upon the explicit condition that<br />
the bidder, his personnel or agents will release and indemnify the owner and his personnel or<br />
agents from and against all liability in respect thereof and will be responsible for personnel injury<br />
(whether fatal or otherwise), loss of or damage to property and any other loss, damage, cost and<br />
expenses incurred as a result thereof.<br />
2.3 For site visit, the intending bidder may contact General Manager (CPP), NALCO, Angul, Orissa<br />
Phone- 06764- 220 158, Telefax – 06764- 220 646 or General Manager (Projects), RITES Ltd,<br />
Bhubaneswar, Phone: 0674 2572690, 09438677075. Fax – 0674 2575 284. or Sr.<br />
DGM(Civil)/RITES, Bhubaneswar, phone-09437283829.<br />
3.0 BIDDING DOCUMENT<br />
3.1 The Bidder is expected to examine all instructions, forms, terms and specifications in the<br />
Bidding Document. The Bidding Document together with all its attachments thereto, shall be<br />
considered to be read, understood and accepted by the Bidder, unless deviations are specifically<br />
stated in seriatim (giving reference s. no. of Bidding Document) by the Bidder. Failure to furnish all<br />
information required by the Bidding Document or submission of a bid not substantially responsive to<br />
the Bidding Document in every respect will be at Bidder’s risk and may result in the rejection of his<br />
bid.<br />
3.2 The Bidders must fulfill the Qualification Criteria given in the Instructions to Bidders and furnish all<br />
necessary documentary evidence in support of Bidder’s experience/ capability as required, along<br />
with the bid. In the absence of the requisite documents, NALCO / RITES reserves the right to reject<br />
the bid without making any reference to the Bidder. Bidders must make their own judgment on<br />
the adequacy of the documents/ information they provide. In case any information provided by<br />
Bidder is found to be incorrect, the bid will be rejected, and the Earnest Money Deposit of<br />
such Bidder will be liable for encashment.<br />
3.3 Bidder must buy Bidding Document by paying the requisite document fee before the sale<br />
closing date & time. In case the Bidding Document is downloaded from website t h e requisite<br />
Bidding Document Fee in the form of DD payable to NALCO shall accompany the bids.<br />
Annexure II, Special Instructions to Bidders Page 5 of 9
4.0 CLARIFICATION OF BIDDING DOCUMENT AND PRE-BID MEETING<br />
4.1 Bidder shall examine the bidding document thoroughly in all respect and if any conflict, discrepancy,<br />
error or omission is observed, bidder may request clarification within the cutoff date and 3 weeks<br />
prior to the bid closing date. Such clarifications request shall be addressed to the following:<br />
GM (Projects), RITES Ltd.,Regional Project Office, Bhagwan Tower(1 st Floor), Cuttack Road,<br />
Bhubaneswar -751006, Phone:-0674-2575493, Fax:0674-2575284, E-mail : bbsrpo@rites.com<br />
4.2 Any failure by bidder to comply with the aforesaid requirement shall not excuse the bidder, after<br />
subsequent award of contract, from performing the work in accordance with the contract.<br />
4.3 Response to queries/ clarifications raised will be sent as expeditiously as possible. The response<br />
shall not form part of the bidding document unless issued as an addendum/ amendment.<br />
4.4 Bidders are expected to resolve all their clarification/ queries to the bidding document and submit<br />
their bid in total compliance to biding document without any deviation/ stipulation/ clarification.<br />
4.5 PRE-BID MEETING<br />
The Tenderer or his official representative is invited to attend a pre-bid meeting which will take place at<br />
the Office of General Manager(Project), CPP, Nalco,Angul on 10.09.2012 at 10.30 hours.<br />
The Tenderers are required to submit any question on issues relating to the tender, in writing or by<br />
telefax or by E-mail so as to reach general Manager(Project), RITES Ltd.,Regional Project Office,<br />
Bhagwan Tower(1 st Floor), Cuttack Road,Bhubaneswar -751006 not later than 3 (three) days before<br />
the date fixed for the meeting.<br />
The purpose of the meeting will be to clarify the issues raised and to answer supplementary questions<br />
on such issues.<br />
Minutes of the meeting including the text of the questions raised (without identifying the source of<br />
enquiry) and the responses given will be uploaded on RITES website. Any modifications of the<br />
Tender Document which may become necessary as a result of the Pre-bid Meeting shall be made<br />
exclusively through the issue of an Addendum / Corrigendum and not through the Minutes of the Pre-<br />
Bid Meeting. The Minutes of the Meeting as described above and the Addendum / Corrigendum, if<br />
any, will be uploaded on RITES website only.<br />
Non-attendance at the Pre-bid Meeting will not be a cause for disqualification of a tenderer.<br />
5.0 AMENDMENT OF BIDDING DOCUMENT<br />
5.1 At any time prior to the bid due date, NALCO / RITES may, for any reason, whether at its own<br />
initiative or in response to a clarification requested by a prospective Bidder, modify the Bidding<br />
Document and issue amendment in the form of Addendum.<br />
Annexure II, Special Instructions to Bidders Page 6 of 9
5.2 Any addendum thus issued will become part of bidding document and bidder shall submit original<br />
addendum/ compliance letter duly signed and stamped in token of his acceptance.<br />
5.3 In order to afford prospective Bidders, reasonable time in which to take the amendment into account<br />
in preparing their bids, NALCO /RITES may, at its discretion, extend the bid due date.<br />
6.0 CONFIDENTIALITY OF BIDDING DOCUMENT<br />
6.1 Bidders shall treat the biding documents and contents therein as strictly confidential.<br />
6.2 The bidding document is and shall remain the exclusive property of the OWNER without any<br />
right to bidder to use them for any purpose except for the purpose of bidding.<br />
7.0 LANGUAGE OF BID<br />
7.1 The bid prepared by the Bidder and all correspondence/ drawings and documents relating to<br />
the bid exchanged by Bidder and NALCO /RITES shall be written in ENGLISH language. Any<br />
printed literature furnished by the Bidder written in another language should be accompanied<br />
by an ENGLISH translation. In case of any conflict, for the purpose of interpretation of the bid, the<br />
ENGLISH translation shall govern.<br />
8.0 FORMAT AND SIGNING OF BID<br />
8.1 The Bidder shall prepare required number of copies of the bid, clearly marking each ‘Original<br />
Bid’ and ‘Copy of Bid’ as appropriate. In the event of any discrepancy between them, the ‘Original<br />
Bid’ shall govern.<br />
8.2 The original and all copies of the bid shall be typed or written in indelible ink and shall be signed<br />
by the Bidder or a person duly authorized to bind the Bidder to the Contract. The name and<br />
position held by each person signing must be typed or printed below the signature. The person<br />
or persons signing the bid shall initial all pages of the bid, except for unamended printed<br />
literature.<br />
8.3 The complete bid shall be without alterations, interlineations or erasures, except as may be<br />
necessary to correct errors made by the Bidder, in which case such corrections shall be rewritten &<br />
initialed by the person or persons signing the bid.<br />
9.0 MODIFICATION AND WITHDRAWAL OF BIDS<br />
9.1 The Bidder may modify or withdraw his bid after the bid’s submission, provided that the<br />
modification/ withdrawal notice is received by the Owners/ Consultant prior to the bid due date &<br />
time.<br />
The Bidder’s modification or withdrawal notice shall be prepared, sealed, marked and despatched<br />
in accordance with the provisions of Bidding Document. A withdrawal notice may also be sent<br />
Annexure II, Special Instructions to Bidders Page 7 of 9
y Cable or Telefax but must be followed by a signed confirmation copy dated not later than<br />
the deadline for submission of bids.<br />
9.2 No bid shall be modified subsequent to the due date & time or extension, if any, for submission<br />
of bids.<br />
9.3 No bid shall be allowed to be withdrawn in the interval between the deadline for submission of<br />
bids and the expiration of the period of bid validity specified by the Bidder. Withdrawal of a bid<br />
during this interval shall result in the forfeiture of Bidder’s Earnest Money Deposit .<br />
10.0 OPENING OF UN-PRICED BIDS<br />
10.1 Un-priced part of the Bid shall be opened in the RITES, Bhubaneswar Office, in the presence<br />
of Bidder’s representatives (duly authorized by a competent person and having the Letter of<br />
Authority who choose to attend, on date, time as mentioned in the Instructions to Bidders. The<br />
Bidder’s representatives, who are present, shall sign a register evidencing their attendance.<br />
Bidders’ whose bids are not opened for any reason, including non-receipt of original Earnest<br />
Money Deposit, will not be allowed to be present during bid opening.<br />
10.2 The Bidder(s) names, modifications, bid withdrawals and the presence or absence of the<br />
requisite Earnest Money Deposit and such other details as the NALCO/RITES, at its discretion,<br />
may consider appropriate will be announced and recorded at the time of opening of un-priced<br />
bids as specified in the Instruction to Bidders/ Tender Documents.<br />
11.0 OPENING OF PRICE BIDS<br />
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<br />
will be advised of date & venue for the priced bid opening. Bidders may depute their<br />
authorized representative, along with letter of authority to attend price bid opening. The price bids<br />
of those Bidders determined to be not substantially responsive will be rejected and will not be<br />
called for price bid opening.<br />
The Bidder’s names, bid prices, modifications and bid withdrawals and such other details as the<br />
Consultant, at its discretion, may consider appropriate, will be read out at the time of opening of<br />
priced bids of technically and commercially acceptable Bidders.<br />
12.0 COMPARISON OF BIDS<br />
12.1 The Consultant will evaluate and compare bids previously determined to be substantially responsive<br />
pursuant to the provisions of the Bidding Document.<br />
12.2 Arithmetical errors will be rectified on the following basis:-<br />
If there is a discrepancy between the unit price and the total price that is obtained by<br />
multiplying the unit price and quantity, the unit price shall prevail and the total price will be<br />
corrected. If there is a discrepancy between the total amount and the sum of total prices, the sum<br />
of the total prices shall prevail and the total bid amount will be corrected. Further, if there is a<br />
Annexure II, Special Instructions to Bidders Page 8 of 9
discrepancy between the quoted lump sum price, and its separate break-up prices (if any), the<br />
quoted lump sum price shall prevail.<br />
13.0 CONTACTING THE OWNER/ CONSULTANT<br />
13.1 No Bidder shall contact the NALCO / R I T E S on any matter relating to its bid, from the time<br />
of bid opening to the time the Contract is awarded.<br />
13.2 Any efforts by a Bidder to influence the NALCO / RITES in the Owner’s/ Consultant’s bid<br />
evaluation, bid comparison or contract award decisions may result in the rejection of the Bidder’s<br />
bid.<br />
14.0 AWARD CRITERIA<br />
The Owner will award the Contract to the successful Bidder whose bid has been determined to<br />
be the lowest evaluated, responsive bid, provided further that the Bidder is determined to be<br />
qualified to satisfactorily perform the Contract.<br />
15.0 OWNER’S/CONSULTANT’S RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL<br />
BIDS<br />
15.1 NALCO / RITESO reserves the right to accept or reject any bid, and to annul the bidding process<br />
and reject all bids, at any time prior to award of contract, without thereby incurring any liability to<br />
the affected Bidder or Bidders or; any obligations to inform the affected Bidder or Bidders of the<br />
ground for the Owner’s/Consultant’s action.<br />
15.2 The submission of any bid connected with these documents and specifications shall<br />
constitute an agreement that the Bidder shall have no cause for action or claim, against the<br />
Owner for rejection of his bid. The Owner shall always be at liberty to reject or accept any bid or<br />
bids at his sole discretion and any such action will not be called into question and the Bidder shall<br />
have no claim in that regard against the Owner.<br />
16.0 ISSUE OF ORDER<br />
16.1 The Owner will send to the successful bidder B r ief Order/ Work Order incorporating all<br />
the terms and conditions agreed between the parties.<br />
16.2 Within 15 days of receipt of the Order, the Bidder shall sign and return it to the Owner for their<br />
records.<br />
17.0 In case of contradiction between relevant Indian Standards, General Conditions of Contract,<br />
Special Conditions of Contract, Specifications, Drawings, Schedule of Prices / Rates, the following<br />
shall prevail in order of precedence:<br />
i) Brief of Order, Detailed Letter of Acceptance along with Statement of Agreed Variations (if any) and<br />
its enclosures.<br />
ii) Schedule of Rates.<br />
iii) Technical Specifications<br />
iv) Drawings.<br />
v) Addendum to Tender Documents (Commercial).<br />
vi) Tender Document Commercial(Indigenous).<br />
vii) Relevant Indian Standards / Specifications<br />
Annexure II, Special Instructions to Bidders Page 9 of 9
.<br />
TENDER DOCUMENTS<br />
COMMERCIAL (INDIGENOUS)<br />
<strong>NATIONAL</strong> <strong>ALUMINIUM</strong> <strong>COMPANY</strong> <strong>LIMITED</strong><br />
(A GOVT. OF INDIA ENTERPRISE)<br />
REGISTERED OFFICE: NALCO BHAVAN,<br />
P/1, NAYAPALLI,<br />
BHUBANESWAR - 751 061<br />
Tender Documents Commercial (Indigenous) Page 1 of 56
.<br />
GENERAL CONDITIONS OF CONTRACT<br />
CONTENTS<br />
Sl. No. Page No.<br />
1.00 APPLICATION 04<br />
2.00 DEFINITION OF TERMS 04<br />
3.00 CONTRACTOR TO INFORM HIMSELF FULLY 06<br />
4.00 SCOPE OF WORK 07<br />
5.00 DESIGN REQUIREMENTS 08<br />
6.00 CONTRACT PRICE 10<br />
7.00 TAXES 10<br />
8.00 PERFORMANCE BOND 11<br />
9.00 PROTECTIVE PAINTING, PACKING & MARKING 12<br />
10.00 SHIPMENT PARTICULARS 14<br />
11.00 INSURANCE 14<br />
12.00 DELIVERY 15<br />
13.00 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION 15<br />
14.00 IMPORT LICENSE AND FOREIGN EXCHANGE 15<br />
15.00 CONTRACTOR’S DOCUMENTS, DRAWINGS AND 15<br />
INSTRUCTION MANUALS<br />
16.00 MISTAKES IN DRAWINGS 18<br />
17.00 MATERIALS AND WORKMANSHIP 18<br />
18.00 SPARE PARTS AND SPECIAL MAINTENANCE TOOLS 19<br />
19.00 COMPLETENESS OF EQUIPMENT 19<br />
20.00 INSPECTION AND TESTING AT CONTRACTOR’S PREMISES 19<br />
21.00 TESTS ON COMPLETION AND TRIAL RUN AT SITE 21<br />
22.00 TAKING OVER 22<br />
23.00 REJECTION OF DEFECTIVE PLANT 22<br />
24.00 COMPLETION CERTIFICATE & FINAL CERTIFICATE 23<br />
25.00 ENGINEER’S DECISION 25<br />
26.00 CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE 26<br />
PURCHASER OR THE CONTRACTOR<br />
27.00 MINTENANCE AND GUARANTEE - WARRANTY PERIOD 27<br />
28.00 NEGLIGENCE 27<br />
29.00 POWER TO VARY OR OMIT WORK 28<br />
30.00 SETTLEMENT OF DISPUTE 28<br />
31.00 TERMINATION OF CONTRACT 29<br />
32.00 DEDUCTION FROM CONTRACT PRICE 29<br />
33.00 CO-OPERATION WITH OTHER CONTRACTORS AND 30<br />
CONSULTING ENGINEERS<br />
Tender Documents Commercial (Indigenous) Page 2 of 56
.<br />
34.00 ASSIGNMENT OF CONTRACT 30<br />
Sl. No. Page No.<br />
35.00 SUBLETTING OF CONTRACT 31<br />
36.00 SUSPENSION OF WORK 31<br />
37.00 FORCE MAJEURE 31<br />
38.00 PROGRESS REPORT AND PHOTOGRAPHS 32<br />
39.00 PATENT RIGHTS 32<br />
40.00 TRAINING OF ENGINEERS 32<br />
41.00 EFFECT AND JURISDICTION OF CONTRACT 33<br />
42.00 TIME IS THE ESSENCE OF CONTRACT 33<br />
43.00 ERECTION SUPERVISION SERVICES 33<br />
44.00 ERECTION PLANT AND MATERIALS 35<br />
45.00 FOREIGN PERSONNEL 50<br />
46.00 DEATH, BANKRUPTCY ETC. 50<br />
47.00 GRAFTS AND COMMISSION ETC. 51<br />
48.00 COMPLETION OF CONTRACT 51<br />
49.00 DEFENSE OF SUITS 51<br />
50.00 ARBITRATION 51<br />
51.00 CORRESPONDENCE 52<br />
52.00 CONTRACT AGREEMENT 53<br />
53.00 PAYMENTS 53<br />
54.00 MISCELLANEOUS 55<br />
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1.00 APPLICATION<br />
Unless otherwise provided in the Contract Agreement, these General Conditions of Contract shall<br />
govern the work of the annexed Specification.<br />
2.00 DEFINITION OF TERMS<br />
In construing these General Conditions and the annexed Specification, the following words shall<br />
have the meanings herein assigned to them unless there is something in the subject or context in<br />
consistent with such construction.<br />
2.01 The “Owner/Purchaser” shall mean the “National Aluminium Company Limited” , a company<br />
incorporated in India, whose Registered Office is situated at NALCO BHAVAN, P/1, Nayapalli,<br />
Bhubaneswar - 751 061.<br />
2.02 “The Contractor” shall mean person, firm or a company whose tender has been accepted by the<br />
Purchaser and shall include his/its heirs, executors, administrators, representatives and permitted<br />
assigns.<br />
2.03 The term Sub-Contractor used herein refers to a party or parties having a direct contract with the<br />
Contractor to whom any part of the contract has been sublet by the Contractor with the consent in<br />
writing of the Owner and shall include his heirs, executors, administrators, representatives and<br />
assigns.<br />
2.04 The “Engineer” shall mean an officer of the owner/purchaser as may be duly appointed and<br />
authorized in writing by the purchaser to act as the Engineer on its behalf for the purpose of the<br />
contract.<br />
2.05 The `Engineer’s Representative’ shall be the person nominated by the Engineer in writing to act on<br />
his behalf.<br />
2.06 The term `Consultants/Consulting Engineer’ refers to consultant(s) nominated by the Engineer in<br />
writing for the contract and referred to throughout in the Contract Documents by `Consulting<br />
Engineer’ or `Consultant’.<br />
2.07 “The Inspector” shall mean any firm or person including any employee of the owner/purchaser as<br />
may be duly appointed and authorized in writing by the owner/purchaser to inspect plant,<br />
equipment and works included by the Contractor.<br />
2.08 `Plant’, ‘Equipment’, ‘Works’ shall mean and include plant, stores and materials to be provided and<br />
work to be done by the Contractor.<br />
2.09 ‘Contract’ means the Notice Inviting Tenders, Conditions of Tendering, and Tender Form, General<br />
Conditions of Contract, Supplementary Conditions of Contract, Technical Specifications, price<br />
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Schedule of Prices & Quantities, Letter of Intent of Purchaser, Drawings, Subsequent amendments<br />
mutually agreed upon, and agreement to be entered under clause “Contract Agreement” of this<br />
General Condition.<br />
2.10 The `Specification’ shall mean the Specification annexed to these General Conditions and any<br />
subsequent modifications thereof and the drawings and Schedules attached thereto (if any).<br />
2.11 `Site’ means the lands and other places on, under, in or through which the Works are to be<br />
executed or carried out and any other lands or places provided by the Owner for the purpose of the<br />
Contract.<br />
2.12 `Tests on Completion’ shall mean such tests as are prescribed by the Specification and/or tests<br />
mutually agreed upon by the Purchaser and the Contractor to be made by the Contractor after<br />
erection of the equipment to prove satisfactory operation as required by the Specification.<br />
2.13 `Commissioning’ shall mean the first successful operation of the plant and equipment after all initial<br />
adjustments, trials, cleaning and reassembly required at site, if any, have been completed.<br />
2.14 `Acceptance Tests’ shall mean such tests as are required to prove the performance guarantees of<br />
the plant given by the Contractor, before taking over of the plant by the Purchaser.<br />
2.15 ‘Initial Operation’, `Reliability Run’ or ‘Trial Operation’ shall mean continuous operation of the<br />
contract plant and materials under varying loads to furnish proof of satisfactory operation for a<br />
specified period which shall not be less than two (2) weeks.<br />
2.16 ‘Commercial Use’ shall mean that use of the equipment which the Contract contemplates or of<br />
which it is to be commercially capable.<br />
2.17 ‘Warranty Period’ shall mean the period of guarantee as explained under clause `Maintenance and<br />
Guarantee’ of these General Conditions.<br />
2.18 ‘Codes’ shall mean the applicable codes of State or Orissa as on the date of Letter of Intent and<br />
any subsequent modification thereof before the plant has been delivered.<br />
2.19 ‘Month’ shall mean calendar month.<br />
2.20 ‘Notice of Award of Contract’ / ‘Letter of Intent’/ ‘Award Letter shall mean the Purchaser’s letter /<br />
Telex conveying his acceptance of the Tender subject to such reservations as may have been<br />
stated therein.<br />
2.21 ‘Erection Supervision’ shall mean the supervision services rendered or exercised by the Contractor<br />
during the erection of the plant as explained under clause `Erection Supervision Services’ of these<br />
General Conditions.<br />
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2.22 `Writing’ shall include any manuscript, typewritten or printed statement under or over signature or<br />
seal as the case may be.<br />
2.23 ‘Approved’, ‘Subject to Approval’, ‘Satisfactory’, ‘Equal to’ ‘Proper’, ‘As directed’, ‘Where directed’,<br />
‘When directed’ ‘Determined by’, ‘Accepted’, `Permitted’, ‘To approval’, or words phrases of like<br />
import are used, the approval, judgment, direction, etc. is understood to be a function of Consulting<br />
Engineer or Purchaser.<br />
2.24 Words importing `Persons’ shall include firms, companies, corporations and other bodies whether<br />
incorporated or not.<br />
2.25 Words importing the singular only shall also include the plural and vice versa where the context<br />
requires.<br />
2.26 ‘F.O.B.’ shall mean delivery free of expenses to the Purchaser on board the vessel at the port of<br />
shipment.<br />
2.27 ‘F.O.R. Destination’ shall mean delivery free of expenses to the purchaser on rail wagons at<br />
destination Railway Station/Siding as may be named.<br />
2.28 ‘F.O.R. Works’ shall mean loaded and stowed or trimmed, free of expenses to the Purchaser on<br />
board rail wagons at the Contractor’s siding or at the nearest Railway Station for transportation.<br />
2.29 ‘Tonne’ shall mean 1000 kilogram weight, `Gallons’ shall mean imperial gallons unless mentioned<br />
specifically.<br />
2.30 `Manufacturers’ works’ or `Contractor’s works’ shall mean the place of work used by the<br />
manufacturer, their collaborators or approved sub-contractors for the performance of the works.<br />
2.31 Construction of Contract<br />
Terms and conditions not herein defined shall have the same meanings as are assigned to them in<br />
the Indian Sale of Goods Act (Act III of 1930) falling that in the Indian Contract Act (Act IX of 1872)<br />
and falling that in the General Clause Act 1897.<br />
3.00 CONTRACTOR TO INFORM HIMSELF FULLY<br />
The Contractor shall be deemed to have carefully examined the General Conditions, Specification,<br />
Schedules and Drawings and also to have satisfied himself as to the nature and character of the<br />
work to be executed and, where necessary, of the site conditions and other relevant matters and<br />
details. Any information thus had or otherwise obtained from the Purchaser, Consulting Engineer or<br />
the inspector shall not in any way relieve the Contractor from his responsibility for supplying the<br />
plant and equipment and executing the work in terms of the specification including all detail and<br />
incidental works and supply of the all accessories or apparatus which may not have been<br />
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specifically mentioned in the specification or drawings, but otherwise necessary for ensuring<br />
complete erection and safe and efficient commercial working of the plant and equipment. If he shall<br />
have any doubt as to the meaning of any portion of these General Conditions and/or specification,<br />
he shall set forth the particulars thereof and submit them to the Engineer in writing for clarification.<br />
4.0 SCOPE OF WORK<br />
4.01 For Manufacture, Supply & Delivery of Plant & Materials<br />
The Contractor shall design, manufacture and deliver suitably packed the plant, equipment and<br />
materials as described in the attached specification F.O.R. Works/F.O.R. Destination and, if of<br />
foreign origin, F.O.B. port of shipment, as the case may be.<br />
The Contractor shall sell and deliver the said plant, equipment and materials to the Purchaser and<br />
Purchaser shall accept the delivery of and pay for at the price agreed upon between the Purchaser<br />
and the Contractor and upon fulfillment of the terms and conditions hereinafter specified or<br />
subsequent agreed modification thereof.<br />
The Contractor shall inform the Purchaser if the plant, equipment and materials or any part thereof<br />
to be supplied under the scope of work shall be of origin and/or manufactured outside the Union of<br />
India in which case the Contractor shall give a certificate to this effect in the form required by the<br />
Purchaser. This certificate shall be called the `Certificate of Origin’. The foreign currency<br />
component for importing of plant and materials manufactured outside of India shall be specified<br />
and the estimated total C.I.F. value shall also be stated. It is clearly understood that the owner shall<br />
not give any of its import licenses for importation of these items.<br />
The Contractor shall also supply the spare parts and special tools at the quoted price and in<br />
quantities mentioned in clause `Spare Parts and Maintenance Tools’ or subsequent modifications<br />
thereof.<br />
The Contractor shall undertake that supply of necessary spare parts and special tools will be made<br />
available at any time later during the life of the plant. The price of the imported spare parts shall not<br />
be in excess of the landed cost plus a reasonable percentage towards handling charges. The price<br />
for indigenous spare parts shall be at fair market price.<br />
The Contractor shall also undertake that before going out of production of any of the spare parts,<br />
he shall give adequate advance notice to the Purchaser so that sufficient quantity of spare parts<br />
might be procured if the Purchaser so desires. Further, the Contractor shall supply the necessary<br />
drawings and specifications of these spare parts which the Contractor proposes to take off his<br />
production range to enable the Purchaser to arrange manufacture of the spa re parts by other<br />
agency.<br />
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4.02 For Erection Supervision Services<br />
The Contractor has to supply erection supervision personnel to supervise the work of erection of<br />
the plant and equipment to be conducted even by other agencies including owner. Classification<br />
and number of personnel required shall be mutually agreed to. The services would be generally as<br />
specified in Clause `Erection Supervision Services’ hereinafter at Clause No. 43.00<br />
4.03 For Erection of Plant & Materials<br />
The Contractor shall render complete erection services of the plant and materials supplied under<br />
the Contract if so required by the Purchaser. The services to be rendered shall be as generally<br />
described in clause `Erection of Plant and Materials’ hereinafter.<br />
5.00 DESIGN REQUIREMENTS<br />
5.01 All equipment and materials shall be designed and manufactured in conformance with standards<br />
stated hereinafter.<br />
5.02 Wind Load<br />
Structures and outdoor equipment shall be designed to withstand a wind load as set forth in the<br />
latest revision of Indian Standards IS: 875 of the Indian Standards Institution.<br />
5.03 Earthquake<br />
In general IS: 1893 shall be followed. Specific conditions/technical specification shall be referred<br />
for specific design criteria.<br />
5.04 Safety Features<br />
The Contractor shall provide adequate guards for all couplings and other moving parts which could<br />
be considered a hazard. Safety, sentinel and relief valves are to be located or piped in such a<br />
manner as to safeguard personnel and property. All safety devices shall be in accordance with the<br />
applicable Government regulations and requirements.<br />
5.05 Language & Measurement System<br />
All documents pertaining to the contract including specifications, schedules, notices,<br />
correspondence, operating and maintenance instructions, drawings or any other writing shall be in<br />
English language.<br />
All instruments, recorders, etc. will be calibrated in the metric (C.G.S./ M.K.S.) system of units.<br />
Details of calibration will be provided later.<br />
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In drawings or specifications wherever both Metric and British units are indicated, the Contractor<br />
shall indicate the equipment dimensions on both the units. Location marking of all equipment shall<br />
be in Metric Units.<br />
5.06 Accessibility<br />
Special attention shall be given to the design, arrangement and assembly of all equipments to<br />
ensure ease of maintenance and renewal of parts.<br />
5.07 Standard Equipment & Materials and Alternates<br />
a) Equipment, material and erection and other services shall be completed in all respects and<br />
in strict accordance with the specifications, except that alternative proposals may be<br />
submitted where stipulated provisions depart from the Contractor’s Standards, provided<br />
that the substitutions are approved as equivalent by the Engineer and the reasons<br />
therefore are stated by the Contractor in his proposal as a result of such substitution.<br />
b) Any request for substitution after the contract is awarded, shall be accompanied with the<br />
difference in price and such substitution can only be made on approval by the Engineer on<br />
behalf of the Purchaser in writing, provided that such substitution does not cause any<br />
addition to the contract price.<br />
5.08 a) All work shall be done in accordance with the applicable portions of the current editions of<br />
the codes and standards of the respective U.S.A., U.K. National and Technical Societies or<br />
equal or with the standards and codes of the Government of India, and in accordance with<br />
the applicable portions of the following codes and standards in particular:<br />
Indian Boiler Regulations<br />
Indian Electricity Act<br />
Indian Electricity Rules<br />
Indian Factories Act<br />
Indian Explosives Act<br />
Indian Standard Institution (IS)<br />
British Standard Institution (BS)<br />
American Society of Mechanical Engineers (ASME)<br />
Institute of Electrical & Electronics Engineers Inc. (IEEE)<br />
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American Petroleum Institute (API)<br />
American Society of Testing Materials (ASTM)<br />
Hydraulic Institute<br />
National Electrical Manufacturer’s Association (NEMA)<br />
American Water Works Association (AWWA)<br />
American Standards Association (ASA)<br />
American Institute of Steel Constructions (AISC)<br />
National Board of Fire Underwriters<br />
Insulated Power Cable Engineers Association (IPCEA)<br />
All the work must be in accordance with the above mentioned codes or equivalent.<br />
b) Where conflicts occur between any of the laws, rules, regulations, standards, and so forth,<br />
specified herein, the more stringent requirements shall govern the work.<br />
6.00 CONTRACT PRICE<br />
The lump sum prices quoted by the Contractor in his bid with additions and deletions as may be<br />
agreed before signing of the Contract, for the entire scope of the work viz. supply and erection of<br />
equipments covered under the specification and documents shall be treated as the Contract Price.<br />
7.0 TAXES<br />
7.01 The Contractor shall include all taxes, duties, royalty of whatever nature, octroi, other local taxes,<br />
etc., if any, in the quoted price.<br />
7.02 Sales tax or any other tax on material required for the work as also tax on works contract shall be<br />
payable by the Contractor and Owner will not entertain any claim whatsoever.<br />
7.03 Notwithstanding anything contain elsewhere in the contract the Owner shall deduct at source from<br />
the payment due to the contractor the taxes as required under 13(A) of Orisaa Sales Tax Act or<br />
amended from time to time or under any other statute. The amount so deducted shall be paid by<br />
the Owner to the Sales Tax authority as per law. This is for the Contractor to deal with the Sales<br />
Tax authority directly in respect of any claim or refund relating to the above tax and Owner shall not<br />
be liable or responsible for any type of payment or reimbursement in this regard.<br />
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7.04 All benefits of taxes duties by way of credit under CENVAT shall be passed on to the<br />
Owner/Purchaser<br />
8.0 CONTRACT - CUM - PERFORMANCE BOND<br />
GUARANTEE FOR DUE EXECUTION OF THE CONTRACT AND PERFORMANCE DURING THE<br />
GUARANTEE PERIOD<br />
The Contractor within thirty (30) days of award of contract shall furnish a Bond by way of a bank<br />
guarantee to be kept alive till 12 months after successful completion of contract in all respects and<br />
equal to ten percent (10%) of the contract price for faithful and due fulfillment by the Contractor of<br />
all obligations under the terms and conditions of the contract and for fulfilling the terms of<br />
guarantee for a period of 12 months after successful completion.<br />
If during the contract period the bond amount gets reduced on account of any recoveries or<br />
otherwise, the contractor shall furnish a bond covering short fall to bring it to 10% of the contract<br />
value. The form of the aforesaid Bond is enclosed.<br />
9.00 PROTECTIVE PAINTING, PACKING & MARKING<br />
The Contractor and/or Manufacturer shall properly clean and/or send blast equipment and apply an<br />
initial coat of rust inhibitor and a flat shop coat of paint (except shop finished equipment). All shop<br />
primer and paints shall be subject to approval of the Engineer. All closely machined parts shall be<br />
covered with an approved protective coating to prevent deterioration of surfaces during<br />
transportation and storage.<br />
The Contractor shall include and provide for securely protecting and packing the equipment so as<br />
to avoid damage in transit under proper conditions and he shall be responsible for all losses or<br />
damage caused or occasioned by any defect in packing.<br />
All equipments shall be packed in accordance with approved packing specifications. All<br />
equipments and parts susceptible to corrosion by exposure to moisture and all electrical<br />
equipments shall be thoroughly protected against damage during transit and storage. The<br />
Purchaser will take no responsibility for any damage done to the equipment enroute to the “site of<br />
work”, or “place of delivery” whichever may be specified due to the packing being faulty. Special<br />
packing with identification mark on packages should be provided for fragile materials. The<br />
identification marking indicating the name and address of the consignee shall be clearly marked in<br />
indelible ink on two opposite side and top of each of the packages. In addition, the Contractor shall<br />
include in the marking gross and net weights, outer dimensions and cubic measurements.<br />
Each bale or package shall be accompanied by a packing Note quoting specifically the name of the<br />
Contractor, the number and date of contract, the name of the office placing the contract and<br />
nomenclature of contents.<br />
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Dimensions of each package shall not exceed the maximum dimensions of packages which can be<br />
accepted for transport over the `broad gauge system’ of the Railway concerned.<br />
10.0 SHIPMENT PARTICULARS<br />
10.01 Shipments<br />
a) Foreign Items<br />
Responsibility of shipment of plant and equipment shall lie with the Contractor wherever<br />
the contract is for complete supply and installation or supply delivered at site basis. The<br />
Contractor shall notify the Purchaser of the date of each shipment from the port of<br />
embarkation as well as date of arrival of such shipment at designated port of arrival for<br />
information.<br />
Responsibility of cleaning the same in the port including all handling shall lie with the<br />
Contractor. Purchaser will only arrange to pay the customs duty as per information on CIF<br />
values given by the Contractor sufficiently in advance.<br />
The Contractor shall give complete shipping information concerning the weight, size,<br />
content of each package including any other information the Purchaser may require.<br />
b) Indigenous Item<br />
For all contracts for supply and installation or supply delivery at site basis, responsibility of<br />
all transportation from works to site shall lie with the Contractor.<br />
The Contractor shall notify the Owner of the date of each shipment from his works and the<br />
expected date of arrival at the site for information of the Purchaser.<br />
The Contractor shall also give all information concerning the weight, size and content of<br />
each packing including any other information the Purchaser may require.<br />
c) The Contractor shall further be responsible for all inland transportation up to site for foreign<br />
items after clearing through the port. Contractor shall also be responsible for making all<br />
necessary arrangements for loading, unloading and other handling right from his works till<br />
the site and also till the equipment is erected, tested and commissioned. He shall be solely<br />
responsible for proper storage and safe custody of all equipment.<br />
10.02 Shipping Documents<br />
After shipment is affected following documents shall be forwarded to the Purchaser:<br />
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a) Foreign Items<br />
Within seven (7) days of shipment following shall be airmailed to the Purchaser for<br />
purpose of progress payment and necessary arrangement of payment of customs duty.<br />
- Application of payment in standard format of the Owner (3 copies)<br />
- Bill of Lading (5 non-negotiable copies)<br />
- Invoice including break-up for customs purposes (6 copies)<br />
- Packing list (6 copies)<br />
- Pre-dispatch clearance certificate or shipping release, if any (3 copies)<br />
- Test certificates, wherever applicable (3 copies)<br />
- Certificate of origin<br />
b) Indigenous items<br />
- Application for payment in standard format of Purchaser (3 copies)<br />
- Invoice (6 copies)<br />
- Packing list (6 copies)<br />
- Pre-dispatch clearance certificate or shipping Release, if any (3 copies)<br />
- Test Certificates wherever applicable (3 copies)<br />
10.03 Demurrage, Wharfage etc.<br />
All demurrage, wharfage and other expenses incurred due to delayed clearance of the material or<br />
any other reason shall be to the account of the Contractor.<br />
10.04 Consignee<br />
All consignment shall be addressed to and the Bill of Lading and other shipping documents shall be<br />
made in the name of the Purchaser’s Office as may be advised.<br />
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11.0 INSURANCE<br />
11.01 The Owner will arrange for INSURANCE of equipment and material, included under the scope of<br />
contract, to cover -<br />
a) Risk in transit by ship/air between Contractor’s port of shipment/air port and Indian port of<br />
entry.<br />
b) Risks in transit by rail/road during inland transportation up to the Project Site.<br />
c) Risks during storage and erection at the Project Site till the plant is fully commissioned<br />
under an open general insurance policy. The Owner shall intimate the name of Insurance<br />
Company and other details in due course.<br />
11.02 The Contractor shall furnish dispatch particulars of each consignment including its value<br />
immediately to the Insurance Company. If for any delay in intimating of dispatch particulars to the<br />
Insurance Company on the part of the Contractor the claims for damages are rejected, the<br />
contractor shall be fully responsible for replacement of the damaged equipment.<br />
11.03 The risks that are to be covered under the insurance shall include, but not limited to, the loss or<br />
damage in transit, theft, pilferage, riot, civil commotion, weather conditions, accidents of all kinds,<br />
fire, war risk, etc. The scope of such insurance shall cover the entire value of the Works from time<br />
to time.<br />
11.04 In respect of equipment damaged in transit or during erection and commissioning, the Contractor<br />
shall replace them expeditiously and the replacement cost payable by the Owner shall be limited to<br />
the invoice of damaged equipment. In case of consignment received at the project site in outwardly<br />
sound condition of package but found shortage/damage on being opened the liability for free<br />
replacement will be accepted by the Contractor.<br />
It is the responsibility of the Contractor to lodge a claim on the Insurance Co. on behalf of the<br />
Owner. On receipt of all relevant document relating to the claim, Owner will pursue the matter with<br />
the Insurance Co.<br />
12.00 DELIVERY<br />
Notification of delivery or dispatch in regard to each and every consignment shall be made to the<br />
Purchaser immediately after dispatch or delivery. The Contractor shall further supply to the<br />
Consignee a price invoice and packing account of all stores delivered or dispatched by him. All<br />
packages, containers, bundles and loose materials forming part of each and every consignment<br />
shall be described fully in the packing account, and full details of the contents of packages and<br />
quantity of materials shall be given to enable the Consignee to check the stores on arrival at<br />
destination.<br />
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12.01 Passage of Risk/Ownership<br />
The title to all Indian materials, delivered by the contractor, shall pass on to the Purchaser on its<br />
being handed over to the nominated transporter.<br />
13.00 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION (LD)<br />
If the contractor fails in the due performance of the contract to supply / erection/ testing/<br />
commissioning the equipment within the time fixed by the contract or any extension thereof, he<br />
shall be liable at the discretion of the Engineer to the Liquidated damages and not by way of<br />
penalty amounting to one half of one percent (1/2%) of the contract price per week. The<br />
contractor’s liability for delay shall not in any case exceed ten percent (10%) of the total contract<br />
price.<br />
If the Contractor shall fail to supply the equipment or any part thereof within a reasonable period<br />
after the expiry of the appointed time or extended time as may be provided for in the contract, the<br />
provisions in Clause No. 28 “Negligence” shall become operative, in addition to the liability of L.D.<br />
as above.<br />
14.00 IMPORT LICENCE AND FOREIGN EXCHANGE<br />
In case of supply of equipment of indigenous manufacture including any imported components, the<br />
Contractor shall arrange for necessary Import License & Foreign Exchange.<br />
In the event of Contractor requiring Actual User’s for import of equipment and/components,<br />
Purchaser shall arrange for obtaining necessary assistance in this regard. Government<br />
authorization may be required to permit the manufacture of certain equipment. The parties shall<br />
assist each other in every manner possible in securing such authorization.<br />
15.00 CONTRACTOR’S DOCUMENTS, DRAWINGS AND INSTRUCTION MANUALS<br />
15.01 The Contractor shall be responsible for developing detail drawings to adapt his equipment and<br />
materials to the requirement indicated in the tender specification.<br />
15.02 Within a reasonable time not exceeding thirty days from the date of receipt Purchaser’s Letter of<br />
Intent, the Contractor shall provide the Purchaser with the following drawings and data:<br />
a) Six (6) marked up copies of technical particulars to make them conforming to accepted<br />
proposals.<br />
b) Outline drawings of all equipment together with weights and sufficient overall dimensions<br />
to enable the Purchaser to design foundations and structures and associated equipment.<br />
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c) Drawing submission schedule indicating list of all drawings with their respective titles and<br />
dates shall be submitted to the Purchaser. The schedule shall also indicate the latest date<br />
by which Contractor shall furnish all design calculations. The schedule shall be amended<br />
or extended by the Contractor in consultation with the Purchaser as and when necessary.<br />
15.03 Within a stipulated time period the Contractor shall submit for approval of the Purchaser the<br />
following drawings and technical data:<br />
a) Dimensional layout drawings of the plant and equipment to be supplied under the contract<br />
and all certified data relating to the design on foundation structures to enable the<br />
Purchaser to arrange for construction of the necessary foundations and civil works.<br />
All information regarding material and size of anchor bolt, nuts, sleeves, inserts and<br />
supports which shall have to be embedded in concrete shall be furnished in the detailed<br />
foundation drawing.<br />
b) Dimensional drawings showing individual equipment being supplied under the contract,<br />
method and sizes of connections to the Purchaser’s other equipment, giving also the limits<br />
of variations of the dimensions.<br />
c) All efficiency and characteristic curves required under the specification.<br />
d) Schematic drawings of all wirings, connections and interlocking diagrams showing the<br />
points where the connections have to be made by the Purchaser.<br />
e) Necessary structural and other calculations and data required for demonstrating fully that<br />
all parts of the equipment to be furnished shall conform to the provisions and intent of the<br />
contract.<br />
The Contractor shall submit six (6) prints of each drawing for approval. Two (2) prints shall be<br />
forwarded to the Purchaser and four (4) prints shall be forwarded to the Consulting Engineer.<br />
When prints of drawings have been marked “Approved except as noted, Resubmission required”<br />
the Contractor shall make necessary corrections and again submit corrected copies for approval as<br />
per details stipulated. Further revision will be shown by number, date and subject in a revision<br />
block.<br />
Upon receipt of the prints which have been marked “Approved” or “Approved except as noted:<br />
Forward Final drawing” the Contractor shall furnish within a reasonable time fourteen (14)<br />
additional prints of each of drawings and one (1) reproducible transparency after minor corrections,<br />
if any, to the Purchaser.<br />
Relevant civil construction drawings if felt necessary by Consulting Engineer, shall be forwarded to<br />
the Contractor in triplicate. He shall review incorporation of information furnished by him, such as,<br />
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anchor bolt location, elevation etc. and return one certified copy each to the Purchaser and to the<br />
Consulting Engineer.<br />
Any manufacturing work in connection with the equipment prior to the approval of drawings shall be<br />
at the Contractor’s risk. The Contractor shall make any change in the designs, with prior approval<br />
of the Engineer, which are necessary to make the equipment conform to the provisions and intent<br />
of the contract, without additional cost to the Purchaser. Approval of Contractor’s drawings shall<br />
not be held to relieve the Contractor of any part of Contractor’s obligations to meet all the<br />
requirements of the contract or of the responsibility for the correctness of the Contractor’s<br />
drawings.<br />
15.04 The details to be furnished shall include, but not restricted to the following:<br />
a) Finals plans and layout giving complete details against the above mentioned arrangement<br />
plans including foundations plans.<br />
b) Assembly, sub-assembly and sectional drawings of every equipment.<br />
c) Complete cabling drawing giving details of cables required, terminal details, layout of<br />
trenches etc.<br />
d) Detailed wiring diagrams and arrangements of conduits for wiring various controls and<br />
instruments up to the required points.<br />
e) Shop drawings of all parts of equipment requiring repairing or replacements.<br />
f) A complete list of special erection tools and tackles required for complete assembly.<br />
15.05 Complete spare part hand books with details and diagrams, separate recommendations shall be<br />
made for the parts required for first one year of operation of important equipment and sent to<br />
Engineer for approval. Parts requiring frequent replacement shall be listed separately from parts<br />
required for ensuring reliability in unforeseen emergencies. On finalization ten (10) set of such<br />
spare part hand books shall be furnished to the Engineer.<br />
15.06 Assembly and erection instruction within a reasonable time after signing of the contract but at least<br />
three (3) months before starting erection the Contractor shall furnish ten (10) sets of the following<br />
for the use of Purchaser’s field Engineers:<br />
a) Descriptive literature and drawings to illustrate the working principles, method of assembly<br />
and dismantling.<br />
b) Instruction book for proper erection and assembly of all equipment and necessary<br />
instructions for checking and recording proper assembly of the plant.<br />
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Erection schedule giving the sequence of erection with reference to package/ assembly/<br />
sub-assembly identification.<br />
c) Instruction sheets for proper balancing, alignment, adjustment, checking and calibrations<br />
as may be necessary.<br />
15.07 All drawings and technical data are to be furnished in English language only.<br />
15.08 Final Drawings and Operation Maintenance Manuals<br />
Before completion of the work, the Contractor shall furnish fourteen (14) complete sets of prints<br />
and one (1) reproducible transparency of all detailed drawings of the equipment actually supplied<br />
and as erected and assembled at site. In addition ten (10) sets of comprehensive manuals for use<br />
in the operation and maintenance of the plant shall be supplied at least six (6) months before the<br />
actual commissioning date to the Engineer.<br />
15.09 Seven (7) copies of monthly fabrication progress report for all equipment and material shall be<br />
supplied to the Engineer.<br />
16.00 MISTAKES IN DRAWINGS<br />
The Contractor shall be responsible for and shall pay for any alterations of the work due to any<br />
discrepancies, errors or omissions in the drawings or other particulars supplied by him whether<br />
such drawings or particulars have been approved by the Engineer or not.<br />
If any dimensions figured upon a drawing or a plan differ from those obtained by scaling the<br />
drawing or plan the dimensions as figured upon the drawing or plan shall be taken as correct.<br />
17.00 MATERIALS AND WORKMANSHIP<br />
All materials used in the manufacture of the equipment shall be selected from the best available for<br />
the purpose, considering strength, durability and best engineering practice. Liberal factors of safety<br />
shall be used through out the design and specially in the design of all parts subject to alternating<br />
stresses or shocks.<br />
All the work shall be performed and completed in a thorough workmanship like manner and shall<br />
follow the best modern practice in the manufacture of high grade equipment notwithstanding any<br />
omissions in the specifications.<br />
Castings shall be free from holes, flaws, cracks or other defects and shall be smooth, close grained<br />
and of true forms and dimensions. No plugged or filled up holes or other defects will ordinarily be<br />
allowed. Such castings are liable to be rejected.<br />
However, the Contractor may rectify minor casting defects by welding or other method in<br />
accordance with the standard manufacturing practice provided such rectification does not affect the<br />
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strength of the casting or impair the efficient working of the plant and prior approval of the<br />
Purchaser is obtained for the same.<br />
18.00 SPARE PARTS AND SPECIAL MAINTENANCE TOOLS<br />
18.01 The spare parts as required for the equipment under supply are listed in respective specification.<br />
The list is not exhaustive but only indicative.<br />
The Contractor shall also supply list of Guaranteed Spares for two years normal operation<br />
indicating parts name, catalogue no., quantity and unit prices on project site delivery basis. If any<br />
short fall is noticed during 2 years from the date of commissioning the same shall be supplied free<br />
of cost by the Contractor.<br />
18.02 In case of machinery and plant, the Contractor shall include provision for such tools as he<br />
recommends to be absolutely essential for proper maintenance and repair of the plant. A detailed<br />
list of the tools along with the itemized prices shall be submitted along with the tender. In the<br />
absence of this list, the tender is liable to be rejected. One new set of all special tools for<br />
maintenance for each type of equipment shall be furnished by the Contractor at his own expense<br />
and shall be dispatched along with the equipment.<br />
18.03 The contractor shall also undertake that supplies of necessary maintenance equipment and spare<br />
parts will be made available for the life of the plant offered through his Agents on a continuous<br />
basis at reasonable price.<br />
19.00 COMPLETENESS OF EQUIPMENT<br />
The equipment shall be complete in every respect with all mountings, fixtures and standard<br />
accessories which are normally supplied even though not specifically detailed in the specification.<br />
The Contractor shall not be eligible for any extra payment in respect of such mountings, fittings,<br />
fixtures and accessories which are needed for safe operation of the equipment as required by<br />
applicable codes of the country though they may not have been included in the contract.<br />
All similar component parts of similar equipment supplied shall be interchangeable with one<br />
another.<br />
The various equipment supplied under this contract shall be subject to the Purchaser’s approval<br />
20.00 INSPECTION AND TESTING AT CONTRACTOR’S PREMISES<br />
The Engineer and his duly authorized representative shall have at all reasonable times access to<br />
the Contractor’s /Sub-contractor’s premises of works, and shall have the power at all reasonable<br />
times to inspect drawings of any portion of the work or examine the materials and workmanship of<br />
the plant during its manufacture there and if part of the plant is being manufactured on other<br />
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premises, the Contractor shall obtain for the Engineer and his duly authorized representative<br />
permission to inspect as if the plant is manufactured on the Contractor’s premises.<br />
The Engineer shall on giving seven (7) days notice in writing to the Contractor setting out any<br />
grounds of objections which he may have in respect of the work, be at liberty to reject any drawings<br />
& all or any part of workmanship if the subject of any of the said grounds of objection, which in his<br />
opinion are not in accordance with the contract. The Contractor shall give due consideration to<br />
such objections and shall either make the modifications that may be necessary to meet the said<br />
objections or shall confirm in writing to the Engineer giving therein that no modifications are<br />
necessary to comply with the contract.<br />
The Contractor shall give the Engineer and his duly authorized representatives notice of any<br />
material being ready for testing and the Engineer or the said representative shall (unless the<br />
inspection of tests is voluntarily waived), on giving twenty four (24) hours previous notice in writing<br />
to the Contractor, attend at the Contractor’s premises (as the case may be) within fifteen (15) days<br />
of the date on which the material is notified as being ready failing which visit, the Contractor may<br />
proceed with the tests which shall be deemed to have been made in the Engineer’s presence. All<br />
standard shop tests, physical and chemical tests required by the Standards or as may be<br />
prescribed or approved by the Engineer shall be conducted by the Contractor. The Engineer<br />
reserves the right to waive any of the above test requirement and to prescribe new test required if<br />
found necessary to expedite the work or to conform to the latest and best practice. Definitions,<br />
methods of measurement, calibration of instruments and required procedure as referred in the<br />
above standard and/or those approved by the Engineer as equivalent shall be followed. The<br />
Contractor shall forthwith forward to the Engineer duly certified copies of the test certificates in<br />
quadruplicate (one copy to the Purchaser and three copies to the consulting Engineer) for<br />
approval. Further ten (10) copies of the shop test certificate shall be bound with the instruction<br />
manuals referred to in clause “Contractor’s documents, drawings and instruction manuals”.<br />
In all cases where contract provides for tests, whether at the premises or works of the Contractor<br />
or any sub-contractor, the Contractor, except where otherwise specified shall provide free of<br />
charge to the Purchaser, such labor, materials, electricity, fuel, water, stores, apparatus and<br />
instruments as may reasonably be demanded to carry out efficiently such tests of the plant, in<br />
accordance with the contract and shall give facilities to the Engineer or his authorized<br />
representative to accomplish such testing.<br />
When the tests have been satisfactorily completed in the Contractor/Sub-contractor’s Works, the<br />
Engineer shall issue a certificate to that effect within fifteen (15) days after completion of test, but if<br />
the tests were not witnessed by the Engineer or his representative the certificate would be issued<br />
within fifteen (15) days of the receipt of the test certificates by the Engineer. No plant shall be<br />
transported before such a certificate has been issued. The satisfactory completion of these tests or<br />
the issue of this certificate shall not bind the Purchaser to accept the plant should it on further tests<br />
after erection, be found not to comply with the contract provisions.<br />
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21.00 TESTS ON COMPLETION AND TRIAL RUN AT SITE<br />
Where possible all tests shall be carried out before dispatch. Should, however, it become<br />
necessary for the final tests as to performance and guarantees to be held over until the plant is<br />
erected at site, they shall be carried out as per agreed procedure within two (2) months or such<br />
time as may be considered reasonable by the Purchaser after commissioning of the equipment.<br />
Inspection and test at site during erection and on completion of erection shall be carried out on any<br />
plant and equipment to satisfy the guaranteed performance of each equipment and the whole<br />
installation as set forth below:<br />
Individual equipment tests:<br />
(I) Inspection and checking of units<br />
(II) Placing in operation<br />
(II) Initial operation<br />
(IV) Reliability tests<br />
(V) Efficiency and consumption tests<br />
(VI) Load tests<br />
The sequence of tests for individual equipment shall be as mutually agreed to between the<br />
Contractor and the Engineer.<br />
Duration of the trial operation of the complete equipment shall be 30 continuous days with available<br />
wagon rakes during this period as mutually agreed and decided. The acceptance test shall be<br />
carried out within two (2) months after the trial run has been satisfactorily completed. Any delay for<br />
carrying out these works for force majeure reasons shall be given due consideration. Should the<br />
result of these tests not come within the margin specified, the test shall, if required, be repeated<br />
after necessary rectification measures recommended by the Contractor within one (1) month from<br />
the date of plant is ready for retest, and the Contractor shall repay to the Purchaser all reasonable<br />
expenses which he may be put to by such tests.<br />
The performance and acceptance tests of the complete installation shall be carried out to prove the<br />
guarantees specified for different equipment. These tests shall be made in accordance with<br />
established and approved procedures. The Contractor shall submit within reasonable time after the<br />
award of contract, detailed procedure for conductance of all tests for approval of the Engineer. The<br />
procedure shall include the following information for such test:<br />
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(I) Loads at which tests will be conducted.<br />
(II) Time and durations of each test.<br />
(II) Instrument locations shown by a schematic diagram for each test. (Calibration certificates<br />
for each instrument shall be furnished before commencement of test).<br />
(IV) All formulas, calculations, conversion factors, correction curves, etc. to be used for test<br />
conductance.<br />
(V) Sample test report forms, and data sheet that will be used to record test results and<br />
valuation of final results.<br />
On completion of all tests, the overall efficiency of the plant shall be determined in accordance with<br />
the procedure mutually agreed upon between the Contractor and the Engineer unless otherwise<br />
covered under the Standards and Specification.<br />
In all cases, where the contract provides for test at the site, the Purchaser, except where otherwise<br />
specified, shall provide, free of charge, such labor, materials, fuel, water, electricity, lubricants as<br />
may be required from time to time and as may reasonably be demanded to carry out such tests of<br />
the plant, material or workmanship in accordance with the contract. Any special apparatus and<br />
precision instruments required for site test shall be provided by the Contractor.<br />
If for any reason, other than the fault of the contractor performance and acceptance tests for any<br />
unit shall not be carried out within sixty (60) days of notice by the Contractor to the Purchaser of<br />
the unit being ready for tests, then the Purchaser will issue an acceptance certificate on the last<br />
day of such period and payments due to the Contractor on acceptance shall be made, but<br />
nevertheless the Contractor, shall if called upon to do so by the Purchaser, within a period twelve<br />
(12) months from the said last date, make the said tests on the same terms as provided in the<br />
contract.<br />
22.00 TAKING OVER<br />
Upon successful completion of all the tests to be performed at site on equipment and systems<br />
furnished and erected by the Contractor, the Engineer shall Issue to the Contractor a taking over<br />
certificate as a proof of the final acceptance of the equipment. Such certificate shall not relieve the<br />
Contractor of any of his obligations which otherwise survive by terms and conditions of the contract<br />
after issuance of such certificate.<br />
23.00 REJECTION OF DEFECTIVE PLANT<br />
If the completed plant or any portion thereof, it is taken over under the clause ‘Taking Over’, be<br />
found defective or fails to fulfill the requirements of the contract, the Engineer shall give the<br />
Contractor notice selling forth particulars of such defects or failure, and the Contractor shall forth<br />
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wile make the defective plant good or to make it comply with the requirements of the contract.<br />
Should he fail to do so within a reasonable time, the Purchaser may reject and, replace at the cost<br />
of the Contractor the whole or any portion of the plant as the case may be, which is defective or<br />
fails to fulfill the requirements of the Contract. Such replacement shall be carried out by the<br />
Purchaser within a reasonable time and at a reasonable price, and where reasonably possible to<br />
the same specification and under comparative condition. The Contractor’s full and extreme liability<br />
under the clause shall be satisfied by the payment to the purchaser of the original contract price<br />
including charges of erection and/or supervision of erection plus the difference if any between the<br />
replacement price of the equipment including charges for erection and /or supervision of erection<br />
and the original contract price including charges for erection and / or supervision of erection in<br />
respect of such defective plant.<br />
In the event of such rejection, the Purchaser shall have the right to operate any and all equipment<br />
as soon as and as long as it is in operating condition, whether or not, such equipment has been<br />
accepted as complete and satisfactory, to enable him to obtain necessary replacement, except that<br />
this shall not be construed to permit operation of any equipment which may become damaged by<br />
such operation before any required alternations or repairs and/or replacement have been made. All<br />
repairs or alternations or replacement required of the Contractor shall be made by the Contractor at<br />
such times as directed and in such manner as will cause the minimum interruption in the use of the<br />
equipment by the Purchaser. Should the Purchaser not so replace the rejected plant within a<br />
reasonable time, the Contractor’s full and extreme liability under his clause will be satisfied by the<br />
repayment of all money paid by the Purchaser to him in respect of such plant.<br />
Nothing in this clause shall be deemed to deprive the Purchaser or affect any rights under the<br />
contract which he may otherwise have in respect of such defects or deficiencies or in any way<br />
relieve the Contractor of his obligations under the contract.<br />
24.00 COMPLETION CERTIFICATE & FINAL CERTIFICATE<br />
24.01 Application for Completion Certificate<br />
When the contractor fulfils his obligation under the contract he shall be eligible to apply for<br />
completion certificate in respect of the work by submitting the completion documents along with<br />
such application for completion certificate.<br />
The owner or his representative shall normally issue to the Contractor the completion certificate<br />
within one month after receiving an application from the Contractor after verifying from the<br />
completion documents and satisfying himself that the work has been completed in accordance with<br />
and as set out in the construction and erection drawings, and the contract documents.<br />
The contractor, after obtaining the completion certificate, is eligible to present the final bill for the<br />
work executed by him under the terms of contract.<br />
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24.02 Completion Certificate<br />
Within one month of the completion of work in all respects the Contractor, shall be furnished with a<br />
certificate by the owner or his representative of such completion but no completion certificate shall<br />
be give nor shall the work be deemed to have been executed until all scaffoldings surplus material<br />
and rubbish is cleared off the site completely nor until the work shall have been measured by the<br />
Engineer, whose measurement shall be binding and conclusive. The work will not be considered as<br />
complete and taken over by the Owner, until all the temporary works, labor and staff colonies etc.<br />
constructed are removed and work site cleared to the satisfaction of the Engineer.<br />
If the Contractor shall fall to comply with the requirements of this clause on or before the date fixed<br />
for the completion of the work, the Engineer may at the expenses of the Contractor remove such<br />
scaffoldings, surplus materials and rubbish and dispose off the same as he thinks fit and clean off<br />
such dirt as aforesaid, and the Contractor shall forthwith pay the amount of all expenses so<br />
incurred and shall have not claim in respect of any such scaffolding or surplus materials as<br />
aforesaid except for any sum actually realized by the sale thereof.<br />
Completion Certificate shall be in 3 parts as follows:<br />
1) Physical/Mechanical completion work.<br />
2) Satisfactory completion of commissioning of equipment with load.<br />
3) Satisfactory completion of guarantee.<br />
The Contractor shall clearly indicate the 3 dates separately.<br />
24.03 Completion Documents<br />
For the purpose of clause 24, the following documents will be deemed to form the completion<br />
documents:<br />
(i) The technical documents according to which the work was carried out.<br />
(ii) Three sets of construction drawings showing therein the modification and corrections<br />
made during the course of execution and signed by the Engineer.<br />
(ii) Completion Certificate for embedded and ‘Covered-up’ works.<br />
(iv) Certificates of final levels as set out for various works.<br />
(v) Certificates of test performed for various works.<br />
(vi) Materials appropriation statement for the materials issued by the owner for the works and<br />
list of surplus materials returned to the owner’s store duly supported by necessary<br />
documents.<br />
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(vi) Physical / Mechanical completion work.<br />
(viii) Satisfactory completion of commissioning of equipments with load.<br />
(ix) Satisfactory completion of guarantee.<br />
The contractor shall clearly indicate the 3 dates separately.<br />
24.04 Final Decision and Final Certificate<br />
Upon the expiration of the period of liability and subject to the Engineer being satisfied that the<br />
works have been duly maintained by the Contractors during monsoon or such period as herein<br />
provided in clause 8.00 and that the Contractor has in all respect duly made up all subsidence and<br />
performed all his obligations under the contract, the Engineer shall (without prejudice to the right of<br />
the Owner to retain the provision of relevant clause hereof) otherwise give a certificate, herein<br />
referred to as the final certificate, to that effect and the Contractor shall not be considered to have<br />
fulfilled the whole of his obligations under the contract until Final Certificate shall have been given<br />
by the Engineer not withstanding any previous entry upon the work and taking possession, working<br />
or using of the same or any part thereof by the Owner.<br />
24.05 Certificate and Payments No Evidence of Completion<br />
Except the final certificate, no other certificates or payment against a certificate or on general<br />
account shall be taken to be an admission by the Owner of the due performance of the Contract or<br />
any part thereof or of occupancy or validity of any claim by the Contractor.<br />
25.00 ENGINEER’S DECISION<br />
In respect of all matters which are left to the decision of the Engineer the Engineer shall, if so<br />
required to do so by the Contractor give in writing a decision there on to the Contractor. All<br />
decisions of the Engineer shall be binding on the Contract.<br />
26.00 CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE PURCHASER OR THE CONTRACTOR<br />
No Certificate of the Engineer on account, nor any sum paid on account by the Purchaser, nor any<br />
extension of time for the execution of the works by the Contractor shall affect or prejudice the rights<br />
of the Purchaser against the Contractor or relieve the Contractor of his obligations of the materials<br />
supplied and no certificate shall create liability for the Purchaser to pay for alterations,<br />
amendments, variations of additional work, not ordered in writing by the Engineer or discharge the<br />
liability of the Contractor for payment of damages, whether due, ascertained or certified or not to<br />
any sum against the payment of which he is bound to Indemnify the Purchaser, nor shall any such<br />
certificate nor the acceptance by him or any sum paid on account or otherwise, affect or prejudice<br />
the rights of the Contractor against the Purchaser.<br />
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27.00 MAINTENANCE AND GUARANTEE – WARRANTY PERIOD<br />
The Contractor shall guarantee in respect of the plant and materials to be furnished by him the<br />
following:<br />
(a) All equipment shall be free from any defect due to faulty design, materials and/or<br />
workmanship.<br />
(b) The equipment shall operate satisfactorily and the performance and efficiencies of the<br />
equipments shall not be less than the respective guaranteed values.<br />
(c) The efficiencies, temperature rises and other performance data furnished for the<br />
equipment.<br />
The guarantees have to be furnished on forms approved by the Engineer and shall be signed by<br />
the Contractor and / or his sub-contractor.<br />
If the Contractor finds, after his tender is accepted, that a variation in work, construction technique<br />
or the quality of materials is necessary to fulfill the guarantees called for, such variations may be<br />
made with the approval of the Engineer, provided the request for changes is made before signing<br />
the contract the changes are to be made without any increase in the contract price.<br />
The above guarantees shall be valid for a period of twelve (12) calendar months commencing<br />
immediately on the satisfactory completion of the final tests at site or thirty six (36) months after<br />
the last consignment to complete the plant is received at site,, whichever may be earlier. This<br />
period of the guarantee shall be called the ‘Warranty period’. During this period, the contractor’s<br />
liability shall be limited to the replacement of any defective parts that may develop in plant of his<br />
own manufacture of those of his sub-contractor’s under the conditions provided for by the contract<br />
under proper use and arising solely from faulty design, materials or workmanship provided always<br />
that such defective parts as are not repairable at site, and are not essential in the meantime in the<br />
commercial use of the plant, are promptly returned to the Contractors Works unless otherwise<br />
arranged. All such replacements of defective parts mentioned above shall be made free of costs at<br />
site by the Contractor and the return of the defective parts to the Contractor’s works shall be the<br />
Contractor’s responsibility and shall be made at his expense. The Purchaser will, however, render<br />
such assistance in this matter as well expedite the same. In the case of defective parts not<br />
repairable at site but essential in the meantime for the commercial use of the plant, the Contractor<br />
shall replace at site free of cost to the Purchaser the said defective parts before the defective parts<br />
are removed to his Works.<br />
If for rectification or replacement of any part of equipment or work due to defective materials,<br />
manufacture or design, the services of the Contractor personnel are requisitioned within the<br />
guarantee period, these services shall be made available free of any cost to the Purchaser.<br />
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If it becomes necessary for the contractor to replace or renew any defective portions of the plant<br />
under this clause, the provisions of this clause will apply to the portions of the plants so replaced or<br />
renewed until the expiration of six (6) months from the date of such replacement or renewal or until<br />
the end of the above mentioned period of twelve (12) months, whichever may be later. If any defect<br />
be not remedied within a reasonable time, the Purchaser may proceed to do the work at the<br />
Contractor’s risk and expenses but without prejudice to any other rights which the Purchaser may<br />
have against the Contractor in respect of such defects.<br />
If the replacement or renewals are of such character as may affect the efficiency of the plant, the<br />
Purchaser shall have the right to give the Contractor within one month of such replacement or<br />
renewal, notice in writing that ‘tests’ on completion be made in which case such tests be carriedout<br />
as provided in clause “tests a completion” and trial run at site hereof. Should such test show<br />
that the plant sustains the guarantee given in the Contract; the cost of the tests will be borne by the<br />
Purchaser. Should the guarantee be not sustained, the cost of the test shall be borne by the<br />
Contractor.<br />
All replacement or renewals to be carried out by contractor during the maintenance period shall be<br />
subject to such clauses of these general conditions as may be considered reasonable by the<br />
Engineer.<br />
Until the final certificate has been issued, the Contractor shall have the right of entry, at his own<br />
risk and expenses by himself or his duly authorized representatives whose names shall previously<br />
have been communicated in writing to the Engineer, at all reasonable working hours upon all<br />
necessary parts of the works, for the purpose of inspecting the working and the records of the plant<br />
and taking notes there from and, if he desires, at his own expense making any tests, subject to the<br />
approval of the Engineer that work will not be unreasonably withheld.<br />
The issue of the Engineer’s Certificate referred to in clause ‘Certificate of Engineer’ shall in no way<br />
expect the contractor from the provision of this clause.<br />
At the end of the maintenance period, the liability ceases. In respect of goods not covered by the<br />
first paragraph of this clause, the Purchaser shall be entitled to the benefit of any guarantee given<br />
to the Contractor by the original supplier or manufacturer of such goods.<br />
28.00 NEGLIGENCE<br />
If the Contractor neglects to execute the work with due diligence and expedition or refuses or<br />
neglect to comply with any reasonable orders given to him in writing by the Engineer in connection<br />
with the work, or contravene the provisions of the contract, the Purchaser may give notice in writing<br />
to the Contractor calling upon him to make good the failure, neglect or contravention complained or<br />
should the Contractor fail to comply with such notice within a period considered reasonable by the<br />
Purchaser from the date of service thereof, in the case of failure, neglect or contravention capable<br />
of being made good within that time or otherwise within such time as may in the opinion or the<br />
Purchaser be reasonably necessary for making it good, then and in such case the Purchaser shall<br />
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have the option and be at liberty to take the work wholly or in part, out of the Contractor’s hand and<br />
may carry on the work envisaged in the contract at a price with any other person or persons to<br />
execute the same or any part thereof and provide any other materials, tools, tackle or labor for the<br />
purpose of completing the works or part thereof. In such event the Purchaser shall without being<br />
responsible to the Contractor for fair wear and tear of the same be entitled to seize and take<br />
possession and have free use of all materials, tools, tackle or other things which may be on the<br />
site, for use at any time in connection with the work to the exclusion of any right of the Contractor<br />
over the same and the Purchaser shall be entitled to retain and apply and balance sum which may<br />
otherwise be then due on the contract by him to the Contractor or such part thereof as may be<br />
necessary, to the payment of the cost of execution of such work as aforesaid.<br />
If the cost of executing the work as aforesaid shall exceed the balance due to the Contractor and<br />
the Contractor fails to make good the deficit, the said materials, tools, tackle, construction plant or<br />
other things, the property of the Contractor as may not have been used up in the completion of the<br />
works, may be sold by the Purchaser and the proceeds applied towards the payment of such<br />
difference and the cost of an incidental to such sale. Any outstanding balance existing after<br />
crediting the proceeds of such sale shall be paid by the Contractor on the certificate of the<br />
Engineer. But when all expenses cost and charges incurred in the completion of the work are paid<br />
by the Contractor, all such materials, tools, tackle, construction plant or other things not used up in<br />
the completion of the works and remaining unsold shall be removed by the Contractor. If the<br />
proceeds of the above sale of the Contractor’s materials, tools, tackle, construction plant etc. are<br />
insufficient to cover the executing the aforesaid work, the balance remaining after crediting the<br />
proceeds of such sale shall be recoverable from the Contractor by encashing the Bank<br />
Guarantee/available/ any other money payable by Purchaser or by action of law.<br />
Not withstanding anything contained above, the Purchaser may determine the contract due to any<br />
breach or failure of the Contractor, without notice before determining the contract as above, if in the<br />
opinion of the Purchaser, the default or defaults committed by the Contractor is/are curable and<br />
can be cured by the Contractor if an opportunity is given to him, then the owner may issue a notice<br />
in writing calling upon the Contractor to cure the default within such time as may be specified in the<br />
notice.<br />
In the event of termination, the security deposit will be forfeited without reference to the Contractor<br />
and if no amount is available towards Security Deposit, an identical amount is recoverable from the<br />
contractor.<br />
29.00 POWER TO VARY OR OMIT WORK<br />
No alternations, amendments, omissions, additions, suspensions or variations of the work<br />
hereinafter referred to as ‘Variations’, under the contract shall be made by the Contractor except as<br />
directed in writing by the Engineer, but the Engineer shall have full power, subject to the provision<br />
hereinafter contained from time to time during the execution of the contract by notice in writing, to<br />
instruct the Contractor to make such variation without prejudice to the contract and the Contractor<br />
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shall carry out such variation and be bound by the same conditions as far as applicable, as though<br />
the said variation occurred in the contract.<br />
If any suggested variations would, in the opinion of the Contractor, if carried out prevent him from<br />
fulfilling any of his obligations or guarantees under the contract, he shall notify the Engineer thereof<br />
within 10 days in writing and the Engineer shall decide forthwith whether or not the same shall be<br />
carried out and if the Engineer confirms his instructions, the contractor’s obligations and<br />
guarantees shall be modified to such and extent as may be justified. In the absence of any such<br />
notification, the Contractor shall be bound to carry out the suggested variations without any<br />
additional financial implication to Purchaser and it will amount to an absolute waiver of any claim<br />
whatsoever.<br />
30.00 SETTLEMENT OF DISPUTE<br />
30.01 Except as otherwise specifically provided in the Contract all disputes concerning question of fact<br />
arising under the Contract s hall be decided by the Engineer subject to a written appeal by the<br />
Contractor to the Engineer, whose decision shall be final to the parties hereto.<br />
30.02 Any disputes or differences including those considered as such by only one of the parties arising<br />
out of or in connection with the Contract shall be to the extent possible settled amicably between<br />
the parties.<br />
30.03 If amicable settlement can not be reached then unresolved disputed issues may be settled by<br />
arbitration as provided subsequently.<br />
31.00 TERMINATION OF CONTRACT<br />
Notwithstanding anything contained elsewhere in this contract, if at any time during the term of this<br />
contract the plans of the Government of India and/ or the State Government change for any<br />
reason, the Purchaser shall have the right to terminate the Contract by notice to the Contractor by<br />
a registered letter. In respect of such changes the material that is complete as ready for<br />
transportation within thirty (30) days after such notice, Purchaser agrees to accept delivery thereof<br />
at the contract price and terms. In the case of the remainder of the undeliverable material, the<br />
Purchaser may elect (a) to have any part thereof completed and take delivery thereof at the<br />
contract price and (b) to cancel the residue (if any) and pay to the Contractor aprorated amount of<br />
the contract price based upon the state of completion to be certified by him. The Contractor shall<br />
deliver all such material in process of manufacture to the Purchaser and shall return to the<br />
Purchaser any funds remaining to the Purchaser’s credit. No payment shall be made by the<br />
Purchaser for any material not yet in process of manufacture on the date of notice of cancellation is<br />
received.<br />
32.00 DEDUCTION FROM CONTRACT PRICE<br />
All costs, damages or expenses which the Purchaser may have paid, for which under the contract<br />
Contractor is liable, may be deducted by the Purchaser from any money due or be coming due by<br />
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him to the Contractor under the contract, or may be recovered by action of law or otherwise from<br />
the Contractor. Further all legal and statutory deductions will be made and the Contractor is not<br />
entitled to any reimbursement or claim what-so-ever except only a tax deduction certificate.<br />
In the event of recovery to the necessary extent becoming impossible owing to insufficiency of the<br />
performance bond and withheld amounts, the balance due to the purchaser, may be recovered in<br />
any way the Purchaser may deem fit.<br />
33.00 CO-OPERATION WITH OTHER CONTRACTORS AND CONSULTING ENGINEERS<br />
The Contractor shall agree to co-operate with the Purchaser’s other contractors and Consulting<br />
Engineers for associated equipment and freely exchange with them such technical Information as<br />
is necessary to obtain the most efficient and economical design and to avoid unnecessary<br />
duplication of equipment. No remuneration shall be claimed from the Purchaser for such technical<br />
cooperation. The Purchaser and consulting Engineer shall be provided with two (2) copies each of<br />
all correspondence addressed by the Contractor to other Contractors in respect to such exchange<br />
of technical information.<br />
If any part of the Contractor’s work depends for proper execution or results upon the work of any<br />
other Contractor, the Contractor shall inspect and promptly report in writing to the engineer any<br />
defects; in such works that render it unsuitable for such proper execution and results. His failure to<br />
so inspect and report shall constitute an acceptance of the other Contractor’s work as fit and<br />
proper for the reception of his work, except as to defects which may develop in the other<br />
Contractor’s work after the proper execution of his work.<br />
34.00 ASSIGNMENT OF CONTRACT<br />
Any assignment of the contract or any part thereof or any rights or obligations there under, by the<br />
Contractor without the prior written consent of the Purchaser shall be void.<br />
The purchaser shall be at liberty to transfer and assign the contract only to Government Company<br />
as defined in the Indian Companies Act-I of 1956, and such Company shall exercise all the rights<br />
and be liable for all obligations of the Purchaser contained herein in the same manner as if the<br />
agreement had been entered into between the said Company and the Purchaser. The purchaser<br />
shall be also at liberty to entrust the carrying out of the agreement only to a Government Institution<br />
and upon the Instructions of the purchaser, the Contractor undertakes to do all things necessary to<br />
carry out of his obligations under the agreement with such institution as may be entrusted by the<br />
purchaser as agent or otherwise. The Purchaser, however, shall not be in either case relieved or<br />
discharged from any of his obligations and liabilities under the contract.<br />
The contractors shall be advised in writing of the date of any such substitution.<br />
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35.0 SUBLETING OF CONTRACT<br />
The Contractor shall not without the consent in writing of the Purchaser, which shall not be<br />
unreasonably withheld, assign or sublet his contract or any substantial part thereof other than for<br />
raw materials, for minor details, or for any part of the works of which the makers are named in the<br />
contract, provided that any such consent shall not relieve the Contractor from any obligation, duty<br />
or responsibility under the contract.<br />
For components/equipments procured by the Contractors for the purpose of the Contract; after<br />
obtaining the written approval of the Owner, the Contractor’s purchase specifications and enquiries<br />
shall call for quality plans to be submitted by the suppliers along with their proposals. The quality<br />
plans called for from the vendors shall set out, during the various stages of manufacture and<br />
installation, the quality practices and procedures followed by the Vendor’s quality control<br />
organization, the relevant reference documents/standards used, acceptance level, inspection of<br />
documentation raised, etc. Such quality plans of the successful vendors shall be discussed and<br />
finalized in consultation with the Engineer and shall form a part of the purchase order/contract<br />
between the Contractor and the vendor. Within 3 weeks of the release of the same purchase<br />
order/contracts for such bought out items/components, a copy of the same without price details but<br />
together with detailed purchase specifications, quality plants and delivery conditions shall be<br />
furnished to the Engineer by the Contractor.<br />
36.00 SUSPENSION OF WORK<br />
The owner reserves the right to suspend and reinstate execution of the whole or any part of the<br />
works without invalidating the provisions of the contract. Orders for suspension or reinstatement of<br />
the works will be issued by the Engineer to the Contractor in writing. The time for completion of the<br />
works will be extended for a period equal to duration of the suspensions. Any necessary and<br />
demonstrable costs incurred by the contractors as a result of such suspension of works other than<br />
force majeure conditions will be paid by the owner, provided such costs are substantiated to the<br />
satisfaction of the Engineer. The owner shall not be responsible for any liabilities if suspension or<br />
delay is due to some default on the part of the Contractor or his sub- Contractor.<br />
37.00 FORCE MAJEURE<br />
37.01 Any delays in or failure of the performance of either parties thereto shall not constitute default here<br />
under or give rise to any claims for damages, if any, to the extent such delays or failure of<br />
performance caused by occurrences such as acts of God or the public enemy, expropriation or<br />
confiscation of facilities by Government authority, compliance with any order or request of any<br />
Government authorities, act of war rebellion, sabotage, fire, floods, explosions, riots or illegal<br />
strikes, provided always that such occurrence result in impossibility of performances of the<br />
contract.<br />
37.02 Only events of Force Majeure which impedes the execution of the contract at the time of its<br />
occurrence shall be taken into cognizance.<br />
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38.00 PROGRESS REPORTS AND PHOTOGRAPHS<br />
The Contractor shall furnish six (6) prints each of progress reports and photographs of the work<br />
done in his shop. Photographs shall be taken when the where indicated by the Engineer or his<br />
representative. Photographs shall be approximately 100 mm x 125 mm in size including a margin<br />
of 5 mm side of fixing. Adequate number of photographs shall be submitted indicating various<br />
stages of manufacture. Each photograph shall contain the date the name of the Contractor and the<br />
title of the view taken.<br />
Monthly progress reports shall be submitted. These shall detail the status of design, procurement<br />
of raw materials and manufacture of the equipment. The Engineer shall advise the Contractor<br />
about the number of copies of progress schedule and photographs he has to submit each month<br />
together with the names and address of persons to whom they are to be sent.<br />
39.00 PATENT RIGHTS<br />
Royalties and fees for patents covering materials, articles, apparatus devices, equipment and<br />
processes used in the plant and equipment shall be deem to have been included in the Contract<br />
Price. The Contractor shall defend any claims which alleged in a suit or proceeding against the<br />
Purchaser that the equipment or any part thereof constitutes an infringement of any patent, it<br />
notified promptly in writing and given authority, Information and assistance for the defense and the<br />
Contractor shall pay all damages and costs awarded against the Purchaser in such suit or<br />
proceeding for the patent infringement. In case the equipment in such suit or proceeding is held to<br />
constitute infringement and the use of the equipment or part is prohibited, the Contractor shall, at<br />
his own expenses, either procure for the Purchaser the right to continue using the equipment or<br />
replace same with a non-infringing equipment or modify it so it become non-infringing or remove<br />
the equipment and refund the purchase price plus the transportation and installation costs thereof.<br />
The foregoing states entire liability of the Contractor for patent infringement and the Purchaser<br />
shall be kept indemnified in this regard.<br />
Notwithstanding any dispute regarding patents Purchaser will have a right to the use of materials,<br />
articles, apparatus, devices, equipment and process till final adjudication of such dispute.<br />
40.00 TRAINING OF ENGINEERS<br />
It so desired by the Purchaser, the Contractor shall undertake to train Engineers to be nominated<br />
by the Purchaser in the manufacture, testing, erection and operation of similar equipment as<br />
covered by the contract. The period of training, number of engineers to be trained, program of<br />
training will be mutually agreed upon. Cost of to and fro traveling for each engineer to the<br />
manufacturer’s factory and their living expenses shall be borne by the Purchaser.<br />
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41.00 EFFECT & JURISDICTION OF CONTRACT<br />
41.01 The contract shall be considered as having come into force from the date of the acceptance of<br />
Letter of Intent.<br />
41.02 The laws applicable to this contract shall be in the laws in force in India. The courts of Orissa shall<br />
have exclusive jurisdiction in all matters arising under the contract.<br />
42.00 TIME IS THE ESSENCE OF CONTRACT<br />
42.01 The time and the date of completion of the works as stipulated in the contractor’s proposal and<br />
accepted by the owner without or with modifications, if any, and so incorporated in the Letter of<br />
Intent, shall be deemed to be the essence of the contract. The Contract shall so organize his<br />
resources and perform his work as to complete it not later than the date agreed to.<br />
42.02 The Contractor shall submit a detailed PERT Network within the time frame agreed above covering<br />
various key phases of the works such as design, procurement, manufacturing, shipment and field<br />
erection activities within thirty (30) days after the date of Letter of Intent. This network shall also<br />
indicate the interface facilities to be provided by the Owner and the dates by which such facilities<br />
are needed.<br />
Contractor shall discuss the network so submitted with the owner. The agreed network which may<br />
be in the form as submitted or in revised form in line with the outcome of discussions shall form<br />
part of the Contract to be signed within sixty (60) days from the date of acceptance of Letter of<br />
Intent. During the performance of the contract, if in the opinion of the Engineer proper progress is<br />
not maintained suitable changes shall be made in the contractor’s operations to ensure proper<br />
progress.<br />
42.03 The above PERT network shall be reviewed and periodic review reports shall be submitted by the<br />
Contractor as directed by the Engineer.<br />
42.04 Within a month of the award of the contract, the Contractor shall make available to the Engineer, a<br />
detailed manufacturing programme, in line with the agreed contract network. Such manufacturing<br />
program shall be reviewed, updated and submitted to the Engineer once every two months<br />
thereafter.<br />
43.00 ERECTION SUPERVISION SERVICES<br />
The Contractor, if required by the Purchaser, shall furnish the services of one or more supervisors,<br />
to render technical advice, assistance and guidance to the Purchaser in connection with the<br />
erection and/or commissioning of equipment subject to the provisions herein after set forth. In case<br />
of complete erection of plant and materials such services shall automatically be included in the<br />
scope of the Contractor and no extra charges shall be applicable.<br />
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The Purchaser; shall pay the Contractor for the service of each supervisor as follows:<br />
(a) As agreed rate; per-calendar day from the date on which supervisor leave his<br />
headquarters up to and including the date of his return thereto. This rate is based up on a<br />
normal 48 hours work-week of six (6) eight-hour workdays, Monday through Saturday.<br />
Sunday will be normally a holiday but any other day of the week may be made a normal<br />
holiday depending upon working conditions.<br />
(b) The Purchaser shall in addition to the charge specified in paragraph above, pay the<br />
Contractor for any overtime work authorized by the Purchaser and performed by the<br />
supervisor at an agreed overtime rate per hour for hours worked in excess of 8 hours per<br />
day and all hours worked on the seventh day. There will be no overtime charge for work<br />
performed on locally recognized or national holiday or time spent in traveling to and from<br />
the supervisors headquarters.<br />
(c) Hours during which the supervisor is ready, willing and able to work up to 48 hours per<br />
week shall be regarded as having actually been worked by him even though his services<br />
are not in fact utilized.<br />
The Purchaser shall secure any labor permit or any other authorization which may be required to<br />
permit the Erection Supervisor to perform the services and any loss of the supervisor’s services<br />
pending the procurement of any such permit or authorization shall be to the Purchaser’s account<br />
and shall be paid for by the Purchaser.<br />
The Purchaser shall furnish, at his own expenses, and assume responsibility for all labor and labor<br />
supervision and shall make available all necessary installation to tools, except such special tools<br />
as may be supplied by the Contractor pursuant to written agreement between the parties. The<br />
supervisor may elect to bring certain personal tools which tools are to remain his property at all<br />
times. The Purchaser shall assist the Supervisor in arranging entry and exit permit for such tools.<br />
If any portion of the work of supervision by the Contractor proves to be defective within one (1)<br />
year from the date of completion of supervision, the Contractor, if promptly notified thereof in<br />
writing, will at his own expense, and at his option, with make repairs or supply replacement parts<br />
directly to or for the equipment and necessary to correct any defect or defects in such equipment<br />
directly resulting from such defective work of supervision on the part of the Contractor and will at<br />
his own expenses, furnish the necessary supervision for such corrections. The contractors liability<br />
in connection with his furnishing a supervisor hereunder shall in no event exceed the cost of<br />
correcting any such defective work of supervision in the manner herein provided and upon the<br />
expiration of the said one (1) year, all such liability shall terminate. In no event shall the Contractor<br />
be liable for special, indirect or consequential damages.<br />
The Contractor shall not be liable for loss of damage due to delays in furnishing the services or in<br />
the work resulting form any cause beyond the Contractor’s reasonable control including<br />
compliance with any Government regulations, orders or instructions, acts of God, acts of omission<br />
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of Purchaser, acts of civil or military authority, fires, strikes, war earthquake, storm, volcanic<br />
eruptions, landslide, riot or delays in transportation. The Purchaser shall advise the Contractor in<br />
writing reasonably in advance of the date that the supervisor shall be required to start performance<br />
of the services.<br />
44.00 ERECTION OF PLANT AND MATERIALS<br />
44.01 General<br />
Unless otherwise mutually agreed to the provisions of this clause shall apply where the services for<br />
erection of plant & material supplied by the contractor are included in the scope of work.<br />
If so desired by the Purchaser, the Contractor shall receive the imported equipment, if any, at the<br />
port of entry, clear them through Customs and make damage report through port broker. The<br />
Contractor shall arrange for payment at prescribed rate of Customs Duty which will be reimbursed<br />
by the Purchaser against Contractor’s valid documents.<br />
The Contractor shall transport all imported equipment from port of entry to the site and unload all<br />
Imported/Indigenous equipment at site. Escort service shall be provided, if necessary and called<br />
for. All storage at port of entry or at railway station will be at Contractor’s charge.<br />
The Contractor shall be responsible for complete installation of the equipment start-up and testing<br />
at site.<br />
All equipment and tools for transportation and erection shall be provided by the Contractor.<br />
All materials and /or equipment, after receipt at site, shall be checked and verified against shipping<br />
documents and all claims against loss or damage in transit shall be intimated to the purchaser. The<br />
materials and/or equipment shall remain under the custody of the Contractor until the plant as a<br />
whole is taken over by the Purchaser upon completion of the work. The Contractor shall take<br />
adequate steps to ensure safety of such materials and / or equipment. Necessary stores receipt<br />
certificates shall be issued to the Purchaser after the stores are checked and certified. No materials<br />
and/or equipment pertaining to the Contract shall be removed from site without the consent in<br />
writing of the Purchaser.<br />
The Contractor shall be responsible for obtaining the correct reference lines for purposes of fixing<br />
the alignment of various equipment.<br />
44.02 Regulation of Local Authorities and Statues<br />
The Contractor shall comply with the rules and regulations of local authorities during the<br />
performance of his field activities. He shall also comply with the minimum wages Act, 1948 and the<br />
payment of wages act (both of the Government of India) and the rules made there under in respect<br />
of any employee or workmen employed or engaged by him or his sub-Contractor.<br />
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All registration and statutory inspection fees, if any, in respect of his work pursuant to this contract<br />
shall be to the account of the Contractor. However, any registration, statutory inspection fees<br />
lawfully payable under the provisions of the Indian Boiler Regulations and any other statutory laws<br />
and its amendments from time to time during erection in respect of the plant equipment ultimately<br />
to be owned by the Purchaser, shall be to the account of the Purchaser. Should any such<br />
inspection or registration need to be re-arranged due to the fault of the Contractor or his sub-<br />
Contractor, the additional fees of such inspection and/or registration shall be borne by the<br />
Contractor.<br />
44.03 Work at Site<br />
In the execution of work, no persons other than the Contractor or his appointed representative,<br />
sub-Contractor and workmen shall be allowed to do work at site, except by the special permission<br />
in writing of the Engineer or his representative, but access to the Works at all times shall be<br />
accorded to the Engineer and his representative and other authorized officials or representatives of<br />
the Purchaser.<br />
Nevertheless, the Contractor shall not object to the execution of work by other Contractors or<br />
tradesmen whose names shall have been previously communicated in writing to the Contractor by<br />
the Engineer and afford them every facility for the execution of their several works simultaneously<br />
with his own.<br />
The Contractor shall at all times provide sufficient fencing, notice boards, lights and watchmen to<br />
protect and warn the public and guard the works, and in default thereof the Purchaser may<br />
provided such fencing, notice boards, lights and watchmen as he may deem necessary and charge<br />
the cost thereof to the Contractor.<br />
The work so far as it is carried out on the Purchaser’s premises shall be carried out at such time as<br />
the Purchaser may approve and so as not to interfere unnecessarily with the conduct of the<br />
Purchaser’s business but the Purchaser shall give the Contractor all reasonable facilities for<br />
carrying out the work. No female labor shall be employed during dark hours.<br />
The Contractor shall not employ for the purpose of the contract any person who is below the age of<br />
eighteen years and shall pay to each laborer, for the work done by such laborer, wages not less<br />
then the wages paid for similar work in the neighborhood. The Engineer shall have the right to<br />
enquire into and decide any complaint alleging that the wages paid by the Contractor to any laborer<br />
for the work done by such laborer is less than the wages paid for similar work in the neighborhood,<br />
and to refuse appointment of labor less than eighteen years of age.<br />
The Contractor shall make regular and prompt payment of wages to the laborers engaged on the<br />
work and in not case the payment shall be delayed more than seven (7) days following the period<br />
for which the wages are due. If it is found the workers are not paid regularly the contract is liable to<br />
be rescinded. The Contractor shall comply strictly with the provisions of Labor Laws in this behalf.<br />
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44.04 Manufacturer’s Supervision<br />
The Contractor may be required to work under the supervision of the manufacturer’s Engineers,<br />
where the Contractor is not the manufacturer. However, this will not relieve the Contractor of his<br />
responsibility of the correctness of quality of workmanship.<br />
44.05 Engineer’s Supervision<br />
All the works shall be carried out under the direction and to the satisfaction of the Engineer. The<br />
Contractor shall be responsible for the correctness of the positions, levels and dimensions of the<br />
works according to the drawings, notwithstanding that he may have been assisted by the Engineer<br />
in setting out the same.<br />
44.06 Contractor’s Representative<br />
The Contractor shall employ at least one competent representative, whose name or names shall<br />
have previously been communicated in writing to the Engineer by the Contractor for approval to<br />
superintend the erection of the plant and carrying our of the work. The said representative, or if<br />
more than one be employed, one of the representative, shall be present at the site, during working<br />
hours, and any written orders or instructions which the Engineer or his authorized representative<br />
may give to the said representative of the Contractor, shall be deemed to have been given to the<br />
Contractor.<br />
The Engineer shall be at liberty to object to any representative or person employed by the<br />
Contractor in the execution of or otherwise of the work who shall misconduct himself or be<br />
incompetent, or negligent, and Contractor shall remove the person so objected to, upon receipt<br />
from the Engineer or notice in writing requiring him to do so and shall provide; in his place a<br />
competent representative at the Contractor’s expenses. The Contractor’s representatives to be<br />
employed for the purpose of the work at site shall be made available when the Purchaser shall<br />
inform the Contractor in writing to the effect. The services of the Contractor’s representative shall<br />
be made available for such period as the Engineer may require and they shall work at all<br />
reasonable times as may be necessary to complete the work within the period specified in the<br />
Contract.<br />
44.07 Program of work and Progress Reports<br />
The Contractor shall submit at such times as may be required by the Engineer, schedules showing<br />
the program and order in which the Contractor proposes to carry out the work, with dates and<br />
estimated completion times of various parts of the work. Such schedules shall be approved by the<br />
Engineer, prior to starting the erection. Such times shall be binding on the Contractor for purpose<br />
of assessing the penalty as called for under subsequent clause. The Engineer may not allow the<br />
Contractor to start work for non-submission of the time schedule of the erection program.<br />
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During the progress of work the Contractor shall submit monthly progress reports and photographs<br />
and such other reports on the erection work and organization, as the Engineer may direct. The<br />
progress indicated be arrived by agreement between the Contractor and the Engineer. The<br />
Contractor shall also submit an anticipated one (1) month progress schedule at the beginning of<br />
each month describing in detail the anticipated progress for the following month. The Contractor<br />
shall also submit every week a list of various categories of men working under him. Monthly<br />
progress reports shall be submitted within the tenth day of the month following the reporting month.<br />
44.08 Man - Power Report<br />
The Contractor shall submit to Engineer, on the first day of every month, a man hour schedule for<br />
the month, detailing the man hours scheduled for the month, skill wise and are wise.<br />
The Contractor shall also submit to the Engineer on the first day of every month, a man power<br />
report of the previous month detailing the number of persons scheduled to have been employed<br />
and actually employed, skill wise and the areas of employment of such labor.<br />
44.09 Extension of Time<br />
The application for extension of time is to be given to owner/purchaser through the Engineer and<br />
the owner/purchase may authorize extension of time after considering the due merits.<br />
Whenever extension of time is granted by the owner/purchaser, the same shall be on the existing<br />
terms and conditions of the contract and without any additional financial liability to the Owner. The<br />
Contractor in any case shall have no claim whatsoever for any type of compensation on account of<br />
any delay attributable to any one.<br />
44.10 Liability for Accident and Damage<br />
The Contractor shall Indemnify the Purchaser against any claims which may be made under the<br />
workman’s Compensation Act, 1923, or any statutory modification thereof or otherwise for or in<br />
respect of any damages or compensation payable in consequence of any accident or injury<br />
sustained by any workman or other person whether in the employment of the Contractor or not. In<br />
every case in which by virtue of the provisions of sub-section (1) of Section 12 of the Workman’s<br />
compensation Act, 1923, the Purchaser is obliged to pay compensation to a workman employed by<br />
the Contractor in execution of the works, the Purchaser will recover from the Contractor the amount<br />
of the compensation so paid and without prejudice to the rights of the Purchaser under sub-section<br />
(2) of Section 12 of the said Act. The Purchaser shall be at liberty to recover such amount or any<br />
part thereof by deducting it from the Performance Bond or from any sum due by the Purchaser to<br />
the Contractor whether under the contract or otherwise.<br />
The Purchaser shall not be bound to contest any claim made against it under Section 12, subsection<br />
(1) of the said Act, except on the written request of the Contractor and upon his giving to<br />
the Purchaser full security for all costs for which the Purchaser might become liable in<br />
consequence of contesting such claim. In the event of claim being made or action brought against<br />
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the Purchaser involving the Contractor and arising out of the matters referred to and in respect of<br />
which the Contractor is liable under this clause, the Contractor shall be immediately notified thereof<br />
and he shall with the assistance, if so required by the Purchaser, but at the sole expense of the<br />
Contractor, conduct all negotiations for the settlement of the same, or of any litigation that may<br />
arise there from. In such case the Purchaser, at the expenses of the Contractor, afford all available<br />
assistance for any such purpose.<br />
The Contractor shall be responsible for all loss, damage or depreciation to the plant until the plant<br />
is taken over in accordance with clause ‘Taking Over’. The Contractor shall, during the progress<br />
other work, properly cover up and protect the plant from injury by exposure to weather and; shall<br />
take every reasonable, proper, timely and useful precaution against accident or injury to the same<br />
from any cause shall be and remain answerable and liable for all accidents or injuries thereto<br />
which, until the same be or be deemed to be taken over under clause ‘Taking Over’ may arise or<br />
be occasioned by the acts or omissions or the Contractor of his workmen or sub- Contractors, and<br />
all losses and damage to the Plant arising from such accidents or injuries as aforesaid shall be<br />
made good in the most complete and substantial manner by and at the sole cost of the Contractor<br />
and to the reasonable satisfaction of the Engineer.<br />
Until the plant shall be or deemed to be taken over as aforesaid the Contractor shall also be liable<br />
for and shall be deemed to have agreed to indemnity the Purchaser in respect of all damage to any<br />
property of the Purchaser or of others occasioned by the negligence or fault of the Contractor or<br />
sub-contractor or his or their workmen or representatives or by defective design, work or material<br />
or otherwise.<br />
The Contractor shall pay all taxes due in India for the personnel employed by the Contractor work<br />
arising out of their services in connection with the contract and obtaining at his (Contractor’s) own<br />
cost ‘work permits’ from competent authorities to enable any foreign personnel to work in India.<br />
The Contractor shall be responsible for all formalities in connection with the passport, obtaining of<br />
visas, police permits, and expenses for customs duties related to personal goods of foreign<br />
personnel to be employed in the erection work. However, the Purchaser shall If requested, assist<br />
the Contractor in obtaining visas and “work permits’ for the foreign personnel to be deputed for the<br />
erection work.<br />
44.11 Cleanliness<br />
During erection, the Contractor shall, without any additional payment, at all times keep the working<br />
and storage areas used by him free from accumulation of waste materials or rubbish. If the<br />
Contractor fails to remove the rubbish, within forty eight (48) hours, after being requested by the<br />
Engineer, the rubbish will be removed by others and cost back charged to the Contractor. Any<br />
inflammable material should be removed forthwith on request by the Engineer.<br />
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Before completion of erection, the Contractor shall remove or dispose of in a satisfactory manner<br />
all temporary structures, packing cases, waste and debris and leave the premises in a condition<br />
satisfactory to the Engineer.<br />
Similarly the labor colony, the offices and the residential areas of the Contractor’s employees and<br />
workmen shall be kept clean & neat to the entire satisfaction of the Engineer. Proper sanitary<br />
arrangements shall be provided by the Contractor, in the work areas office and residential areas of<br />
the Contractors.<br />
44.12 Co-ordination with the Purchaser’s Engineers<br />
The Contractor shall at all times work in co-ordination with the Purchaser’s Engineers and afford<br />
them every facility to become familiar with the erection and maintenance of the equipment.<br />
In respect of observance of local rules, administrative matters, co-ordination with other Contractors<br />
and the like, the Contractor and his personnel shall work under the Purchaser’s Engineer in charge<br />
of the work.<br />
44.13 Work and Services to be provided by the Purchaser<br />
Unless otherwise agreed upon, the following works and services shall be provided by the<br />
Purchaser for carrying out complete erection work:<br />
(a) Water Supply<br />
Water supply for construction purpose will be provided by the Purchaser at one mutually<br />
agreed point at site. Drinking water will also be made available at one central point at site.<br />
The Contractor shall make his own arrangement for any further distribution. Such<br />
distribution pipe network shall have the prior approval of the Engineer at site so as not to<br />
interfere with the layout and progress of other construction works. The water supply shall<br />
be free of cost. Contractor shall ensure that there is no wastage of water. On completion of<br />
the work, the Contractor shall remove all such work and shall reinstate and make good any<br />
work disturbed to the satisfaction of the Engineer.<br />
(b) Power Supply<br />
(I) Electric power will be supplied at 400/440 V and shall be metered and charged at<br />
applicable rates.<br />
(II) Supply for execution of work will be made available at one point only. This point<br />
will not be more than 500 meters away from the Contractor’s premises. The<br />
Contractor shall make his own arrangement at his own cost for distribution of<br />
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power to different worksites. This arrangement shall however, be coordinated and<br />
laid with approval of the Engineer. Any change in the alignment of the Contractor’s<br />
distribution lines necessitated by his work or another work must be done at<br />
Contractor’s cost. The Engineer also reserves the right to change the location of<br />
point of supply whether necessitated by his work or another work and the<br />
Contractor shall make his own arrangement at his own cost for extending his<br />
distribution line to the new location of supply point. A 3 phase armored cable shall<br />
be used by the Contractor for connecting their equipment to Purchaser’s point<br />
supply.<br />
(III) The Purchaser shall not however, guarantee the supply of electricity and no<br />
compensation for any failure or short supply of electricity will be entertained and<br />
this does not relieve the Contractor of his responsibility for timely completion of the<br />
work as stipulated in the Contract.<br />
(IV) It shall be the responsibility of the Contractor to provide and maintain the complete<br />
installation on the load site of the supply with due regard to safety requirement at<br />
site. All cabling, equipment, installations etc. shall comply in all respects with the<br />
latest statutory requirements and safety provisions, i.e. as per given in the<br />
Central/State Electricity Acts and Rules etc. The Contractor will ensure that his<br />
equipment and Electricity wiring etc. are installed, modified and maintained by a<br />
licensed Electrician / Supervisor and before power is supplied, a test certificate is<br />
to be produced to the Engineer for his approval.<br />
(V) At all times, IEA Regulations shall be followed failing which the Purchaser has a<br />
right to disconnect the power supply without any reference to the Contractor. No<br />
claim shall be entertained for such disconnection by the Engineer. Power supply<br />
will be reconnected only after production of fresh certificate from authorized<br />
electrical supervisors.<br />
(VI) The Purchaser will not liable for any loss or damage to the Contractor’s equipment<br />
as a result of variation in voltage or frequency or interruption of power supply or<br />
other loss to the Contractor arising there from.<br />
(VII) The Contractor shall ensure that the Electrical equipment installed by him are such<br />
that average power factor does not fall below 0.9 at this premises. In case P.F.<br />
falls below 0.9 in any month, he will reimburse to the purchaser at the rate same<br />
as OSEB’s rate for per unit fall of P.F. determined from time to time by Purchaser<br />
all units consumed during the month.<br />
(VIII) The power supply required for Contractor’s colony near the plant site will be<br />
determined by the Purchaser and shall be provided as per State Electricity Board’s<br />
Rules and other Statutory provisions applicable for such installations from time to<br />
time. In case of power supply to Contractor’s colony, the power will be made<br />
available at a single point and the Contractor shall make his own arrangement at<br />
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his own cost for distribution to the occupants of the colony as per Electricity Rules<br />
& Acts. The site area and colony shall be sufficiently lighted to avoid accidents.<br />
(IX) The Contractor will have to provide and install his own light and power meters<br />
which will be governed as per Central/State Govt. Electricity Rules. The meters<br />
shall be sealed by the Purchaser.<br />
(X) In case of damage to any of the Purchaser’s equipment on account of fault,<br />
intentional or unintentional on the part of the Contractor, the purchaser reserves<br />
the right to recover the cost of such damage from the contractor’s bill.<br />
(XI) After completion of work, the Contractor shall promptly dismantle, at his own cost<br />
distribution and other facilities that he may have erected and shall also remove the<br />
same within a reasonable time fixed by the Engineer and on his failure to do so the<br />
Purchaser will be entitled to realize from his reasonable compensation fixed by the<br />
Engineer and also to remove them at the cost of the Contractor.<br />
(XII) Only motors up to 3HP will be allowed to be started direct on line. For motors<br />
above 3 HP and up to 100 HP suitable starting devices approved by the Purchaser<br />
Engineer, shall be provided by the Contractor. For Motors above 100 HP slip ring<br />
induction motors with suitable starting devices as approved by the Engineer shall<br />
be provided by the Contractor.<br />
(XIII) The single line distribution system with loadings and specifications shall be<br />
submitted to the Engineer for his approval before the system is installed. The<br />
system shall conform to Central/State Statutory provisions Act, with latest<br />
amendments and to the Approved specifications of the company. The installations<br />
have to be inspected and approved by the Electrical Inspector, Govt. of Orissa<br />
before energisation.<br />
(XIV) The total requirement of power shall be indicated by the tenderer in his tender and<br />
confirmed within thirty days from the date of Letter of Intent.<br />
(d) Land for Contractor’s Use<br />
(I) The Purchaser will at his own discretion and convenience and for the duration of<br />
the execution of the work make available near the site, land for construction of<br />
Contractor’s field office, godowns, workshops and assembly yard required for the<br />
execution of the contract. The Contractor shall at his own cost construct all these<br />
temporary buildings and provide suitable water supply and sanitary arrangement<br />
approved by the Engineer.<br />
(II) On completion of the works undertaken by the Contractor, he shall remove all<br />
temporary works erected by him and have the site cleared as directed by<br />
Engineer. If the Contractor fails to comply with these requirements, the Engineer at<br />
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the expenses of the Contractor will remove such surplus and rubbish materials<br />
and dispose off the same as he deems fit and get the site cleared as aforesaid,<br />
and the contractor shall forthwith pay the amount of all expenses so incurred and<br />
shall have no claim in respect of any such surplus materials disposed off as<br />
aforesaid. But the Purchaser reserves the right to ask the Contractor any time<br />
during the pendency of the contract to vacate the land by giving 7 days notice on<br />
security reasons on national interest or otherwise. A token rent of Rs. 100/-<br />
(Rupees one hundred only) per hectare or part thereof per annum or part thereof<br />
shall be charged for the land so occupied.<br />
(III) Land for residential accommodation for staff and labor will be made available at<br />
the discretion of the Engineer and rent for the same will be as decided by the<br />
Engineer according to location and area taken by the Contractor.<br />
(e) Electricity and drinking water at normal charges for labor quarters at a central point within<br />
the land provided by the Purchaser. The cost of distribution, if any, shall be borne by the<br />
Contractor.<br />
(f) Assistance to the Contractor in obtaining Indian visas, residential or working permits for the<br />
permits for the personnel, if necessary.<br />
(g) Water and electricity as may be required for the initial starting up of the equipment free of<br />
charge to Contractor.<br />
(h) Necessary Engineers, operators and other personnel for start – up commissioning and<br />
acceptance tests of the equipment free of charge to Contractor.<br />
(i) Assistance in obtaining priorities for transportation, customs permit etc.<br />
(J) Suitable access to site and possession of the site shall be afforded to the Contractor by the<br />
Purchaser.<br />
44.14 Work and Services to be provided by the Contractor<br />
Unless otherwise agreed upon, the following work and services shall also be provided under the<br />
erection contract.<br />
(i) Clearing, unloading the equipment from the rail or road transport to Contractor’s<br />
transport/vehicle and delivery the same to storage area. Demurrage charges, if incurred at<br />
rail head or at site for default of the Contractor shall be paid by him<br />
(ii) Opening of packing cases, Inspection and checking of materials. Repair and replacement<br />
of contract material damaged or lost in transit or at site.<br />
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(iii) Final adjustment of foundation levels by chipping and dressing, checking location,<br />
elevation etc. of anchor bolts and grouting or anchor bolts and base plates.<br />
(iv) Complete erection of the equipment covered under the contract, final preparation for<br />
testing, commissioning, final run and acceptance tests and putting the plant into<br />
commercial operation.<br />
(v) All consumable stores required for the above work, except those mentioned under Clause<br />
44.13 (i).<br />
(vi) Watch and ward to ensure security and safety of materials under the custody.<br />
(vii) Furnishing of residential accommodation to erection labor and other personnel.<br />
(viii) Daily transport for his erection personnel to and fro between residence and site.<br />
(ix) All erection tools and lifting tackles, also all equipment, tools and tackles for transportation<br />
of all equipment to site. A list of such tools and tackle and equipment shall be submitted to<br />
the purchaser before commencement of site work. These tools and tackle shall not be<br />
removed from the site without written permission of the Engineer.<br />
(x) All ladders, platforms, temporary supports and facilities required for handing of heavy<br />
packages at site required for erection.<br />
(xi) Necessary clerical staff, supervisory personnel skilled and unskilled labor.<br />
(xii) Third Party Insurance at site and insurance of Contractor’s personnel employed at site as<br />
required under Workmen’s Compensation Act.<br />
(xiii) Site offices and covered storage as required.<br />
(xiv) Postage, telephone and telegraph expenses.<br />
(xv) Cleaning up of site during and after erection.<br />
(xvi) Applying final paint to all equipment, piping, hanger etc. covered under the contract.<br />
(xvii) Necessary supervisory personnel with approved license as per provisions of Indian<br />
Electricity rules.<br />
(xviii) If the Contractor uses his own crane, he must have a skilled crane operator.<br />
(xix) Contractor must take all safety precautions during work and the workmen must use safety<br />
belts, tested gloves, masks and other devices as necessary for safety of personnel<br />
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(xx) Contractor should provide identity badges for his employees. These should be properly<br />
displayed during working hours.<br />
(xxi) The Contractor shall employ only competent and skilled workmen fully experienced and<br />
capable of performing duties assigned for them. When local laws required the employee<br />
shall be required to acquire certificate of competency for his work from the competent<br />
authority.<br />
(xxii) Communication<br />
The Contractor will make his own arrangement for all his communications needs such as<br />
telephone, telex etc. at his site office and his residential area. Purchaser will assist in<br />
getting the above facilities, in case he finds and difficulty.<br />
(xxiii) First – Aid<br />
The Contractor shall provide necessary first-aid facilities for all his employees,<br />
representatives and workmen working at site. Enough number of contractor’s personnel<br />
shall be trained in administering first-aid.<br />
(xxiv) Welfare facilities<br />
44.15 Lines and Grades<br />
Contractor shall provide in his labor colony all necessary standard welfare facilities like<br />
canteen, shopping facility etc.<br />
All the works shall be performed to the lines/alignments, grades and elevations indicated on the<br />
drawing. The Contractor shall be responsible to locate and layout the works area. Basic horizontal<br />
and vertical control points will be established and marked by the Engineer at site at suitable points.<br />
These points shall be used as datum/reference points for the works under the contract. The<br />
Contractor shall inform the Engineer well in advance of the times and places at which he wishes to<br />
do work in the area allotted to him, so that suitable datum reference points may be established and<br />
checked by the Engineer to enable the Contractor to proceed with his works. Any work done<br />
without being properly located may be removed and/or dismantled by the Engineer at Contractor’s<br />
expenses.<br />
44.16 Fire Protection<br />
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(a) The work procedures that are to be used during the erection shall be those which minimize<br />
fire hazards to the extent practicable. Combustible materials, combustible waste and<br />
rubbish shall be collected and removed from the site at least once each day. Fuels, oil and<br />
volatile or flammable materials shall be stored away from the construction and equipment<br />
and materials storage area in safe containers. Adequate precaution shall be taken in<br />
handling and storage of flammable gas. Care shall be taken to avoid and reduce hazards<br />
from electrical short circuits and faults. Untreated canvas paper, plastic or other flammable<br />
flexible materials shall not at all be used at site for any other purpose unless otherwise<br />
specified. If any such materials are received with the equipment at the site, the same shall<br />
be removed and replaced with acceptable material before moving into the construction<br />
area of storage.<br />
(b) Similar corrugated paper fabricated cartons etc. will not be permitted in the construction<br />
area either for storage or for handling of materials. All such materials used shall be of<br />
water proof and flame resistant type. All the other materials such as working drawings<br />
plans etc. which are combustible but are essential for the works to be executed shall be<br />
protected against combustible resulting from welding sparks, cutting flames and other<br />
similar fire sources.<br />
(c) All the Contractor’s supervisory personnel and sufficient number of workers shall be<br />
trained for fire - fighting and shall be assigned specific fire protection duties. Enough of<br />
such trained personnel must be available at site during the entire period of the Contract.<br />
(d) The contractor shall provide enough fire protection equipment of the types and number for<br />
the ware - houses, office, temporary structures, labor colony area etc. Access to such fire<br />
protection equipments shall be easy & kept open at all times.<br />
44.17 Materials Handling & Storages<br />
(a) All the equipments furnished under the Contract and arriving at site shall be promptly<br />
received, unloaded and transported and stored in the storage spaces by the contractor.<br />
(b) The Contractor shall be responsible for examining all the shipment and notify the engineer<br />
immediately of any damages, shortages; discrepancy etc. for the purpose of Engineer’s<br />
information only. The Contractor shall submit to the Engineer every week a report detailing<br />
all the receipts during the week. However, the Contractor shall be solely responsible for<br />
any shortages or damage in transit, handling and/ or storage & erection of the equipment<br />
at site. Any demurrage, wharfage and other charges claimed by the transporters, railways<br />
etc. shall be to the account of Contractor.<br />
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(c) The Contractor shall maintain an accurate & exhaustive record detailing out the list of all<br />
equipment received by him for the purpose of erection & keep such record open for the<br />
inspection of the Engineer at any time.<br />
(d) All equipments shall be handled very carefully to prevent any damages or loss. No bare<br />
wire, rope, slings etc. shall be used for unloading and/ or handling of the equipment<br />
without the specific written permission of the Engineer. The equipment stored shall be<br />
properly protected to prevent damages either to the equipment or to the floor where they<br />
are stored. The equipment from the store shall be moved to the actual location at the<br />
appropriate time so as to avoid damage of such equipment at site.<br />
(e) All electrical panels, control gear, motors and such other devices shall be properly dried by<br />
heating before they are installed and energised. Motor bearings, slip rings, commutators<br />
and other exposed parts shall be protected against moisture ingress and corrosion during<br />
storage and periodically inspected. Heavy rotating parts in assembled conditions shall be<br />
periodically rotated to prevent corrosion due to prolonged storage.<br />
(f) All the electrical equipment such as motors, generators, etc. shall be tested for insulation<br />
resistance at least once in three months from the date of receipt till the date of<br />
commissioning and a record of such measured insulation values maintained by the<br />
Contractor. Such records shall be open for inspection by the Engineer.<br />
(g) The Contractor shall ensure that all the packing materials and protection devices used for<br />
the various equipment during transit and storage are removed before the equipment are<br />
installed.<br />
(h) The consumables and other supplies likely to deteriorate to storage must be thoroughly<br />
protected and stored in a suitable manner to prevent damage or deterioration in quality by<br />
storage.<br />
(i) All the materials stored in the open or dusty location must be covered with suitable<br />
weatherproof and flame-proof covering material wherever applicable.<br />
(j) If the materials belonging to the Contractor are stored in areas other than those earmarked<br />
for him the Engineer will have the right to get it moved to the area earmarked for the<br />
Contractor at the Contractor’s cost.<br />
(k) The Contractor shall be responsible for making suitable indoor storage facilities to store all<br />
equipment which required indoor storage. Normally, all the electrical equipment such as<br />
motors, control gear, generators, exciters and consumables like electrodes, lubricants etc.<br />
shall be stored in the closed storage space. The Engineer, in addition, may direct the<br />
Contractor to move certain other materials which in his opinion will require indoor storage<br />
areas which the Contractor shall strictly comply with.<br />
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44.18 Construction Management<br />
(a) The field activities of the Contractors working at site will be coordinated by the Engineer<br />
and the Engineer’s decision shall be final in resolving any disputes or conflicts between the<br />
contractors and tradesmen of the Purchaser regarding scheduling and co-ordination of<br />
work. Such decision by the Engineer shall not be a cause for extra compensation or<br />
extension of time for the Contractor.<br />
(b) The Engineer shall hold weekly meetings of all the Contractors working at site, at a time<br />
and a place to be designated by the Engineer. The Contractor shall attend such meetings<br />
and take notes of discussions during the meeting and the decisions of the Engineer and<br />
shall strictly adhere to those decisions in performing his works. In addition to the above<br />
weekly meetings, the Engineer may call for other meetings either with individual<br />
contractors or with selected number of contractors and in such a case the Contractor, if<br />
called, will also attend such meetings.<br />
(c) Time is the essence of the Contract and Contractor shall be responsible for performance of<br />
his woks in accordance with the specified construction schedule. If at anytime, the<br />
Contractor is falling behind the schedule, he shall take necessary action to make good for<br />
such delays by increasing his work to comply with the schedule and shall communicate<br />
such actions in writing to the Engineer, satisfying that his action will compensate for the<br />
delay. The Contractor shall note be allowed any extra compensation for such action.<br />
(d) The Engineer shall however not be responsible for provision of additional labor and/ or<br />
materials or supply or any other services to the Contractor except for the co-ordination<br />
work between various entities as set out earlier.<br />
44.19 Safety Regulations<br />
(a) Without prejudice to the general obligation under the statutes the Contractor shall ensure<br />
the safety of all the workmen, materials and equipment either belonging to his or to others<br />
working at site.<br />
b) The Contractor will notify the Engineer of his intention to bring on to site any equipment or<br />
any container, with liquid or gaseous fuel or other substance which may create hazard.<br />
The Engineer shall have the right to prescribe the conditions under which such equipment<br />
or container may be handled and used during the performance of the works and the<br />
Contractor shall strictly adhere to such instructions. The Engineer shall have the right to<br />
inspect any construction plant and to forbid its use, if in his opinion it is unsafe. No claim<br />
due to such prohibition shall be entertained by the Purchaser.<br />
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c) Where it is necessary to provide and / or store petroleum products or petroleum mixtures<br />
and explosives, the Contractor shall be responsible for carrying out such provision and / or<br />
storage in accordance with the rules and regulations laid down in Petroleum Act, 1934,<br />
Explosive Act 1948 published by the Chief Inspector of Explosives of India. All such<br />
storage shall have prior approvals of the Engineer. In case any approvals are necessary<br />
from the Chief Inspector of Explosives or any statutory authorities, the Contractor shall be<br />
responsible for obtaining the same.<br />
d) The Contractor shall be responsible for provisions of all safety notices and safety<br />
equipment required both by the relevant legislations and the Engineer as he may deem<br />
necessary.<br />
e) The Contractor shall be responsible for the safe storage of his and his sub - contractor’s<br />
radioactive sources, if any.<br />
f) In no circumstances will the Contractor interfere with fuses and electrical equipment<br />
belonging to the Purchaser or other Contractors.<br />
g) Before the Contractor connects any electrical appliances to and plug or socket belonging<br />
to the other Contractor or Purchaser, he shall -<br />
i) Satisfy the Engineer that the appliance is in good working condition;<br />
ii) Inform the engineer of the maximum current rating, voltage and phases of the<br />
appliances;<br />
iii) Obtain permission of the Engineer detailing the sockets to which the appliances<br />
may be connected.<br />
h) The Engineer will not grant permission to connect until he is satisfied that -<br />
i) The appliance is in good condition and fitting with a suitable plug;<br />
ii) The appliance is fitting with a suitable cable having two earth conductors, one of<br />
which shall be an earthed metal sheath surrounding the cores.<br />
i) No electric cable in use by the Contractor/Purchaser will be distributed without prior<br />
permission. No weight of any description will be imposed on any such cable and no ladder<br />
or similar equipment will rest against or he attached to it.<br />
j) No work shall be carried out on any live equipment. The equipment must be made safe by<br />
the Engineer and permit - to - work issued before any work is carried out.<br />
k) The Contactor employs the necessary number of qualified, full time electricians to maintain<br />
his temporary electrical installation.<br />
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45.00 FOREIGN PERSONNEL<br />
45.01 The Contractor shall submit to the purchaser data on all personnel he proposes to bring into India<br />
for the performance of the works under the contract at least sixty (60) days prior to their departure<br />
to India. Such data will include for each person the name, his present address, his assignment and<br />
responsibility in connection with the works, and a short resume of his qualification, experience etc.<br />
in relation to work to be performed by him.<br />
45.02 Any person unsuitable and unacceptable by the purchaser shall not be brought to India. Any<br />
person brought to India, if found unsuitable or unacceptable by the purchaser, the Contractor shall<br />
within a reasonable time make alternative arrangements for providing a suitable replacement and<br />
repatriation of such unsuitable personnel.<br />
45.03 No person brought to India for the purposes of the works shall be repatriated without any consent<br />
of the purchaser in writing, based on a written request from the Contractor for such repatriation<br />
giving reasons for such an action to the Engineer. The purchaser may give permission for such<br />
repatriation that the progress of work will not suffer due to such repatriation.<br />
45.04 The Contractor and his expatriate personnel shall respect all India Acts, Laws, rules and<br />
regulations and shall not in any way interfere with Indian political and religious affairs and shall<br />
conform to any other rules and regulations the Government of India, the purchaser and the<br />
Engineer may establish from time to time, on them.<br />
The Contractor expatriate personnel shall work and living in close coordination and coordination<br />
with their co workers and the community and shall not engage themselves in any other<br />
employment either part - time or full - time nor shall they take part in any local politics.<br />
45.05 The purchaser shall assist the Contractor, to the extent possible in obtaining necessary permits to<br />
travel to India and back by issue of necessary certificates and other information needed by the<br />
Government agencies.<br />
46.00 DEATH, BANKRUPTCY ETC.<br />
If the Contractor shall die or dissolve or commit any act of bankruptcy or being a Corporation,<br />
commence to be wound up except for reconstruction purposes or carry on its business under a<br />
receiver, the executors, successors or other representatives in law of the estate of the Contractor<br />
or any such receiver, liquidator or any person in whom the contract may become vested, shall<br />
forthwith give notice thereof in writing to the purchaser and shall for one month, during which he<br />
shall take all reasonable steps to prevent a stoppage of the work, have the option of carrying out<br />
the contract subject of the approval of Purchaser and subject to his or their providing such<br />
guarantee as may be required by the Purchaser but not exceeding the value of works for the time<br />
being remaining unexecuted, provided however that nothing above said shall be deemed to relieve<br />
the Contractor or his successors of his or their obligations under the contract under any<br />
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circumstances. In the event of stoppage of the works the period of the option under this clause<br />
shall be fourteen (14) days only, provided that should be above option be not exercised, the<br />
contract may be terminated by the purchaser by notice in writing and the same power and<br />
provisions reserved to the Purchaser in clause `Negligence’ in the event of taking the work out of<br />
the Contractor’s hands shall immediately become operative.<br />
47.00 GRAFTS AND COMMISSION ETC.<br />
Any graft, commission, gift or advantage given promised or offered by or on behalf of the<br />
Contractor or his partner, agent, officers, director, employee or servant or any one on his or their<br />
behalf in relation to the obtaining or to the execution of this or any other contract with purchaser,<br />
shall in addition to any criminal liability which it may incur, subject the contractor to the cancellation<br />
of this and other contracts and also to payment of any loss or damage to the purchaser resulting<br />
from any cancellation. The purchaser shall then be entitled to deduct the amounts so payable from<br />
any money otherwise due to the Contractor under the contract.<br />
48.00 COMPLETION OF CONTRACT<br />
Unless otherwise terminated under the provisions of any other relevant clause, this contract shall<br />
be deemed to have been completed all the expiration of the guarantee period as provided for under<br />
the clause entitled `Guarantee Period’ as provided for under the clause entitled `Guarantee’ and<br />
only on issue of a certificate to that effect and not otherwise.<br />
49.00 DEFENCE OF SUITS<br />
In any action in court is brought against the purchaser or Engineer or an officer or agent of the<br />
purchaser, for the failure or neglect on the part of the contractor to perform any acts, matters,<br />
convenants or things under the contract, or for damage or injury caused by the alleged omission or<br />
negligence on the part of the Contractor, his agents, representatives or his sub-contractors,<br />
workmen, suppliers, or employees, the Contractor shall in all such cases indemnify and keep the<br />
purchaser, and the Engineer and / or his representative harmless from all losses, damages,<br />
expenses or decrees arising of such action.<br />
50.00 ARBITRATION<br />
All disputes or differences arising under the contract whether during or after completion of the<br />
contractor or whether before or after determination, for closure or breach of the contract (other than<br />
those in respect of which the decision of any person is by the contract expressed to the final and<br />
binding) shall after written notice by either party to the contract to the other of them and to the<br />
Appointing Authority hereinafter mentioned be referred for adjudication to a sole Arbitrator to be<br />
appointed as hereinafter provided.<br />
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For the purpose of appointing the sole Arbitrator referred to above, the CMD NALCO who shall be<br />
Appointing Authority will send within thirty days of receipt of the notice to the Contractor a panel of<br />
three names of persons.<br />
The Contractor shall on receipt of the names as referred select any one of the person names to be<br />
appointed as a sole Arbitrator and communicate his name to the Appointing authority within thirty<br />
days of receipt of the names. The Appointing Authority shall there upon appoint the said person as<br />
the sole Arbitrator. If the Contractor fails to communicate such selection as provided above within<br />
the period specified, the Appointing Authority shall make the selection and appoint the selected<br />
person as the Sole Arbitrator.<br />
If the Arbitrator so appointed is unable to / unwilling to act or resigns his appointment or vacates his<br />
office due to any reason whatsoever sole arbitrator or shall be appointed as aforesaid. The work<br />
under the contract shall not be stopped during the arbitration proceedings.<br />
The Arbitrator shall be deemed to have entered on the reference on the date he issues notices to<br />
both the parties fixing the date of first hearing.<br />
The Arbitrator may, from time to time, with the consent of the parties, enlarge the time for making<br />
and publishing the awards.<br />
The Arbitrator shall give a separate award in respect of each dis pute or difference and shall give a<br />
reasoned and speaking award / awards.<br />
The venue of arbitration shall be at Bhubaneswar. However, if the situation so warrants, it may as<br />
and when required, he held at the place where the site of work is situated.<br />
The fees, if any, of the Arbitrator shall, if required to be paid before award is made and published,<br />
be paid half and half by each of the parties. The cost of the reference and of the award including<br />
the fees, if any, of the Arbitrator shall be in the discretion of the Arbitrator who may direct to and by<br />
whom and in what manner, such costs or any part thereof shall be paid and may fix or settle the<br />
amount of costs to be so paid.<br />
The award of the arbitrator shall be final and binding on both the parties.<br />
Subject to aforesaid the provisions of the Arbitration Act 1940 or any statutory modification or reenactment<br />
thereof and the rules made there under, and for the time being in force, shall apply to<br />
the arbitration proceeding under this clause.<br />
For Public Sector Enterprises guidelines as per circular of BPE No. 15.9.86 - BPE (FIN) dtd.<br />
30.03.1989 as amended from time to time will be applicable for resolving any disputes.<br />
51.00 CORRESPONDENCE<br />
The Purchaser shall ordinarily correspond with the Contractor at the address furnished by the<br />
Contractor.<br />
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The Contractor shall ordinarily forward two (2) copies of all correspondence relating to this contract<br />
to the Purchaser and two (2) copies to the Consulting Engineer or his representative as may be<br />
requested.<br />
Two (2) copies of all correspondence from the Contractor to Purchaser’s other Contractors for<br />
associated plants shall be forwarded to the Purchaser and the Consulting Engineer.<br />
All drawings and correspondence to the Purchaser and the Consulting Engineer shall be<br />
transmitted by the Contractor via Air Mail or alternatively by means involving the minimum time of<br />
transit.<br />
52.00 CONTRACT AGREEMENT<br />
If so desired by the Purchaser, a formal Agreement shall be entered into by the Contractor with the<br />
Purchaser for the proper fulfillment of the Contract.<br />
The expenses of completing and stamping the Agreement shall be paid by the Contractor, and the<br />
Purchaser shall be furnished free of charge with an executed stamped counterpart of the<br />
Agreement as also copies of the Agreement as may be required by the purchaser.<br />
Any tender drawing, technical data and / or correspondence which forms the basis of an order or a<br />
contract aforesaid, or which may be furnished by the Contractor for the Purchaser’s approval or<br />
information as provided under the said order or contract, shall be in English and it is in any other<br />
language, a complete translation in English shall have to be duly furnished. The Purchaser shall<br />
not be bound to consider any tender drawing, technical data or correspondence which is not<br />
furnished in English.<br />
53.00 PAYMENTS<br />
53.01 The payment to the Contractor for the performance of the works under the contract will be made by<br />
the purchaser as per the guidelines and conditions specified herein. All payments made during the<br />
contract shall be on account of payments only. The final payment will be made on completion of all<br />
the works and on fulfillment by the Contractor of all his liabilities under the contract.<br />
53.02 Currency of Payment<br />
The payments for the foreign currency potion of the contract price will be made in the currency of<br />
the bid. If the bid is in a currency other than that of the country of origin of goods, payment may be<br />
made in an amount equivalent to the bid price in the currency of the country of origin. The Indian<br />
Rupees portion of contract price stated in the contractor’s bid will be paid in Indian Rupees.<br />
53.03 Payment Schedule<br />
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The Contractor shall prepare and submit to the Engineer for approval, break-up of the contract<br />
price. The contract price break-up shall be interlinked with the agreed detailed PERT Network of<br />
the Contractor setting forth his starting and completion dates for the various key phases of works.<br />
Any payment under the contract shall be made only after the contractor’s price break-up is<br />
approved by the Engineer. The aggregate sum of the contractor’s price break down shall be equal<br />
to the lump sum contract price.<br />
53.04 Application for Payments<br />
The Contractor shall submit application for the payments in the prescribed proforma of the<br />
purchaser.<br />
The foreign contractor shall submit to the Engineer separate applications for payment in different<br />
currencies whenever payment is to be made in more than one currency.<br />
Each such application shall state the amount claimed and shall set forth in details, in the order for<br />
the payment schedule particulars of the works including the works executed at site and of the<br />
equipment shipped/brought on to the site pursuant to the contract up to the date mentioned in the<br />
application and for the period covered since the last preceding certificate, if any.<br />
Every interim payment certificate shall certify the contract value of the works executed up to the<br />
date mentioned in the application of the payment certificate, provided that no sum shall be included<br />
in any interim payment certificate in respect of the works that, according to the decision of the<br />
Engineer, does not comply with the contract, or has been performed, at the date of certificate<br />
prematurely.<br />
53.05 Terms of Payment<br />
Subject to any deduction which the Purchaser may be authorized to make under the contract, the<br />
Contractor shall, on the certificate of the Engineer be entitled to payments generally as follows:<br />
A) Supply<br />
- 80% shall be paid for each consignment dispatched pro-rata against presentation<br />
of each invoices and evidence of shipment/dispatch.<br />
- 10% shall be paid after completion of erection.<br />
- 10% shall be paid after completion of satisfactory commissioning and performance<br />
guarantee tests.<br />
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B) Marine Freight and Insurance<br />
The ocean freight wherever payable shall be paid on production of invoices, evidence of<br />
shipment and other supporting documents for ocean freight and marine insurance<br />
components. In case of contracts inclusive of ocean freight and marine insurance total of<br />
the payments shall not exceed the total amount quoted by the Contractor in his bid.<br />
C) Inland Transportation and Inland Insurance<br />
Inland transportation (including port handling) shall be paid after the equipment has been<br />
received at site on production of invoices for such charges. Wherever this is included in the<br />
contract the aggregate of all such invoices shall not exceed the total amount indicated by<br />
the Contractor in his proposal.<br />
D) Erection Services<br />
54.00 MISCELLANEOUS<br />
54.01 Entire Agreement<br />
- 80% shall be paid for the progress made during the month on monthly progress<br />
bills against certification by the Engineer.<br />
- 10% shall be paid on completion of erection and Tests on Completion.<br />
- 10% shall be paid on completion of the successful commissioning and guarantee<br />
tests.<br />
These General Conditions together with the specification, tender drawing and guaranteed technical<br />
particulars, tender data with subsequent agreed modification thereof shall constitute the entire<br />
Agreement between the parties in respect of the subject matter hereof. No variation or modification<br />
of the contract or waiver of any of the terms and conditions thereof shall be deemed valid unless in<br />
writing and signed by the parties hereto.<br />
54.02 General Conditions of Contract, the tender specifications and other contract / tender documents<br />
are to be taken as mutually explanatory to one another. However, in case of conflict between these<br />
documents, the technical specification, special conditions of the contract and general conditions of<br />
the contract shall have precedence in that order.<br />
54.03 Endorsement of Terms<br />
The failure of either party to endorse at any time any of the provisions of the contract or any rights<br />
in respect thereto or to exercise an option herein provided shall in no way be construed to be a<br />
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waiver of such provisions, rights or option or in way to effect the validity of the Contractor. The<br />
exercise by either party of any of his rights here in shall not preclude or prejudice either party from<br />
exercising the same or any other right it may have hereunder.<br />
54.04 Contract Labor Regulation & Abolition<br />
The Contractor shall be responsible for all statutory obligations under Contract Labor (Regulation &<br />
Abolition) Act 1970. E.S.I. and Provident Fund Acts, as applicable, for their labor and staff engaged<br />
in executing this work. The Contractor will also keep the Purchaser indemnified against all claims<br />
and disputes arising out of death or injury to their workmen and staff. It will be necessary for the<br />
contractor to ensure that proper safety measures are followed by their workmen to avoid<br />
accident/damage/loss to life and property. Approved safety belts must be used by their workmen<br />
when working at any height. Charges for above are deemed included in the quoted rates and<br />
accepted amount.<br />
54.05 Recover of Damages<br />
Nothing contained in the conditions or in any other part of this Contract shall be construed as<br />
preventing the Purchaser from the Contractor any damages to which the purchaser may be entitled<br />
in law as a consequence of any breach by the Contractor of any of the terms of this Contract.<br />
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1.0 SCOPE<br />
ADDENDUM TO TENDER DOCUMENT (COMMERCIAL)<br />
Page 1 of 11<br />
ANNEXURE - IV<br />
1.1 The subject enquiry is being issued on turnkey basis with entire responsibility of design,<br />
engineering up to Commissioning and handing over of plant / equipment / system to the Owner.<br />
Owner intends to enter into two separate contracts (if placed) as follows to rationalize tax liability as<br />
per legal provision of country and also for operational convenience.<br />
(a) Basic design, engineering, supply of equipments and materials including all necessary<br />
accessories, Spares at Site<br />
(b) Unloading, storage, handling of equipments at site, complete Construction, Erection, Testing and<br />
Commissioning services, Supervision and Training Services<br />
1.2 The Contract-cum-Performance Bank Guarantee for 10% of Total Order Value for both the<br />
contracts shall be furnished by the vendor to the Owner.<br />
2.0 PAYMENT TERMS<br />
2.1 Following Payment Terms will be applicable:<br />
(i) For Supply (including Design & Engineering):<br />
(i) 80% payment on prorate basis against presentation of dispatch documents.<br />
(ii) 10% payment shall be made after completion of erection.<br />
(iii) Balance 10% payment shall be made after final handing over of equipments to the Owner<br />
at site.<br />
(ii) Inland Transportation<br />
Charges for inland transportation shall be paid after the equipment is received at Site against<br />
invoices.<br />
(iii) Site Work<br />
(i) 90% against monthly progressive billing duly certified by Site In- charge.<br />
(ii) 10% within 30 days of final handing over of the equipment to Owner at site.<br />
2.2 Invoices should be submitted along with certificate stating “It is certified that Cenvatable/ VAT<br />
Invoices have been issued in the name of consignee, for full amount of Excise Duty/ Sales Tax/<br />
Service Tax charged in the Invoice, as per rules in force. Vendor agrees to reimburse Excise Duty/
Tender Notice No. - …………..............<br />
2.3 NOTE:<br />
Sales Tax/ Service Tax, if documents are not found to be in order for claiming Cenvat/ VAT<br />
benefits.”<br />
(i) Final Handing Over:<br />
Final Handing Over shall mean Commissioning including acceptance of PG Tests. However, in<br />
case PG Test could not be conducted within 6 months from commissioning, for reasons not<br />
attributable to vendor, last 10% payment will be released against a Bank Guarantee of equal<br />
amount valid for 12 months initially and extendable thereafter.<br />
(ii) Payment for indigenous supply shall be through Bank against dispatch documents. Payment<br />
through bank shall be as per normal banking procedure.<br />
Direct Payment can be made through e-payment mode through SBI as well as NEFT/RTGS mode<br />
through designated enabled branches. In case of Direct Payment, duly filled Bank Mandate form in<br />
duplicate should be furnished with due authentication from bidder’s Banker<br />
3.0 TAXES & DUTIES<br />
3.1 All taxes and duties including Excise Duty and concessional CST/ VAT but excluding Sales Tax on<br />
Works Contract will be paid against Documentary Evidence at actuals limited to amount quoted in<br />
price bids. However, statutory variations (on finished products) will be allowed against<br />
documentary evidence. Vendor shall provide break up along with billing schedule subject to ceiling<br />
limit quoted in price bid.<br />
3.2 Service Tax and E-cess applicable should be clearly indicated with ceiling limit to be paid against<br />
documentary evidence and invoice raised in line with Service Tax Rule to enable NALCO to avail<br />
Cenvat.<br />
3.3 Vendors are required to quote prices inclusive of Works Contract Tax and no variation is payable<br />
on this account. In case vendor insists on WCT variation, rate of WCT and amount should be<br />
mentioned in the bid, without which statutory variation will not be admissible.<br />
3.4 It is to be noted that the Contractor shall be required to submit the documentary evidence(s) for<br />
Excise Duty paid by them to concerned authorities for Owner to claim CENVAT benefit.<br />
3.5 Necessary Cenvatable documents such as Transporter’s copy of Challan / Bill of Entry Triplicate<br />
Copy for availing Cenvat benefit to be given in NALCO’s name indicating consignee as NALCO for<br />
availing Excise Duty, Copy of Registration with Central Excise Authority and any other document<br />
required by the Owner shall be furnished by Contractor to enable Owner to claim CENVAT.<br />
3.6 The classification of goods as per Central Excise Customs Tariffs should be correctly done to<br />
ensure that CENVAT benefits is not lost by the Owner on account of any error on the part of the<br />
Contractor. The Owner shall be at liberty to withhold the payment of cenvatable duties (viz. Central<br />
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Tender Notice No. - …………..............<br />
Excise Duties, Countervailing Duties of Customs etc.) If the requirements as specified in the clause<br />
are not fulfilled by the Contractor. The price of materials shall stand reduced accordingly.<br />
3.7 The Contractor shall furnish the details of Excise Duty and CD/CVD component included his price<br />
for the purpose of cenvat benefit.<br />
The amount of ED and CVD indicated as part of Quoted Price is for information only. Contractor is<br />
required to pay all taxes & duties nevertheless and must furnish Cenvatable documents for the<br />
amount of ED and CVD paid by him, subject to minimum of the amount of ED and CVD indicated<br />
by him in his bid.<br />
3.8 Entry Tax shall be paid by NALCO for consignments coming from outside Orissa. For supplies to<br />
be made from Orissa, Entry Tax shall be paid by Seller and should be mentioned in the Invoices for<br />
reimbursement by NALCO.<br />
4.0 INSURANCE<br />
4.1 The Owner will arrange for insurance of equipment and material under the scope of the Contract as<br />
detailed in Tender Documents - Commercial.<br />
4.2 The Contractor shall deal directly with the Insurance Company. The Contractor will be required to<br />
lodge all the claims of his part of the contract directly and arrange settlement as expeditiously as<br />
possible by complying with the required formalities and proper follow ups.<br />
4.3 The contractor shall bear the entire cost of corresponding with the Insurer and arrange all<br />
documents/informations facilitating inspection/discussions by the officials/surveyors deputed by the<br />
Insurer. The Contractor shall make all efforts to get settlement of claim at the earliest and no time<br />
extension for completion of work will be given for delay on this account.<br />
4.4 In respect of equipment damaged in transit or during erection & commissioning, the contractor shall<br />
arrange for replacement/ repair expeditiously. The replacement cost payable by the owner shall be<br />
limited to the invoice cost of damaged equipment. The cost payable for repair shall be mutually<br />
settled.<br />
4.5 Contractor shall be liable solely to adhere to the requirements of the insurer for settlement of<br />
claims without prejudice to the rights of Contractor / NALCO / Insurer. Following steps are listed,<br />
however not exhaustively, for the information of contractor.<br />
(a) Timely information for conducting survey.<br />
(b) Protecting the rights of insurer while issuing acknowledgments.<br />
(c) Lodging of monitory claims in time and furnishing of requisite documents to surveyors /<br />
insurers.<br />
(d) Taking necessary precautions so that the loss/damage is not aggravated further.<br />
(e) Damaged goods to be protected fully.<br />
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Tender Notice No. - …………..............<br />
4.6 Employees State Insurance Act<br />
(i) The Contractor agrees to and does hereby accept full and exclusive liability for the compliance with<br />
all obligations imposed by the Employee State Insurance Act 1948 and the Contractor further<br />
agrees to defend, indemnify and hold Owner harmless for any liability or penalty which may be<br />
imposed by the Central, State or Local authority by reasons of any asserted violation by Contractor<br />
or his Sub-contractor of the Employees’ State Insurance Act, 1948 and also from all claims, suits or<br />
proceeding that may be brought against the Owner arising under, growing out of or by reasons of<br />
the work provided for by this Contractor, whether brought by employees of the contractor, by third<br />
parties or by Central or State Government authority or any political sub-division thereof.<br />
(ii) The Contractor agrees to fill in with the Employee’s State Insurance Corporation, the Declaration<br />
forms, and all forms which may be required in respect of the Contractor’s or his Sub-contractor’s<br />
employees, who are employed in the WORK provided for or those covered by ESI from time to<br />
time under the Agreement. The Contractor shall deduct and secure the agreement of his subcontractor<br />
to deduct the employee’s contribution as per the first schedule of the Employee’s State<br />
Insurance Act from wages and affix the Employees Contribution Card at wages payment intervals.<br />
The contractor shall remit and secure the agreement of his sub-contractor to remit the State Bank<br />
of India, Employee’s State Insurance Corporation account the Employees contribution as required<br />
by the Act. The Contractor agrees to maintain all Cards and Records as required under the Act in<br />
respect of employees and payments and the contractor shall secure the agreement of his subcontractor<br />
to maintain such records. Any expenses incurred for the contributions; making<br />
contributions or maintaining records shall be to the Contractor’s or his Sub-contractor’s account.<br />
(iii) Owner shall retain such sum as may be necessary from the total value of contract until the<br />
Contractor shall furnish satisfactory proof that all contributions as required by the Employees State<br />
Insurance Act, 1948 have been paid. This will be pending on the Contractor when the ESI Act is<br />
extended to the place of work.<br />
4.7 Workmen’s Compensation & Employer’s Liability Insurance<br />
Insurance shall be effected by Contractor for all their employees engaged in the performance of<br />
this Contract. If any of the work is sublet, the Contractor shall require his sub-contractor to provide<br />
workman’s Compensation and employer’s liability insurance for the later’s employees if such<br />
employees are not covered under the Contractor’s insurance.<br />
4.8 Comprehensive Automobile Insurance<br />
This insurance shall be in such a form to protect the Contractor against all claims for injuries,<br />
disability, disease and death to members of public including the Owner’s men and damage to the<br />
property of others arising from the use of motor vehicles, during on or off the Site Operations,<br />
irrespective of the ownership of such vehicles.<br />
4.9 Comprehensive General Liability Insurance<br />
This insurance shall protect the Contractor against all claims arising from inuries, disabilities,<br />
disease or death of members of public or damage to property of others, due to any act or omission<br />
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on the part of the Contractor, his agents, his employees, his representative and Sub-Contractors or<br />
from riots, strikes and civil commotion. This insurance shall cover all the liabilities of the contractor<br />
arising out of the relevant clauses of enquiry documents.<br />
The hazards to be covered will pertain to all the works which and areas where, the Contrctor, his<br />
Sub-Contractors, his agents and his employees have to perform work pursuant to the contract.<br />
The above are only illustrative list of insurance covers normally required and it will be the<br />
responsibility of the contractor to maintain all necessary insurance coverage to the extent both in<br />
time and amount to take care of all his liabilities either direct or indirect, in pursuance of the<br />
contract.<br />
4.10 Any other Insurance required under Law or Regulations or by Owner<br />
Contractor shall also carry and maintain any and all other Insurance(s) which he may be required<br />
under any law or regulation from time to time without any extra cost to Owner. He shall also carry<br />
and maintain any other insurance which may be required by the Owner.<br />
4.11 Accident or Injury to Workmen<br />
Owner shall not be liable for or in respect of any damages or compensation payable at law in<br />
respect or in consequence of any accident or injury to any workman or other person in the<br />
employment of the Contractor or his Sub-Contractor and the Contractor shall indemnify and keep<br />
indemnified the Owner against all such damages and compensation and against all claims,<br />
demands, proceedings, costs, charges and expenses, whatsoever in respect or in relation thereto.<br />
5.0 CONSTRUCTION, ERECTION OF PLANT AND MATERIAL<br />
5.1 Contractor’s Material brought on the Site<br />
The Contractor shall bring to Site all equipments, components, parts, materials, including<br />
construction equipment, tools and tackles for the purpose of the Works under intimation to the<br />
Owner. All such goods shall, from the time of their being brought vest in the Owner, but may be<br />
used for the purpose of the Works only and shall not on any account be removed or taken away by<br />
the Contractor without the written permission of the Owner. The Contractor shall nevertheless be<br />
solely liable and responsible for any loss or destruction thereof and damage thereto.<br />
5.2 Work & Services to be provided by the Owner<br />
Works and services which shall be provided by the Owner for carrying out complete work at Site<br />
shall be as defined in the technical part of the Enquiry Documents and its clarification up to award<br />
of Contract.<br />
(a) Water supply for construction purpose may be provided by the Owner at one mutually<br />
agreed point at Site. Drinking water will also be made available at one central point at<br />
Site. The Contractor shall make his own arrangement for any further distribution. Such<br />
distribution pipe network shall have the prior approval of the Engineer at Site so as not to<br />
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interfere with the layout and progress of other construction works. Supply of water shall be<br />
charged from Contractor at the rates prevailing at Site.<br />
Contractor shall ensure that there is no wastage of water. On completion of the work, the<br />
Contractor shall remove all such work and shall reinstate and make good any work<br />
disturbed to the satisfaction of the Engineer.<br />
(b) Cranes, if available, will be provided by Owner on payment of rent to the Owner.<br />
5.3 Work and Services to be provided by the Contractor<br />
The following work and services shall also be provided under the contract :<br />
(i) Material transportation to erection site at Contractor’s risk and cost.<br />
(ii) All construction activities to complete the plant as per the specifications agreed by the<br />
Owner. The activities shall be included but not limited to building structures, rooms,<br />
foundations for equipments and accessories and stack etc.<br />
(iii) Labor license for contractor and sub-contractor’s labor if required / applicable as per State<br />
Govt.<br />
5.4 Owner’s Lien on Equipments<br />
The Owner shall have lien on all equipments including those of the Contractor brought to the Site<br />
for the purpose of construction, erection, testing and commissioning of the plant. The Owner shall<br />
continue to hold the lien on all such equipments throughout the period of Contract. No material<br />
brought to the Site shall be removed from the Site by the Contractor and / or his Sub-contractors<br />
without the prior written approval of the Owner.<br />
5.5 Protection of Work<br />
The contractor shall have total responsibility for protecting his Works till it is finally taken over by<br />
the Owner. No claim will be entertained by the Owner or the Consultant for any damage or loss to<br />
the Contractor’s Works and the Contractor shall be responsible for the complete restoration of the<br />
damaged works to its original condition to comply with the specifications and drawings. Should any<br />
such damage to the Contractor’s Works occur because of other party not under his supervision or<br />
control, the Contractor shall make his claim directly with the party concerned. If disagreement or<br />
conflict or dispute develops between the Contractor and the party or parties concerned regarding<br />
the responsibility for damage to the Contractor’s Works the same shall be resolved as per the<br />
provisions of the clause entitled ‘Co-operation with other Contractors’. The Contractor shall not<br />
cause any delay in the repair of such damaged works because of any delay in the resolution of<br />
such disputes. The Contractor shall proceed to repair the work immediately and no cause thereof<br />
will be assigned pending resolution of such dispute.<br />
Page 6 of 11
Tender Notice No. - …………..............<br />
5.6 Security<br />
The Contractor shall have total responsibility for all equipments and materials in his custody stored,<br />
loose, semi-assembled and / or erected by him at Site. The Contractor shall make suitable security<br />
arrangements including employment of security personnel to ensure the protection of all materials,<br />
equipment and works from theft, fire, pilferage and any other damages and loss. All materials of<br />
the Contractor shall enter and leave the Project Site only with the written permission of the Owner<br />
in the prescribed manner.<br />
Contractor’s employees shall wear identification badges while on the work at Site.<br />
5.7 Contractor’s Area Limits<br />
The Owner will mark-out the boundary limits of access road, parking spaces, storage and<br />
construction areas for the Contractor and the Contractor shall not trespass the areas not so<br />
marked out for him. The Contractor shall be responsible to ensure that none of his personnel<br />
move out of the areas marked out, for his operation. In case of such a need for the Contractor’s<br />
personnel to work, out of the areas marked out for him, the same shall be done only with the<br />
written permission of the Owner.<br />
5.8 Contractor’s Co-operation with the Owner<br />
In cases where the performance of the Site Work by the Contractor affects the operation of the<br />
system facilities of the Owner such Site Work of the Contractor shall be scheduled to be performed<br />
only in the manner stipulated by the Owner and the same shall be acceptable at all times to the<br />
Contractor. The Owner may impose such restriction on the facilities provided to the Contractor<br />
such as electricity, water, etc. as he may think fit in the interest of the Owner and the Contractor<br />
shall strictly adhere to such restrictions and co-operate with the Owner. It will be responsibility of<br />
the Contractor to provide all necessary temporary instrumentation and other measuring devices<br />
required during start-up and operation of the equipment systems which are erected by him. The<br />
Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants<br />
required for the equipment supplied and erected by him, so as to make such equipments ready for<br />
operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants<br />
unless otherwise specified elsewhere in these documents and specifications.<br />
5.9 Protection of Property and Contractor’s Liability<br />
5.9.1 The Contractor shall be responsible for any damage resulting from his operations. He shall also be<br />
responsible for protection of all persons including members of public and employees of the Owner<br />
and the employees of other Contractors and Sub-Contractors and all public and private property<br />
including structurs, building, other plants and equipments and utilities either above or below the<br />
ground.<br />
5.9.2 The Contractor will ensure provisions of necessary safety equipment such as barriers, sign-boards,<br />
warning lights and lamps, etc. to provide adequate protection to persons and property. The<br />
Contractor shall be responsible to give reasonable notice to the Owner and the Owner of public or<br />
private property and utilities when such property and utilities are likely to get damaged or injured<br />
Page 7 of 11
Tender Notice No. - …………..............<br />
during the performance of his works and shall make all necessary arrangements with Owners,<br />
related to removal and/or replacement of such property and utilities.<br />
5.10 Painting<br />
All exposed metal parts of the equipment including piping, structures railing, etc. wherever<br />
applicable, after installation unless otherwise surface protected, shall be first painted with at least<br />
one coat of suitable primer which matches the shop primer paint used, after thoroughly cleaning all<br />
such parts of all dirt, rust, scales, greases, oil and other foreign materials by wire brushing,<br />
scraping or sand blasting, and the same being inspected and approved by the Engineer for<br />
painting. Afterwards, the above parts shall be finished with two coats of a alloyed resin machinery<br />
enamel paints. The quality of the finish paint shall be as per the standards of ISI or equivalent and<br />
to be of the colour as approved by the Owner.<br />
5.11 Unfavorable Working Conditions<br />
The Contractor shall confine all his field operations to those works which can be performed without<br />
subjecting the equipment and materials to adverse effects, during inclement weather conditions,<br />
like monsoon, storms, etc. and during other unfavourable construction conditions. No field<br />
activities shall be performed by the Contractor under conditions which might adversely affect the<br />
quality and efficiency thereof unless special precautions or measures are taken by the Contractor<br />
in a proper and satisfactory manner in the performance of such works and with the concurrence of<br />
the Consultant/Owner. Such unfavorable construction conditions will in no way relieve the<br />
contractor of his responsibility to perform the works as per the schedule.<br />
5.12 Protection of monuments and reference points<br />
The Contractor shall ensure that any finds such as relic, antiquity, coins, fossile, etc. which he may<br />
come across during the course of performance of his works either during excavation of elsewhere,<br />
are properly protected and handed over to the Owner. Similarly, the Contractor shall ensure that<br />
the bench marks, reference points, etc. which are marked out either with the help of Owner or by<br />
the Owner shall not be disturbed in any way during the performance of his works. If any work is to<br />
be performed which may disturb such reference, the same shall be done only after these are<br />
transferred to other suitable locations under the direction of the Owner.<br />
6.0 CONSTRUCTION<br />
6.1 Rules and Regulations<br />
6.2 Safety<br />
Contractor shall observe all national and local laws, ordinaces, rules and regulations pertaining to<br />
the work, and shall be responsible for extra costs arising from violations of same.<br />
Contractor shall take all necessary measures to protect the work and workmen against accidents<br />
and occupational disease. They shall observe and comply with all Government safety regulations<br />
as specified by the Owner.<br />
Page 8 of 11
Tender Notice No. - …………..............<br />
The Contractor shall be responsible for following the proper procedures in reporting accidents or<br />
incident.<br />
The Owner’s Safety Engineer located in Site will be immediately notified by faster means possible<br />
of any accident which involves the following:<br />
(a) Death from any cause whatsoever.<br />
(b) A fractured skull, arm, thigh or spine, fore-arm or leg.<br />
(c) A dislocated shoulder.<br />
(d) The amputation of arm or hand, or of one or more fingers on the same hand, or of a leg or<br />
a foot.<br />
(e) The loss of sight of an eye.<br />
(f) Any other serious bodily injury, including internal bleeding or burns or asphyxia where such<br />
injury is likely to endanger life, cause permanent incapacity or temporary incapacity of 5<br />
days or more.<br />
6.3 In case of death, the Contractor shall be responsible for immediately notifying the nearest Indian<br />
Police so that they can make the proper investigation in accordance with the law.<br />
7.0 FOREIGN LIABILITY CLAUSE<br />
It is expressly understood and agreed by and between (the Corporation0 and M/s National<br />
Aluminium Company Limited (The Indian PSU) that M/s National Aluminium Co. Ltd. (the Indian<br />
PSU) is entering into this agreement solely on its own behalf and not on behalf of any other person<br />
or entity. In particular, it is expressly understood and agreed that the Government of India is not a<br />
party to this agreement and has no liabilities, obligations or rights hereunder. It is expressly<br />
understood and agreed that M/s National Aluminium Co. Ltd. (the Indian PSU) is an independent<br />
legal entity with power and authority to enter into contracts solely in its own behalf under the<br />
applicable Law of Indian and General Principles of Contract Law. The (Company) expressly<br />
agrees, acknowledges and understands that M/s National Aluminium Co. Ltd. (the Indian PSU) is<br />
not an agent, representative or delegate of the Government of India. It is further understood and<br />
agreed that the Government of India is not and shall not be liable for any acts, omissions,<br />
commissions, breaches or other wrongs arising out of the Contract. Accordingly (corporation)<br />
hereby expressly waives, releases and foregoes any and all actions or claims including cross<br />
claims, impleader claims or counter claims against the Government of India arising out of this<br />
contract and covenents not to sue the Government of India as to any manner, claim, cause of<br />
action or thing whatsoever arising of or under this agreement.<br />
8.0 CLAUSE 44.02: REGULATION OF LOCAL AUTHORITIES & STATUES (TENDER DOCUMENT<br />
COMMERCIAL - INDIGENOUS)<br />
8.1 The following is to be read along with Clause 44.02:-<br />
(a) The payment of minimum wages to Contract Labour shall be as per the rates notified by the<br />
central Government as per Minimum Wages Act,1948 and as adopted by the NALCO<br />
Management from time to time plus any additional element and statutory dues thereon.<br />
Page 9 of 11
Tender Notice No. - …………..............<br />
(b) The Minimum wage as notified by the Chief Labour Commissioner (central) has a variable<br />
component as Special allowance which is linked to average AICPI for Industrial Workers,<br />
which keeps on changing every six months. The Contractor has to absorb all such variations<br />
due to increase in Minimum wage in their quoted price and no claim whatsoever on this<br />
account shall be entertained.<br />
(c) Where the Minimum wages notified by the concerned State Government are higher than the<br />
rates notified by the Central Government, the States Government rates should apply in<br />
concerned scheduled employment as long as the same remains higher than the Central<br />
Government rates.<br />
(d) The classification on workers in different categories will be as per the notification issued by the<br />
Central Government fixing the minimum wages for the above scheduled appointment.<br />
8.2 The classification of workers in different categories will be as per the notification issued by the<br />
Central government fixing the minimum wages for the above scheduled appointment. Where the<br />
minimum wages notified by the concerned State Government are higher than the rates notified by<br />
Central Government, the State Government rates should apply in concerned scheduled<br />
employments.<br />
9.0 GUARANTEE PERIOD<br />
Guarantee Period shall be 12 months from commissioning (including acceptance of<br />
Performance Guarantee Tests) or 24 months from completion of erection, whichever is earlier.<br />
All other provisions of the clause remain unaltered.<br />
10.0 CONTRACT PERFORMANCE GUARANTEE<br />
Supplier will be required to submit Contract - cum - Performance Bank Guarantee (CPBG) for 10%<br />
of Total Order Value (Supply + Transportation + Supervision + Site Work) for the complete<br />
package within 30 days of placement of order with validity up to 3 months beyond Guarantee<br />
Period. All payments shall be released after receipt of CPBG.<br />
11.0 CONSTRUCTION POWER<br />
Construction power rate indicated in Tender Documents Commercial is modified as “As applicable<br />
at Site” in place of Rs. 1/- per KWH.<br />
12.0 PRICE REDUCTION SCHEDULE<br />
(i) Liquidated Damages (LD) wherever mentioned in NIT documents, is to be read as Price Reduction<br />
Schedule (PRS).<br />
(ii) The Contractor’s liability for delay shall not in any case exceed five percent of the total contract<br />
price.<br />
All other provisions of these clauses remain unaltered.<br />
Page 10 of 11
Tender Notice No. - …………..............<br />
13.0 POWER TO VARY OR OMIT WORK<br />
13.1 In partial modification to clause No. - 29 of GCC - Indigenous the last sentence of this clause is<br />
amended as follows:<br />
“In the absence of any such modification, the contractor shall bind to carry out the suggested<br />
variations. Any addition or deletion to price will be discussed between purchaser and contractor<br />
and settled.”<br />
13.2 All other provisions of this clause remain unaltered.<br />
Note: The terms and conditions mentioned herein will prevail over the terms mentioned in tender<br />
document commercial (indigenous).<br />
Page 11 of 11
IMPORTANT<br />
AGREED TERMS & CONDITIONS (INDIGENOUS)<br />
NALCO, SMELTER PLANT<br />
(FOR INDIGENOUS BIDDERS)<br />
Page 1 of 7<br />
ANNEXURE - V<br />
1. This questionnaire must be filled in against all Serial nos. & enclosed with the Un-priced offer.<br />
Non submission or submission of incomplete questionnaire may lead to rejection of the offer.<br />
2. All commercial terms except the deviations to Tender Documents - Commercial (Indigenous),<br />
Addendum to Tender Documents and other attachments of NIT must be given in this<br />
questionnaire itself and not elsewhere in the quotation. In case of contradiction, the terms<br />
given below shall prevail. The deviations to Tender Documents - Commercial (Indigenous),<br />
Addendum to Tender Documents and other attachments of NIT, if any must be listed in a<br />
separate Annexure.<br />
Sl. Descriptions Vendor’s confirmation<br />
No. with details<br />
(A) TECHNICAL:<br />
1. (i) Acceptance of Technical specifications and scope<br />
of supply as per attached Annexure - I -<br />
Technical Specification.<br />
(ii) In case of deviations, confirm that the same has<br />
been highlighted separately.<br />
2. Confirm that data sheets/ technical questionnaire<br />
duly filled in are attached, wherever required.<br />
3. Confirm Spare parts list, wherever required with<br />
item wise prices have been submitted for<br />
following categories of Spares.<br />
(a) Mandatory Spares<br />
(b) Commissioning Spares<br />
(c) Recommended Spares for One Year<br />
normal operation and maintenance<br />
(d) Special Tools & Tackles<br />
4. It is noted that deviations to terms & conditions<br />
shall lead to loading of prices or rejection of offer.
Sl. Descriptions Vendor’s confirmation<br />
No. with details<br />
5. Confirm that the quoted prices are based on FOR/<br />
FOT Despatch point including packing &<br />
forwarding.<br />
(i) If quoted on Ex- works basis, indicate P&F<br />
charges in terms of percentage.<br />
(ii) Indicate despatching station.<br />
6. Confirm you have quoted prices strictly in the<br />
price schedule format enclosed with NIT<br />
documents.<br />
7. Please confirm that firm freight charges inclusive<br />
of applicable Service Tax and E-cess up to Site is<br />
quoted in price bid.<br />
(a) In case you have not quoted the freight charges<br />
separately in the Price Schedule, please quote<br />
the same in terms of % of the quoted price.<br />
(b) Confirm that freight charges for Recommended<br />
Spares for One Year normal O&M have been<br />
quoted separately and the freight for all other<br />
supplies are included in freight of Main<br />
Equipment.<br />
8. Confirm Transit insurance is excluded from the<br />
quoted prices. If inclusive, indicate rebate for<br />
excluding the same.<br />
9. Indicate rate of Central Sales Tax/Orissa VAT<br />
payable extra.<br />
(i) CST without concessional Form.<br />
(ii) CST with concessional Form.<br />
(iii) Orissa VAT<br />
Page 2 of 7
Sl. Descriptions Vendor’s confirmation<br />
No. with details<br />
10(a) Statutory increase in Excise Duty & Education<br />
cess beyond contractual delivery date shall be to<br />
vendor’s account but any reduction up to actual<br />
date of despatch shall be to owner’s account.<br />
(b) Indicate present rate of Excise Duty & Education<br />
Cess applicable on the supplies (including<br />
Spares) and whether the same is included/<br />
excluded from quoted prices.<br />
(c) If there is any increase in ED & E-cess at the time<br />
of supplies for any reasons, other than statutory,<br />
including turnover, confirm the same will be borne<br />
by the vendor.<br />
(d) If ED & E-ces is presently not applicable, confirm<br />
whether the same will be borne by the vendor in<br />
case it becomes leviable later.<br />
(e) In case (c) or (d) is not acceptable, advise<br />
maximum rate of ED & E-cess chargeable.<br />
11. Entry Tax on supplied items shall be paid by<br />
Nalco directly to Tax Authorities. However, any<br />
Entry Tax applicable for items and consumables<br />
etc used for Erection/ Commissioning shall be to<br />
Seller’s account.<br />
12. Confirm submission of following documents with offer:<br />
1) Valid Excise Regn. Certificate.<br />
2) Valid Sales Tax Regn. Certificate.<br />
3) Valid Service Tax Regn. Certificate.<br />
4) TIN (Tax Identification No.)<br />
13. Confirm in case of delay on a/c of vendor, any<br />
new or additional taxes and duties imposed after<br />
contractual delivery shall be to vendor’s account.<br />
Page 3 of 7
Sl. Descriptions Vendor’s confirmation<br />
No. with details<br />
14. Confirm acceptance to delivery/ Completion<br />
period as mentioned in NIT documents.<br />
15. Confirm acceptance to Price Reduction Schedule<br />
clause specified in Tender Documents.<br />
16. Confirm acceptance of relevant terms of payment<br />
as per the NIT documents attached.<br />
17. Confirm that the quoted prices are firm and fixed<br />
till complete execution.<br />
18. Confirm that Contract cum Performance/<br />
Performance Bank Guarantee wherever required<br />
will be furnished for value and terms & conditions<br />
as per document attached with NIT.<br />
19. Confirm that Bank Guarantee for equivalent<br />
amount of Free Issue Materials, wherever<br />
applicable, shall be furnished.<br />
20. Confirm acceptance of Guarantee/ Warranty as<br />
per documents attached with NIT.<br />
21. Confirm that quoted prices are inclusive of all<br />
Testing charges as required in the NIT.<br />
22(i) All other Commercial terms & conditions shall be<br />
as per Tender Documents - Commercial<br />
(Indigenous), Addendum to Tender Documents -<br />
Commercial and other documents attached with<br />
the NIT. Confirm.<br />
(ii) In case of deviations, confirm clause wise<br />
comments have been specified in a separate<br />
Annexure.<br />
(iii) All the terms & conditions have been indicated in<br />
this format including Annexure and have not been<br />
repeated elsewhere. It is noted that terms &<br />
conditions indicated elsewhere shall be ignored.<br />
Page 4 of 7
Sl. Descriptions Vendor’s confirmation<br />
No. with details<br />
23. Confirm that all taxes, duties and levies of any<br />
kind payable by Seller up to the stage of handing<br />
over of the system to Owner shall be borne by<br />
you.<br />
25. Import permit/ Licence, if required shall be the<br />
responsibility of the Seller and any expenditure<br />
towards the same shall be borne by you. Please<br />
confirm.<br />
26. In case of any Imported supply to be quoted in<br />
INR by Indian Associate, confirm that all<br />
variations in Customs Duty and Foreign<br />
Exchange till complete execution of the contract<br />
shall be to Seller’s account.<br />
27. The vendor is required to state whether any of the<br />
Directors of vendor is a relative of any of the<br />
Directors of Owner or the vendor is a firm in which<br />
any Director of Owner or his relative is a partner<br />
or the vendor is a Private Company in which any<br />
of the Directors of Owner is a member or Director.<br />
28. Confirm that the offer shall be valid up to 4<br />
months from the bid due date/ extended bid due<br />
date.<br />
29. Please furnish Annual Report containing Balance<br />
Sheet and Profit and Loss Account for the last<br />
three years.<br />
30. Confirm that net worth of your company during<br />
the last financial year is positive.<br />
31. As soon as shipment/ dispatch is made, the Seller<br />
shall intimate NALCO’s Underwriters the dispatch<br />
details t the address which shall be furnished<br />
later.<br />
32. The Vendor is required to state whether M/s AP/<br />
ALCAN has any shareholding/ management<br />
control in your Company.<br />
Page 5 of 7
Sl. Descriptions Vendor’s confirmation<br />
No. with details<br />
33. Please note that you have not been banned or<br />
de-listed by any Government or Quasi<br />
Government agencies or PSU.<br />
34. Confirm that in case of conflicting version of<br />
various terms & conditions at different places,<br />
Owner can choose any version.<br />
35. Please furnish name and address of the official to<br />
whom correspondence should be sent including<br />
telephone number/ fax number and e-mail id. If email<br />
id is not available, an undertaking is to be<br />
given that e-mail id is to be registered within 2<br />
weeks of bid submission<br />
Place: Signature:<br />
Date: Name :<br />
Page 6 of 7<br />
Designation :<br />
Seal :
SL.<br />
NO.<br />
REFERENCE OF NIT DOCUMENT<br />
DOCUMENT CLAUSE NO.<br />
DEVIATIONS TO NIT DOCUMENTS<br />
SUBJECT DEVIATIONS<br />
NOTE: This shall be submitted along with the Un - priced Offer. Deviation mentioned anywhere else in the<br />
offer shall not be considered.<br />
Page 7 of 7<br />
Signature:<br />
Date: Name :<br />
Designation :<br />
Seal :
Tender Notice No. - …………………...............<br />
ITEM: WAGON TIPPLER AND CONVEYOR SYSTEM<br />
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT<br />
1.0 SUPPLY OF MAIN EQUIPMENT<br />
1.1 Design, Engineering, Manufacturing, Procurement,<br />
Inspection, Assembly, Painting, Testing at Supplier’s<br />
works, Packing & Forwarding and Supply of Wagon<br />
Tippler & Accessories including Commissioning & Start-up<br />
Spares, Tools & Tackles , first fill of oil & lubricants/ oil and<br />
consumables as per Annexure - I - Technical Specification<br />
of NIT on FOT Dispatch point basis including packing &<br />
forwarding (break - up of prices to be submitted as per<br />
Annexure - A attached herewith)<br />
1.2 Supply of Mandatory Spares, as per NIT (itemized prices to<br />
be furnished along with the price bid) on FOT dispatch<br />
point basis including packing & forwarding<br />
1.3 Others if any to complete the Scope (Pl specify)<br />
SUB TOTAL (1.0)<br />
2.0 FREIGHT, INSURANCE, TAXES & DUTIES ON ITEMS<br />
UNDER SUB HEADING 1.0<br />
2.1 Total & maximum Excise Duty & E-cess on ED (Amount<br />
payable against Cenvatable Invoices )<br />
2.2 Total & maximum Central Sales Tax (Considering CST<br />
Declaration form to be furnished by NALCO, wherever<br />
applicable/ admissible)<br />
2.3 Total & Maximum Orissa VAT applicable for items to be<br />
supplied from within the state of Odisha<br />
PRICE SCHEDULE FORMAT<br />
INDIGENOUS SUPPLY (IN INDIAN<br />
Rs.)<br />
(M/s …………..)<br />
Page 1 of 7<br />
Annexure - VI<br />
ERECTION/ TESTING/<br />
COMMISSIONING SERVICES AT<br />
SITE , SUPERVISION & TRAINING<br />
SERVICES (IN INDIAN Rs.)<br />
(M/s ……………….)
Tender Notice No. - …………………...............<br />
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT<br />
2.4 All other taxes & duties currently applicable (Please specify<br />
the nature of Tax/ Duty & its rate)<br />
2.5 Inland freight charges up to Site including Service Tax & Ecess<br />
on same<br />
2.6 Transit Insurance up to Site (Optional) inclusive of all<br />
taxes<br />
SUB TOTAL (2.0)<br />
3.0 SUPPLY OF ONE YEARS O&M SPARES FOR<br />
3.1<br />
TROUBLE FREE OPERATION - OPTIONAL<br />
Supply of vendor recommended Spares for One year O&M<br />
on FOT dispatch point basis (itemized prices to be<br />
furnished along with the price bid, list of spares to be<br />
furnished along with un - priced bid)<br />
3.2 Total & maximum Excise Duty & E-cess on ED (Amount<br />
payable against Cenvatable Invoices )<br />
3.3 Total & maximum Central Sales Tax (Considering CST<br />
Declaration form to be furnished by NALCO, wherever<br />
applicable/ admissible)<br />
3.4 Total & Maximum Orissa VAT applicable for items to be<br />
supplied from within Orissa<br />
3.5 All other taxes & duties currently applicable (Please specify<br />
the nature of Tax/ Duty & its rate)<br />
3.6<br />
Inland freight charges up to Site including applicable<br />
3.7<br />
Service Tax & E-cess<br />
Transit Insurance up to Site (Optional) inclusive of all<br />
taxes<br />
SUB TOTAL (3.0 )<br />
INDIGENOUS SUPPLY (IN INDIAN<br />
Rs.)<br />
(M/s …………..)<br />
Page 2 of 7<br />
ERECTION/ TESTING/<br />
COMMISSIONING SERVICES AT<br />
SITE , SUPERVISION & TRAINING<br />
SERVICES (IN INDIAN Rs.)<br />
(M/s ……………….)
Tender Notice No. - …………………...............<br />
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT<br />
4.0 UNLOADING, STORAGE, HANDLING &<br />
TRANSPORTATION OF EQUIPMENT/ MATERIALS AT<br />
SITE<br />
4.1 For Main Equipment under Sl. No. - 1.0 above<br />
4.2 For One Year O&M Spares under Sl. No. - 3.0 above<br />
4.3 Total & Maximum Service Tax for 4.1<br />
4.4 Total & Maximum E-cess for 4.1<br />
4.5 Total & Maximum Service Tax for 4.2<br />
4.6 Total & Maximum E-cess for 4.2<br />
SUB TOTAL (4.0)<br />
5.0 CONSTRUCTION, ERECTION, TESTING,<br />
COMMISSIONING AND PERFORMANCE GUARANTEE<br />
TESTS<br />
5.1 Civil & Structural Work as per NIT<br />
5.2 Erection - Mechanical<br />
5.3 Electrical and Instrumentation works<br />
5.4 Testing, Commissioning and Performance Guarantee<br />
Tests.<br />
5.5 All statutory/contingency insurance coverage e.g. third<br />
party liability, ESI, workmen compensation etc.<br />
5.6 Total for Construction, Erection, Testing,<br />
Commissioning and Performance Guarantee Tests<br />
5.7 Insurance coverage for storage erection & commissioning<br />
etc. (Optional)<br />
5.8 Orissa VAT on Works Contract (Works Contract Tax) as<br />
currently applicable<br />
INDIGENOUS SUPPLY (IN INDIAN<br />
Rs.)<br />
(M/s …………..)<br />
Page 3 of 7<br />
ERECTION/ TESTING/<br />
COMMISSIONING SERVICES AT<br />
SITE , SUPERVISION & TRAINING<br />
SERVICES (IN INDIAN Rs.)<br />
(M/s ……………….)
Tender Notice No. - …………………...............<br />
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT<br />
5.9 Any other Indian taxes/ duties currently applicable<br />
5.10 Total & maximum Service Tax.<br />
5.11 Total & maximum E- cess on Service Tax.<br />
5.12 Others, if any.<br />
NOTES:<br />
SUB TOTAL (5.0)<br />
GRAND TOTAL ( SUM OF 1.0 T0 5.0 )<br />
INDIGENOUS SUPPLY (IN INDIAN<br />
Rs.)<br />
(M/s …………..)<br />
Page 4 of 7<br />
ERECTION/ TESTING/<br />
COMMISSIONING SERVICES AT<br />
SITE , SUPERVISION & TRAINING<br />
SERVICES (IN INDIAN Rs.)<br />
(M/s ……………….)<br />
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<br />
the case may be.<br />
2. In the Price Schedule no column should be left blank.<br />
3. The quoted prices shall include charges towards testing & all documentation required as per NIT.<br />
4. Any correction in the quotation shall be initialed by the bidder, otherwise the offer shall be rejected.<br />
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<br />
account. Liability of Works Contract Tax on Erection/ Testing/ Commissioning for Service Contract i.e. Contract C shall be solely of Contractor.<br />
NALCO would deduct WCT in line with NIT provisions while releasing payment to Contractor and deposit the same with Sales Tax Authority and<br />
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<br />
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<br />
consideration by them, irrespective of whether such WCT amount has been indicated separately or not. Accordingly, there would be no loading (i.e.<br />
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<br />
mentioned in the price schedule by a bidder shall be considered for evaluation of his price.<br />
6. Applicable Service Tax & E-cess on Service Tax will be paid at actuals subject to documentary evidence limited to the maximum amount quoted.
Tender Notice No. - …………………...............<br />
7. Entry Tax on supplies against supply of items shall be paid by NALCO directly to Tax authorities.<br />
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.<br />
The contract vis-à- vis payment operations shall be done, however, as per approved Billing schedules only.<br />
9. The Contract (s) prices, will remain firm & unchanged until complete execution excepting for statutory variations, if any on the rates of taxes &<br />
duties included in the Contract price ( as per break ups specified in the Billing schedule) and also excepting for imposition of any fresh statutory<br />
levy/ tax.<br />
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<br />
shall be made at actuals against submission of Cenvatable ED invoices but limited to the quoted ED & E-cess on ED.<br />
11. Optional prices shall not be considered for evaluation. However, the optional prices shall be valid during execution of Contract and could be<br />
exercised by NALCO, in case NALCO decides the same.<br />
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<br />
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 &<br />
4.6 shall not be considered for evaluation.<br />
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<br />
- priced format.<br />
14. Bidder shall submit Price break - up along with quantity and unit price for the following in Priced & Un-priced format:<br />
(a) Mandatory Spares<br />
(b) Commissioning & Start-up Spares<br />
(c) Tools & Tackles<br />
(d) Spares for One Year O&M<br />
Page 5 of 7<br />
Bidder’s Signature:<br />
Bidder’s Stamp:<br />
Date:
Tender Notice No. - …………………...............<br />
Description of Item<br />
ANNEXURE-A TO PRICE SCHEDULE FORMAT<br />
01. Design, Manufacture and Supply of Wagon Tippler System 25 tips / hour design<br />
capacity (20 tips per hour guaranteed output) complete with tippler platform with rails,<br />
cradle, top & side clamps, etc. including all electricals and instrumentation and required<br />
other connected accessories.<br />
02. Design, Manufacture and Supply of Side Arm charger (25 wagons per hour) 20 wagons<br />
per hour guaranteed capacity complete with all rails and travel mechanism.<br />
03. Design, Manufacture and Supply of Apron feeder (1200 TPH) complete with dribble<br />
conveyor, feeder pans, suitable for underground hopper of tippler complete with drives,<br />
base plates and accessories required for fixing in foundation and other connected<br />
accessories complete.<br />
04. Design, Manufacture and Supply of Receiving belt conveyor system 1200 TPH<br />
guaranteed capacity, 1200 mm belt width suitable for transport of coal received from<br />
apron feeder to existing conveyors BC-103 & BC-115 in plant including pent house,<br />
junction tower complete with stringers, supports, Idlers, Belt, Pulleys, chutes and safety<br />
devices, foundations, supports overhead gallery and trestle etc. with all electricals and<br />
plc control accessories.<br />
05. Design, Manufacture and Supply of Dust control system at Wagon Tippler House,<br />
transfer points of conveyor complete with all civil, mechanical and electricals works.<br />
06. Design, Manufacture and Supply of E.O.T.<br />
Crane 25T / 5T capacity suitable to handle the erection and Maintenance requirements<br />
of wagon tippler, apron feeder, etc.<br />
07. Design and supply of Mono rail hoists of appropriate capacity for equipments, drivers,<br />
pulley and Gear reducers, apron feeder at various location within the terminal points<br />
complete with all accessories.<br />
08. Design and supply of Fire hydrant system covering Wagon Tippler House, Conveyor<br />
Galleries, Transfer House etc. extending from existing fire water grid in the vicinity<br />
within Plant area with all necessary accessories complete.<br />
Page 6 of 7<br />
Unit of<br />
measurement<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
Quantity Unit Price
Tender Notice No. - …………………...............<br />
Description of Item<br />
09. Design and supply of Service water connections at Transfer Towers, tippler house, at<br />
each floor level complete system extending from the existing header near the new track<br />
hopper with all accessories for complete system.<br />
10. Design and supply of Illumination and lighting system for Wagon Tippler House,<br />
Transfer Towers, Conveyor Galleries and control rooms etc. with all accessories.<br />
11. Design and supply of ACSR cables, rail poles, insulators, hardware fittings, 33KV/6.6KV<br />
transformer complete, breakers, isolators, CT, PT, LA, switch gear, etc. for HT system<br />
as per scope of work.<br />
12. Design and supply of cables, 6.6KV/415V transformer complete, switch gear, panels,<br />
etc. LT system as per scope of work.<br />
Page 7 of 7<br />
Unit of<br />
measurement<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
Lump sum 1<br />
13. Supply of all control cables, Panels, PLCs etc. complete for the system. Lump sum 1<br />
LUMP SUM PRICE TOTAL<br />
Quantity Unit Price
Page 1 of 2<br />
ANNEXURE - VII<br />
PROFORMA OF CONTRACT CUM PERFORMANCE GUARANTEE BY SELLER/CONTRACTOR<br />
(To be executed on non-Judicial stamped paper of appropriate value)<br />
B.G. No. - ……………… Date: …………………<br />
WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its Office at<br />
Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter called "the Company/Owner")<br />
which expression shall unless repugnant to the subject or context includes its legal representatives,<br />
successors and assigns), has entered into a contract with M/s. ………………../ has placed a purchase<br />
order on M/s. ………………… (hereinafter referred to as “Contractor(s)/Seller(s)”) which expression shall<br />
unless repugnant to the subject or context includes their legal representatives, successors and assigns) for<br />
.............................. on the terms and conditions as set out inter alia, in the company Contract No/P.O.<br />
No.............................. dt............. and various documents forming part thereof herein after referred to as the<br />
“said contract” which expression include all amendments, modification and/or variation thereto and where<br />
as the Contractor/Seller has agreed for due execution of the entire contract and guarantees its performance<br />
including any parts executed through any others agencies/sub-contractors.<br />
AND WHEREAS one of the conditions of the “said contract” is that “contractor/seller shall furnish to the<br />
owner a Bank Guarantee from a bank for ......% (............. percent) of the total value of the “said contract”<br />
against due and faithful performance of the “said contract” including defects liability obligations and the<br />
performance guarantee obligations of the contractor/seller for execution/supplies made under the “said<br />
contract”.<br />
2. We ……………………….. Bank having its branch office at …………………. do hereby agree and undertake<br />
to pay the amount due and payable under this guarantee without any demur merely on a demand from the<br />
Company stating that in the opinion of the company which is final & binding, the amount claimed is due by<br />
reason of default made by the Contractor(s)/ Seller(s) in performing any of the terms and conditions of the<br />
said Contract including defects liability obligations, in fulfilling the performance Guarantee obligation or loss<br />
or damage caused to or would be caused to or suffered by the Company by reason of any breach by the<br />
said Contractor(s)/Seller(s) of any of the terms and conditions of the contract. Any such demand made on<br />
the Bank by the owner shall be conclusive as regards the amount due and payable by the Bank under this<br />
guarantee. However our liability under this guarantee shall be restricted to Rs..................<br />
(Rupees........................... only)<br />
3. We undertake to pay to the Company any money so demanded not withstanding any dispute or disputes<br />
raised by the Contractor(s)/Supplier(s) in any suit or proceeding pending before any office, court or Tribunal<br />
relating thereto, our liability under this present being absolute and unequivocal. The payment so made by<br />
us under this bond shall be a valid discharge of our liability for payment there under. Our liability to pay is<br />
not dependent or conditional on the owner proceeding against the contractor(s)/seller(s).<br />
4. The guarantee herein contained shall not be determined or affected or suspended by the liquidation or<br />
winding up, dissolution or change of constitution or insolvency of the said Contractor(s)/ Seller(s) but shall<br />
in all respects and for all purposes be binding and operative until payment of all money due or liabilities<br />
under the said Contract(s)/Order(s) are fulfilled.
5. We ……………………… Bank further agree that the guarantee herein contained shall remain in full force<br />
and effect during the period that would be taken for the performance of the said Contract(s)/Order(s) and<br />
that it shall continue to be enforceable till all the dues of the Company under or by virtue of the said<br />
Contract(s)/Order(s) have been fully paid and its claims satisfied or discharged or till a duly authorised<br />
officer of the Company certifies that the terms and conditions of the said Contract(s)/Order(s) have been<br />
fully and properly carried out by the said Contractor(s) and accordingly discharge this guarantee.<br />
6. We ................................. Bank further agree with the Company that the Company shall have the fullest<br />
liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the<br />
terms and conditions of the said Contractor(s)/ Order(s) or to extend time of performance by the said<br />
Contractor(s)/Seller(s) from time to time or to postpone for any time or from time to time any of the powers<br />
exercisable by the Company against the said Contractor(s)/Seller(s) and to forbear or enforce any of the<br />
terms and conditions relating to the said Contractor(s)/Seller(s) and we shall not be relieved from our<br />
liability by reason of any such variation or extension being granted to the said Contractor(s)/Seller(s) or for<br />
any forbearance, act or omission on the part of the Company or any indulgence by the Company to the said<br />
Contractor(s)/Seller(s) or by any such matter or thing whatsoever which under the law relating to sureties<br />
would but for this provision have effect of so relieving us.<br />
7. Notwithstanding anything contained herein before, our liability shall not exceed Rs…………………..<br />
(Rupees ………………….. only) and shall remain in force till …………….. unless a demand or claim under<br />
this guarantee is made on us within three months from the date of expiry we shall be discharged from all<br />
the liabilities under this guarantee.<br />
8. We ………………… Bank, lastly undertake not to revoke this guarantee during its currency except with the<br />
previous consent of the Company in writing. We further undertake to keep this Guarantee renewed from<br />
time to time at the request of Contractor(s)/Seller(s).<br />
Date: ......................Bank<br />
Corporate Seal of the Bank By its constitutional Attorney<br />
Page 2 of 2<br />
Signature of duly<br />
Authorised person<br />
on behalf of the Bank<br />
With seal & signature code<br />
BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX.
Tender Notice No. - ………….<br />
PROFORMA FOR BANK GUARANTEE FOR EARNEST MONEY DEPOSIT<br />
(To be executed on non-Judicial stamped paper of appropriate value)<br />
B.G. No_____________ Date____________<br />
Page 1 of 2<br />
ANNEXURE - VIII<br />
1. WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its<br />
Office at Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter referred as<br />
"The Owner/ Company" which expression shall unless repugnant to the subject or context includes<br />
its legal representatives, successors and assigns), has issued tender paper vide its Tender No.<br />
.............. for................................... (hereinafter called “the said tender”) to M/s............................<br />
(hereinafter called “the said Tenderer(s)” which expression shall unless repugnant to the subject or<br />
context includes their legal representatives, successors and assigns) and as per terms and<br />
conditions of the said tender, the tenderer shall submit a Bank Guarantee for Rs.____________<br />
(Rupees ___________________________ Only) towards earnest money in lieu of cash.<br />
2. We___________________ Bank having its branch office at _________________ do hereby<br />
undertake to pay the amounts due and payable under this guarantee without any demur merely on<br />
a demand from the Company stating that in the opinion of the company, which is final & binding,<br />
the amount claimed is due because of any withdrawal of the tender or any material alteration to the<br />
tender after the opening of the tender by way of any loss or damage caused or would be caused or<br />
suffered by the Company by reason of any breach by the said tenderer(s) of any terms and<br />
conditions contained in the said tender or failure to accept the letter of Intent/Agreement or that the<br />
amount covered under this Guarantee is forfeited. Any such demand made on the Bank by the<br />
owner shall be conclusive as regards the amount due and payable by the Bank under this<br />
Guarantee. However our liability under this guarantee shall be restricted to an amount not<br />
exceeding Rs........................... (Rupees……………. Only).<br />
3. We undertake to pay to the Company any money so demanded notwithstanding any dispute or<br />
disputes raised by the tenderer(s) in any suit or proceeding pending before any office, court or<br />
Tribunal relating thereto, our liability under this present guarantee being absolute and unequivocal.<br />
The payment so made by us under this bond shall be a valid discharge of our liability for payment<br />
there under. Our liability to pay is not dependant or conditional on the owner proceeding against<br />
the tenderer(s).<br />
4. The guarantee herein contained shall not be determined or affected or suspended by the<br />
liquidation or winding up, dissolution or change of constitution or insolvency of the said tenderer(s)<br />
but shall in all respects and for all purposes be binding and operative until payment of all money<br />
due or liabilities under the said tender are fulfilled.<br />
5. We _________________ Bank Ltd., further agree that the guarantee herein contained shall remain<br />
in full force and effect during the period that would be taken for the finalisation of the said tender<br />
and that it shall continue to be enforceable till the said tender is finally decided and order placed on
Tender Notice No. - ………….<br />
the successful tenderer(s) and/or till all the dues of the Company under/or by virtue of the said<br />
tender have been fully paid and its claims satisfied or discharged or till a duly authorised officer of<br />
the Company certifies that the terms and conditions of the said tender have been fully and properly<br />
carried out by the said tenderer(s) and accordingly discharges the guarantee.<br />
6. That the Owner/Company will have full liberty without reference to us and without affecting this<br />
guarantee to postpone for any time or from time to time, the exercise of any of the power of the<br />
owner under the tender.<br />
7. Notwithstanding anything contained herein before, our liability shall not exceed Rs.__________<br />
(Rupees________________________________ Only) and shall remain in force till<br />
__________unless a demand or claim under this guarantee is made on us within three months<br />
from the date of expiry, we shall be discharged from all the liability under this guarantee.<br />
8. We __________________ Bank, lastly undertake not to revoke this guarantee during its currency<br />
except with the previous consent of the Company in writing. We further undertake to keep this<br />
Guarantee renewed from time to time on the request of the Tenderer(s).<br />
Date: ......................Bank<br />
Corporate Seal of the Bank By its constitutional Attorney<br />
BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX.<br />
Page 2 of 2<br />
Signature of duly<br />
Authorised person<br />
on behalf of the Bank<br />
With seal & signature code
Tender Notice No. - …………..<br />
1. State Bank of India<br />
2. State Bank of Bikaner and Jaipur<br />
3. State Bank of Hyderabad<br />
4. State Bank of Mysore<br />
5. State Bank of Patiala<br />
6. State Bank of Travancore<br />
7. Allahabad Bank<br />
8. Andhra Bank<br />
9. Bank of Baroda<br />
10. Bank of India<br />
11. Bank of Maharashtra<br />
12. Canara Bank<br />
13. Central Bank of India<br />
14. Corporation Bank<br />
15. Dena Bank<br />
16. Indian Bank<br />
17. Oriental Bank of Commerce<br />
18. Punjab National Bank<br />
19. Punjab and Sind Bank<br />
20. Syndicate Bank<br />
21. Union Bank of India<br />
22. UCO Bank<br />
23. Vijaya Bank<br />
24 IDBI Bank<br />
(Twenty Four Banks)<br />
LIST OF STANDARDISED BANKS<br />
SCHEDULED PUBLIC SECTOR BANKS (INDIAN)<br />
Page 1 of 3<br />
ANNEXURE - IX
Tender Notice No. - …………..<br />
1. ING Vysya Bank<br />
2. Axis Bank<br />
3. SBI Commercial & International Bank Ltd.<br />
4. ICICI Bank<br />
5. HDFC Bank<br />
6. Yes Bank<br />
7. Indus Ind. Bank<br />
8. Kotak Mahindra Bank<br />
LIST OF STANDARDISED BANKS<br />
SCHEDULED PRIVATE SECTOR BANKS (INDIAN)<br />
(Eight Banks)<br />
SCHEDULED FOREIGN BANKS<br />
1. American Express Bank Ltd.<br />
2. Bank of American NT & SA<br />
3. Bank of Tokyo Ltd.<br />
4. BNP Paribas<br />
5. Barclays Bank Plc<br />
6. Citi Bank NA<br />
7. Deutsche Bank AG.<br />
8. Hongkong and Shanghai Banking Corporation<br />
9. Standard Chartered Bank<br />
10. JP Morgan Chase Bank NA<br />
(Ten Banks)<br />
Page 2 of 3
Tender Notice No. - …………..<br />
To<br />
National Aluminium Company Limited,<br />
NALCO Bhawan,<br />
Plot No. P/1, Nayapalli,<br />
Bhubaneswar - 751061<br />
Dear Sir,<br />
ECS MANDATE FORM<br />
ELECTRONIC CLEARING SERVICES/ELECTRONIC FUND TRANSFER/INTERNET<br />
BANKING MANDATE FORM<br />
Sub: Authorization for release of payment due from NALCO, Corporate Office, Bhubaneswar through Electronic Clearing Services (RBI)/<br />
Electronic fund transfer (RBI/SBI)/ Internet Banking (SBI).<br />
Refer Order No……………..dt……………and/or Tender/Enquiry/Letter No……………..dt……………..<br />
(Please fill in the information in CAPITAL LETTERS. Please TICK wherever it is applicable)<br />
1. Name of the Party :<br />
2. Address of the party :…………………………………………<br />
………………………………………….<br />
…………………………………………<br />
City:……………. Pin Code:…………..<br />
E-mail Id:<br />
3. Particulars of Bank:<br />
Bank Name Branch Name<br />
Branch Place Branch City<br />
Pin Code Branch Code<br />
MICR No.<br />
(9 Digits code number appearing on the MICR Band of the cheque supplied by the Bank. Please attach Xerox copy of a cheque of<br />
your bank for ensuring accuracy of the bank name, branch name and code number)<br />
Account Type ? Savings ? Current ? Cash Credit ?<br />
Account Number(as appearing in the Cheque<br />
Book)<br />
4. Date from which the mandate should be effective:<br />
I hereby declare that the particulars given above are correct and complete. If any transaction is delayed or not effected for<br />
reasons of incomplete or incorrect information, I shall not hold National Aluminium Company Limited responsible. I also undertake to advise any<br />
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.<br />
Place:<br />
Date:<br />
Signature of the party/Authorized<br />
Signatory<br />
----------------------------------------------------------------------------------------------------------------------------- ------------------------------------------------------------------------<br />
Certified that particulars furnished above are correct as per our records.<br />
Bank’s Stamp:<br />
Date:<br />
(Signature of the Authorized Official from the Banks)<br />
Page 3 of 3
Tender Notice No. - …………..<br />
A. Basic information<br />
Name of the organization<br />
Address<br />
Telephone No<br />
Name of the Proprietor<br />
Nature of Business<br />
License Number and date of<br />
expiry<br />
Social Accountability 8000 Compliance Format<br />
Page 1 of 5<br />
Annexure - X<br />
Employees Staff (Total Number) Workmen (Total Number)<br />
Permanent<br />
Casual<br />
Badli<br />
Temporary<br />
Contracted<br />
B. Information regarding Social Accountability<br />
What is the minimum age required to join ___________ Years<br />
your organization?<br />
What types of certificates (Like mark sheet, Original Copy / Xerox<br />
birth certificate) you keep with you?<br />
Do you require to keep any kind of deposit Yes/No<br />
inform of cash at the time of employment?<br />
Do you provide safe & healthy work environment Yes/No<br />
as per statutory requirement?<br />
If directly not provided by you, do you get Yes/No<br />
health & safety benefits from NALCO?
Tender Notice No. - …………..<br />
Are you certified for SA 8000? Yes/No<br />
If Yes, please submit a copy of SA8000 Certificate along with this<br />
filled up questionnaire<br />
Have you undergone Code of Conduct Audit (COC Audit) Yes/No<br />
in last 2 years ?<br />
If yes, please submit a copy of Code of Conduct Audit Report<br />
along with this filled up questionnaire<br />
Have your sub-suppliers been certified for SA 8000? Yes/No<br />
Have your sub-suppliers undergone Code of Conduct Audit Yes/No<br />
(COC Audit) in last 2 years?<br />
Do you provide personal protective equipment(s) Yes/No<br />
to your employees free of cost?<br />
Do you provide safety training to your employees? Yes/No<br />
Do you ensure canteen facility for your employees? Yes/No<br />
If not, do you get the facilities from NALCO Yes/No<br />
What types of medical benefits you provide to your employees?<br />
Do you allow trade union and collective bargaining in<br />
your organization? Yes/No<br />
If no, how do you ensure freedom of expression?<br />
Page 2 of 5
Tender Notice No. - …………..<br />
Incase of non-performance of any employee, how do you deal with such situations?<br />
What are the procedures of hiring/promotion/ remuneration in your organization?<br />
Do you provide appointment letter to your employees? Yes/No<br />
Do you maintain a documented terms and conditions Yes/No<br />
of employment?<br />
Do you maintain a disciplinary procedure? Yes/No<br />
If no, how do you terminate your employee?<br />
How do you ensure that your employees are not discrimination on the basis of cast creed, gender,<br />
religion, age and dieses?<br />
Page 3 of 5
Tender Notice No. - …………..<br />
How many shift you have? _______ shifts<br />
What is the official working time? _______ hours<br />
Which day is off day in your organization? ____________<br />
In case, a person works in off day or holiday, how is he/she compensated?<br />
Do you pay overtime to your employees as per law? Yes/No<br />
What is the lowest amount (salary/wage) you pay to Rs._______/-<br />
your employees?<br />
Is there any case of deduction in wage? Yes/No<br />
In case, it is yes, what are the general reasons for such deduction?<br />
Is there any apprentice period in your organization? Yes/No<br />
If yes, what is the apprentice period in your organization? ___________<br />
Do you have any international certification Yes/No<br />
If yes, please specify<br />
Page 4 of 5
Tender Notice No. - …………..<br />
Do you receive, handle or promote goods and/or services Yes/No<br />
from supplier/subcontractors or sub-suppliers<br />
Do you receive, handle or promote goods and/or services Yes/No<br />
from supplier/subcontractors or sub-suppliers who are<br />
classified as home worker?<br />
If yes, what steps you have taken to ensure that they get similar level of protection as afforded to<br />
directly employed employees?<br />
Have you taken care to look into issues related to child labor Yes/No<br />
Forced labor, health & safety, working hours and remuneration<br />
of your suppliers<br />
We do hereby declare that our organization is committed to social accountability. We will promptly<br />
implement remedial/corrective actions identified against the requirement and promptly inform your<br />
organization. We also declare that the sub contractors/sub supplier’s performances are monitored<br />
by us. Moreover, we declare that if invited, we shall participate in awareness program as well as<br />
monitoring program organized by you.<br />
We declare that the above-mentioned information is correct.<br />
Signature:<br />
Designation:<br />
Date Seal of the organization<br />
Page 5 of 5
1.0 General<br />
PACKING, MARKING, SHIPPING AND DOCUMENTATION<br />
SPECIFICATIONS FOR INDIGENOUS MATERIALS<br />
NALCO<br />
ANNEXURE-XI<br />
1.1 This specification forms an integral part of the relevant PURCHASE ORDER, in addition to the<br />
specifications, drawings and instructions explicitly listed in the PURCHASE ORDER.<br />
1.2 Seller shall strictly comply with all applicable prescriptions in the specifications. Lack of relevant<br />
information and/or documents shall not absolve the SELLER of his responsibilities and any loss<br />
arising out of non -compliance shall be to supplier’s account.<br />
2.0 Project<br />
Name of OWNER, Project location and some other relevant information are as per Bid document.<br />
3.0 Packing<br />
3.1 The packing specifications incorporated herein are supplementary to the internal and external<br />
packing methods and standards as per current rules of IRCA goods tariff Part -I. All packing shall<br />
be done in such a manner so as to reduce volume as much as possible. Fragile articles should<br />
be packed with special packing materials depending on the type of materials.<br />
3.2 Items shipped in bundles must be securely tied with steel wire or strapping. Steel reinforcing<br />
rods, bars, pipes, structural materials, etc. shall be bundled in uniform lengths and the weight<br />
shall be within the breaking strength of the securing wire or strapping.<br />
3.3 All delicate surfaces on equipment/materials should be carefully protected and painted with<br />
protective paint/compound and wrapped to prevent rusting and damage.<br />
3.4 All mechanical and electrical equipment and other heavy articles shall be securely fastened to the<br />
case bottom and shall be blocked and braced to avoid any displacement/shifting during transit.<br />
3.5 Attachments and spare parts of equipment and all small pieces shall be packed separately in<br />
wooden cases with adequate protection inside the case and wherever possible should be sent<br />
along with main equipment. Each item shall be suitably tagged with identification of main<br />
equipment, item denomination and reference number of respective assembly drawing. Each item<br />
of steel structure and equipments shall be identified with two erection markings with minimum<br />
lettering height of 15 mm. Such marking will be followed by connection numbers in indelible<br />
ink/paint. A copy of the packing list shall accompany the material in each package.<br />
3.6 All protrusions shall be suitably protected by providing a cover comprising of tightly bolted<br />
wooden discs on the flanges.<br />
3.7 Wherever required, equipments/materials/instruments shall be enveloped in polyethylene bags<br />
containing silicagel or similar dehydrating compound.<br />
3.8 All pipes shall be packed as under:<br />
a) Upto 50mm NB in Wooden cases/crates.<br />
b) Above 50mm NB and upto 100mm NB in Bundles and the bundles should be strapped at<br />
minimum three places.<br />
c) Above 100mm NB in loose.<br />
Individual cases/bundles must contain the pipes of same size and length. Ends should be<br />
capped.<br />
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ANNEXURE-XI<br />
3.9 Pipes with threaded or flanged ends shall be protected with suitable caps/covers before packing.<br />
Line pipes shall be transported only on Flat bed trailers. Semi low bed/low bed trailer shall not be<br />
used.<br />
The trailers used for transportation of Line Pipes shall be equipped with adequate pipe supports,<br />
having as many round hollow beds as there are pipes to be placed on the bottom of the trailer<br />
bed. Total width of the supports shall be at least 10% of the pipe length. These supports shall be<br />
lined with a rubber protection and shall be spaced in a manner as to support equal load from the<br />
pipes. The rubber protection must be free from all nails and staples where pipes are in contact.<br />
The second layer and the following layers shall be separated from each other with adequate<br />
number of separating layers of protective materials such as straw in plastic covers or mineral<br />
wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of<br />
trailers used for transportation shall be covered by non -abrasive material like rubber belts or<br />
equivalent. Care shall be exercised to properly cover the top of the stanchions and other<br />
positions such as reinforcement of the trailer body rivets etc. to prevent damage to the coated<br />
surface.<br />
3.10 Detailed packing list in waterproof envelope shall be inserted in the package together with<br />
equipment/material. One copy of the detailed packing list shall be fastened outside the package<br />
in waterproof envelope and covered by metal cover.<br />
3.11 The Seller shall be held liable for all damages or breakages to the goods due to the defective or<br />
insufficient packing as well as for corrosion due to insufficient protection.<br />
3.12 Packaged equipment or material showing damage, defects or shortages resulting from improper<br />
packaging material or packing procedures or having concealed damage or shortages, at the time<br />
of unpacking shall be to the seller’s account.<br />
4.0 Marking<br />
4.1 Each package shall be marked on three sides with proper paints/indelible waterproof ink as<br />
follows:<br />
OWNER<br />
PROJECT<br />
DESTINATION<br />
Purchase Order No..................................................................................................... Net<br />
Wt.....................…………….... Kgs Gross Wt...................................... Kgs.<br />
Dimensions.......................................................X....................X...........................CM.<br />
Package No. (Sl. No. of total packages).........................................................................<br />
Seller’s Name.............................................................................................................<br />
4.2 Additional marking such as ‘HANDLE WITH CARE’, ‘THIS SIDE UP’, ‘FRAGILE’ or any other<br />
additional indications for protection and safe handling shall be added depending on the type of<br />
material.<br />
4.3 Specific marking with paint for ‘SLINGING and ‘CENTRE OF GRAVITY’ should be provided for all<br />
heavy lifts weighing 5 Tons and above.<br />
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4.4 In case of bundles/bags or other packages, wherever marking cannot be stenciled, the same<br />
shall be embossed on metal or similar tag and wired securely at two convenient points.<br />
5.0 Shipment<br />
5.1 Despatch of materials shall be made in accordance with the relevant terms of the Purchase<br />
Order. Any change in mode of transport shall be resorted to only after prior approval in writing.<br />
Seller shall ensure despatch of equipments/materials immediately after they are inspected and<br />
released. All consignments shall be booked in the name of Owner and not under self-basis.<br />
5.2 Despatch by Road<br />
(a) The Seller shall be responsible for despatch of materials on DOOR-DELIVERY basis<br />
through a reliable Bank -Approved transport company unless otherwise the transport<br />
company is named by OWNER/CONSULTANT.<br />
(b) The SELLER shall ensure with Transport Company the delivery of materials within a<br />
reasonable transit period. SELLER shall also obtain from transporter, particulars of Lorry<br />
Number, Transporter’s Challan Number, destination of lorry (if transshipment is involved),<br />
Transporter’s Agent at destination, if any, etc. and intimate same to General<br />
Manager (Projects), CPP, Nalco, Angul with copy to Resident Construction Manager at<br />
RITES, (respective Project Site).<br />
5.3 Despatch by Rail<br />
5.3.1 The SELLER shall be responsible for:<br />
(a) Despatch by the shortest possible route. The Seller shall as far as possible, despatch<br />
the materials by the fastest goods train like QTS, Super Express Goods, etc. wherever<br />
such facilities exist.<br />
(b) Correct classification of goods and freight charges.<br />
(c) Obtaining clean Railway Receipts without any qualifying remarks.<br />
5.3.2 As “SMALLS”<br />
Should there be any restriction for movement by a particular route, the Railway<br />
authorities should be requested to move goods by the next alternative route, subject to<br />
prior consent of NALCO/RITES.<br />
When the materials that are ready do not make up a wagonload by weight/volume or for minimum<br />
freight payable for a wagon the despatch should be affected as “smalls”.<br />
SELLER should obtain from the Railway, the particulars of wagon in which the “Smalls” have<br />
been loaded, station at which sealed, train Number and date/time of movement and transmit the<br />
same to the Resident / Visiting Inspector, General Manager (Projects), CPP-Nalco , RCM-RITES<br />
(concerned Site) for monitoring their movement.<br />
5.3.3 As Wagon Loads<br />
Consignments, though of lesser weight, but otherwise constituting a “wagon load” by volume<br />
should be dispatched as “wagon load” paying the freight applicable to a minimum wagon load or<br />
at the smalls rate, whichever is advantageous, as per Rule-164 of IRCA Goods Tariff Part -I (Vol.I)<br />
When consignments call for full wagon(s), indents should be placed with the Railway Station<br />
concerned after predetermining accurately the type and number of wagons required. In case of<br />
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SPECIFICATIONS FOR INDIGENOUS MATERIALS<br />
ANNEXURE-XI<br />
covered wagons, it should be ensured that the same are watertight. If a particular type of wagon<br />
is in short supply, request should be made to the Railway Authorities to supply the next suitable<br />
type of wagon. Suitable packing in the wagon shall be done, wherever necessary, to ensure<br />
maximum safety of the material in transit.<br />
When ODC packages are involved, the SELLER shall apply to the Railway Authorities with<br />
loading sketches showing overall dimensions and the wagon proposed to be utilized sufficiently in<br />
advance for obtaining movement sanction and to establish firm transportability. Copies of all<br />
such correspondence together with loading sketches should be sent to NALCO and Consultant<br />
RITES. ODC packages shall be loaded, packed and lashed strictly in accordance with the<br />
Railway Regulations. Should there be any delay/difficulty in obtaining the required wagon(s), the<br />
SELLER shall inform Resident Inspector and General Manager (Projects), CPP-Nalco , RCM-<br />
RITES immediately giving details of the required number of wagons, type, carrying capacity, etc.<br />
and indent number so that the matter may be taken up with the Railway Authorities concerned.<br />
After despatch, SELLER shall obtain from the Railway Authorities, particulars of the wagon/train<br />
number, date of movement and destination junction for the particular train and furnish the same to<br />
General Manager (Projects), CPP-Nalco , RCM-RITES for follow-up action on movement, as<br />
may be necessary.<br />
After despatch of the equipment from dispatching station, if movement of the wagon is held-up<br />
due to improper/loose lashing resulting in shifting of the load and consignment is required to be<br />
readjusted/refixed the vendor shall be responsible to arrange for the same as per Railway<br />
requirements. Similarly, in case some infringement in dimensions of the loaded consignment is<br />
detected by Railway Authorities after its movement from despatching station and if it is required to<br />
be corrected either by adjustment of the load or by cutting a few protrusions the same shall be<br />
arranged by vendor at their cost.<br />
5.4 Shipment by Air<br />
Wherever SELLER is instructed by OWNER/CONSULTANT to airfreight any material, the<br />
SELLER shall take prompt action for the same. Immediately after air shipment is effected, the<br />
Seller shall intimate by Fax / E-mail, the details of airway bill number and date, flight number,<br />
number of packages etc. to the Resident Inspector, Consultant RITES, General Manager<br />
(Projects), CPP-Nalco , Resident Construction Manager -RITES, (respective Project Site).<br />
5.5 Destination<br />
The consignments should be despatched as indicated in bid document/Purchase Order.<br />
5.6 Advance Information<br />
Immediately after a shipment is made, SELLER shall send advance information as to the<br />
particulars of materials, value, Purchase Order Number, date of despatch, railway receipt<br />
number, wagon number/goods consignment note number, truck number, name of transport<br />
company and their destination office/associate’s address etc./Airway Bill Number and flight details<br />
by way of Fax / E-Mail to Resident / Visiting Inspector, Consultant RITES, Resident<br />
Construction Manager- RITES, (respective Project Site) and NALCO.<br />
5.7 Transmission of Despatch Documents<br />
Seller shall, within 48 hours of the despatch of the material depending upon the payment terms of<br />
the Purchase Order, either negotiate through OWNER’s Bankers or forward direct by Registered<br />
Post, the railway receipt/consignment note/Airway Bill to the Owner at project site accompanied<br />
by the original invoices, packing lists and challans.<br />
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ANNEXURE-XI<br />
The SELLER shall be responsible for any delay in clearance of the consignment at destination<br />
and consequent wharfage/demurrage, if any, due to delay in transmittal of the Railway Receipt,<br />
Consignment Note/Air Way Bill. Copies of such despatch advise together with 2 copies of<br />
invoices and packing lists shall be simultaneously distributed to OWNER’s (HO & Site),<br />
Consultants (HO & Site) etc.<br />
6.0 Transit Risk Insurance<br />
All equipments/ materials will be insured for transit risk by OWNER unless otherwise specified.<br />
The Insurance cover will be provided from warehouse - to - warehouse.<br />
7.0 Despatch through Approved Transporters<br />
All materials must be despatched through OWNER/CONSULTANT approved transporters, list of<br />
which may be obtained from the OWNER’s/CONSULTANT’s nearest branch/regional office.<br />
--x--<br />
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